720017Re-useable beer kegsClosedGRD Development of PrototypeInnovate UKThis project aims to replace the stainless steel kegs currently used by breweries to distribute their draft beer, by lower cost, lighter, reusable, plastic kegs. In particular to obtain the approval of a major brewery for a new plastic 50 litre keg. We have already developed a successful beer cask, which although not explicitly pressurised, shows that it is possible to produce a low-cost, high density polyethylene (HDPE) cask which can survive been heat sterilised and pass through brewery handling systems, including a drop test. However, this leaves pubs, breweries, and the beer distribution system having to handle both plastic and metal containers, with their different handling characteristics. In order to move to an all plastic distribution system, we need to show that it is also possible to develop a low-cost, plastic pressure vessel which will also withstand the higher pressures developed when CO2 gas is used to pressurise the beer within the keg. We already have design calculations, and computer simulations (FEA) showing that a specially designed, very thick walled, blow moulded HDPE pressure vessel, together with a novel design of interlocking protection components and helped by a supporting band around the centre should be able to withstand this pressure. Such a container might require our proprietary low permeability coating, however we think it possible to develop such a keg. We are therefore proposing to design and manufacture the first non-welded, re-usable plastic beer keg. To achieve this will require us to push the boundaries of the blow moulding process to produce the extremely thick walls needed for the pressure vessel, as well as overcoming a series of other technical hurdles and risks. Once we have established that high density polyethylene blow moulding can be used for manufacturing pressure vessels, and even tolerate being sterilised (or hot filled), metal replacement moves will follow in other areas, with consequent saving of cost and weight.