WB - Basic Course Tba

Basic Course TBA
Training Document
This Training Document is intended for Training purpose
only, and must not be used for other purpose.
The Training Document is not replacing any instructions
or procedures (e.g. OM, MM, TeM, IM, SPC) intended
for specific equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to the equip-
ment specific documentation.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or trans-
mitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocopying,
recording or otherwise, without permission in writing from Technical Training Centre.
Issue 3/0109
2001, Tetra Brik Packaging Systems AB, Technical Training Centre
Technical Training Centre
Contents
1 Guide to the Basic Course TBA
2 Basic Machine Introduction
3 Documentation
4 Pasteurisation and UHT
5 Sterile System
6 Peroxide
7 Cleaning In Place
8 Central Lubrication System
9 Hydraulic System
10 Cooling Water System
11 Pneumatic System
12 Steam System
13 Electrical System
14 Maintenance Routines
15 Packaging Material
16 Hygiene
17 Package Integrity
Guide to the Basic
Course TBA
1
Technical Training Centre 1/9902 1-1 TM-00066 Training Document. For training purpose only.
Guide to the Basic
Course TBA
Introduction
The Basic Course TBA provides basic knowledge about the function and
construction of Tetra Brik Aseptic filling machines. It is a self-instructional
course which describes and explains the components, functions and systems
that are common to Tetra Brik Aseptic filling machines.
Students guide
The course intends to prepare you for higher level machine courses. By
performing the studies according to this schedule, you will achieve a level of
knowledge that will make further training more efficient.
To be able to to achieve the full value of the course, you will need help and
support from a more experienced colleague, who will be your mentor.
Schedule Study Study the sections Basic Machine Introduction, Documen-
tation and Pasteurisation and UHT. Also study the attached
brochures, containing general information on Tetra Pak.
Discuss Discuss the above mentioned sections with your mentor. Ask
him/her to explain, if you have any questions.
Study Study the sections Sterile Systemand Peroxide.
Watch Watch the video Clean Conscience referred to in the Hygiene
section.
Study Study the section: Cleaning In Place.
Visit Visit at least one production plant together with your mentor.
Study the various Tetra Pak equipment during production.
Follow the packaging material from the storage room, through
the filling machine and distribution equipment, all the way to the
storage for finished products. Let your mentor explain the
routines to you.
Study Study the sections: Central Lubrication System, Hydraulic
System, Cooling Water System, Pneumatic System, Steam
System, Electrical System and Maintenance Routines.
Visit Visit a production plant together with your mentor. Focus on the
function of the filling machine and the operators task. Study the
different diagrams for the supply systems and try to follow them
in the machine. Locate the electrical components that are
mentioned in the section Electrical System.
Study Study the section Packaging Material.
Perform Perform the Package Integrity TBA Computer Based Training
Program referred to in the Package Integrity section.
him/her to explain, if you have any questions. Practice how to
check package integrity together with your mentor.
Visit Visit a packaging material plant. Let someone guide you and
explain the different processes. Compare this information to
what you have learned in the section Packaging Material.
Mentors guide
As the students mentor you have a very important role. You must support the
student with your knowledge and experience during the studies. It is you who
will introduce the student, theoretically and practically, to the Tetra Brik
Aseptic systems, and answer questions that arise.
You should also make sure that the student get enough time to perform the
studies. After certain sections of the students schedule, you must devote time
to discuss the various subjects with the student. You should also supervise that
the student has fully understood all sections.
Basic Machine
Introduction
2
Basic Machine
Introduction
What does the filling machine do?
Starting out from a reel of packaging material, the TBA filling machine pro-
duces filled packages. The packaging material is first sterilised and then for-
med into a tube. The tube is filled with product and then shaped and cut into
individual packages.
The package
There is a range of Tetra Pak packages, all deriving their origin from the same
forming technique.
Reel of
packaging material
The packaging material
is sterilised
The packaging
material is formed
into a tube
The tube is filled with
product
The tube is shaped
and cut into individual
packages.
Tetra Brik, Base Tetra Brik, Slim
Tetra Brik, Sqare Tetra Prisma
Tetra Wedge
Tetra Fino
Package terminology
Creases Creases are the folding instructions on the packaging material, to ensure the
packages final shape. The creases are pressed into the material by the creasing
tools in the converting process.
Seals The longitudinal seal (LS) is accomplished when forming the packaging ma-
terial into a tube. It seals the package along the side. A strip of laminated plas-
tic, the LS-strip, covers the seal on the inside. The area of the overlap joint is
called the longitudinal overlap.
The transversal seal (TS) is made when the tube is filled with product. It seals
the package at top and bottom. The sealing takes place below the product level
in the tube.
Fins The fins are the areas, at top and bottom of the package, where it is sealed and
cut.
Flaps The flaps would be the corners of the package, if you flattened it out. When
shaping the package, the flaps are folded down and in, and then sealed to the
package body.
Machine introduction
Tetra Brik filling machines are built from so called modules or main groups
with similar functions in the various machines. The machines may also have
different additional equipment and accessories.
To learn more about this, please unfold the next page. The example shows a
Tetra Brik Aseptic TBA/19 filling machine, equipped with an Automatic Spli-
cing Unit (ASU).
bottom transversal seal (TS)
bottom fin
bottom flap
bottom flap
longitudinal
creases
top flap
top transversal seal (TS)
top fin
top flap top flap top flap
LS-strip top crease
bottom crease bottom flap
bottom flap
longitudinal seal (LS)
longitudinal
overlap
(L.S. overlap)
1. 2. 3.
cut
Aseptic chamber
The packaging material will be dried with heated air.
In machines with deep baths, as shown in the example, an aseptic
environment around the sterilised packaging material is maintained with an over-
pressure of heat-sterilised air. This takes place in the aseptic chamber.
In machines with shallow baths, which have no aseptic chamber, heat-sterilised
air will be blown into the tight tube. This way a sterile area is maintained where
the tube is to be filled with product.
The packaging material will be formed into a tube and sealed
longitudinally. Finally, the tube will be filled with product.
Learn more about sterilisation in the Sterile system chapter.
Strip applicator
The strip applicator applies a plastic strip, the LS-strip, along one
edge of the packaging material. The strip is applied on the inside of
the packaging material and is intended to prevent product from being
soaked into the raw paper edge of the longitudinal seal. The strip will
also support the seal.
Only half of the LS-strip is sealed to this edge of the packaging
material. The other half will be sealed to the other edge later,
when the packaging material is formed into a tube.
Learn more about the LS-strip in the Packaging material chapter.
ASU Automatic splicing unit
The automatic splicing unit splices reels of packaging materi-
al. This means that production can continue uninterrupted
when one reel of packaging material comes to an end.
During splicing though, the packaging material has to remain
still in the splicing head. The magazine provides the neces-
sary supply of material so that the machine does not have to
stop.
Learn more about packaging material in the Packaging material chapter.
Peroxide bath
The packaging material will be sterilised in the peroxide bath.
In machines with deep baths, as shown in the example, the packaging
material will be immersed into warm peroxide and both sides will be
sterilised.
In machines with shallow baths the inside of the packaging material will
merely be covered with cold peroxide and the sterilisation will be
finished in the tube heater.
Learn more about sterilisation in the Sterile system chapter.
Jaw system
In the jaw system the tube is sealed
transversally and cut into separate
packages. The sealing is made by
induction heating, using the aluminium
in the packaging material to melt the
plastic.
It is important that the package design,
with the creases, appear in accordance
with the jaws. This is controlled and
corrected by the jaw system.
Final folder
In the final folder the separate package gets its final shape.
The fins are folded and the flaps are folded and sealed.
Hot air is used to seal the flaps. The plastic outer coating on
the package material is heated and the flaps are pressed
against the sides and the bottom of the package. When the
plastic gets cool the flap is sealed.
Drive system
The drive system includes motor, gear and cam
package. These parts run the jaw system and
also the final folder on certain machines. How
the drive system gets the jaw system to perform
its movements, differs between the machine
systems.
Operator panel
The operator panel allows the
operator to communicate with the
machine. It is used to start and
stop or make the machine take any
other action.
PullTab unit
Note! The PullTab unit is not shown in this example.
The PullTab unit is additional equipment, providing
the packaging material with a PullTab opening be-
fore it enters the peroxide bath.
The PullTab opening is created by punching a hole
in the packaging material. The hole is sealed with
plastic on the inside and aluminium on the outside.
Learn more about the PullTab in the
Packaging material chapter.
1
3
5
6
7
4
3 4
5
6
7
LS-strip
longitudinal seal
lastic
aluminium
2
reel of
packaging material
operator panel
fin flap
fin
flap
sealed
shallow
bath
Electrical cabinet
In the electrical cabinet a great part of the electrical
components are included, such as:
temperature regulators
control system (PLC)
contactors
IH-unit, etc.
Learn more about the electrical components in the Electrical system chapter.
Service unit
The service unit includes parts and supply systems
needed for the machine function, for example:
the water- and air system
the lubrication- and hydraulic oil system
parts of the sterile-, pneumatic- and peroxide
systems (TBA machines)
Learn more about this in the respective chapter.
8 9
11
9
10
8
10
11
2
1
Documentation
3
Documentation
Introduction
A certain number of manuals are delivered together with each filling machine
from Tetra Pak. They can be either machine specific, i.e. they are valid only
for one specific machine, or they can apply to several machine types. If the
manual is not machine specific you must ensure that the information required
is valid for the correct variant.
Each manual starts with an introduction, describing its contents and how to use
the manual. The manuals that are included with a machine delivery are marked
with series and machine numbers which must correspond with the numbers on
the machine.
This section describes the types of manuals that are included in the machine
delivery.
IM Installation Manual
The Installation Manual is not machine specific. It describes what is important
regarding the installation of the actual machine type.
It describes areas such as:
safety
technical data
preparations before the installation
installation drawings
installation checks and preparations for commissioning. Commissioning
refers to the procedure when Tetra Pak hands over the machine and the
responsibility to the customer.
disassembly and return of the machine to Tetra Pak
OM - Operation Manual
The Operation Manual describes the steps to be taken by the operator and
how to handle the machine. It is not machine specific, since it contains e.g.
information about the optional equipment for the machines.
MM - Maintenance Manual
The Maintenance Manual contains information about service and maintenance
of the machine. The manual is divided into sections according to the main
groups.
It describes among other things:
how to check and replace components
how to perform the settings
special tools and templets required for settings
TPMS, the maintenance system of the machine
TPMS = Tetra Pak Maintenance
System
EM - Electrical Manual
The Electrical Manual is machine specific. This means that you have to ensure
that the manual used is registered for the actual machine. Even if two machines
have the same development step, the contents in the electrical manuals may
still separate them. Each change in the electrical machine system has to be
documented in the Electrical Manual. The manual also contains spare part lists
for two main groups of the machine; the electrical cabinet and the operator
panel.
SPC - Spare Parts Catalogue
The Spare Parts Catalogue is divided according to the main groups of the
machine. A Spare Parts Catalogue contains for instance:
spare parts numbers
information about machine parts
exploded drawings of components and accessories
Two of the main groups, the electrical cabinet and the operator panel, are not
included since these spare part lists are part of the Electrical Manual.
Pasteurisation and UHT
4
Pasteurisation and
UHT
Introduction
Pasteurisation and UHT are different methods for heat treatment of products,
like milk. The product is heat treated in order to extend the shelf life and to
ensure that the product does not contain any bacteria able of causing illness for
people.
Fresh milk from a healthy cow is practically free from bacteria, but must be
protected against infection as soon as it leaves the udder. Bacteria capable of
spoiling the milk are everywhere. Careful attention must be paid to hygiene
when producing milk. Anyhow, it is impossible to completely exclude
bacteria from milk. As soon as bacteria gets into milk they start to multiply,
and unless the milk is chilled, it will be spoiled by the bacteria.
Heat treatment All types of heat treatment are made to kill micro-organisms. Examples of
micro-organisms are bacteria, yeast, mould and virus. When the raw material
arrives at the production plant, it most truly contains micro-organisms, that
sooner or later will spoil the product. To extend the shelf life, you have to treat
the product with heat. The raw material may also have been infected by
micro-organisms able of causing illness for people. The heat treatment will kill
all such micro-organisms.
What type of heat treatment you use, depends on the product and the wanted
shelf life of the product.
Pasteurisation of milk When pasteurising milk the aim is to kill all unwanted micro-organisms and
all micro-organisms able of causing illness for people. The term pasteurisation
commemorates Louis Pasteur, who in the middle of the 19th century made his
fundamental studies of the lethal effect of heat treatment on micro-organisms
and the use of heat treatment as a preservative technique.
Pasteurisation followed by quick and immediate cooling, is one of the most
important processes in the treatment of milk. If carried out correctly, these
processes will supply milk with longer shelf life without the product being
damaged. Temperature and pasteurisation time are very important, which
must be specified precisely in relation to the quality of the milk and its shelf
life requirements, etc. One example of a common type of pasteurisation is
75 C for 15 seconds.
UHT = Ultra High Temperature
UHT UHT treatment is a technique for preserving liquid food products by exposing
them to brief intense heating, normally to temperatures in the range of
135-140 C during 4 seconds. This kills micro-organisms which would
otherwise destroy the products. UHT is a continuous process which takes
place in a closed system that prevents the product from being contaminated by
airborne micro-organisms. The product passes through heating and cooling
stages in quick succession. Before start of production, the plant must be
pre-sterilised in order to avoid reinfection of the treated product.
Raw
milk
Separation
Cream
Standardi-
sation
Homoge-
nisation
Pasteuri-
sation
Milk
storage
Filling
machine
Skim milk
When the raw
milk arrives at the
milk production,
the cream is
separated from
the skim milk.
Then the milk is
standardised, i.e.
you set the fat
content of the
milk. This is done
by returning
some of the
cream to the skim
milk.
In order to pre-
vent forming of
layers it is
homogenised.
Then you divide
the fat globales
into smaller
parts.
At pasteurisation
the micro-organ-
isms that may
cause illness for
people are killed.
The milk is
cooled and
packed either
immediately or
stored in storing
tanks before it is
packed.
Milk production
Raw
milk
Separation
Cream
Standardi-
sation
Homoge-
nisation
Pasteuri-
sation
Milk
storage
Filling
machine
Skim milk
UHT
When the raw
milk arrives at the
milk production,
the cream is
separated from
the skim milk.
Then the milk is
standardised, i.e.
you set the fat
content of the
milk. This is done
by returning
some of the
cream to the skim
milk.
In order to pre-
vent forming of
layers it is
homogenised.
Then you divide
the fat globales
into smaller
parts.
At pasteurisation
the micro-organ-
isms that may
cause illness for
people are killed.
The milk is
cooled and
packed either
immediately or
stored in storing
tanks before it is
packed.
UHT treatment
kills all micro-or-
ganisms able of
destroying the
product.
UHT milk production
Pasteurisation of high acid
products
To be considered as an high acid product, the pH value must be below 4.6.
Most fruit juices are high acid products. High acid products are heat treated in
order to kill the micro-organisms able of multiplying in a product with a pH
value of below 4.6. The product will then be commercially sterile and gets a
long shelf life if packed aseptically.
Note!
The examples above show the principle for the most common variants of milk
and juice production. However, there are several other variants.
Commercially sterile
product
A UHT treated product or a pasteurised high acid product is commercially
sterile. A commercially sterile product contains no micro-organisms able of
multiplying. This means that the shelf life is very long if packed aseptically.
Packaging
The package should protect the product and preserve its food value and
vitamins on the way to the consumer. The package should also protect the
product from mechanical shock, light and oxygen
Packaging of chilled
products - Dairy
Chilled products tend to be perishable, so a clean, taintless package is
absolutely essential. The product also has to be kept cool all the time, from
pasteurisation until it is consumed.
Aseptic packaging Aseptic packaging has been defined as a procedure consisting of sterilisation
of the packaging material, filling with a commercially sterile product in a
sterile environment, and producing packages which are tight enough to
prevent recontamination. The packages are hermetically sealed. For products
with a long non-refrigerated shelf life the package must also give almost
complete protection against light and atmospheric oxygen. An unopened
package thus protects the product from the environment - there is no need for
storing it cool until it has been opened.
An aseptic package also requires that the product is transported aseptically,
from the UHT treatment or pasteurisation, to the filling machine. This means
that all pipes, storage tanks, etc must be sterile.
Concentrate
Mixing
Pasteuri-
sation
Water
Concentrate and
water are mixed.
At pasteurisation
those micro-or-
ganisms able of
multiplying in a
high acid environ-
ment, i.e. pH val-
ue below 4.6, are
killed.
The final fruit
juice product is
packed either im-
mediately or
stored in aseptic
storing tanks be-
fore it is packed.
Juice production
Juice
storage
Filling ma-
chine
Sterile System
5
Sterile System
Introduction
The sterile system sees to that the product is packed with a sterile packaging
material and in a sterile environment. The sterile system is part of the filling
machine and is found in all machines that produce aseptic packages.
The following is required to get the product aseptic:
A commercially sterile product, i.e. a product free from micro-organisms
that may multiply.
Aseptic transfer to the filling machine.
Sterilised packaging material, i.e. free from micro-organisms.
A sterile surrounding, where the package is filled with product.
An aseptic package.
The sterile system has three main functions. Their principles are a bit different
depending on whether the machine has a closed aseptic chamber and a deep
bath or an open chamber and a shallow bath.
Machine sterilisation - A machine with a closed aseptic chamber is steri-
lised by peroxide, while machines with an open chamber are sterilised by
heat-sterilised air.
Sterilisation of packaging material - The packaging material is sterilised
by peroxide, before it touches with the product. In machines with deep
baths the packaging material is covered on both sides with warm peroxide,
and with that the sterilisation is finished. In shallow baths the packaging
material is only covered on the inside with cold peroxide, but the sterilisa-
tion is not finished until after the heating of the tube heater.
Maintain sterile surrounding - After the sterilisation heat-sterilised air
maintains the sterile surrounding and the peroxide is vaporised.
Aseptic = Prevents reinfection
Sterilized
packaging
material
Sterile
surrounding
Aseptic
transfer
Commercially
sterile food
Aseptic packages
The Sterile System
Peroxide = Hydrogen peroxide =
H
2
O
2
Deep baths
Machine sterilisation Before start of the production the machine has to be sterilised. The following
describes the most important moments for machine sterilisation.
At preheating the elements are warmed up to enable that the packaging
material can be sealed.
In order to make the machine sterile the aseptic chamber has to be closed.
This is done by creating a tight tube of the packaging material.
The sterilisation starts with spraying peroxide into the aseptic chamber. A
thin film of peroxide will cover all the surfaces.
When the spraying has started you cannot open the aseptic chamber without
losing the overpressure and, thus, losing the aseptic surrounding. Therefore,
there are door monitors on all doors of the aseptic chamber. If a door is
opened after the spraying has started you will have to start again from the
beginning with the machine sterilisation. If there has been product in the
machine, then you have to clean the machine too.
The aseptic surrounding is also lost if the packaging material tube is opened.
This is the operators task to watch, since there is no other monitoring.
At drying heat-sterilised air is blown into the aseptic chamber in order to
vaporise the peroxide. The overpressure from the heat-sterilised air will
now keep the aseptic chamber sterile.
When the machine sterilisation is finished you will get a message that the
machine is ready for production.
Aseptic chamber
Squee-gee rollers
Air
Peroxide
Product
Water
Peroxide tank
Filling machine with a deep bath.
Water ring compressor
Peroxide
bath
Packaging
material
Water separator
Air superheater
Heat exchanger
Product
Tight tube
Sterilisation of packaging
material
Before the tube is filled with product the packaging material has to be sterile.
The packaging material will be sterilised when it passes a bath with warm
peroxide. Squee-gee rollers will remove surplus peroxide and let it flow back
to the bath.
The peroxide is stored in a peroxide tank. You fill up the peroxide bath by
overfilling, i.e. overfill the bath and let the surplus flow back to the peroxide
tank. During production overfilling takes place continuously in order to
maintain the level of the bath and to screen off particles from the peroxide.
This is called top filling.
Heat exchangers with warm water are used to warm up the peroxide. Since
peroxide is corrosive you cannot use electrical heaters in the peroxide.
The packaging material may not stay too long in the peroxide bath since the
edges of the packaging material are unprotected and will soak the peroxide.
Thus, the bath is filled just before the packaging material starts to move and is
emptied when it stops.
Critical factors for the sterilisation:
Peroxide concentration - The operator has to check that the peroxide
concentration is correct.
Peroxide temperature
Time - By checking the level of the peroxide bath and the speed of the
packaging material, the sufficient contact time between the packaging
material and the peroxide will be ensured.
Maintain sterile surrounding With an overpressure of heat-sterilised air in the aseptic chamber, the machine
is kept sterile and all residues of peroxide vaporise.
An air superheater will warm up the air so that it becomes sterile.
The heat-sterilised air is cooled in the heat exchanger in order not to
expose the packaging material and the product to too high temperatures.
The water ring compressor is the motor in the circulation and soaks air from
the aseptic chamber. The air is cooled in the water ring compressor or in a
separate cooler by the mixture with water. Then the residues of peroxide
vapour in the air will condense. This will prevent the peroxide concentra-
tion in the aseptic chamber from getting too high.
A water separator will separate the water. As the water contains peroxide
it cannot circulate.
After finished production the machine must stay in WEAC position during a
few minutes before the operator is allowed to open the doors to the aseptic
chamber. In the WEAC-position you switch off all heaters so that the air can
circulate and remove the peroxide vapour from the aseptic chamber. This is
done to avoid that the operator might risk to get in touch with the peroxide
vapour when the aseptic chamber is opened.
WEAC = Work Environment
Aseptic Chamber
Shallow baths
Machine sterilisation Before start of the production the machine has to be sterilised. The following
describes the most important moments for machine sterilisation.
At preheating the elements are warmed up to enable that the packaging
material can be sealed.
Since the chamber is open you cannot make it aseptic. By creating a tight
tube, however, and blowing down sterile air into the tight tube, a sterile
area is formed where the tube is to be filled with product.
The pipes of the machine are sterilised with heat-sterilised air.
The air and the machine are slightly cooled before the machine is ready for
production.
Sterilisation of packaging
material
Before the tube can be filled with product the packaging material will have to be
sterilised. The packaging material will be sterilised when the applied peroxide
is vaporised in the tube heater.
The shallow peroxide bath is always filled and provided with peroxide from a
can. Rubber rollers pull up cold peroxide from the bath and apply it on the
inside of the packaging material. By adjusting the pressure between the rubber
rollers you can set the amount of peroxide to be applied to the packaging
material.
Product
Air
super-
heater
Water separator
Air
Peroxide
Product
Water
Rubber rollers
Peroxide can
Packaging
material
Tube heater
Peroxide bath
Water ring compressor
Filling machine with a shallow bath.
Tight tube
Sterile area
Cooler
The peroxide is mixed with a wetting agent, PSM, to enable that the peroxide
covers the surface with a uniform film and does not split up because of surface
tension.
Critical factors for the sterilisation
Peroxide concentration
The surface tension of the peroxide - The mixture between peroxide and
wetting agent and peroxide is circulating between the bath and the tank to
remain well mixed.
Peroxide vaporisation - It is essential that a sufficient amount of peroxide
vaporises in the tube heater. The amount depends on the temperature and the
humidity in the filling chamber. This is estimated by means of a table. To
estimate the total consumption you can measure the amount that disappears
from the peroxide can.
It is also important that all peroxide is vaporised before the packaging
material reaches the product. If not, residues of peroxide might get into the
product.
A weakness for shallow baths is that all peroxide consumed by the machine
will be vapour in the air. Therefore, an exhausting device above the
machine is needed.
Maintain sterile surrounding By blowing heat-sterilised air into the tube the machine is kept sterile and the
residues of peroxide vaporises.
An air heater will warm up the air to make it sterile.
The heat-sterilised air is cooled in the cooler in order not to expose the
packaging material and the product to too high temperatures.
The water ring compressor soaks air from the chamber. The air is cooled in
the water ring compressor or in a separate cooler by the mixture with water.
Then the residues of peroxide vapour in the air will condense.
A water separator will separate the water. As the water contains peroxide
you cannot let it circulate.
Machine stop
This part about machine stop only concern machines with deep baths.
Different stops mean different steps to restart the machine.
At a normal stop the tube is emptied before the machine stops. When you
restart the machine the packaging material, located in the aseptic chamber
and in the peroxide bath during the stop, must be disposed of.
The machine stops with the tube filled with product during a short stop.
Since the product in the filling pipe is exposed to high temperature the
machine may be idle only during a limited time. When restarting the
machine the packages, that might not have been fully sealed, will have to be
disposed of. Also the packaging material, being in the peroxide bath during
the stop, will have to be rejected. Short stop is only available on machines
with deep baths.
If a door with a door monitor is opened while the machine is running, the
machine will stop immediately in so called safety stop. Start after a safety
stop takes place as after a normal stop.
At an emergency stop the machine will stop immediately. The motors stop
and all pneumatics are vented. You will have to clean the machine and
perform machine sterilisation before it can be restarted.
Pneumatic = A way of producing
movements by means of compres-
sed air.
Peroxide
6
Peroxide
Introduction
Hydrogen peroxide, H
2
O
2
, is often called Peroxide. Peroxide is used as a
sterilisation agent in Tetra Pak filling machines. It is a clear, colourless fluid
which is odourfree in small concentrations but has a somewhat pungent smell
at higher concentrations. The peroxide is not particularly toxic and it is simple
to handle, since the residues of water and oxygen gas are harmless.
Decomposition
In pure form and at a low pH-value peroxide is a relatively stable compound.
The decomposition into water and oxygen gas takes place when the peroxide
gets polluted, for instance by metals.
It is accelerated by:
heat
high pH-value
light
When the peroxide is polluted by metallic chlorides, e.g. chlorides of copper,
chrome, or iron, it can decompose very quickly. The decomposition can also
take place at very low proportions of pollutions, a few ppm.
When the peroxide concentration is higher than 30% it might cause ignition
in case of contact with wood, paper, cloth, or such. Peroxide itself is not
flammable but the oxygen gas, created by decomposition, may facilitate
ignition and maintain the burning.
Some metals have catalytic influence on peroxide. This means that the metal
accelerates the decomposition into water and oxygen gas. Pure passivated
acidproof metals, such as steel or aluminium, does not have any catalytic
influence on peroxide and can be used as construction materials. At the
passivating process coatings inside e.g. pipe lines are removed by rinsing with
distilled water and peroxide.
Safety
Peroxide is a chemical product, which is corrosive in contact with eyes and
skin as well as by consumption. Furthermore, inhalation of peroxide steam
or peroxide mist is very irritating for nose and throat.
Where the peroxide is handled and stored:
an emergency shower and eye flushing equipment shall be easily
accessible,
a water hose must be reachable in order to dilute and wash away any
spillage,
persons working with peroxide shall wear tight-fitting safety glasses,
protective rubber gloves, shoes made of plastic or rubber, and a protective
apron.
Hydrogen
Hydrogen
Oxygen
Oxygen
Peroxide molecule
ppm = parts per million = 10
-6
Catalysis = Change of reaction
rate.
Persons working with peroxide must be aware of the risks involved as well
as the local safety rules and they must follow the safety instructions about
peroxide provided in the Tetra Pak manuals.
Personal injuries Below is a brief description of injuries that could occur when working with
peroxide
Skin - Peroxide with a higher concentration than 10% is corrosive in
contact with skin. The skin turns white because small blisters of oxygen gas
are formed in the skin, called emphysema.
Eyes - Peroxide is very irritating to the eye and might cause permanent
damage on the cornea.
Inhalation - Inhalation of peroxide vapour or peroxide mist may cause
severe pain in nose and throat as well as sneezing and coughing. In high
concentrations there is risk of bronchitis and fluid in the lungs, so called
pulmonary edema.
Consumption - Consumption of peroxide causes smarting pain, stomach
pain, and corrosive damages. The peroxide will quickly decompose into
water and oxygen gas, which distends the stomach and there is a risk that
it may burst.
Handling Peroxide is a chemical with relatively small handling risks. However, those
who handle the peroxide must know the risks.
Peroxide must be handled with care in order to avoid any spillage.
If peroxide is spilled, remove it with lots of water.
Keep the peroxide in its original packing as long as possible.
Emptied peroxide must never be returned to the original packing.
Tetra Pak recommends that the special filling station is used when
emptying the original packing into the container.
Storage According to the safety precautions peroxide must be stored:
in a dark and cool place.
protected against every risk of pollution.
separate from combustible material.
in a properly ventilated area.
Cleaning In Place
7
Cleaning In Place
Introduction
Cleaning In Place is usually shortened CIP. It is a method used for cleaning of
filling machines and process equipment without having to disassemble them.
A production cycle is always completed with CIP. It is important to clean
directly after the end of the production in order to prevent the product from
getting dry and that the microbiological growth does not start.
What is cleaned with CIP?
On a Tetra Brik machine the following parts are cleaned without dismantling
AP valve
Control valve
Upper filling pipe
The filling machine is cleaned separately, in most cases with a separate
cleaning device, intended only for cleaning of the filling machine.
On machines with a lower filling pipe, the lower filling pipe is cleaned
manually. This method is called COP which is an abbreviation of Cleaning
Out of Place.
AP = Aseptic product
Cleaning device
Upper filling pipe
Control valve
AP-valve
The figure shows two filling machines. The upper
machine is in production and the lower one is
being cleaned.
Hot air
Preheated and
cooled air resp.
Steam
Product
Detergent
Lower filling pipe
A
B
C
What is required for cleaning?
There are four important cleaning factors
Flow
A turbulent flow of water is required to remove product remnants. This is
achieved by the speed of the detergent which is 1.5-3.0 m/min. The flow
must be at least 8000 l/h in order to reach this speed in the AP-valve.
Chemicals
Chemicals are used to dissolve the product remnants.
Temperature
Correct temperature of the detergent is important to dissolve the product
remnants.
Time
It is essential that the detergent maintains contact with the product remnants
long enough in order to be able to dissolve them.
The effects of the chemicals
The product remnants contain sugar, fat, protein, salt, and minerals. Warm
water is sufficient to dissolve sugar. But to dissolve fat and protein a strong
alkali is required. Salt and minerals are a very small part of the product and
they usually disappear with the other dissolved components of the product
remnants. In cases where salt and minerals do not disappear, acid has to be
used. The quantity of salt and mineral deposits varies due to the degree of
hardness of the rinsing water and the pH-value of the product.
Alkali = NaOH
NaOH = Caustic soda
W
A
T
E
R
A
L
KAL
I
A
C
I
D
Fat
Sugar
Salt and
mineral
Protein
The figure shows applicable chemicals that dissolve
the product remnants. Water is used to dissolve
sugar. But to dissolve fat and protein alkali is
needed. When salt and mineral deposits remain,
acid is required.
The ladder in the cleaning programmes
The contents of a cleaning programme may vary. On the whole, however, two
cleaning programmes are used, daily cleaning and weekly cleaning.
Daily cleaning Daily cleaning is done once per day and includes the following steps:
1. Cold rinsing
Cold water forces product remnants out of the pipes.
2. Warm rinsing
Warm water dissolves sugar and heats the pipes before the alkali cleaning.
3. Alcali cleaning
Alcali dissolves fat and proteins.
4. Cold rinsing
Cold water forces alkali and product remnants out of the pipes.
5. Final rinsing
Final rinsing takes place until the pH-value of the rinsing water, which
comes out of the pipes, is equal to incoming water.
Weekly cleaning If too many lime deposits have been built up in the pipes, a weekly cleaning is
performed after the daily cleaning. This can be done as often as required.
Weekly cleaning includes the following steps:
6. Acid cleaning
Acid cleaning dissolves salt and minerals.
7. Cold rinsing
Cold water forces the acid out of the pipes.
8. Final rinsing
Final rinsing takes place until the pH-value of the rinsing water, which
comes out of the pipes, is equal to incoming water.
Final cleaning and intermediary cleaning
The worst that can happen in connection with the production of food is that
toxic components enter the product. Since strong alkalis and acids are used for
cleaning it is important to check that no detergent can leak into the product.
Final cleaning Before final cleaning can start, make sure that there is no product in the
product line. Then turn a key and choose final cleaning. This is one of the ac-
tions for the daily care. Tetra Pak recommends that final cleaning takes place
once per day.
AP-valve, cleaned by final cleaning.
Steam
Water
Air
Detergent
Detergent
A
B
C
Intermediary cleaning Intermediary cleaning is used only if you have to clean the filling machine
while there is still product in the product line. The AP-valve has a steam bar-
rier which prevents the detergent from leaking into the product. This also
means, however, that the space in the steam barrier will not be cleaned. This
space will be cleaned only at the final rinsing procedure.
AP-valve, cleaned by intermedi-
ary cleaning.
Steam
Product
Water
Air
Detergent
A
B
C
Central Lubrication
System
8
Central Lubrication
System
General
The central lubrication system provides lubrication to the machine.
Lubrication reduces wear and prolongs the lifetime of components in the
machines.
At a pressure stroke, the oil is fed from a lubrication pump through the main
line to the dosing valves. From the dosing valves the oil is dosed to the
bearings, bushings, sliders etc. that should be lubricated. The quantity of
lubrication oil to each lubrication point, is dependent on the size of the dosing
valve, compare A and B in the figure above.
The central lubrication system used in Tetra Brik machines, is a high pressure
system. The lubrication pump is pneumatic and the oil pressure is 5-7 MPa
at the pressure stroke. It is a one way system, which implies that the oil is
consumed at the lubrication points.
The central lubrication system of each machine is documented as a diagram.
In order to simplify and make the diagram easier to read, the various
components are shown as symbols. It is very important that the correct central
lubrication diagram is used when working with a particular machine. There are
many models and versions of machines, and some of them have been rebuilt
or modified and differ from their original design.
Basic function of the lubrication system
B
A
To lubrication point
Lubrication
oil
Lubrication pump
Main line
Dosing valve
Components
A description of the main components in the central lubribrication system
follows below.
Oil tank The lubrication oil is kept in a tank with a built in pump.
The lubrication oil tank is equipped with filling connection, venting pipe,
level sensor, level glass and a built in pump.
Pressure guard The pressure guard monitors the oil pressure. If the pressure does not reach the
preset value, an alarm will be activated. The pressure guard can also monitor
that the discharge pressure is continued properly after a pressure stroke.
Level
glass
Venting pipe
Filling connection
Built in pump
Main line
Level sensor
Main line
Pressure gauge The central lubrication system can be equipped with a pressure gauge which
shows the pressure in the high pressure side of the system.
Central lubrication pump The lubrication pump is a pneumatic single acting piston. The pump feeds the
oil with a required pressure at each pressure stroke. The oil pressure is nine
times higher than the incoming air pressure. The pump is also responsible for
the important decompression, i.e. the discharge pressure, in the main line after
reaching the end of the pressure time.
The central lubrication pump consists of an air cylinder with an air piston
which put pressure on the pump cylinder piston. The pump also contains a
mounted locating head, which includes all the necessary valves, connections
to the suction pipe and the main line.
Level sensor The lubrication oil tank is equipped with a level sensor that will activate an
alarm when the oil level is too low.
Main line
Suction pipe
Mounted locating head
Return spring
Pump cylinder piston
Air cylinder
Air piston
Incoming air pressure
Maximum level
Minimum level
When the level is below the minimum level a signal is sent to the control
system of the machine. The minimum level is set at a level which prevents the
suction tube from sucking air into the system. The maximum level can be used
to control automatical filling.
Oil filter When refilling the central lubrication tank, the oil is fed through a hose
provided with a filter mounted in line in the hose. The filter will take away dirt
and particles that may interfere with the function of the pump, dosing valves
etc.
Distribution block Distribution blocks are used as junctions for the hoses that distribute the oil to
different dosing valves in the machine.
Dosing valve The dosing valves ensure that the correct amount of lubrication oil is fed to the
lubrication points. It works like a mechanically operated volumetric piston
pump.
The dosing valve consists of a piston housing with a piston that at a pressure
stroke, forces the oil upwards, through the non return valve and into the
lubrication pipe. It also contains the return spring which forces the piston
back into its rest position after the pressure stroke.
Lubricating
pipe
Non return
valve
Piston
Piston housing
Return spring
Dosing chamber
Function
The oil is fed from the central lubrication pump through the main line and
the distribution blocks to the dosing valves. From the dosing valves the oil
is distributed to the lubrication points with set quantities of 10 mm
3
, 30 mm
3
,
or 50 mm
3
, independent of each other. It is the size of the piston in the dosing
valve that determines the amount of oil to be dosed. The PLC of the machine
controls and supervises the lubrication system.
PLC
Basic sketch of a central lubrication system
Dosing valves
Distribution block
Dosing valves
Pressure guard
Filling connection
Lubrication oil
Compressed air
Central lubrication
pump
Main line
Button for manual
lubrication
The lubrication cycle can be devided into three phases:
Rest position - At the rest position the air piston does not move.
The lubrication pump and the dosing chambers are filled with oil.
Pressure stroke - At the pressure stroke oil is fed to the lubrication points.
The air piston in the lubrication pump goes up and forces the oil into the
system. The oil passes a non return valve and continues through the main
line to the dosing valves. The dosing valve piston goes up and forces the oil
through a non return valve into the lubrication pipe and out to a lubrication
point.
Air piston
Dosing
chamber
Lubrication oil
Compressed air
Main line
Non return
valve
Lubricating
pipe
Piston
Air piston
Non return
valve
Lubrication oil
Compressed air
Discharge pressure - At the discharge pressure, the lubrication pump and
the dosing chamber in the dosing valve, will be refilled with oil.
The return spring of the air piston, forces the piston back to its rest position.
Lubrication oil flows from the lubrication oil tank through the suction pipe
into the pump cylinder. At the same time the main line is decompressed
through the non return valves.
The dosing chamber is then refilled with oil through the small gap between
the piston housing and the piston. The non return valve in the dosing valve
is closed which prevents a return flow of the oil.
At the discharge pressure, the system is decompressed to a lower pressure of
approx. 0.2-0.5 MPa. The lower remaining pressure is important for refilling
the dosing valves. If there is no remaining pressure, air might enter the system
through leaks. The time needed for the discharge pressure depends on:
the viscosity of the oil
the running temperature
the size of the system
The next pressure stroke must not occur until the dosing valves have been
refilled i.e. the system has been decompressed.
Pump cylinder
Piston
housing
Dosing
chamber
Suction pipe
Non return
valves
Air piston
Return
spring
Non return
valve
Piston
Lubrication oil
Compressed air
Lubrication cycles There are two different lubrication cycles. The diagram below shows an
example.
Single lubrication pulse - During production the machine will be
automatically lubricated with one lubrication pulse every 15 min. The
interval may vary from one machine to another.
Long lubrication cycle - A long lubrication cycle consists of a number of
lubrication pulses within a set time interval. It is automatically initiated
from PLC at different occasions e.g. when:
- the machine is initially started
- the machine has been cleaned by external cleaning
A long lubration cycle can also be initiated by pushing the button for manual
lubrication e.g. when:
the main lines need to be lled up after an interference or a service
Refilling Information on the proper type of oil to be used in the central lubrication
system, can be found in the Maintenance Manual and the Operation Manual.
The central lubrication tank can be filled manually or automatically.
Manual refilling - The central lubrication tank is refilled by using a
transportable pump and tank. The hose is connected to the oil tank in the
machine by way of a quick release coupling. The oil is then pumped from
the transportable oil tank into the lubrication tank.
10 s 10 s
10 s 10 s 10 s 10 s 10 s
15 min
30 s
8 s
2 s
8 s
8 s 8 s
2 s
2 s 2 s
30 s 30 s 30 s
Single lubrication pulse
Long lubrication cycle
Lubrication
Checking
- oil level
- pressure
Lubrication
Checking
- oil level
- pressure
A transportable oil tank connected to the oil tank in the machine
Automatic refilling - In an automatic filling set up, the lubrication tanks of
each machine are connected to a central storage. The oil is pumped out to
the machines.
A solenoid valve is mounted at each oil tank, and when the oil level is low,
the solenoid valve opens and refilling take place. When the proper level has
been reached, the filling valve closes and the filling ends.
Bleeding The central lubrication system does not work if air enters the system. If air has
entered the system, it must be bled to restore its proper function.
Function check A function check of the lubrication system is made according to the service
interval and at every interference in the system. Then for example oil pressure
and the function of the dosing valves are checked.
PLC PLC
Set up for automatic refilling
Hydraulic System
9
Hydraulic System
General
Hydraulics are a way to create movement by means of hydraulic oil under
pressure. In Tetra Brik filling machines, hydraulics is used in order to create
the high pressures, the distinctive positions and fast movements, which are
needed for sealing and cutting as well as for movements in the final folder.
When the hydraulic oil is fed at a high pressure to the hydraulic cylinder, the
piston moves outwards. When the pressure releases, the return spring will
press the oil out of the cylinder and the piston will move inwards.
The hydraulic system of the machine is documented as a diagram. In order
to simplify and facilitate the understanding of the diagram, the various
components are shown as symbols. The shape of the hydraulic system varies
according to the machine type, development step, and possible rebuilding of
the machine. Therefore, it is essential that the appropriate hydraulic diagram
is used when working on the machine.
Components
Below is a description of the main components of the hydraulic system.
Hydraulic oil tank The hydraulic oil tank functions as a reservoir for the hydraulic oil in the
system. Some components of the hydraulic system, are placed on the oil tank.
The hydraulic oil is filled into the tank by an external pump. At the time of
filling, the hydraulic oil is filtered through a filter attached to the filler hose.
Hydraulic oil with pressure
Hydraulic oil not under pressure
Functional principle for hydraulics
Hydraulic oil Hydraulic oil
Piston
Hydraulic cylinder Hydraulic cylinder
Return spring
Filling
connection
Pressure reducing
valve
Pressure gauges
Level- and temperature transmitter
Pressure regulator
Hydraulic oil tank
The hydraulic oil in the tank may be drained through a drain valve. The tank
is open to the surroundings and thus not pressurised.
Level transmitter and
temperature transmitter
The level transmitter can indicate two or three levels; high, low and if a third
exist, soon low level.
The built in temperature transmitter, senses the temperature. It is normally set
at 70 C. If the temperature exceeds the set level, an alarm will indicate that
the temperature is too high.
Oil cooler The oil cooler cools the hydraulic oil.
The oil cooler is a type of heat exchanger in which water is used as a cooling
media. The cooling water can be re-circulated. The heat is created by the
friction, formed when the oil is transported in the hydraulic system.
Hydraulic oil pump A hydraulic oil pump is used in order to pressurise the hydraulic oil. The pump
is a gear pump, driven by an electric motor.
Oil cooler, length section
Hydraulic oil Hydraulic oil
ooling
ater
Cooling
water
Oil cooler, cross section
Inlet
Outlet
Filter A filter strains solid particles and other impurities, which may block valves
and cylinders. Particles and impurities could also in other ways, have a
negative influence on the function of the hydraulic system. The filter has an
indicator, which shows whether the filter is blocked and needs to be replaced.
An internal overpressure valve protects the filter against too high pressures.
This may happen if the filter is blocked and the oil cannot pass. In order to
prevent damage to the filter, the overpressure valve will open at a set pressure
and let the oil pass through.
Non-return valve Non-return valves are used in order to control the flow directions of the
hydraulic system.
Accumulator The accumulator is used in order to keep an even pressure in the system when
the various valves open and close.
An accumulator is a pressurised vessel, divided into two chambers. The upper
chamber is filled with pressurised nitrogen and the lower one is filled with
hydraulic oil. The upper chamber functions as a counter pressure, i.e. it will
press oil out to the system when the consumption is higher than the pump
supply, and it will let the oil in, when the consumption is lower than the pump
supply.
Inlet Outlet
Filter
Indicator
Overpressure
valve
Pressurised nitrogen
Hydraulic oil
Pressure regulator A pressure regulator sets the system pressure. The system pressure is used for
the catch cylinders, for example. A pressure gauge shows the system pressure.
Pressure reducing valve The pressure-reducing valve is used in order to reduce the system pressure, for
example to the cutting cylinders. A pressure gauge shows the pressure.
Throttling The throttlings are used to reduce the flow in the pipe, for exampel to the
cylinders. A lower flow during the pressurisation, reduces the speed of the
pistons in the cylinders. This reduces the risk of mechanical damage when the
cylinder reaches its final position. However, the throttling will not influence
the final pressure in the cylinder.
Hydraulic oil with full pressure
Hydraulic oil with reduced pressur
Valve Valves direct the hydraulic oil to and from the cylinders. When the valve is
open, oil is fed into the cylinder at high pressure. When the valve is closed, the
pressure is released and the oil flows back into the tank. The valves are either
electrically controlled by a signal from the machine control system, or
mechanically controlled by a cam.
Impulse transmitter When mechanically controlled, the valve functions as part of a, so-called,
impulse transmitter. This transmitter is connected to the jaw system by a
timing belt in order to remain synchronised with the jaw system. The impulse
transmitter consists of cams and valves. The cams affect the valves by one
high part of the cam and one low part of the cam.
The low part of the cam opens the valve and the cylinder is pressurised.
The high part of the cam closes the valve and ensures that the cylinder is
unaffected. During high cam, the oil from the cylinder is directed back to
the tank.
Note!
The situation can also be reversed, i.e. the low part of the cam closes the valve
while the high part opens the valve and pressurises the cylinder. It depends on
how the system is designed.
Open valve Closed valve
Cylinder
Flow outlet
Flow inlet
Cylinder
Cam
Function
The working principle of a hydraulic system is shown below.
The motor-driven pump (1) suctions hydraulic oil from the hydraulic oil tank
(2) through the cooler (3). The level transmitter (4) and the
temperature transmitter (5) are mounted in the tank. The pump forces the
hydraulic oil through the filter (6) and pressurises the accumulator (7). On
the filter there is an indicator (8), which shows when the filter is blocked and
needs to be replaced. The pressure regulator (9) sets the system pressure. In
front of the cylinders there are throttlings (10) in order to reduce the speed of
the pistons in the cylinders, and by that, prevent damage to these components.
To some parts of the system, the pressure is reduced by a pressure reducing
valve (11). A cam (12), or an electric signal from the control system, operates
the valves (13) to the cylinders (14).
The hydraulic cylinders perform mechanical movements in the machines.
The catch cylinders are connected to the catches. When the cylinder is
activated, the inductor and the pressure jaw are pulled together, causing
pressure on the packaging material tube. This pressure is used for sealing
the transversal seal, and as a hold-down for the cutting. The return
movement takes place when the oil pressure is released and the spring
forces the catches back.
The cutting cylinder is connected to the knife, which cuts the packaging
material tube into single packages. When the cylinder is pressurised, the
knife will move forwards, cutting the tube. The return movement takes
place when the oil pressure is released and the spring forces the knife back.
The pull-down device and the pressure device, shape the package in the
final folder. This is valid for machine types TBA/9 and TBA/19 only.
The cylinders in the pull-down device and the pressure device, are operated
by hydraulic oil and have spring returns.
Force The hydraulic pressure determines the force, by which the hydraulic
cylinder will affect the load. When the pressure decreases, also the force
decreases. Consequently, when the pressure increases, so does the force. The
pressure is set by a pressure regulator.
M
2
1
3
4 5
7
9
8
10
13 12 13
14
11
10
14
6
Speed By throttling the flow to the cylinder, the speed of the piston
movement can be regulated. This is done by the use of throttlings on the con-
nections between valves and cylinders.
Hydraulic oil In order to maintain an efficient flow of energy in a hydraulic system, the
correct type of hydraulic oil must be used. Information about which oil type to
be used for the different machines, is found in the Maintenance Manual as well
as in the Operation Manual.
The following is required for an oil to function properly in a hydraulic system.
The hydraulic oil must have a viscosity to seal small gaps and clearances, in
order to avoid leakage. The hydraulic components often lack elastic seals.
The hydraulic oil must lubricate the components in order to reduce the
wear. Since the clearances and gaps in the hydraulic components are small,
there is a risk of direct contact between the parts in a components. When
there is direct contact, the material is worn off and the gaps in the compo-
nents increase. Worn components cause capacity losses and leakage risks.
The hydraulic oil must chill and carry off the friction heat from
efficiency losses in the system.
Impurities, which enter the hydraulic oil, may damage the system.
Air Under normal pressure the hydraulic oil binds only a small amount
of air. However, under pressure, the hydraulic oil is capable of binding
much more air. Air is released when the pressure decreases and small air
bubbles are formed. In the tank, the air is separated from the hydraulic oil.
When hydraulic oil containing air, is pressurised, it turnes elastic and it will
take a longer time to reach the correct pressure. This may affect the
function of the system. Furthermore, air in the hydraulic oil will decrease
the possibility to build up a lubricating film, and thus reduce the lubrication
effect on the components.
Water Hydraulic oil naturally contains 0.01-0.02% of water. At higher
concentrations, the water may appear in a free state, which may damage the
system. The water may appear from condensation, leaking water coolers, or
leaking components.
Water in the hydraulic oil may cause corrosion on the components in the
system and decrease the capability to build up a lubricating film. When the
proportion of water in the hydraulic oil is high, the oil may get thicker and
thus block the filter.
Solid impurities Solid impurities in the hydraulic oil could cause
problems in pumps, valves and cylinders. The solid particles are filtered
out into two filters; one in the filling hose and one after the pump.
Safety The pressure must be discharged when working in hydraulic systems. An
accumulator is pressurised up to 70 Bar. When the system is to be vented,
the pressure must be reduced to a maximum of 40 bar, in order to decrease
the risk of splashing.
Furthermore, the handling instructions from the manufacturer must be
followed, since the hydraulic oil may be health hazardous and allergenic.
Symbols
The table below contains the symbols that normally are used in Tetra Pak
hydraulic system diagrams.
Symbol Meaning
Accumulator
Non-return valve
Valve, electrically operated
Valve, cam operated
Manual valve
Cylinder with oil return
Cylinder with spring return
Filter
Throttling
Cooler
Pump
Tank
Motor
Level transmitter
Temperature transmitter
Pressure gauge
Pressure indicator
Pressure regulator
Pressure reducing valve
Symbol Meaning
M
Cooling Water System
10
Cooling Water
System
General
Tetra Brik filling machines use water to cool different components, like:
inductors in the jaw system
guide rails in the final folder
oil in the hydraulic system
air in the electrical cabinet
The cooling water system can either be open or circulating. Circulating
cooling water is used when the temperature of the ordinary water supply
is too high, over 20 C. In an open system, the water is consumed, while
a circulating system uses the same water over and over again.
Many machines have a separate water cooling system. This means that there
is some kind of heat exchanger between incoming water and water to be
cooled. In an open separate water cooling system, the cooler is part of the
machine.
The cooling system of the machine is documented by means of a diagram.
To simplify the construction and make it easier to understand, the diagram is
made up of symbols for the different components. The design of the cooling
water system varies depending on machine type, development step and
rebuilds. Thus it is important to use the correct cooling water diagram when
working on the machine.
Open cooling water system
Chilled unit
From cooler
Return to cooler
Cooler
Drain
Chilled unit
Circulating cooling water system
Circulating separate cooling water system
Chilled cold water
Chilled unit Chilled unit
Cold water
C
o
o
l
e
r
H
e
a
t

e
x
c
h
a
n
g
e
r
H
e
a
t

e
x
c
h
a
n
g
e
r
H
e
a
t

e
x
c
h
a
n
g
e
r
Open separate cooling water system
Cooling water In order to be able to cool efficiently, the water must be of adequate quality
and temperature. Data on water quality to be used for the different machines
can be found in the IM, MM or OM.
The kind and quality of the water differs. Below some examples:
Raw water is a surface or ground water. Depending on where it is taken, it
contains different ingredients and impurities.
Drinking water is produced from raw water. Drinking water must not
contain components that may cause illness.
Deionized water is produced from drinking water. In deionized water you
control the amount of hardening ions.
Totally desalinated water is also produced from drinking water. All salt
ions, both positively and negatively charged ions, are removed.
Components
A cooling water system is built up of many components. The most important
and frequent ones, are described below.
Manual valve Manual valves are opened and closed manually.
Electrically controlled
valve
An electrically controlled valve receives a control signal from the machine
control system when to open and close.
Pressure gauge A pressure gauge displays the pressure in the cooling water system.
Over-pressure valve In order to protect the cooling water system, there might be an over-pressure
valve included in the system.
The overpressure valve opens up if the pressure in the cooling water system
exceeds a preset pressure. Water is then released, causing the pressure to
decrease in order to avoid damages to the cooling water system.
Filter The filter is used to filter off solid particles and other impurities which may
clog valves and narrow passages, or in any other way affect functions in the
cooling water system.
Overpressure valve
Magnet device The magnet device prevents forming of lime deposits in the cooling water
system. It is built up of a mechanical filter and a magnet device.
Mechanical filter - The filter basket (1) collects any solid impurities in the
water. Inserted in the filter basket there is a magnet rod (2), collecting any
magnetic impurities like iron chips. The magnet has a plastic cover to
prevent corrosion.
Magnet separator - This consists of two permanent magnets (4) forming
a gap (3), through which the water flows.
The function of the magnet separator can be described like this:
Between the magnets (4) there is a heavy magnet field. The magnet field
affects the lime in the flowing water so that the lime deposit formed in the
cooling water system does not adhere to the cooling water channels. Instead
the lime deposit will follow the cooling water out to the return line. The
function of the magnet device is temporary.
Water tank There is a water tank in some machines, and it works as a reservoir for
the water.
1
2
3
4
Magnetically treated water. The
crystals do not gather and do not stick
on surfaces.
Magnet field
4
4
Untreated water. The crystals gather
and stick easily on surfaces.
Accumulator The accumulator is a vessel containing air. The air can be compressed, to take
up any pressure variations caused by temperature variations.
Temperature sensor A temperature sensor monitors the temperature and signals the control system
if the temperature raises above or falls under the preset values.
Thermostat The thermostat is used to keep a constant temperature by regulating the flow
and thus the supply of colling water to a component.
Pressure guard A pressure guard monitors the pressure and signals the control system if the
pressure raises above or falls under the preset values.
Heat exchanger Heat exchangers are used in a cooling water system to transfer heat from one
circuit to another, without any direct contact between the medias. The two
main types used are tube heat exchanger and plate heat exchanger.
Water pump The water pump circulates cooling water, used to cool various components.
Non-return valve Non-return valves are used in the cooling water system to direct the flows.
Throttle A throttle is used to set a desired flow through a component or a part of the
cooling water system. The throttle can be fixed or adjustable.
Flow meter The flow meter is a floating body meter used to measure small liquid flows
with high accuracy.
Plate heat exchanger
Cold water
Hot water
In the valve housing of the flow meter, made of transparent plastic, there is a
conical passage with its narrowest part turned downwards. In the passage there
is a ball affected by the flow of the water.
When the flow increases, the ball is lifted. Due to the fact that the passage is
conical, the ball will stabilise in a specific position, and the flow can be read
on the graduated scale.
Constant flow valve In order to make the water flow to the water ring compressor independent of
the pressure in the water line, there is a constant flow valve fitted just before
the compressor.
The acting part of the valve is a soft rubber washer. In the middle of the washer
there is a hole, through which the water flows. The size of the hole varies
depending on the water pressure, and thus keeps the water flow through the
valve constant.
Low water pressure - The shape of the rubber washer makes the hole in
the middle relatively large, i e water with low pressure flows through a
large hole.
High water pressure - The rubber washer is deformed so the diameter of
the hole is small. This will cause the rubber washer to reduce the water jet,
but as the water pressure is high, the same amount of water will flow
through the valve as when the pressure is low.
Low water flow High water flow
The constant flow valve is designed for a fixed flow.
Low water flow High water flow
The shape of the rubber washer at low and high water pressure, respectively in a
constant flow valve.
LIME SEPARATOR
VALVE PANEL
Cold water
A1 Z3 Z5
B4
GUARD
B7
JAW SYSTEM
TS
sealing
L
R
Y32
M5
Sealing
unit
FINAL FOLDER
(K50)
Cooler
hydraulic
system FM2 FM3
Compressor
(M7)
Scrubber
Separator
SERVICE UNIT
Z1
Cirk. cold
water inlet
A2
Drain
Cirk. cold
water outlet
M
A4
Conductivity sensor The conductivity sensor monitors the electrical conductivity in the water, and
signals the control system if the conductivity raises above or falls under the
preset values.
Softening filter A softening filter is a container with a bed material, often consisting of small
polystyrene balls. When the water gets in contact with the bed material, there
is an exchange of ions. Thus the amount of hardening ions in the water is
reduced and you get a soft, so called dehardened water.
Function
The cooling water is used to cool the inductors, the guides in the final folder,
the hydraulic oil and the sterile air. The diagram below describes a system that
may be run both open and recirculated.
Water connection B shall always be connected and valve A1 open, as there
is always a need for consumption water to cool components in the service unit.
For circulated cooling water, the water connections A and E shall also be
connected, and the valves A2 and A4 be closed.
The circulating water enters the system at connection A, is filtered in filter Z1
and flows further on to the jaw system and final folder. The pressure is
monitored by the pressure guard B7. The water flow through the inductors
in the jaw system can be read on flow meters FM2 and FM3. At point D the
circulated cooling water turns back and flows out at outlet E.
For an open cooling water system only water connection B shall be
connected and the valves A1, A2 and A4 be open. The cooling water enters at
connection B, is filtered in filter Z3 and flows through the lime separator
Z5.
A
D
B
E
Simplified cooling water system for a TBA/19
C
At point C the water flow is branched and the consumption water flows on to
the service unit. The remaining water flows pass the open valve A4 and into
the system. The pressure is indicated on the pressure gauge M5. At branching
point D the cooling water is drained through valve A2.
The following is a separate closed cooling system with three separate circuits
One circuit is cooling the heat sources on the machine and it is called the water
cooling unit. It is a closed circuit. The water used in this circuit must be totally
deionized in order to remove all particles that could clog the cooling pipes in
the transversal sealing inductors. Approximately 10% of the total flow is
circulated through a total deionizing filter C/A.
The second circuit is called compressor unit. It is a closed circuit and it is
actually the cooler in the machine. In this system, which is identical to a
refrigerator, gas is used as media.
The third circuit is an open circuit, meaning that the water is drained off after
being used to cool the compressor unit.
When the water cooling unit is filled with water, valve V is open and the
water flows through the deionizing filter, C/A. The temperature of the water
in this circuit should be 12 C. This is monitored by sensor B2 after the heat
exchanger K2. To maintain that temperature, the compressor unit takes up
the heat energy needed from the water cooling unit in the heat exchanger K2
(evaporator) in which the gas will be evaporated. This energy will then be
transferred by the gas to another heat exchanger K1 (condenser), where the
energy will be transferred to the water in the open circuit. The gas will be
condensed after the condenser.
M
C/A
Q
P
T
M
M1
P1
A2
B5
U1
F1
B2
B1 O2
K
2
O1
K
1
B4
P2
M2
T P
P
B3
P
Z2
Water panel
Compressor unit
Jaw unit Final folder Pull Tab
TSsealing
Water cooling unit
Guide cooling
Inductor
H
e
a
t

e
x
c
h
a
n
g
e
r
H
e
a
t

e
x
c
h
a
n
g
e
r
Cold water
V
Simplified cooling water diagram for a TBA/21
Symbols
The table below contains the symbols that normally are used in Tetra Pak
cooling water system diagrams.
Symbol Meaning
Accumulator
Deionizing lter
Non-return valve
Electrically controlled valve
Manual valve
Filter
Throttle, adjustable
Constant ow valve
Cooler
Water pump
Motor
Water tank
C/A
M
Heat exchanger
Cooling coil
Deaerator
Flow meter
Pressure gauge
Conductivity sensor
Temperature sensor
Pressure guard
Pressure regulator
Symbol Meaning
Q
T
P
Pneumatic System
11
Pneumatic System
Introduction
The technology of using compressed air to create movement is termed
Pneumatics. In the Tetra Pak packaging machines and distribution equipment,
compressed air is used to:make components move, operated by pneumatic
cylinders
make components move, operated by pneumatic cylinders
control and operate valves
create vacuum and supply air nozzles with air
The pneumatic system consists of two parts. One part is located external to the
machine; in it, the required pressure is generated. The external pneumatics
include compressor, air conditioning unit, main air supply line, etc. The other
part is inside the machine and includes regulators, valves, cylinders, etc.
The air used in the pneumatic components must be clean and dry; pressure and
flow rate must also be as required. The recommended values are specified in
the installation manual (IM) for the machine concerned. In some systems, the
components are factory prelubricated once and for all, requiring no further oil
or grease; air for these components must be as free from oil as possible.
However, if such a component is once mist lubricated, it must always be mist
lubricated from then on.
The pneumatic system of each machine is documented in the form of a
diagram. In order to simplify its construction and make the diagram easier to
read, the various components are shown as symbols.
As there are many models and versions of machines, and some of them have
been rebuilt or modified to differ from their original design, it is very
important that the correct, updated, and currently valid pneumatic diagram is
used when working with a particular machine.
Cylinder Valve
Pressure regulator Shutoff Pressure
Air conditioning units
The first unit the air passes through on its way to the machine is the air
conditioning unit. It consists of a separator, pressure regulator with pressure
gauge, and, on some machines, lubricator. Normally, a shutoff valve is built
into the conditioning unit.
Separator The purpose of the separator is to remove water and other pollutants that might
be present in the compressed air. The separator consists of a filter element and
a reservoir with a drain valve. The filter element may be made of sintered
bronze. The input air is made to rotate, so that water drops and the larger solid
particles are flung outwards against the inner surface of the reservoir.
Condensated liquid runs down to to bottom of the reservoir, where it is
removed through the drain valve when the input air is turned off.
Pressure regulator The purpose of the pressure regulator is to provide air at a constant pressure,
independent of the load on the system. It is a form of pressure reduction valve,
and its function will be explained under the heading of Valves.
Pressure gauge The pressure gauge indicates the pressure setting.
Lubricator The lubricator (mist lubricator) provides the compressed air with oil. The
injected amount of oil is proportional to the flow rate of the air and can be
preset. In systems whose components are factory prelubricated, no oil must be
added to the compressed air, as oil would wash out the grease in the
prelubricated components.
Separator
Pressure gauge
Pressure regulator
Lubricator
Shutoff valve
Air conditioning unit symbol
Valves
The purpose of valves is to regulate the flow rate and pressure of the
compressed air and control its flow direction. The valves are controlled and
operated either manually, by means of electrical signals from the PLC, or
pneumatically by other valves.
Valves are subdivided into two groups seat valves and slide valves. These
groups differ in their design.
Seat valve The seat valve controls the flow of air by means of its valve head and seat. The
valve head only has to move a short distance to change over but needs
considerable changeover force.
Slide valve The slide valve controls the air flow by means of a movable slide. To change
over, the slide has to move a relatively long distance, but the force needed for
it is small.
In respect of their purpose, valves are grouped as follows:
directional valves, controlling the flow direction of the compressed air, for
instance to operate the reciprocating movement of the piston in a pneumatic
cylinder.
flow rate regulating valves, controlling the amount of air per time unit, for
instance to control the speed of the piston in a pneumatic cylinder.
pressure regulating valves, controlling the pressure in the pneumatic
system.
Before proceeding, we shall take a look at the symbols for the valves, and how
they are constructed and function.
Seat
Valve head
Housing
Return spring
Nonactuated Actuated
Housing
Return spring
Nonactuated Actuated
Slide
Valve symbols The valve symbols denote the function of the valves but not their design. This
means that valves that look differently, due to the way they are designed and
constructed but function in the same manner, are shown with the same symbol.
The illustration shows the working principle of a slide valve, which may be in
either of two positions.
This valve can be shown simplified as a symbol.
The symbol consists of a square, with the ducts through which the air is able
to pass shown as arrows. To the left and right of the square, the manner in
which the valve is controlled is symbolised, for instance with a horizontal line
for pneumatic control. The lines above and underneath the square represent the
ports connected to the input and output air lines.
Valve
Pilot air
Outlet.
Vent.
Pilot air
Slide
Position 1
The valve has received pilot air on the
lefthand side. The passage between in-
let and outlet is open, and the vent is
closed
Position 2
The valve has received pilot air on the
righthand side. The inlet is closed, and
the passage between outlet and vent is
open.
Inlet.
Valve housing
Inlet
Pilot air
Outlet
Vent
Pilot air
Position 1
The valve symbol is shown with
open passage between inlet and
Position 2
The valve symbol is shown with
open passage between outlet and
The function of the valve is illustrated by means of symbols. Each position the
slide may be in is shown as a symbol, and the symbols are drawn after one
another. The ports are only shown on the symbol in active position in the
pneumatic diagram, which is the starting position of the valve.
To make it easier to identify them, the ports are numbered: input air port
No 1; output air port No 2; vent port No 3. The pneumatic signal ports take
their numbers from the ports they provide passage between; for instance, port
No 12 connects input and output air.
As the valve in the example has three ports and a slide which may be in two
positions, it is termed a 3/2 valve. Similarly, a fiveport valve with a
threeposition slide becomes a 5/3 valve.
The valve may be operated in several ways. Other than pneumatically, it can
be operated manually, by a spring, or electrically. The different ways are
shown as symbols. In the following example, an electrically operated 5/2 valve
with spring return operates a double-action pneumatic cylinder.
The various forms of valve symbols used in our pneumatic diagrams are
explained in greater detail in the section of this text where the function of the
valves is described.
Pilot air
Active part of
Outlet
Position 1
The pilot air is received on the lefthand side
of the symbol, which means that the lefthand
side of the symbol is active. Compressed air
passes through the valve and can actuate a
cylinder
Inlet
Vent
Position 2
The pilot air is received on the right-
hand side of the symbol, which means
that the righthand side of the symbol is
active. The air in the
cylinder can be evacuated.
Compressed air supply.
1
2
3
12
Control signal
Cylinder
Return spring
Vent port
Inlet port
Outlet ports
Vent port
The control signal is received on the
lefthand side of the symbol. Compressed
air passes through the valve and into the
plus compartment of the cylinder, while its
minus compartment is vented.
The control signal is discontinued, and
the return spring moves the slide. The
compressed air is now directed to the mi-
nus compartment of the cylinder, while
its plus compartment is vented.
5
4
1
14
2
3
Monostable directional
valve
The monostable valve features spring return, i e in idle position, the slide is
always in the same position. One advantage of this type of valve is that it is
possible to operate a cylinder in both direction with only one control signal
output from the PLC.
Electrically controlled, monostable valves are used extensively in Tetra Pak
machines. The pilot air is controlled by means of an solenoid, powered by 24
or 48 V DC from a PLC output. The pilot air system is an integral part of the
directional valve.
In those cases where the valve receives air with a reduced pressure, which is
lower than the changeover pressure of the valve, the pilot valve can be
supplied separately with air from the pneumatic system. On some valves, for
instance Mecman Series 581, changeover is effected by turning the seal
between the valve proper section and the control section upside down. Then
control port No 14 in the connection plate is connected directly to the
compressed air system.
Electrically controlled,
monostable directional
Pilot valve
From PLC
Solenoid
Cylinder
Seal
4 2
3 1 5
14
monostable directional
valve with separate air
Pressure regulator
Electrically controlled, monostable valve with
Solenoid
Pilot valve
From PLC
Seal
1 5 3
14
4 2
Bistable directinal valve The valve has no spring return, and thus the slide can be in either of two idle
positions, depending on which one of the two solenoids was most recently
activated. Consequently, two outputs from the PLC are always required to
control a bistable valve.
Valves of the bistable type are used if, for instance, it is desirable that the
cylinder is to remain in the position it moved to as a result of the most recent
valve operation, even if the the output signal is discontinued. The same
standard principle for numbering the ports applies to this kind of valve. Pilot
air at port No 12 connects ports No 1 and No 2, pilot air at port No 14 connects
ports No 1 and No 4, in both cases admitting passage of input air.
2
14
5
From PLC
From PLC
12
4
1 3
3-positioned directional
valve
This valve type is used, for instance when a cylinder is to remain in position at
an emergency stop. Below, an electrically controlled 5/3 valve is illustrated.
The valve can be in three positions. In addition to the two positions of a
2position valve, the 3position valve has a middle position with all ports
closed(as exemplified above) or open for venting. Two PLC outputs are
required to control the valve. If there is no signal when the system is
depressurised, the return spring puts the valve in its middle position.
Electrically controlled, 3
positions directional valve
with closed middle posi-
1
2
3
4
5
12 14
1 3 5
1 3 5
2 4
12 14
2 4
12 14
No control signal to ports No 12 and No 14 means that the return spring
On port No 12 receiving a control signal, the slide moves to the left in
the picture. This means that port No 1 is connected to port No 2, and
On port No 14 receiving a control signal, the slide moves to the right in the
picture. This means that port No 1 is connected to port No 4, and port
Soft-start valve This type of valve is used in order to make pressurisation of the pneumatic
system soft and smooth.
The three positions of the telescoping slide are illustrated, somewhat
simplified. When the control signal is received, the slide moves up against the
variable stop, opening a narrow connection between ports No 1 and No 2
(pressurisation phase). When the pressure has risen to approximately 75% of
the pressure in the compressed air supply line, the valve opens all the way. On
depressurisation or at an emergency stop, the valve provides full flow directly
between ports No 2 and No 3 (depressurisation).
1
Variable stop
Telescoping slide
2 3
12
1 2 3
12
1 2 3
12
Idle position.
In idle position, ports No 2 and No 3 have an
open connection. The pneumatic system is
Pressurisation phase.
During the pressurisation phase, the connection
between ports No 1 and No 2 is partly open, and
pressurisation has begun. The width of the open-
ing is regulated by means of a variable stop (limit
Full flow.
When the pressure has risen to approximately
75% of the pressure in the compressed air supply
line, the connection between ports No 1 and No
Throttle valve This kind of valve is used to regulate the flow of air, which is restricted equally
much in both directions.
If throttles are incorporated in a directional valve, they are fitted in the outlet
ports and consist of brass screws. Normally, such throttles are factory fitted in
most of our directional valves. Normally, they provide adequate speed
regulation accuracy.
Throttle check valve This kind of valve is used when the air is to be regulated in one flow direction
only.
In order to achieve better accuracy in speed regulation, throttle check valves
can be used, for instance fitted in the end sections of the cylinders. This is done
when the cylinder is located remote from the directional valve. If throttle
check valves are being used, the throttles integral with the directional valves
must be fully open; adjustment must only be made by means of the throttle
check valves.
Shut-off valve This is a manually operated ball valve, used to shut the supply of air to the
entire pneumatic system. Normally, it is built into the air conditioning unit.
Pressure switch The pressure switch triggers an alarm to the control system, if the pressure
drops below a preset value. This value can be adjusted.
1 2
Throttle valve Throttle fitted in
directional valve
1 2 1 2
When the air flows from port No 1
to port No 2, it must pass through
the throttle and can thus be regulat-
ed.
If, on the other hand, the air flows from
port No 2 to port No 1, it passes through
the check valve without being regulat-
ed.
Pressure regulator Correctly set pressure is a condition of correct speed control and correct force.
For this reason, a pressure regulator is a always fitted in the air conditioning
unit. To enable the pressure regulator to function well, there must be a pressure
difference between input and output air of not less than 0.8 bar. Some
machines have an extra pressure regulator within the pneumatic system for the
purpose of allowing the reduction of the air pressure to some of the cylinders.
The valve plate of the seat valve is operated by the diaphragm, which in its turn
is actuated by the outlet pressure of the pressure regulator. The force created
by this pressure is balanced by the spring force on the other side of the
diaphragm. By increasing the spring force by turning the set screw, the seat
valve is opened and is kept open until the outlet pressure exceeds the spring
force. Thus the diaphragm and the spring force together maintain a constant,
preset outlet pressure. If the pressure on the outlet side drops, for instance due
to air used in moving a cylinder, the seat valve opens again.
Vacuum ejector with valve This valve generates underpressure through its ejector effect. It is used, as an
example, to supply a vacuum to suction cups. There are two types of vacuum
valves. One type which is electrically controlled and generates a release pulse
when the direction of flow is reversed. The other type in entirely pneumatic
and generates the release pulse by means of a builtin accumulator.
Outlet pressure
Force spring
Diaphragm
Inlet port
Outlet port
Seat
Valve plate
1
3
2
1 3
2
Pneumatically controlled
Electrically controlled
Cylinders
The purpose of a pneumatic cylinder is to perform a movement, powered by
compressed air.
In simple terms, the pneumatic cylinder consists of a cylinder housing with
two end sections, a piston with piston rod, and two connections to the
pneumatic system.
The piston is provided with sealrings, separating the two compartments. The
front end section has a piston rod guide and seal.
When compressed air is admitted into the plus compartment (pressurisation),
and the air in the minus compartment is vented, or evacuated
(depressurisation), the piston rod extends out of the cylinder the piston
performs a plus stroke. If the flows of air are reversed, the piston rod is
withdrawn into the cylinder the piston performs a minus stroke.
Double-action cylinder The cylinder described above is a doubleaction cylinder with singleside
piston rod. This means that both the plus stroke and the minus stroke are
performed powered by compressed air, and that there is a piston rod at one end
only.
Connection
Piston rod
Front end
Plus compartment Minus compartment
Piston Cylinder housing Connection Rear end
Plus stroke
Minus stroke
Single-action cylinder In the singleaction cylinder, a spring effects the minus stroke.
Rod-less cylinder Such a cylinder is doubleacting, but its piston rod has been replaced by an
attachment sliding along the outside of the cylinder shell. The movement may
be transferred to the attachment mechanically or by means of magnets.
Magnetic piston sensor A magnetic piston sensor is fitted on the cylinder for the purpose of giving the
PLC information on the current piston position. This information is then
utilised by the PLC as a precondition of, for instance, the changing over a
directional valve etc.
When replacing a cylinder with a magnetic piston, it is important that the
replacement cylinder also has a magnetic piston. A cylinder with the correct
length of stroke and diameter, but without magnetic piston, will not actuate the
magnetic piston sensors.
Piston rod
Spring
End section
Connection Piston Connection End section Cylinder
Attachment
Fully electronic magnetic piston
sensor; when the magnetic field of
the piston alters the resistance in
a semiconductor element
inside the sensor, an output
signal is transmitted to the PLC;
the sensor has a switchoff delay
Doubleaction cylinder with mag-
Magnetic piston
Magnetic piston sensor
The direction, force, and speed of movement of the piston rod can be
controlled. To ensure that the piston rod stops moving softly and smoothly,
there are also end position dampers. The various functions are explained in the
following.
Direction of movement The direction of movement is controlled by directional valves..
In order to control the movements of a doubleaction cylinder, a fiveport
valve is required. As the valve is actuated by a control signal, its slide changes
over, and the compressed air is led to the plus compartment of the cylinder,
while the minus compartment is vented. The piston performs a plus stroke. If
the control signal is discontinued, the return spring of the valve moves the
slide back again, and the flow of air reverses direction; the minus compartment
is filled with air, the plus compartment is vented, and the piston makes a minus
stroke.
Force The force which the piston rod exerts on the load, is regulated by varying the
pressure of the air reducing the pressure decreases the force. The pressure is
controlled by means of a pressure regulator.
Pressure regulator Valve Cylinder
Speed The speed of the piston is regulated by varying the flow of air on the return
side in the cylinder. This is done by means of the throttles in the valve, or with
throttle check valves fitted in the line between the valve and cylinder.
The reason why throttling is done on the return side of the cylinder is to make
the movement smooth.
If the cylinders used are small, or the air lines between cylinder and valve are
long, the alternative of employing throttle check valves offers better speed
regulation accuracy; the valve throttles must in this case always be fully open.
Speed regulation by means
Speed regulation by means of
throttle check valves; throttles in
Throttle in
valve outlet
Throttle check
Correct (vented air throttled)
Wrong (input air throttled)
Pressure
Time
Dampening The movement of the piston is dampened at both end positions by builtin
dampers in the cylinder end sections. The dampening effect is regulated with
adjustment screws. The purpose of the dampers is to decelerate, i e slow down
and stop, the piston a smoothly. In this way, damage to the cylinders, caused
by the piston striking the cylinder end section with some force, is eliminated.
Dampening also reduces vibrations in the machine. If, on the other hand, the
dampening effect is too great, the piston may bounce back and come to a stop
with a jerk.
In order to successfully set both speed and dampening, it is important first to
make sure that the pressure in the system is correct. Thereafter, the cylinder
speed can be set, and lastly, the dampening effect.
Double-action cylinder with vari-
The air on the vent side of the cylinder passes through
Adjustment
A protrusion on the piston closes the central opening in the
end section, so that the vented air is forced through the nar-
row duct, in which the adjustment screw enables the flow,
and thus dampening effect on the piston, to be regulated.
Piston
Cylinder end
Time
Piston po-
Undamped
Damped too much
Correctly damped
Main air supply line
The main air supply line should form a ring main line through the premises;
this will allow the users of air to receive it from two directions. There should
be a drop of 510 mm per metre in the direction of flow. Underneath the lowest
point in the ring line, a condensate drain cock is to be fitted. The output
connections to the users should be fitted on the top side of the main line piping;
this will keep condensate water and dirt from following the air into the user
device. There should also be a pressure gauge to make it possible to check that
correct air pressure is being maintained.
The diameter of the main line piping depends on its length as well as the
number of pipe bends and elbows, connections, and valves in the line. The
larger the number of such components that the air must pass, the bigger the
pipe diameter must be to prevent excessive pressure drop up to the points
where the air is used.
The pipelines should be be installed so that they are easily accessible for
checking that they are tight.
Condensate water
Pressure gauge
Shutoff
Air user
Air user
Function principle
This is an example of a principle diagram of a pneumatic system:
The input compressed air passes through manual valve A1, water separation
filter Z1, and pressure regulator T1; pressure gauge U1 indicate the pressure.
If the pressure drops below a preset value, pressure switch B06 indicates a
warning by lighting a signal lamp on the control panel. The pressure switch
should be connected as the last component in the system in order to sense the
pressure drops created by the other components.
Pressure
Valve panel
A1
YO00
C3
2
4
2
2
Z1
U1
T1
Y01
Y02
Y03
Y08
C4
C2
C1
Z04
U03
T03
U04
T04
Z2
B06
U05
T05
Hot melt pump
Valve cabinet
Suction cups
2
4
3
2
1
3
1
5
Pressurisation valve YO00 is used to make pressurisation of the system slow
in order to allow cylinders in wrong positions to return smoothly to their
correct idle positions. The pressurisation time can be adjusted by means of an
adjustment screw in this valve. Valve YO00 also has a safety function, for
instance if an emergency stop requires the system to be instantly
depressurised.
Valve Y01 is a 3position valve with closed middle position. If, for instance,
the machine is emergency stopped, the valve moves to the middle position,
and cylinder C1 remains in the position it was in at the stop.
Valve Y02 is monostable and electrically controlled. It has throttles in its
outlet ports for regulating the speed of cylinder C2.
Valve Y03 is also monostable and electrically controlled, but its pilot valve is
supplied with air separately from a line, connected before softstart valve
YO00. This means that valve Y03 does not have to wait for the slow buildup
of pressure via the softstart valve but changes over instantly as soon as valve
A1 opens. The separate supply of air also allows valve Y03 to be supplied with
air at a reduced pressure, for instance to limit the force of cylinder C3.
Pressure regulator T04 regulates the pressure to cylinder C4. This cylinder acts
as an air spring, and for this reason, an accumulator is connected to the air line.
Pressure regulator T05 regulates the pressure to the hot melt pump and thus
controls the amount of hot melt adhesive to be extruded.
Y08 consists of a vacuum ejector and two valves. When the righthand valve is
activated, compressed air flows from port 1 to port 3 and, due to the ejector
effect, a vacuum is generated at port 2, to which the suction cups are
connected. When the lefthand valve is activated, compressed air is supplied
directly to the suction cups, which thus are receive a blast of air, releasing their
suction and blowing their ducts clear.
Silencer Z2 is common to the whole pneumatic system.
The designations in the diagram follow a certain system, usually consisting of
a letter and a number. The components which the compressed air comes to first
are given the same number, in this case 1, but different letters to denote their
functions: A for manual valve, Z for filter, and T for pressure regulator. The
number of a valve, for instance Y02, determines the numbers of the following
components. The output lines from the valve are given numbers beginning
with 2, followed by the number of the outlet port, i e numbers 22 and 24. The
cylinder is designated C2.
Whenever setting is done in the pneumatic system, it is important to do it i the
right order:
1. input pressure
2. speed (throttle check valves or valve throttles
3. dampening (end position dampers in cylinders)
A manual valve
B cylinder
C cylinder
T pressure regulator
U pressure gauge
Y electrically controlled
valve
YO pressurisation valve
Control line
Pressurisation
Depressurisation
Valve panel
Valve cabinet
Vacuum line
Symbols
The following table, which is an excerpt from the Tetra Pak Standards (DS
208.35), lists the symbols that are normally used in our pneumatic diagrams.
Symbol Meaning
Singleaction cylinder with return
stroke by spring.
Doubleaction cylinder with
singleended piston rod.
Doubleaction cylinder without pis-
ton rod.
Doubleaction cylinder without pis-
ton rod, with variable dampening at
both end positions.
Doubleaction cylinder with variab-
le dampening at both end positions.
Doubleaction cylinder with variab-
le dampening at both end positions
and magnetic piston.
Torque cylinder.
2/2 directional control valve,
controlled by pressure acting against
return spring.
return spring.
controlled by solenoid with
return spring.
3/3 softstart valve.
return spring.
controlled by solenoid with return
spring.
controlled by solenoid valve with
separate air supply.
controlled by solenoid in both
directions.
5/3 directional control valve, closed
in middle position, controlled by
solenoid and return spring.
5/3 directional control valve, open
in middle position, controlled by
solenoid and return spring.
Variable throttle valve.
Nonreturn valve with variable
throttle check.
Rapidexhaust avlve.
Pressure regulator with relief port,
spring controlled. Adjustable spring
force.
Shutoff valve with exhaust port.
Silencer
Accumulator
Separator with water trap and
automatic drain.
Lubricator.
Air conditioning unit,
consisting of filter, pressure regula-
tor, pressure gauge, and lubricator.
Pressure gauge.
Electric pressure switch with
changeover contact and
variable pressure setting.
Magnetic piston sensor.
Ejector.
Steam System
12
Steam System
General
Steam is used for sterile barriers and sterilisation of machine parts in the
Tetra Brik filling machines.
Sterile barrier A sterile barrier (also called a steam barrier) prevents unsterile air and
impurities from the outer environment from entering into the production.
Sterile barriers are also used to prevent different media from being mixed,
for instance product and cleaning liquid.
Sterilisation During sterilisation with steam, the steam flows through the component or
through the system in such a manner that all air will be evacuated, enabling
the steam to get a direct contact with all the surfaces that need to be sterilised.
During heating, while the components are still cold, condense forms on the
surfaces. Since this condensate is continuously drained by steam traps, the
flowing steam will heat the surfaces. Heating continues until the surfaces have
reached the same temperature as the incoming steam. The sterilisation period
starts when all the surfaces have reached a temperature of 121C and all the air
has been evacuated from the system.
A-valve
B-valve
C-valve
Cleaning liquid
Steam
Product
Sterile barrier
Example of a sterile barrier between product and cleaning liquid
Steam When water is heated to its boiling point, it cannot absorb any more heat. If
the heat supply should continue, the water will be transformed into gas, i.e.
into steam. When the boiling water is enclosed in a room, the formed steam
has to be compressed in order adjust to the limited space. This will result in
the fact that the pressure in the occluded room will increase. At a steam
pressure of 200 kPa, the steam temperature will be approxamtely 121C.
Components
Below are the most important components in a steam system:
Steam traps and deaerators will automatically allow air and condensate to
pass through. They will however close against steam.
Filters are used to remove impurities and particles. Steam that meets
surfaces with product contact will have to be filtered through a steam filter
with a grade of 1 m. In this case it means that particles bigger than 1 m
will get stuck in the filter.
A pressure regulator is used to set the steam pressure which in its turn
controls the temperature (see table).
For many TBA filling machines it is now possible to get a temperature
controlled sterile barrier. It has been introduced in order to control and reduce
the steam temperature at the product valve during production. This means that
you can avoid overheating, thus reducing the cleaning difficulties caused by
burnt product remnants.
One high and one low temperature are set with the two pressure regulators in
the filling machine. By controlling the steam flow you can choose either a high
or a low steam temperature - high for sterilisation and low during production.
160
140
120
100
80
60
40
20
0

0
3
0

6
0
9
0
1
2
0
1
5
0
1
8
0
2
1
0
2
4
0
2
7
0
3
0
0
3
3
0
3
6
0
3
9
0
Steam table
T
e
m
p
e
r
a
t
u
r
e

C
Absolute pressure kPa
Construction
The picture shows the construction of a steam system and how it works.
A valve (1) is opened and a mixture of condensate and air flows out through
the steam trap (3).
When the prefilter (2) has been heated, the steam trap (3) closes and the
valve (4) may be opened. Steam now flows into the system through the steam
filter (7). Condensate is drained through the steam trap (8). When the
pressure has been stabilised, the correct pressure can be set using the pressure
regulator (5). The pressure gauge (6) shows the pressure.
The steam may now be used for a sterile barrier or for the sterilisation. A
temperature transmitter (9) detects the temperature of the steam and con-
densate is drained through a steam trap (10).
All parts of the system must have been drained downwards to a steam trap.
It is also vital that all the tubes in the system are properly insulated in order to
avoid condensation of the steam.
Steam
Product
Detergent
Water
Pressure gauge (6)
Pressure regulator (5)
Valve (1)
Temperature transmitter (9)
Prefilter (2) Steam filter (7)
Steam trap (8)
Steam trap (3)
Valve (4)
Steam trap (10)
Electrical System
13
Electrical System
Introduction
The electrical system in a Tetra Brik filling machine, contains a great number
of electrical components and is documented in the Electrical Manual. This sec-
tion describes the functions of the most important and common components,
and also how the Electrical Manual is designed and how it should be used.
Components
Safety relay The safety relay is used to supervise the emergency stop function as well as
the safety stop function on the machine. The relay can have one or two input
channels, which must be activated in order to keep the safety output relay ac-
tivated. For example, opening a safety door will cause the input channel to de-
activate the output relay, the safety relay will release, and the machine will
stop instantly.
To be able to restart the machine, the cause of the stop must be attended to and
the relay has to be reset. The relay and the alarm will reset simultaneously. The
reset function also implies that the safety relay is functioning.
A1 S13 S24 X2 41 13 23 33
A2 S14 S23 X3 42 14 24 34
Reset
/Test
2
1 1 1 1
2 2 2
In
B
In
A
JOKAB SAFETY
TYPE: JSBR4
24VDC
On
In
Out
Example of a safety relay
This relay is fulfilling the highest
degree of safety relay conditions
(cathegory 4).
Overload protection The overload protection is used to protect, for example an electric motor, from
current surges and sometimes it substitutes fuses.
An overload protection device is equipped with two different disconnecting
functions, one thermal and one magnetic:
The thermal function will trip when small overflows occur during a
prolonged time period, f.i. in case of an overload. The tripping limit for this
function is adjustable.
The magnetic function will trip when fast, high overflows occur, for exam-
ple in case of a short circuit.
Surge filter A surge filter protects the electrical equipment in the machine from overvolt-
age peaks, such as lightning. When a very powerful peak occurs and the filter
trips, an indicator on the filter changes from green to red. The machine will set
an alarm, but still be working. The surge filter is used, and will have to be
exchanged to protect the equipment from another overvoltage peak.
2 4 6
1 3 5
Example of an overload protection,
front panel
Over loadprotection, function diagram
PU 4 C-R PU 4 C-R PU 4 C-R PU 4 C-R PU 4 C-R
U
H
: 230 V~ U
H
: 230 V~ U
H
: 230 V~ U
H
: 230 V~
U
H
: 230 V~
U
max
: 275 V~ /
350 V-
U
max
: 275 V~ /
350 V-
U
max
: 275 V~ /
350 V-
U
max
: 275 V~ /
350 V.
I
N
: 6 A
802 152 802 152 802 152 802 152 802 152
12 14 11
Example of a surge filter with indicator relay function
Interference filter Interference filters are used to protect external electrical systems from
disturbances created in the filling machine (EMC-filter). In general, such a
filter consists of a combination of capacitors and coils, that will eliminate
electrical disturbances from getting in or out through the incoming lines.
Solid state relay A solid state relay can be described as an optical electronic relay. In other
words, the control side is electrically disconnected from the power circuit.
Inside there is a LED that gives a light pulse to a transmitter (opto coupler).
Solid state relays are most commonly used when fast, frequent changes with
high power, are required.
Current relay Current relays are used in filling machines to supervise that certain important
components consume power and thus function. For example the short stop
element is supervised on some of the filling machines. This function does not
need to be temperature controlled. It is enough to know that the short stop
element consumes power, in order to guarantee the function.
EMC=Electro Magnetic Compatibility
LED = Light Emitting Diode
Power
circuit
Zero detection
And
Trigger
circuit
Photo
detector
Input
circuit
2 3
4 1
+
Solid state relay, function diagram
Example of a solid state
relay, front panel
A1
12 14
11 E1 E2 E3
Y2 Y1 M A2
Current relay, front panel
DC - Motor Drive control This card is used to amplify control signals in order to drive a DC-motor.
The driver has three internally pre-setable motor speeds chosen by two digital
input signals. One externally, analog controlled speed, is determined via three
control inputs; Ext. Speed A, B, C. Only one of them should be used.
The driver is short circuit protected on all outputs. If the motor armature output
is short-circuit, the unit will switch off and indicate an alarm. This condition
is the same as if the current limit had been exceeded for more than 5 seconds.
The red alarm indicator will flash at current limit and show a steady light if the
unit is switched off due to overload or short circuit. The driver is reset by
switching power off, or by clearing the logical control signals. The motor field
output is protected by a fuse.
The different internal speeds are selected with logical signals. These should be
used to control the motor.
1
2
8
7
6
5
4
3
11
9
10
1. Power indicator
2. Trip, indicates an overload on the output.
Flashing at current limit. Fixed light, when
switched off due to overload.
3. Ext Speed, indicates that external speed is
selected.
4. Internal speed 1, indicates that internal
speed 1 is selected.
5. Internal speed 2, indicates that internal
6. Internal speed 1 + 2, indicates that internal
7. Potentiometer for setting internal speed 1.
10. Acc. Ramp, potentiometer for setting
acceleration ramp.
11. IxR compensation. Adjustment for
different motor powers. Too high settings
will result in unstable motion.
Example of a DC motor drive control,
front panel
Brake card The brake card is used to control the braking force in a powder brake. It is
used, for example, in filling machines equipped with a PullTab unit.
Stepping
motor driver card
The stepping motor driver card functions as a control unit for a stepping motor.
It generates the electric pulses, which run the motor. A stepping motor has live
voltage even when it stands still. The change of angle of the motor, is control-
led by the pulses, generated by the card. To make the motor shaft rotate cor-
rectly, the switches on the side panel of the card have to be adjusted according
to the description in the MM-book. For example, filling machines equipped
with a PullTab unit, have this card.
Example of a brake card,
front panel
Example of a stepping motor
driver card, front panel
Level regulator relay The level regulator relay monitors the levels of conducting liquids. It controls
the actuation of pumps or valves to regulate the levels. It is also suitable for
protecting submersible pumps from running empty, and protecting tanks from
overflow.
The operating principle is based on a change in the resistance measured
between immersed or non immersed electrodes. The electrodes may be
replaced by other sensors or probes, which transmit values representing
variations in resistance. Because of this, the sensitivity of the relay is adjusta-
ble and has to be set according to the conductivity of the liquid.
50 k
Function
Time value s R-value
R
U
R-sector
(x0.1)
(x10)
A1 A2
15
25
16
18
28
26
Example of a level regulator relay,
front panel
TMCC & Photocells
TMCC TMCC is a general control card, used for various functions. TMCC means
Tetra Pak Multipurpose Compact Controller. The figure illustrates how
TMCC is used for the purpose of design correction.
The following functions are included in a TMCC program for design
correction:
Register code decoding - This part of the program decodes the signals from
the photocells, converting them into a design signal.
Angle decoding - This part decodes the angle values utilized in the design
control.
PID regulation - Here the design deviation is computed and the stroke of
the folding flaps determined. The computation consists of a PID algorithm.
Output data to DMC (servomotor) - This part of the program provides data
for the DMC on the folding flap stroke for some machine systems, for
example TBA/21.
Communication with PLC and terminal (PC).
The TMCC is based on a microprocessor card. In order to use the TMCC for
various functions, a program which is adapted to the required function, must
be installed.
One reason for using a TMCC for certain specific functions, is that the TMCC
operates faster than if the function had been part of the PLC program.
Design
Angle encoder
Servomotor
TMCC
Photocells
Register code
PID regulation
Angle decoding
PLC
DMC Output data to DMC
Terminal
Communication
with PLC and
Settings
There are a number of LEDs on the front panel of the TMCC card, which may
have different functions depending on the actual function of the card.
Photocell To ensure correct package design, which means that sealing and cutting the
packaging material must be performed correctly, the machine must synchro-
nise the packaging material with the jaw system. The photocells read a printed
register code on every package. When the register code passes the photocells,
a signal is generated, which the TMCC uses to ensure a correctly printed de-
sign.
The photocell reads tints of dark and light, which are translated into a binary
code. By adjusting the photocell, the breaking point of the photocell can be
determined, i.e. how dark will a field have to be for the photocell to generate
a logic one (1). The photocell recognises the intensity of light and translates
dark and light fields of the register code into a binary code, i.e. logic ones (1)
and zeroes (0). Dark (black) = 1, and light (white) = 0. To make the photocells
able to read the register code, they must be correctly focused and positioned,
vertically as well as horizontally.
8 7
6
5
4
3
210F
E
D
C
B
A 9
(SW1)
FAULT
(Terminal)
POWER
S1
S2
S3
S4
S5
S6
S7
S8
FAULT (red) lights up when the
TMCC is being programmed
POWER (green) indicates that
the TMCC is powered with the
voltage
S1 - S8 (yellow) function accord-
ing to specified application,
dependent on the program used
Example of a TMCC card,
frontpanel
Printed register code and photocell
TPMC PLC
TPMC PLC is used as a control unit in Tetra Pak machines. TPMC is short for
Tetra Pak Machine Controller.
Addressing Each input and output has a unique address which determines its location in
the rack. The address is also a bit in the memory where status for that particular
input or output is stored so that the program can use the information.
The addresses are octal and consist of five positions. These digits have the
following significance:
The first position specifies the type of module in which the address is located:
I=input module, O=output module, E=encoder module, AI=analog input
module and AO=analog output module.
The second position specifies in which rack the address is located. It may be
0 - 7.
The third position specifies in which module position within a rack the
address is located. It may be 0 - 7. In each rack there are eight module
positions.
The fourth and fifth positions specify an input or an output within a module.
It may be 00 - 07 or 10 - 17 for input modules, output modules and encoder
modules. For analog input and output modules, it may be 00 - 03.
Below is shown how racks and module positions are addressed.
O07.06
3 2 1 PS
7 6 5 4
3 2 1 0
7 6 5 4
3 2 1 0
7 6 5 4
3 2 1 0
7 6 5 4
Central unit
Address O07.06 is output No 06 in an
output module. The module is fitted in
position 7 in rack 0 (main rack)
Main rack 0
Power supply unit
A TPMC system can have a maximum of
seven expansion racks.
Module positions 0-7 (1-7, power supply unit fitted in position 0)
Module positions 0-7
Expansion rack 1
Expansion rack 2
Expansion rack 3
Expansion rack 7
Example of a TPMC PLC system
GE Fanuc PLC
A GE Fanuc PLC system consists of one or more racks, so called baseplates,
where the CPU is placed in the first baseplate. Each baseplate has one slot for
a power supply unit and 5 or 10 module slots, depending on the model of
the baseplate. The modules can be:
CPU
digital input
digital output
analog input
analog output
thermo electrical
Each module has a position number, for example A004. When a module is
given a position number, one standard to be followed is that the last two
figures of the number, correspond to rack and slot. In this example rack is 0
and slot is 4 (A104). The position number of a module is described in the
Electrical Manual (EM), mounting drawing electrical cabinet.
References The inputs/outputs of a module have unique references (addresses). The
reference is the connection between the PLC program and a physical input/
output. The references of the inputs/outputs for a module, are described in the
Electrical Manual (EM), circuit diagram.
PS
1 2 3 4 5 6 7 8 9 10
PS
1 2 3 4 5 6 7 8 9 10
PS
1 2 3 4 5 6 7 8 9 10
Rack 0
Rack 2
Rack 1
Example of a GE Fanuc PLC system
CPU
Electrical Manual -EM
The EM-section is built upon examples from Tetra Pak Corporate Standard
and from the EM TBA/19.
Purpose of Electrical
Manual
The purpose of the Electrical Manual is to provide service technicians and
electricians with all information on the electrical equipment required for
service and maintenance.
The Electrical Manual is designed according to Tetra Pak Corporate Standard.
This standard applies to processing modules, packaging machines, distribution
equipment, machine lines and converting machines.
The Electrical Manual contains a great number of various parts. Some of them
are as follows.
Mounting drawing The mounting drawings, also referred to as component location, are links
between the abstract logic of circuit diagrams and the physical dimensions and
features of electrical components.
The electrical components are located in different zones which may be defined
as:
electrical cabinet
operating panel
Example of a mounting drawing, el cabinet
AIR DUCT
AIR DUCT
D
1
0
0
G
1
0
0
A
1
0
2
A
1
0
3
A
1
0
4
A
1
0
5
A
1
0
6
A
1
0
7
S S
A
1
1
1
G
1
0
1
A
1
1
2
A
1
1
3
A
1
1
4
A
1
1
5
A
1
1
6
A
1
1
7
A
1
1
8
A
1
1
9
A
1
2
0
G
1
0
2
S S S S S S S S S
A100
A101
A135
K
100
K
101
K
102
K
103
K
104
K
105
K
106
K
107
K
108
K
110
K
111
S S S S S S
A
300
A
301
A
302
A
303
A
Q
003
Q
004
Q
005
Q
006
Q Q
012
Q S S
008
Q
010
Q
011
Q
013
Q S
S S S S
F
0
0
1
F
0
0
2
F
0
0
3
S
F
0
0
5
F
0
0
9
F
0
0
6
A
F
0
0
6
B
F
0
0
6
C
F
0
0
4
S S
F
1
0
0
A
F
1
0
0
B
F
1
0
0
C
F
1
0
1
A
F
1
0
1
B
F
1
0
1
C
F
1
0
2
A
F
1
0
2
B
F
1
0
2
C
F
1
0
3
A
F
1
0
3
B
F
1
0
3
C
F
1
0
4
S S S S S S
X011 XL1b3
AIR DUCT
AIR DUCT
F104
Q003
XL1b3
Z002
Q002
Q001
F
0
0
7
F
0
0
8
Z001 X300
0080
A
A VIEWAA
V001
K
2
0
0
K
2
0
1
K
2
0
2
K
2
0
3
K
2
0
4
K
2
0
5
VIEWBB
AIR DUCT
B
B
305
E005
K
2
0
6
S
SS
S S S
A
1
2
1
X003
LEFT HAND SIDE
A
307
Z
0
0
3
009 007
X25
K
113
S S
M003 M002
S S S
S
X
0
0
1
:
0
0
3
X010
V
0
0
1
K
2
0
0
K
2
0
3
K
2
0
6
M003
S
AIR DUCT
1
1
MOUNTING DRAWING, EL. CABINET
5271008:07
Circuit diagram A circuit diagram illustrates the implementation of any system, piece of
equipment etc.
It presents information necessary for:
understanding the function of a circuit
manufacture
testing and trouble shooting
installation or maintenance
A circuit diagram contains:
all components and connections used on the machine
graphic symbols representing the components or functions of the circuit
representations of the connections among those components or functions
item designations
terminal designations
information necessary to trace paths and circuits
supplementary information necessary for the understanding of the function
Q006:1
13 14
M.B062
P
II IV
M.B016B
C NC
M.B016A
C NC
M.B048B
C NO
M.B048A
C NO
M.B045
t
2
3
4
1
293
294
292
X001
157 159
X001
241
X001
242
M.X007
31
M.X007
30
M.X007
29
M.X007
28
L
1
2
L
1
1
L
1
0
M.B104
BK BN
BU
I036
I035
I034
I033
01
I037
I038
I039
I040
09 /A8
/A7 08
07 /A6
/A5 06
/A4 05
/A3 04
/A2 03
02 /A1
A104
X001
243
Q012:1
14 13
X001
158
M.X007
32
M.X007
33
A
B
C
463
X001
464
X001
465
X001
M.B016A
M.B016B
Q006
M.B062
M.B048A
M.B048B
JAWSYSTEMOVERLOAD, LEFT
JAWSYSTEMOVERLOAD, RIGHT
OVERLOAD PROTECTION
STERILE AIR PRESSURE
PEROXIDE BATH
BOTTOMCOVER, POSITION
SH.10
2
4
V0
V
M.B045 HYDRAULIC UNIT
TEMPERATURE
2
4
V
LOWLEVEL
Q012 PEROXIDE BATH, WATER PUMP
X001:462 SH.45
X001:461 SH.45
PEROXIDE BATH
WATER LEVEL
M.B104 STERILE AIR PIPE
POSITION
SH.10
X001:467 SH.56
X001:468 SH.56
COMPRESSOR
A305:15 SH.27
PLCIN A104,OPERATION MONIT.
4438441:02
Example of a circuit diagram
Position summary A position summary is a list showing the sheet on which a component,
identified by its position number, can be found.
Example of a position summary
Connection diagram A connection diagram provides information on physical connections between,
for example, components, devices, assemblies, and installations.
It presents information necessary for:
manufacture
testing and trouble-shooting
installation and maintenance
A connection diagram contains:
graphic symbols representing components
representations of connections between the components
item designations
terminal designation
Example of a connection diagram
316
W
317
W
310
W
M.B024
567
B
U
B
K
B
N
UNREELING
MOTOR, CONTROL
SPEED
W
314
M.B025
89
1
0
B
U
B
K
B
N
UNREELING
MOTOR, GUARD
W
315
1
1
1
2
1
3
1234
1
2
5
0
2
2
5
1
3
2
5
2
4
2
5
3
2
5
4
2
5
5
2
5
6
M.M018
12
12
1 2
M
2
4
6
2
4
7
W
361
6
1
1
6
1
1
X001
M.X014
PEROXIDE TANK
FILLING
2
5
7
2
5
8
2 1
2 1
2 1
M.Y041
PULL DOWN
DEVICE
2
5
9
2
6
0
2 1
M.Y042
PRESSURE
DEVICE
2 1
2 1
2 1
2
4
8
2
4
9
W
405
M.B116
MEMBRANE
LEAKAGE SENSOR
2 1
CLEANINGOF
PRODUCTION VALVE
1234
5
5
LEAKAGE SENSOR AND SERV. UNIT
6153025:07
Mains connection A mains connection drawing shows the connection between the mains and the
electrical cabinet.
Line summary A line summary is a list showing the position numbers and internal connection
order of the control voltage lines. It may also show the sheet number and wire
size and colour.
F001
1
N
2
3
5 PE
L1 (R)
L2 (S)
L3 (T)
CUSTOMERS FUSE BOX MAINS
4
MAIN VOLTAGE 400/230V
AREA TOCABLE 4x25/16 AND
SETTINGVALUE OF Q002 63/400
2
2 1
Q001
4 3
6 5
1
2
3
4
5
1
3
5
FILLINGMACHINE CONNECTION
ACCORDINGTODIAGRAM"MAINS"
Q002
N
X003
X011:47
0
1
2
3
Z002
N
Z001
1
X300
5
9
13
2
X300
6
10
14
FUSES (SLOW) F001 100A
MAINS CONNECTION
6153106:02
Example of a mains connection diagram
Examplel of a line summary
Terminal summary A terminal summary is a list of terminals, identified by their position number
and sheet numbers.
Example of a terminal summary
Protecting bonding circuit The protecting bonding circuit drawing, also referred to as ground connection,
shows all protective bonding of components, electrical cabinets, mounting
plates, etc.
BE-list and CE-list In the Electrical Manual a BE-list and CE-lists are included.
The BE-list consists of the main groups of the electrical equipment, such as
electrical cabinets, control panel, standard equipment, etc.
The CE-list consists of the different main groups divided into parts. It is here
that spare part numbers will be found.
Program documents In this chapter all necessary information of the program in the PLC will be
found. A sequence diagram will also be found here. The sequence diagram
will show what is activated in the machine and when it was activated. This
diagram is useful for trouble-shooting.
Identification of wiring Tetra Pak use wires according to a specified standard to be able to identify the
different circuits, see the sign below.
Example of a protecting bonding circuit diagram
How to use the EM
How to use the EM explains how to find your way through the chapter
Circuits diagrams, Component location, Connection diagrams, Mains
connection diagrams and Program documents in the EM.
The first page in each chapter is always a table of contents, listing all
drawings included in the chapter.
The documents in the above-mentioned chapters are identified by:
a main number (1)
a sheet number (2)
a version number (3)
The sheet number is the consecutive numbering of the sheets which belong to
the main number and is used as a reference in the diagrams.
In the circuit diagrams, the sheets(s):
5 - 88 are the drawings
89 shows the protection bonding circuit
90 is the line summary
91 is the terminal summary
99 is the list of alteration messages
The mains connection diagram shows how the machine should be connected
to the local supply, the dimensions of the connection cable and the connection
of the matching transformer. It is needed when the supply voltage is other than
3x230V/400V. The matching transformer drawing, shows the value of the
fuses in the customers fuse box, cable areas and connection to and inside the
matching transformer
Note!
Always follow local regulations regarding the dimensions of the connection
cable.
1 2 3
1 Main number
2 Sheet number
3 Version number
The PLC-listing in the section Program documents consists of a ladder
diagram, a cross reference list, a volume depending document and a sequence
diagram.
The following pages demonstrate some examples of how to use the EM.
F001
1U11U9
1
N
1V11V9
1W11W9
2U
2V
2W
1 2
N
1
X300
5
9
13
2
X300
6
10
14
2
3
5 PE
L1 (R)
L2 (S)
L3 (T)
MAINS
1
2
3
4
5
1
2
3
5
MATCHINGTRANSFORMER CONNECTION
ACCORDINGTODIAGRAM6153107:01
MAIN VOLTAGE 200600V EXCEPT 400/230V
1
U3
V3
W3
1PE 2PE
2 1
Q001
4 3
6 5
1
2
3
4
5
1
3
5
FILLINGMACHINE CONNECTION
ACCORDINGTODIAGRAM"MAINS"
Q002
N
X003
X011:47
0
1
2
3
Z002
N
Z001
MAINS CONNECTION
CUSTOMERS FUSE BOX
Example of a mains connection diagram
Numbering systems for components
The position number is divided into three parts:
prefix (1)
function designation (2)
running number (3)
Prefix (1) The prefix shows the location of the component. Position numbers without a
prefix indicate that the component is fitted in the electrical cabinet.
the prefix M indicates that the component is fitted on the machine, outside
the electrical cabinet
the prefix P indicates that the component is fitted on a separate control
panel
Function designation (2) The function designation is indicated in accordance with international
standards, see table below.
M
3
U W
3 12
V
M.M007
M M 006
1 2 3
1 Prefix
2 Function designation
3 Running number
Designation Signification in electrical diagram
A Assemblies, Subassemblies
B Transducers
C Capacitors
D Binary element, Delay devices, Storage devices
E Miscellaneous
F Protective devices
G Generators, Power supplies
H Signalling devices
K Relays, Contactors
L Inductors, Reactors
M Motors
N Analogue elements
P Measuring equipment, Testing equipment
Q Switching devices for power circuits
R Resistors
S Switching devices for control circuits selectors
T Transformers
Running number (3) The electrical components are given numbers in a consecutive non-logical or-
der.
U Modulators, Changers
V Tubes, Semiconductors
W Transmission paths, Waveguides aerials
X Terminal, Plugs, Sockets
Y Electrically operated mechanical devices
Z Terminations, Hybrids, Filters, Equalizers, Limiters
Designation Signification in electrical diagram
M M 006
1 2 3
1 Prefix
2 Function designation
3 Running number
How to trace a cable
Example: How to trace No. 5
Go to the Connection diagrams chapter.
Find cable No.5. (1)
Note the component connected to the cable (M.M004). (2)
Go to the Circuit diagrams chapter.
Go to the Position summary (first page(s) in the Circuit diagrams.
The sheet No. is located opposite the component No. (pos. M.M004). (3)
This tells you on which sheet in the Circuit diagrams the connection is
shown.
Go to sheet 11 in the Circuit diagrams. (4)
Find the component (M.M004). (5)
If the component, as in this example, is controlled by a separate component,
the sheet reference for this component (sheet 62) is found in the Circuit
diagrams. (6)

Q010
1 3 5
2 4 6
13
14
Q011
1 3 5
2 4 6
13
14
M
3
M.M001
2W
2V
2U
1U
1V
1W
X001 11 12 13 X001 14 15 16
Q013
1 3 5
2 4 6
M
3
M.MPLE
W U V
46 X001 47 48
1 M.X002 2 3
M
3
M.M004
W U V
25 X001 26 27
Q008
1 3 5
2 4 6
13
14
2,5mm 2 BK 2,5mm 2 BK 2,5mm 2 BK 2,5mm 2 BK
K008
sh.62
1 3 5
2 4 6
K010
sh.62
1 3 5
2 4 6
K011
sh.62
1 3 5
2 4 6
K013
sh.63
1 3 5
2 4 6
B B B C C C D D D E E
Q003
1 3 5
2 4 6
13
14
6mm2 BK
K003
sh.35
1 3 5
2 4 6
A A A E
LOW
SPEED
HIGH
SPEED
SH.57 SH.57
MAIN MOTOR EXTERNAL
CONVEYOR
CLEANINGSYSTEM
CIRCULATION PUMP
SH.57
L1
L2
L3
A A A
XL1
3
XL2
3
XL3
3
Sh.14
L1
L2
L3
SH.57
L4
L5
L6
MOTORS
4438411:07
M
3
W U
M
3
W U
M
3
U W
M
3
U W
304
W
5
W
301
W
308
W
X001
2
1
2
2
2
4
2
3
2
5
2
6
2
7
2
8
2
9
3
0
3 123 12
V V
3 123 12
M.M004 M.M005
CLEANINGSYSTEM
CIRC. PUMP
HYDRAULIC PUMP
3
1
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
3 123 12
3 123 12
V V
M.M010 M.M007
PEROXIDE PUMP COMPRESSOR,
INLET
MOTORS
6153006:05
44384 - 11:07
61530 - 06:05
1
2
4
5
6
3
contd
Find the controlling component (K008). (8)
The figure 11 is a reference back to sheet 11. (9)
The output (Q016) is a reference to the PLC-listing in the Program
documents chapter. (10)
Go to the Program documents chapter to see the use in the program.
Go to the cross reference list at the beginning of the PLC-listing and find
the output (Q016). (11)
Note the rung Nos. in which the output is used (for example rung 29). (12)
Go to the PLC-listing and find rung 29. (13)
K010
A2 A1
K011
A2 A1
K008
A2 A1
K011
21 22
K010
21 22
K010
43 44
K011
43 44
K111
sh.32
9
1
5
K111
sh.32
10
2
6
B A
B B A
A
B A
A C
C
C
C
11 11 11
62 35
62
11 11 11
62 35
31 62
11 11 11
35
20
18 /B7
Q015
19 /B8
Q016
/B6 17
Q014
Q013
16 /B5
15
Q012
/B4
K019
A2 A1
12
C B
P002
+
0
V 0
V
2
4
V
K010
K011
K008
MAIN MOTOR
MAIN MOTOR
CLEAN. SYSTEM
P002 HOUR METER
LOWSPEED
HIGH SPEED
CIRC. PUMP
K019 BENDINGROLLER
35
PLCOUT A114, EMERGEN. MODULE
4438462:07
44384 - 62: 07
7
8
9
10
11
13
12
contd
The prefix M indicates that the component is fitted on the machine.
Go to the Component location to find the position of the component
(M004). (14).
M4
X8
X2
X72
E1A E1B
X71 L1 L2
X73 X74
B44
E1C
B61
B80,12
E1C
B53
B104
B117
B51
B116
B50
B55
M13
14
How to trace a component
Example: How to trace sensor M.B104
Go to the Circuit diagrams chapter
Go to the Position summary (first page(s) in the Circuit diagrams).
The sheet No. (sh.41) is located opposite the component No. (pos M:B104).
This tells you on which sheet in the Circuit diagrams the connection is
shown. (1), ( 2)
Find the component (M:B104). (4)
Note the connections (X001, 463-465). (5)
Go to the Connection diagrams chapter,
Find the connection (X001, 463-465). (6)
The Connection diagram shows how the sensor is connected (in this case
via a connection box).
The input (1033) is a reference to the PLC-listing in the chapter
Program documents. (7)
4
5
7
4
5
8
4
5
9
4
6
0
4
6
1
4
6
2
4
6
3
4
6
4
4
6
5
4
6
6
4
6
7
4
6
8
M.B071
W
454
AIR INLET VALVE
POSITION
B
K
B
N
B
U
M.B094
W
455
SUCTION VALVE
POSITION
B
K
B
N
B
U
M.B104
W
456
STERILE AIR
PIPE POSITION
B
K
B
N
B
U
M.B117
W
413
REGULATINGVALVE
OPEN POSITION
B
K
B
N
B
U
TOWER, INDUCTIVE SENSORS
6153044:04
Q006:1
13 14
M.B062
P
II IV
M.B016B
C NC
M.B016A
C NC
M.B048B
C NO
M.B048A
C NO
M.B045
t
2
3
4
1
293
294
292
X001
157 159
X001
241
X001
242
M.X007
31
M.X007
30
M.X007
29
M.X007
28
L
1
2
L
1
1
L
1
0
M.B104
BK BN
BU
I036
I035
I034
I033
01
I037
I038
I039
I040
09 /A8
/A7 08
07 /A6
/A5 06
/A4 05
/A3 04
/A2 03
02 /A1
A104
X001
243
Q012:1
14 13
X001
158
M.X007
32
M.X007
33
A
B
C
463
X001
464
X001
465
X001
M.B016A
M.B016B
Q006
M.B062
M.B048A
M.B048B
JAWSYSTEMOVERLOAD, LEFT
JAWSYSTEMOVERLOAD, RIGHT
OVERLOAD PROTECTION
STERILE AIR PRESSURE
PEROXIDE BATH
BOTTOMCOVER, POSITION
SH.10
2
4
V0
V
M.B045 HYDRAULIC UNIT
TEMPERATURE
2
4
V
LOWLEVEL
Q012 PEROXIDE BATH, WATER PUMP
X001:462 SH.45
X001:461 SH.45
PEROXIDE BATH
WATER LEVEL
M.B104 STERILE AIR PIPE
POSITION
SH.10
X001:467 SH.56
X001:468 SH.56
COMPRESSOR
A305:15 SH.27
PLCIN A104,OPERATION MONIT.
4438441:02
44384 -41: 02
5 4 5
6
7
3
2 1
contd
Go to the Program documents chapter to see the use in the program. (8)
Go to the cross reference list at the end of the PLC.listing, find the input
(I0033) and note the rung Nos. of the block in which the inputs are used (for
example rung 26). (9),
Go to the PLC-listing and find rung 26. (10)
9
8
10
Supply voltage
The supply voltage in the electrical cabinet is named:
L01 - L09: power voltage
L10 -: control voltage
L10 is reserved for 0 V, control voltage
L11 is reserved for 24 V, control voltage
L20 is reserved for 0 V, safety circuits
How to find out about line connection order
Example: Line connection order of supply line 30.
Go to the Circuit diagrams chapter. The line connection order is shown in
the Line summary (sheet 90). (1)
Find the line (L 30) and its terminal position (XL30,2). (2), (3)
The position list shows the connection order of the supply line
(K019,A1). The sheet No. (sh.62) is located opposite the terminal No.
(pos. K019,A1). (4)
Go to the Circuit diagram and find the component (K019). (5)
Find the supply line for the component. (6)
409
L
3
0
L
3
0
L
3
1
408
X001
K010
A2 A1
K011
A2 A1
K008
A2 A1
K011
21 22
K010
21 22
K010
43 44
K011
43 44
K111
sh.32
9
1
5
K111
sh.32
10
2
6
B A
B B A
A
B A
A C
C
C
C
11 11 11
62 35
62
11 11 11
62 35
31 62
11 11 11
35
A114
20
18 /B7
Q015
19 /B8
Q016
/B6 17
Q014
Q013
16 /B5
15
Q012
/B4
14 /B3
Q011
11 12 /B1
Q009
13 /B2
Q010
K019
A2 A1
12
C B
9
M.X034
10
M.X034
9
10
P002
+
0
V 0
V
2
4
V
M.X034:8 SH.61
K010
K011
K008
MAIN MOTOR
MAIN MOTOR
CLEAN. SYSTEM
P002 HOUR METER
LOWSPEED
HIGH SPEED
CIRC. PUMP
K019 BENDINGROLLER
35
PLCOUT A114, EMERGEN. MODULE
4438462:07
44384 - 62: 07
6
5
1
2 3
4
How to trace a terminal
Example: Connection in connection terminal box M.X007, block 14-15.
Go to the Connection diagrams chapter.
Find the connection box (M:X007) terminal block 14-15). (1), (2)
Note the component connected (M.Y043). (3)
Go to the Circuit diagrams chapter.
Go to the Terminal summary (after the Circuit diagrams drawings).
The sheet No. (sh. 71) is located opposite the terminal No. (pos M:X007),
terminal block (14-15). This tells you on which sheet in the Circuit
diagrams the connection is shown. (4), (5), (6)
Find the component (M:Y043). (8)
Note the connections (X007, 14-15). (9)
The output (%Q082) is a reference to the PLC-listing in the Program
documents chapter. (10)
X001
236
M.X007
15
M.X007
14
L
1
1
L
1
0 A119
10
08 /A7
Q087
09 /A8
Q088
/A6 07
Q086
Q085
06 /A5
05
Q084
/A4
04 /A3
Q083
01 02 /A1
Q081
03 /A2
Q082
M.Y043
2 1
L
1
0
2
4
V
0
V
M.Y043 DRIVE UNIT, BRAKE
M.X007:13 SH.69
M.X007:16 SH.39
0
V
A400:20 SH.33
A400:22 SH.33
A400:23 SH.33
A400:24 SH.33
DESIGN ENABLE
VOLUME ENABLE
VOLUME CLOCK
VOLUME DATA
A001:26 SH.12
BENDINGROLLER
ENABLE
PLCOUT A119
4438471:02
2 1 2 1
NC
NO C
102
W
011
W
010
W
106
W
107
W
M.B010
CRANK
POSITION
1
5 123456789
1
0
1
1
1
2
1
3
1
4
B
N
B
U2 12 1 B
N
B
U
B
K
B
N
B
U
B
K
M.X007
M.B011 M.B012 M.Y022 M.Y043
MAIN
MACHINE,
CLUTCH
DRIVE UNIT,
BRAKE
SIDE PROTECTOR,
POSITION
LEFT RIGHT
B
U
B
N
B
U
B
N
1212
2 5
B
N
B
U
2 5
M.X007 BODY AND DRIVING UNIT
6153023:02
44384 - 71: 02
1
3
4
5
6
7
8 9 9
10
2
contd
The prefix M indicates that the component is fitted on the machine.
Go to the Component location chapter to find the position of the
component (Y043) on the machine. (11)
Go to the Program documents chapter to see the use in the program. (12)
Go to the cross reference list at the end of the PLC-listing and find the
output (%Q0082). (13)
M6
M5
Y107
Y1
Y102
Y86
Y25
Y23
Y19
Y17
Y9
Y8
Y7
Y6
Y5
Y3
Y2
Y27
Y26
Y24
Y21
Y20
Y105
Y106
Y14
Y13
Y12
X33 X35
X32 X34
S28
S14
B14
R1
SPLICING TABLE
B9
B108
M16
B236
B1
X1
Y41 Y42
B45
B7
B2
B6
Y32
Y31
Y29
Y39
Y51
B10
Y33
B11
B30
Y22
Y43
B16A
B20
B13
R5
ABC
B15
Y109
B118
B119
B4
R36
B48B
B38
B112
B37A B37B
B21B
B85
S4
B46
B21C B21A
B47
10-23-96 15:21
13
12
11
Maintenance Routines
14
Maintenance
Routines
Operators Maintenance
Care and maintenance of the machine is important in order to produce a good
product and to avoid unintentional stops.
Recommended maintenance routines for the machine are fully described in
the Operation Manual. Care and maintenance is performed by the machine
operator and can be divided into two parts:
Care after finished production includes among other things cleaning of
the machine, manual and CIP. Checking for possible damages due to
normal wear and tear are further examples of daily maintenance.
Weekly care and maintenance covers a more extensive cleaning and
maintenence, than care after finished production.
Maintenance techniques
Maintenance includes a wide range of different activities. We can divide them
into five main categories:
Programmed maintenance or time scheduled maintenance is used when
replacement of a component follows a time schedule. The lifetime of the
components are often based upon experience. This technique can be used
for most mechanical components, such as bearings, bushings etc.
Condition based maintenance is initiated by some kind of a check. The
check could be either objective or subjective. The checklists in TPMS are
mainly subjective checks by means of the senses e.g. looking, hearing and
feeling. Objective checks are for example when some physical parameters,
such as vibrations or pressure drops, are measured. Objective measures are
often initiated by programmed maintenance e.g. measure of vibration level
every week. More complicated equipment is sometimes supplied with
measuring devices that can perform continous measurements.
Corrective maintenance is another word for reparation. The problem is
corrected when it occurs. This is mainly used on components where the
fault occurs suddenly, e.g. electrical components. For most electrical
components it is almost impossible to set intervals or detect faults with
condition based maintenance.
Preventive maintenance is used to prevent a breakdown or standstill from
happening. It can be used where intervals can be predetermined or faults
can be detected by condition based maintenance.
Designing out maintenance is a way to reduce the maintenance cost for
equipment by constantly improving its design.
CIP = Cleaning In Place
TPMS = Tetra Pak Maintenance
System
TPMS - Tetra Pak Maintenance System
Tetra Pak Maintenance System (TPMS), has been practised by Tetra Pak since
1989. It was developed with the main goal of reducing downtime and costs for
preventive maintenance.
Basically TPMS consists of three main parts:
Maintenance
Evaluation
Improvement
The major difference between TPMS and other maintenance systems is that
TPMS is used as a tool and the need is estimated at the design phase of the
machine.
The central part in TPMS is the Maintenance Recommendations File, MRF.
This file is compiled by the product companies, by collecting information
about the different maintenance actions on the machine, required spare parts,
tools etc. The maintenance recommendations are then distributed to the
different market companies.
TPMS is based on a continuous reevaluation of the maintenance system based on
recurrent feed back from the customers.
Care and maintenance are involved in the developement phase of the machine. This
implies that machine designs that could cause service problems, can be avoided.
Checklists A checklist is a list of all the work that should be performed during one
maintenance occasion.
Check overviews about the service life of different components, are based
on information from suppliers as well as from people with personal
experience. The first step in creating maintenance recommendations for a
machine, is to collect this information.
Tailor made checklists are checklists that are machine specific. Based on
an agreement between the customer and Tetra Pak, more or less of the
maintenance work will be put on the customers checklist. The checklists
refer to all technical documentation e.g. MM, Maintenance Manual and
SPC, Spare Parts Catalogue.
Rotation units, spare parts and tools are of importance for a good
maintenance program. In addition to the maintenance checklists, customers
receive reports of the required items for each service. This ensures that
everything is available on site when it is needed.
Line maintenance TPMS covers all components that are crucial for the
production line. Most of the components, from the milk intake to the
palletisers, are made according to maintenance recommendations.
Service cycles TPMS is based on two different service cycles: The short service cycle is
performed every 250 hours and is used for filling and distribution machines.
Normally this service is performed by the customer. The expanded service
cycle is performed every 1000 hours and is normally performed by Tetra Pak.
But this is just a recommendation. Each customer decides together with
Tetra Pak, how much of the service they want to perform themselves. The
service is different from one time to another since there are different check-
points on the lists.
Evaluation Evaluation is one of the corner-stones of the TPMS concept. When a service
has been performed, either by Tetra Pak or the customer, the service results are
entered into a software. The engineers notes and comments, constitute valua-
ble information for the next service.
The diagram shows the recomended maintenance intervals for various components.
Reporting back TPMS issues a statistical report which Tetra Pak uses to for improvements.
Maintenance recommendations - When a few maintenance services
have been performed, a local update meeting takes place. During this
meeting the customer and Tetra Pak staff discuss the checklist content
and how it can be improved. The results of this meeting are later used
at an international meeting where Tetra Pak service specialists discuss
experiences from their markets. Thus, the user will benefit from experience
gained in other countries, as well.
Machine design - The statistical results of the TPMS system play a key
role in the development of new machines. It is at the development stage that
the maintenance needs are determined.
TPMS concept - The third feature that Tetra Pak constantly improve is of
course the TPMS concept as such. This is done in close cooperation with
the system users.
Improvement Improvements take place on two different levels. The first one is on a national
level. In these improvement meetings, local service engineers, system
specialists and others, discuss the performed services, how the services could
be improved and different ways to involve the customers in improving the
maintenance recommendations.
On a regular basis the product companies arrange central update meetings
where representatives from different countries get together and discuss
machine performance and service results. Such meetings generally result in
updated maintenance recommendations and influence over the machine
development. The cycle is completed when the new recommendations are
used during services, and later on, evaluated again during an update meeting.
Availability A streamlined production unit requires high availability. This is made possible
by Tetra Pak Maintenence System:
Reduction of downtime - TPMS is designed to reduce the downtime due
to maintenance. TPMS will inform about the approximate time for the
service so that a service can be scheduled together with the production
management in order to have the least interference possible on the
production.
Improvement is a continous process that takes place on two different levels - national
and international.
Avoiding breakdown - A breakdown can have many different causes e.g.
incorrect handling or the lack of maintenance. One fact about breakdowns
is that they lead to loss of production.
Predicting maintenance cost - Since less breakdowns due to the lack of
maintenance will undoubtedly occur, we will be able to come closer to the
truth when it comes to maintenance costs.
Optimizing spare parts handling - Spare parts are expensive to stock.
As a consequence of less breakdowns and the possibility to plan the use of
maintenance spare parts, it will be possible to reduce the stock of spare
parts. A safety stock is however always required.
How to read the checklist
The checklists contains all the check items (position numbers) for an
individual machine and a specific maintenance occation.
All information about what and how to maintain the equipment, is originally
created by the Tetra Pak product companies; Tetra Brik, Tetra Rex, Processing
Systems etc. The checklist overviews are somtimes adjusted by the Tetra Pak
market company due to local needs and conditions.
The TPMS checklists are generated from a database software called SMA and
the checklists are normally printed at your local service station. After you have
performed the maintenance, the result of your work can be reported back into
the SMA application. The information will be used later on, when both the
equipment and the maintenance instructions are beeing updated and improved.
The last page of the checklist, is a Comments Page where you can note items
that are not possible to include on the earlier pages. It could be remaining
work, suggested rebuildings, etc.
Below are exampels of different sections of the checklists. Each section is
followed by a list where the marked fields are explained.
Checklist - Front page
1.
2.
3.
4.
5.
6.
7.
8.
9. 10.
11. 12.
13.
14.
15.
16.
17. 18.
19.
20.
22.
21.
Juice & Milk Plant
J & M Plant A
96.06.20
Eric
1 Issued by Name of the person who created the
Maintenance Recommendations.
2 Issue date Date when the Maintenance Recom-
mendations were created
3 Approved by The name of the person who is Product
Responsible
4 Customer Where the equipment is installed
5 Line no. In what line the equipment is installed
6 Notes If additional information is needed for
the one who will perform the mainte-
nance
7 Start date The date the maintenance was started
8 Start time The time the maintenance was started
9 Completion date The date the maintenance was com-
pleted
10 Completion time The time the maintenance was com-
pleted
11 Total used time The man hours it took to perform the
maintenance excluding lunch breaks,
other activities, etc.
12 Hour meter The value of the hour meter on the ll-
ing machine when the maintenance was
started
13 Performers signature Signature from the one who performed
the maintenance, (Tetra Pak or cus-
tomer) or if more than one person, the
one responsible for the work
14 Customer signature Signature from the person responsible
for maintenance at the plant.
15 Machine Type E.g. 648152 Same on all pages
16 Machine No E.g. 12346/1234 Same on all pages
17 List Variant Showing List Variant and List Text
from the checklist overview.
Same on all pages
18 Responsible Customer, Tetra Pak or All (Both) Same on all pages
19 Interval The interval the checklist is valid for,
e.g. 5000h
Same on all pages
20 Issue date Date when the maintenance recommen-
dations was created
Same on all pages
21 Page No 1/... if more pages will follow.
2. if last page
Same on all pages
22 Printing information When and by whom the list is printed Same on all pages
Checklist - Check items
23.
24. 25. 26. 27. 28.
29. 30. 31. 32.
33.
34.
35.
23 Selection/Description Describing where on the equipment to nd the item to
check. Name of details selected from the SMA 3 phrase
library
24 Action Denes what to do with the check item. Check, change,
clean, etc. 22 pre dened action codes to select.
The Document Reference below (pos 26) refers to the
correct page in the Maintenance Manual for further
information
25 S (selection code) Possibility to dene the amount of work selected for
customer and Tetra Pak. 3 = Customer and 7 = Tetra
Pak
26 Document Reference Where to nd further information in Maintenance
Manual (MM) or equivalent
27 Time The expected time, in minutes, it will take a trained
technican to perform the check item. This time is used
when planning the work- and down time for the main-
tenance
28 Interval At what interval the check item should be performed.
29 Pos No Position number is the check items identity. Used
when evaluating statistical results and to identify the
check items when lists are printed in different lan-
guages
30 Result Code Here is where the technician lls in the result of the
maintenance.
A=Satisfactory, B=Adjusted, C=Replaced, D=Remain-
ing
It is mandatory to set a C if the action code is set to
Change. If D, there has to be a comment on the last
page regarding the reason
31 C (notes on the last page) If the performer has made a comment for a position
number on the last page, he should make a mark in this
column
32 Notes Here the measurements should be noted, e.g. 62 volts,
34 mm., etc. If the check item is connected to a Rota-
tor on request the question Replace next time? (Yes/
No) appears here.
33 Info - Result Code This is information about the possible result codes that
should be lled in
34 Total Expected Worktime The expected time it is supposed to take to perform this
maintenance
35 Total Expected Downtime This time is set to either the same time as Total
Expected Worktime or to zero. The later means that it
is possible to perform the check item during the
machine is in operation
Checklist - Comment Page
36.
37.
36 Pos no The position number that the comment is valid for.
Note! It is also possible to make general comments about the equip-
ment, or parts of it.
37 Comment E.g. notes about recommended rebuildings, problems on the equipment,
etc.
Checklist - Connected items list
38.
39.
40.
41.
38 Pos no The position number of the check item were the spare part or tool
is connected.
39 Description The description of the Spare part or tool
40 Item Identity The part number of the Spare part or tool
41 Used Quantity The amount of Spare parts or tools needed for this check item
Packaging Material
15
Packaging Material
Introduction
Besides constituting a container, giving the steadiness needed to shape and
maintain the shape of the package, the packaging material protects the product
from being affected by the environment.
Furthermore, the packaging material gives information about the contents of
the package, and makes it easy to transport and handle.
Construction
The packaging material is a laminate, which means that it is built by several
layers. The structure of the packaging material varies depending on the prod-
uct being packed. Further information is given in section Different material for
different products, page 15-5.
A typical TBA material is built, from outside and inwards, as shown in the pic-
ture and description below.
1. Outer coating protects the package against external humidity.
2. Printing
3. Paper board, bleached or claycoated, offers a good printing sur-
face.
4. Paper board, unbleached, strengthens the package.
5. Lamination, a plastic layer which enables the paper board to stick
to the aluminium layer.
6. Aluminium protects against oxygen and light.
7. Internal coating 1 offers adhesion against the aluminium layer.
8. Internal coating 2 offers tightening against the product and enables
package sealing.
TBA = Tetra Brik Aseptic
Construction of the packaging material.
1
2
3
4
5
6
7
8
The picture below describes what type of effects the different layers in the
material protects against.
The converting process
The converting process is what takes place when the paper board is trans-
formed into packaging material, ready to use. The process can be divided into
three phases:
Printing and creasing.
The design is printed on the paperboard which continues through the creas-
ing tools. The creasing tools create creases, which means the folding
instructions on the package, as well as opening perforations and holes for
straws.
Moisture
of water Light Odours
Product Flavour
Micro-or-
ganisms Oxygen
Paper board, bleached
or claycoated
Paperboard, unbleached
Lamination
Aluminium
Internal coating 1
Internal coating 2
Outer coating
Printing
Printing press, flexography
Printing Creasing
Crease pattern and opening perforation on the packaging material
Opening perforation
Crease pattern
Lamination
The roll will be transported to the laminator. In the laminator different lay-
ers will be added to the printed paperboard. First the paperboard passes
through a flame treating unit in order to burn off dust and to make it easier
for the plastic layer to stick. When all layers have been applied on the
paperboard, the thickness of the different plastic layers, and the surface of
the packaging material, will be checked according to specifications.
Slitting
After lamination, the roll is transferred to the slitter where it is slit into
reels. The slitting process is almost fully automatic. If any defect on the
packaging material is detected, the reel will be sent to rewinding; the faulty
part will be cut off, and the reel will be spliced. Each approved reel is
wrapped in shrinking film and stacked on a pallet.
Plastic The plastic used in the packaging material is a PolyEthylene. PolyEthylene is
thermoplastic, which means that it can be melted and shaped more than once.
There are different kinds of PolyEthylene. The most common ones are
HDPE High Density PolyEthylene
LDPE Low Density PolyEthylene
Tetra Pak mainly uses LDPE.
PolyEthylene possesses positive as well as negative properties. Positive prop-
erties are:
It is water proof.
It enables sealing of the package.
It is possible to apply in thin layers.
It is transparent and thus does not affect the printed design.
It is neutral, meaning that it does not affect the product.
It is chemically resistant, meaning that it does not react with other sub-
stances.
Negative properties are:
It does not resist much heat or cold.
It is fat-soluble.
It does not protect the product against oxygen.
Roll = Roll of packaging material
several packages wide.
Lamination
Slitting
Adhesion plastic In all j-materials, for example TBA/j, the packaging material contains a type
of adhesive plastic as internal coating 1, see page 15-1, that offers a strong and
durable adhesion to the aluminium. This prevents the product from penetrating
the plastic and the plastic will not unstuck from the aluminium layer.
Paperboard Paperboard is used as main support, to allow the package to stand up, to main-
tain its shape also with product inside, and to sustain a certain amount of phys-
ical exposure.
The type of paperboard used varies due to type and size of the package and
printing technique involved. The most common types of paperboard are du-
plex, unbleached and bleached.
Duplex consists of two layers of paperboard; one thin bleached
(white) layer, to print on, and one unbleached (brown) layer,
which strengthens the material. Duplex is the most common
material and a standard for TBA packages. The picture on
page 15-1 shows a duplex material.
Unbleached material merely consists of unbleached (brown) paperboard
with the design printed on the brown surface.
Bleached material merely consists of bleached (white) paperboard.
Claycoat All types of paperboard can also be claycoated. This means that the board is
coated with a layer of white clay offering an even and white surface with ex-
cellent printing properties.
Aluminium Aluminium offers good barrier qualities. It protects the product against light,
oxygen, odour, and external humidity. It can be laminated into very thin layers
and only a small amount is used for each package. The thickness of the alu-
minium layer is less than 7 m.
Furthermore, aluminium possesses good conductivity, which enables sealing
by so called induction heating. Packaging material without an aluminium layer
cannot be sealed by this method.
K-film Packaging material containing K-film in the innermost layer, is used when
packing aggressive products and products that are sensitive to residual fla-
vours. Examples of aggressive products are: tomato products, alcohol, oil, and
feta cheese. Water, and other small-tasting products, are sensitive to residual
flavours.
K-film is manufactured through film blowing techniques. This method means
that the plastic is stretched and oriented in length as well as transversal direc-
tion. K-film is applied to the material as ready-made film, unlike other plastic
coatings which are applied by extruding a thin layer of melted plastic onto the
packaging material.
K-film decreases the possibility for residual flavours to affect the product. It is
also tighter than extruded film, which makes it more difficult for aggressive
products to penetrate the plastic and cause microscopic cracks. When using K-
film, there is no risk of corrosion in the aluminium layer.
Duplex
Unbleached
Bleached
Claycoated
Different materials for different products
The type of packaging material chosen depends on what product is to be
packaged. The most common types of packaging materials provided by
Tetra Pak are:
TBA/m Used for UHT milk products, sweet and condensed milk,
flavoured milk products, and soya bean products.
TBA/j Used for juice and drinks, flavoured milk products, soya bean
drinks, coconut drinks, tea, coffee, and vinegar products with
maximum 1% acetic acid.
TBA/w Used for wine and alcoholic drinks with less than 20% alco-
hol.
TBA/m MF Used for the same products as TBA/m.
TBA/j MF Used for the same products as TBA/j.
TBA/w MF Used for the same products as TBA/w.
TBA/jk Used for products that will be heated in their package.
TBA/wk Used for alcoholic drinks with more than 20% alcohol.
TBA/ok Used for oil products.
TBA/tk Used for tomato products, dressings, soups, and sauces.
TBA/ak Used for water.
TBA/lk Can be used instead of any TBA material with k-film.
TWA/j Used for juice products in Tetra Wedge Aseptic machines.
TFA/j Used for juice products in Tetra Fino Aseptic machines.
Strips
Two types of strips are used in Tetra Brik packages: Longitudinal seal strip,
generally called LS-strip, and PullTab strip.
LS-strip The longitudinal seal strip is applied on the inside of the packaging material,
covering the edge of the longitudinal seal. It prevents the product from soaking
into the packaging material, so called edge suction. The strip also ensures pro-
tection against oxygen and contributes to the sealing of the tube.
Tetra Pak uses three different strip core polymers, depending on the oxygen
permeability desired:
HDPE High Density PolyEthylene
PET PolyEthylene Terephtalate
EVOH Ethylene Vinyl Acetate with Alcohol groups
From these polymers three basic types of LS strips have been developed:
LHL has a core of HDPE, coated on both sides by LDPE. This strip
is suitable for products that do not require a dense oxygen bar-
rier, for example pasteurised milk.
Outside LDPE layer, 12 g/m
2
Paperboard and printing
Lamination layer LDPE, 25 g/m
2
Aluminium foil, 17 g/m
2
Adhesive polymers, 6 g/m
2
Inside LDPE layer, 29 g/m
2
Example of TBA/j material
MF
has
k = a layer of k-film has been
added on the inside
PPP/PPPW has a core of PET, coated with primed layers of LDPE. This
strip is suitable for products that require a dense oxygen bar-
rier, and has been developed to resist alcoholic products.This
is the standard strip for all TBA materials.
LSE has a core of EVOH, coated with primed layers of LDPE. This
strip is suitable for products that require a massive oxygen bar-
rier.
PullTab strip When producing packages with PullTab openings, a hole is punched into the
packaging material before it enters the filling machine. A patch is applied on
the inside of the packaging material, covering the hole. Then the PullTab strip
is applied on the outside of the packaging material, covering the hole and the
part of the patch left uncovered by the hole.
To enable this, the patch and the PullTab strip must consist of different mate-
rials. The patch is made of a multi layer blown film, composed with a core of
EVOH, coated with primed layers of LDPE. This gives a dense barrier against
oxygen and a thin enough patch to make the PullTab easy to tear off. The Pull-
Tab is made of a laminated foil, composed of printed aluminium, which pro-
vides mechanical strength and aesthetics, and LDPE which enables sealing to
the patch and the packaging material.
LSESTRIPS
7,5/0,075
EVOH
Primer
LDPE
Primer
LDPE
PPPSTRIPS
7,5/0,075
Primer
LDPE
PET
Primer
LDPE
LHLSTRIPS
7,5/0,1
HDPE
LDPE
LDPE
Longitudinal seal strip
Packaging material
Longitudinal seal and different types of LS strips.
LHL PPP/PPPW LSE
PullTab opening
EVOH
Primer
LDPE
Primer
LDPE
LDPE
Al
TBA patch and PullTab strip
Different printing methods
Printing is the process of applying ink to create colours, words and designs.
Tetra Pak uses different printing methods such as Flexo, Offset and Rotogra-
vure, as described below.
Flexo Flexo has become the most common printing method and it is today used for
all types of designs.
Flexo is a relief printing method. One roller collects the colour, transfers it to
the colour transfer roller (anilox roller), which applies the colour onto the cli-
ch. The clich applies the design directly onto the packaging material.
The plates used for flexo printing are flexible and could be made of mouldable
natural or synthetic rubber compounds or of photo polymer materials.
There are two types of flexo printing:
Lineflexo Used for more simple designs without any photos.
Flexo process Used for photographic designs (CT).
The main difference between lineflexo and flexo process is that process is a
four-colour print method. The design is built by screen patterns. Using the four
process colours; yellow, magenta, cyan and black, applied one after another in
balanced amounts, makes it possible to represent any tint. As for line printing,
the desired tint is first prepared in a bucket and then poured into the printing
machine.
The pictures below show examples of a typical line design and a typical proc-
ess design.
Relief printing = Printing method
where the cliche sections, which
transfer the colour, are raised.
Anilox roller = A laser engraved
roller that has a specific pattern
of holes or cups.
Function principle for Flexo
Counter
pressure
roller
Packaging material
Clich
Colour transfer roller
(anilox)
Roller, collecting
the colour
CT = Continuous Tone. Like in a
photograph or an illustration.
Screen pattern = small dots
Yellow Cyan
Magenta
K Key colour
Process design Line design
Offset Offset is used for designs with photographic pictures. Compared to flexo proc-
ess, offset yields a somewhat better quality of the picture.
Offset is a flat printing method. A colour roller applies the colour on the print-
ing plate. The colour is then transferred to a rubber roller, which applies the
design onto the packaging material.
The principle of offset printing is that certain parts of the printing plate are
water-repelling while other parts absorb the water. Damp is continuously
transferred to the printing plate from the dampening roller. As the printing col-
our contains a certain amount of grease, it will not stick to the wet surfaces.
The colour will only stick to the water-repelling surfaces.
The offset printing plate is made from a sheet of aluminium.
Offset, like flexo process, is a four-colour print method. The design is built by
screen patterns. Using the four process colours; yellow, magenta, cyan and
black, applied one after another in balanced amounts, makes it possible to rep-
resent any tint.
Rotogravure Rotogravure is a printing method that is rather rare today. It yields an extreme-
ly high printing quality and may be used for exclusive printed designs or very
large series.
Rotogravure is a gravure printing method. The printed design is engraved in a
clich. The clich will collect the colour itself. Excess colour will be removed,
leaving colour only in the engravings. When the packaging material is pressed
against the clich, the colour will soak into it.
Since the engravings can vary in depth, the gravure printing method offers a
variation between 0 and 100% of colour saturation. This is the answer to the
extremely high printing quality. i
Colour roller
Dampening roller
Printing plate
Counter pressure
roller
Packaging material
Rubber roller
Function principle for Offset
Flat printing = Printing method,
where the sections which transfer
the colour are in level with the
plate.
Gravure printing = Printing method
where the immersed sections col-
lect the colour and transfer it to the
paper.
Packaging material
Counter pressure
roller
Clich
Colour
Scraper
Function principle for Rotogravure
Production Order Label and Pallet Label
Production order label and Pallet label are labels on the packaging material
reel and on the pallet containing reels.These labels contain information about
the content and are used, as an example, for claims.
The Production order label contains the following information:
1. Place of production
2. Production order number
3. Web position number (reel number)
4. Identification number
5. Type of packaging material
6. Volume of package
7. Quantity of packages on the reel
8. Date of production
9. Customer address
10. Bar-code containing parts of above information
The Pallet label contains the following information:
1. Production order number
2. Pallet number
3. Reel number
4. Quantity of packages on the reel
5. Quantity of packages on the pallet
1
2
3
4
5
7
8
6
9
10
Production order label
Production order label
Packaging Material Claims
Packaging material claims, usually cost a lot of money.Therefore, every effort
must be made to use the packaging material produced and delivered. As a rule,
a claim will not be accepted by Tetra Pak if the packaging material was pro-
duced and delivered within specification.
One condition for accepting a packaging material claim, is that the filling ma-
chine is upgraded to recommended standard and adequately maintained. Pack-
aging material claims will not be accepted if the material has not been stored
in accordance with local recommendations or recommended storage condi-
tions in the Installation Manual.
Below follows a description of how a packaging material claim is handled:
1. The customer makes his complaint to the Area Technical Service Man-
ager, on a packaging material report form, or in accordance with the local
producer.
2. The Area Technical Service Manager confirms the complaint by returning
a copy of the packaging material report form to the customer.
3. As a first step, the Technical Service Department sends a service engineer
to the customer to investigate the nature of the complaint.
4. The packaging material on hold is moved to a separate location and
clearly marked. When the complaints are involving suspicious packaging
material, the producer is contacted and the responsible market is informed.
5. A detailed description of the fault in accordance with the Fault Code List
Packaging Material, the disturbances occurred on the packaging machine
and the name of the person who inspected the goods, are given on the
claim report form. The original of the completed claim report form is sent
to the receiver at the producing plant together with representative samples
of the faulty packaging material, two meters from each reel.
1
2
3
2
5
4
Pallet label
Pallet label
Fault Code List
Packaging Material
L009
The Fault Code List consists of seven head groups. Within these groups there
are ten sub groups, each sub group consists of ten detailed fault denomina-
tions. The head group, 900 Filling machine, is intended to be used by Techni-
cal Service as an indication to the producer of how the packaging material
behaves in the filling machine. The codes 100-800 are used to give a more pre-
cise direction of where the fault occurs on the packaging material. This to en-
able faster handling of the claim.
More detailed information are available from Market Companies in these doc-
uments:
General Rules For Packaging Material Claims, G007
Packaging Material Claims and Complaints, I011
Fault Code List Packaging Material, L009
Recommendations
Storage Tetra Brik packaging material is supplied in protected and palletised reels,
which are sufficiently resistant to any damage it might be exposed to in the
course of normal handling and storage.
Below follows some advice to ensure maximum utilisation of the packaging
material:
1. Keep the storage premises clean and use them exclusively for the
packaging material.
2. The optimal temperature range for storing the packaging material is
between 10 and 30 C. Do not allow the temperature to fall below 0 C.
3. Maintain a relative humidity between 30 and 70%. Do not store the
packaging material in excessively damp or moist areas. No pipes etc.
which may produce condensation should run through the storage
premises.
4. It is important that the packaging material attains a temperature close to
that of the packaging room. Therefore it is advisable to withdraw it from
the storage premises one day before use and keep it in a suitable place
inside the packaging room.
5. Under normal circumstances, reels of packaging material are double-
wrapped. Each reel is tightly shrink-wrapped and each pallet is enclosed in
shrink material. Do not remove this until shortly before the reel is placed
in the machine.
Fault Code List Packaging Material L 009
4. Fault Code List Packaging Material
Tetra Pak Carton Packaging Division Carton Support
6. Always store the reels on pallets and not directly on the floor. Position the
pallets at a sufficient distance from the walls to ensure efficient handling
of the pallets.
7. Pallets can be stacked three high provided a rigid divider board is placed
on top of the lower pallets. The transportation pallet is only a one-way unit
and its strength has limitations, therefore avoid excessive scuffing and
chafing.
Handling Always take the greatest care when handling the packaging material. Below
follows some advice:
1. Before touching the packaging material, disinfect your hands.
2. The packaging material must never touch the floor.
3. Do not remove the shrink wrapping from the reel until you have placed it
in the trolley.
4. Unwind one revolution of the packaging material from the reel and check
for damages. If damages are found on the packaging material, be sure to
remove enough packaging material to avoid this to enter the filling
machine.
5. Keep the Production order label.
Hygiene
16
Hygiene
Training Video
Tetra Pak has made every effort to minimise the risk of reinfection of the
product when filled in the filling machine. In order to fulfil this aim, everyone
working in or visiting the filling room must contribute. To assist
in this matter, Technical Training Centre has produced the video film
Clean Conscience.
Content The video covers some aspects of the personnal hygiene and cleanliness
involved in the filling room work, essential to avoiding reinfection of the
product. The running time of the video is 6 minutes.
How to use We recommend the video to be shown to all new employees during their
introduction and to visitors and people working temporarily in the filling
room. We also recommend that all operators get a chance to review the
video when needed. The video can be studied alone or in groups.
Package Integrity
17
Package Integrity
Computer based training program
The quality of a package containing any food product, is essential to the
consumer. Tetra Pak has done a lot to assure that the machine will produce
packages of a high quality. Still the package integrity must be checked
regulary during the production run. The CD, Package Integrity TBA, is an
interactive training programme that will help you to set up and perform this
procedure.
Content The training program gives you knowledge of how to perform a complete
package integrity check for an aseptic production. However, laboratory
personnel may need more in-depth training.
The training programme covers the following subjects:
Information on package material and longitudinal strip
Package check including PullTab
Electrolytic test procedures
Ink test including syringe test
How to use The CD is self-instructional. To get the most out of this training, we
recommend that a practical test in packages is performed in the presence
of a mentor.

WB - Basic Course Tba

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