Tetra Pak Training Catalogue

CUSTOMER TRAINING Your Y our competence competence guide guide to food safety safety and operational operational efficiency

CUSTOMER TRAINING Your Y our competence competence guide guide to food safety safety and operational operational efficiency efficiency

WELCOME Invest in key skills for ensuring food safety and operational efficiency Tetra Pak offers a complete range of tailored training services ser vices and solutions that maximize your uptime, reduce your costs and help you reach and sustain your desired performance per formance levels. levels. Our experts expert s provide the latest training t raining methods, methods, technologies and tools to help you increase productivity and ensure food safety through trained tr ained operator, maintenance, quality and management personnel.

Customized, professional training from Tetra Pak helps you: • • • •

Ensure product quality quality and food safety Reach and sustain desired desired productivity and performance performance targets Reduce maintenance costs and downtime Ensure staff safety, skills and motivation

Our training services cover Tetra Pak® filling machines and distribution equipment and target all levels of customer personnel. Our unique operator certification verifies that operators hav have e the required skills to run equipment in the safest and most efficient ef ficient way. way.

Adapted to your specific needs Take advantage of our 60 years of experience in the food and beverage industry. Our 50 certified technical training instructors and 1,600 accredited field service engineers use well-proven methodologies combined with practical hands-on training. Courses includes workbooks, textbooks, videos and self-study aids, covering every aspect of aseptic and safe food production. Our training courses include equipment-specific introductions that give all staff a better understanding of the complete production line. They are normally held on-site using your equipment, adapted to your needs. They cover the key areas of operation, maintenance and quality control/assurance.

We also offer a wide range of competence development programmes off-site at our 17 Technical Training Centres around the world. Together we can plan and provide customized training that ensures problem-free production for your plant. You’ll find an overview of our complete range of training services on the following pages. If you have any questions, or want to talk to us about tailoring courses to your exact requirements, please contact your nearest Tetra Pak Technical Service representative. We’ll get back to you immediately.

Thomas Borgström Director Technical Support, Tetra Pak January 2014

TRAINING PORTFOLIO OVERVIEW

OPERATE YOUR EQUIPMEN T

T A H W

O H W

MAINTAIN YOUR EQUIPMENT

ENSURE QUALITY AND FOOD SAFETY

Operator training Operator certification

Maintenance training

Quality assurance training Manage aseptic production

Filling and distribution equipment operators

Technical staf f involved in the maintenance of filling and distribution equipment

Senior management Middle management Operational staff Quality assurance/ quality control st aff

contents 1. Operate your equipment Operator training Operator certification

2. Maintain your equipment Maintenance training – Filling machines – Distribution equipment

3. Ensure quality and food safety Quality assurance training Manage aseptic production

4. Always close to you 5. Abbreviations

WE’VE HAD GREAT CO-OPERATION WITH TETRA PAK WHEN IT COMES TO THE TRAINING OF OUR PERSONNEL European customer

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OPERATE YOUR EQUIPMENT Our professional operator training gives your staff the skills they need to safely and efficiently operate filling and distribution equipment.

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G N I N I A R T R O T A R E P O

GENERAL INTRODUCTION FILLING MACHINE INTRODUCTION FILLING MACHINE OPERATION DISTRIBUTION EQUIPMENT OPERATION

SAFETY AND HYGIENE

Newly employed or experienced? The above training modules help your operators acquire and maintain all the skills they need to perform their duties in the best way.

OPERATOR TRAINING

Benefits: • Ensure the competence level needed for operating Tetra Pak ® filling and distribution equipment • Meet requirements for product safety • Build the foundation for further competence development

Operator training overview FILLING MACHINES

DISTRIBUTION EQUIPMENT

Operator training on filling machine includes the following modules, which can be tailored to your operators’ specific training needs:

Operator training on distribution equipment includes the following modules, which can be tailored to your operators’ specific training needs:

• General introduction • Filling machine introduction • Filling machine operation

• General introduction • Filling machine introduction • Distribution equipment operation

Depending on previous experience, we recommend participation in all three modules above.

Depending on previous experience, we recommend participation in all three modules above.

Based on your needs we also provide tr aining on “Safety and hygiene” focusing on food safety and personnel safety. We specify a recommended number of hours for each module.

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1

OPERATOR TRAINING

General introduction

This training module provides participants with general information about Tetra Pak services and systems. Who is it for?

All participants in Tetra Pak technical training.

Subjects

• • • • • • • •

Tetra Pak organization and products Tetra Pak documentation Technical training services Tetra Pak Maintenance System (TPMS) Packaging Line Monitoring System (PLMS) Hygiene aspects What affects shelf life and how can shelf life be prolonged? Aseptic and non-aseptic packaging

Hours

4

1

OPERATOR TRAINING

Filling machine introduction

This training module is designed to introduce participants to the lling machine (FM) and its components. It also provides a short introduction to other units in the filling line. Who is it for? Mechanics, electricians and operators involved in the operation of the filling line. This introduction also benefits quality control personnel and supervisors.

Subjects

• Machine components and functions. • Basic knowledge of how to operate the machine.

Hours

See table on next page

OPERATOR TRAINING

Filling machine introduction Operator training on all Tetra Pak® lling machine systems In the table below you will find information on the duration of the filling machine introduction training module for each filling machine system in our e quipment portfolio. Filling machine system

Tetra Pak ® A1 for Tetra Classic ® Aseptic Tetra Pak ® A1 for Tetra Fino ® Aseptic Tetra Pak ® A3/Flex PullTab™ Tetra Pak ® A3/Flex DIMC Tetra Pak ® A3/Speed Tetra Pak ® A3/CompactFlex Tetra Pak ® A6 Tetra Pak ® Simply 8 TBA/8 TBA/8 PullTab™ TBA/8 DIMC TBA/19 Tetra Pak ® C3/Flex Tetra Rex ®/27 and Tetra Rex ®/28 Extended Hygiene Tetra Top ®/3 Extended Hygiene Tetra Pak ® R1 Tetra Pak ® R2 Tetra Rex ®/7 Tetra Rex ®/8 Tetra Rex ®/18 Tetra Rex ®/22 TB/19 TB/21 TBA/3 TBA/3 for Tetra Fino ® Aseptic TFA/3 TBA/9 TBA/21 TBA/22 TCA/65

Hours

14 12 20 20 14 18 N/A 18 14 14 14 14 16 14 10 8 8 14 14 14 12 8 24 10 10 10 10 20 14 8

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1

OPERATOR TRAINING

Filling machine operation

This training module helps operators perform their regular duties according to the operation manual (OM), including package checks and daily/weekly care. Who is it for? Mechanics, electricians and operators involved in the operation of the filling line. This introduction also benefits quality control personnel and supervisors.

Subjects

• • • • • •

Safety and hygiene Production preparation Production Daily care Weekly care Package evaluation

We provide operator training on our entire lling machine portfolio (see next page).

Hours


OPERATOR TRAINING

Filling machine operation Operator training on all Tetra Pak® lling machine systems In the table below you will find information on the duration of the filling machine introduction and filling machine operation training module for each filling machine system in our equipment por tfolio. Filling machine system

Tetra Pak ® A1 for Tetra Classic ® Aseptic Tetra Pak ® A1 for Tetra Fino ® A septic Tetra Pak ® A3/Flex PullTab™ Tetra Pak ® A3/Flex DIMC Tetra Pak ® A3/Speed Tetra Pak ® A3/CompactFlex Tetra Pak ® A6 Tetra Pak ® Simply 8 TBA/8 TBA/8 PullTab™ TBA/8 DIMC TBA/19 Tetra Pak ® C3/Flex Tetra Rex ®/27 and Tetra Rex ®/28 Extended Hygiene Tetra Top ®/3 Extended Hygiene Tetra Pak ® R1 Tetra Pak ® R2 Tetra Rex ®/7 Tetra Rex ®/8 Tetra Rex ®/18 Tetra Rex ®/22 TB/19 TB/21 TBA/3 TBA/3 for Tetra Fino ® Aseptic TFA/3 TBA/9 TBA/21 TBA/22 TCA/65

Hours

20 20 26 28 26 24 24 24 24 22 28 28 20 20 16 8 8 22 22 20 16 19 20 18 18 18 24 28 26 16

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1

OPERATOR TRAINING

Distribution equipment operation We provide operator training on our entire distribution equipment (DE) portfolio. This training module gives DE operators the skills to perform their regular duties according to the operation manual (OM), including daily/weekly care. Subjects: • Safety and hygiene

• Production preparation

• Production

• Daily care

• Weekly care

In the table below you will find information on the duration of the DE operation training block for ever y piece of distribution equipment in our por tfolio. Distribution Equipment Accumulator Easy Ride Plus Accumulator for Tetra Wedge ® Aseptic Accumulator Helix 10 Accumulator Helix 30 for Tetra Prisma ® Aseptic Accumulator Helix 30 Cap Applicator 30 (ReCap) Cap Applicator 30 (ScrewCap) Capper 25 Cardboard Packer 30 Cardboard Packer 32 Cardboard Packer 32 Lid Cardboard Packer 78 Film Wrapper 68 Line Controller 30 Line Controller 30 Plus Multi Shrink 30 Speed Multi Shrink 62 Package Divider 122 Palletizer 30

Hours 4 4 2 2 2 6 6 2 8 4 4 4 8 4 6 8 6 4 8

Distribution Equipment Pallet Wrapper 30 Robot Palletizer 30 Robot Pallet Wrapper 30 Straw Applicator 1 Straw Applicator 30 Straw Applicator 30 for Tetra Classic ® Aseptic Straw Applicator 30 for Tetra Prisma ® Aseptic Straw Applicator 30 for Tetra Wedge ® Aseptic Tetra Cardboard Packer 12 Tetra Cardboard Packer 22 Tetra Cardboard Packer 70 Tetra Cardbo ard Packer 71 Tetra Cardboard Packer 78 Tetra Cap Applicator 21 Tetra Cap Applicator 45 Tetra Cap Applicator 47 Tetra Cap Applicator 49 Tetra Cap Applicator 88 Tetra Crate Packer 83

Hours 8 8 8 4 4 4 4 4 8 6 4 4 4 4 4 4 4 4 6

Distribution Equipment Tetra Easy Ride Tetra Film Wrapper 32 Tetra Film Wrapper 66 Tetra Film Wrappe r 67 Tetra Handle Applicator 32 Tetra Helix 21 Tetra Helix 22 Tetra Roll Container Packer 85 Tetra Straw Applicator 21 Tetra Straw Applicator 22 High Speed Tetra Straw Applicator 46 Tray Shrink 30 Tray Shrink 51

Hours 4 6 6 6 4 5 2 6 4 4 4 6 6

Once your operators have passed a DE operation training block on a specific piece of distribution equipment, they can also attend the DE line operation training block.

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OPERATOR TRAINING

Distribution equipment line operation In this training block participants gain an understanding of how to operate the complete DE line smoothly. It will also prepare them for operator certification on the DE line. Who is it for? For DE operators. Prior to this training block participants should at tend the DE Operation training block for each piece of distribution equipment included in the DE line they will operate.

Subjects

• • • • • • • • •

Safety Different ways to stop a machine Line components Conveyor lubrication Hot melt Supply of materials Package checks Care and cleaning Start up

Hours

6

1

OPERATOR TRAINING

Safety and hygiene Safety is fundamental when it comes to both packaged food and the personnel involved in operations. That’s why this training module puts extra focus on safety and hygiene. Who is it for? Package evaluation: All personnel involved in the ope ration and maintenance of the filling machine. Laboratory and quality control personnel will also benefit from this training. We recommend that participants have taken part in the filling machine introduction prior to this module. Safe peroxide handling: For all filling machine personnel who can come in contact with peroxide.

Block

Subjects

Hours

Package evaluation This block is designed to give participants theoretical and practical knowledge of package integrity checks.

• • • • • •

Aseptic production Package forming Transversal sealing Longitudinal sealing Inside layer ruptures PullTab

12

Safe peroxide handling This block is designed to train participants in handling peroxide in a safe way.

• • • • • • • • •

Use of peroxide Safety regulations Basic properties of peroxide Risks with peroxide Protective equipment Actions at personal injuries Disposal and dilution Filling Concentration measuring

6

1

THE OPERATORS NOW FIND IT A LOT EASIER TO PERFORM THEIR DUTIES. IT’S LESS STRESSFUL FOR THEM AND THEY FEEL MORE CONFIDENT IN THEIR SKILLS. THEY KNOW HOW TO CONTROL, RUN AND SHUT DOWN THE MACHINES. Asian customer

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N O I T A C I F I T R E C R O T A R E P O

OPERATOR CERTIFICATION

Operator certification verifies that an operator has the right competence to run a filling line correctly and safely.

Based on your needs, we can provide: • Filling equipment operator certication • Distribution equipment operator certication

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OPERATOR CERTIFICATION

Benefits: • Veries your operators’ competence on the entire lling line • Provides a comprehensive evaluation of operators’ competence, including an online theoretical test and an on-site practical skills assessment under the supervision of Tetra Pak experts • Identies possible competence gaps

WRITTEN ASSESSMENT This part consists of a multiple-choice test on operating specific equipment. The operator must pass this written assessment before proceeding to the practical assessment. PRACTICAL ASSESSMENT According to a global standardized assessment, a Tetra Pak assessor super vises the operator during normal production to verify that the operator can safely and correctly run a specific line/equipment. The practical test covers three areas: • Production start-up • Production and production control • Weekly care

The test follows a predened checklist to ensure objectivity. CERTIFICATION Operators who pass the certification process successfully receive a certificate which proves that they can operate the equipment in a safe and correc t way.

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MAINTAIN YOUR EQUIPMENT Mechanical, electrical and automation training from Tetra Pak gives your staff the skills to safely and cost efficiently maintain filling machines and distribution equipment. Usually held on-site, we adapt our maintenance training to your specific needs. Qualified Tetra Pak Technical Service staff provide all training materials and instructions.

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G N I N I A R T E C N A N E T N I A M

GENERAL INTRODUCTION FILLING MACHINE INTRODUCTION FILLING MACHINE MAINTENANCE, ELECTRICAL AND AUTOMATION DISTRIBUTION EQUIPMENT MAINTENANCE

SAFETY AND HYGIENE

Newly employed or experienced? The above training modules help your maintenance staff acquire and maintain all the skills they need to perform their duties in the best way.

MAINTENANCE TRAINING

Benefits: • Ensure the competence level needed for maintaining Tetra Pak ® filling and distribution equipment • Secure safety for staff and equipment • Build the foundation for further competence development

Maintenance training overview FILLING MACHINES


Maintenance training on the filling machine includes the following modules, which we tailor to your staff ’s specific training needs:

Maintenance training on distribution equipment includes the following modules, which we tailor to your operators’ specific training needs:

• General introduction • Filling machine introduction • Filling machine maintenance, electrical and automation

• General introduction • Filling machine introduction • Distribution equipment maintenance

Depending on previous experience, we recommend participation in all maintenance training modules above in the order they are listed.

Based on your needs, we also provide a tr aining module on “Safety and hygiene” focusing on food safety and personnel safety. We specify a recommended number of hours for each module.

2


General introduction

2

This training module provides participants with general information about Tetra Pak services and systems. Who is it for?

All participants in a Tetra Pak training programme.

Subjects

• • • • • • • •

Tetra Pak organization and products Tetra Pak documentation Technical training services Tetra Pak Maintenance System (TPMS) Packaging Line Monitoring System (PLMS) Hygiene aspects What affects shelf life and how can shelf life be prolonged? Aseptic and non-aseptic packaging

Hours

4


Filling machine introduction

2

This training module is designed to introduce participants to the filling machine and its components. It will also provide a short introduction to other units in the filling line. Who is it for? Mechanics, electricians and operators involved with the operation of the filling line. The introduction will also benefit quality control personnel and supervisors.

Subjects

• Machine components and functions. • Basic knowledge of how to operate the machine.

Hours



Filling machine introduction on all Tetra Pak® lling machine systems In the table below you will find information on the duration of the filling machine introduction training module for each filling machine system in our e quipment portfolio. Filling machine system ®

Hours ®

Tetra Pak A1 for Tetra Classic Aseptic Tetra Pak ® A1 for Tetra Fino ® Aseptic Tetra Pak ® A3/Flex PullTab™ Tetra Pak ® A3/Flex DIMC Tetra Pak ® A3/Speed Tetra Pak ® A3/CompactFlex Tetra Pak ® A6 Tetra Pak ® Simply 8 TBA/8 TBA/8 PullTab™ TBA/8 DIMC TBA/19 Tetra Pak ® C3/Flex Tetra Rex ®/27 Tetra Rex ®/28 Extended Hygiene Tetra Top ®/3 Extended Hygiene Tetra Pak ® R1 Tetra Pak ® R2 Tetra Rex ®/7 Tetra Rex ®/8 Tetra Rex ®/18 Tetra Rex ®/22 TB/19 TB/21 TBA/3 TBA/3 for Tetra Fino ® Aseptic TFA/3 TBA/9 TBA/21 TBA/22 TCA/65

14 12 20 20 14 18 – 18 14 14 14 14 16 – 14 10 8 8 14 14 14 12 8 24 10 10 10 10 20 14 8

2


FILLING MACHINES

2 Filling machine maintenance, electrical and automation

This training module contains two parts – Filling machine maintenance – Electrical and automation Filling machine maintenance is intended for your maintenance staff and includes

practical work needed to perform maintenance on the equipment. It enables participants to perform all tasks according to the TPMS customer lists and use the TPMS checklists. It also lays the foundation for performing basic troubleshooting on mechanical parts. Electrical and automation is designed for your technical staff involved in maintenance

of the machine and it helps them understand the safety system of the equipment. It also teaches them to use the machine manuals and replace and set electrical components that do not require special software.

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2 Tetra Pak ® A1 for Tetra Classic ® Aseptic Tetra Pak ® A1 for Tetra Fino ® Aseptic Tetra Pak ® A3/Flex Tetra Pak® A3/Speed

maintenance training for filling machines

Tetra Pak® A3/CompactFlex Tetra Pak® A6 Tetra Pak® Simply 8 Tetra Pak® TBA/8 TBA/19 Tetra Pak® C3/Flex Tetra Rex®/27 Extended Hygiene and Tetra Rex®/28 Extended Hygiene Tetra Top®/3 Tetra Pak ® R1 Tetra Pak® R2 Other Tetra Pak ® filling machine systems


FILLING MACHINES

Tetra Pak® A1 for Tetra Classic Aseptic

2

Filling machine maintenance, electrical and automation Filling machine maintenance

This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra Classic ® Aseptic.

Block

Subjects

Hours

Mechanical 1*

• Automatic Splicing Unit (ASU) • Drive system • Jaw system

28

Mechanical 2*

• Sterile air system • Box cooling • Peroxide concentration gas sensor

24

Mechanical 3*

• Supply systems • Filling system

14

Mechanical 4*

• Tube forming • Peroxide system

12

Design correction/ Package integrity

• Design correction • Package evaluation • Sealing systems

14

* These blocks should be taken in the order indicated here.

continued


FILLING MACHINES

Tetra Pak® A1 for Tetra Classic Aseptic

2

Filling machine maintenance, electrical and automation Electrical and automation

This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A1 for Tetra Classic ® Aseptic. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra Classic ® Aseptic.

Block

Subjects

Electrical and automation

• Electrical equipment • Safety precautions • How to read the electrical manual

Hours

8


FILLING MACHINES

Tetra Pak® A1 for Tetra Fino® Aseptic

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra Fino ® Aseptic.

Block

Subjects

Hours

Mechanical 1*

• Automatic Splicing Unit (ASU) • Drive system • Jaw system

28

Mechanical 2*

• Sterile air system • Box cooling • Peroxide concentration gas sensor

24

Mechanical 3*

• Supply systems • Filling system

14

Mechanical 4*

• Tube forming • Peroxide system

12

Design correction/ Package integrity


14


continued


FILLING MACHINES

Tetra Pak® A1 for Tetra Fino® Aseptic

2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A1 for Tetra Fino® Aseptic. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra Fino ® Aseptic.

Block

Subjects


• Electrical equipment • Safety precautions • How to read the electrical manual

Hours

8


FILLING MACHINES

Tetra Pak® A3/Flex

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A3/Flex.

Block

Subjects

Hours

Mechanical 1*

• Documentation • Supply systems

22

Mechanical 2*

• • • •

Drive system Jaw system Final Folder Unit (FFU) Design correction

22

Mechanical 3*

• • • • •

Sterile air system Peroxide system Filling system Cleaning In Place (CIP) External cleaning system

16


continued


2

cont’d

FILLING MACHINES

Tetra Pak® A3/Flex

Filling machine maintenance, electrical and automation

Block

Subjects

Optional equipment DIMC Flex

• • • • •

Optional equipment PullTab

• Operation • Service and settings • Sealing evaluation

22

Optional equipment HI

• Headspace by Injection (HI)

8

Design correction/package integrity


14

Troubleshooting and preventive maintenance according to Tetra Pak Maintenance System

• Maintenance concepts • Maintenance checklist

10

Machine operation Supply systems Paper web Punch Cap forming

Hours

24

continued


cont’d

FILLING MACHINES

Tetra Pak® A3/Flex

2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A3/Flex. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A3/Flex.

Block

S u bj e c t s

Hours

iLine automation

• • • • •

Line integration Electrical equipment Machine control Networks Drive systems

12

Machine automation

• • • • • •

TMCC Sealing systems Filling system Design correction system Machine process instruments TPOP

10


FILLING MACHINES

Tetra Pak® A3/Speed

2


This training module provides participants with theoretical and practical practic al knowledge of the different parts part s and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A3/Speed.

Block

S u bj e c t s

Mechanical 1*


20

Mechanical 2*

• Jaw system • Design correction

12

Mechanical 3*

• • • • •

16


Hours


continued


2

cont’d

FILLING MACHINES



Block

Subjects

Hours

Optional equipment HI

• Headspace by Injection (HI)

4

Optional equipment TPA FFU

• TPA Final Folder Unit (FFU)

8


• Design correction • Inductive Heating (IH) principal

10



8

continued


cont’d

FILLING MACHINES


2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A3/Speed. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A3/Speed.

Block

Subjects

Hours

iLine automation

• • • • •


12

Machine automation

• • • • • •


10


FILLING MACHINES

Tetra Pak® A3/CompactFlex

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A3/CompactFlex.

Block

Subjects

Hours

Mechanical 1*


22

Mechanical 2*

• • • • • •

Drive system Jaw system Design correction Automatic Splicing Unit (ASU) Automatic Strip Splicing Unit (ASSU) Strip Applicator (SA)

22

Mechanical 3*

• • • • •


16


continued


2

cont’d

FILLING MACHINES



Block

Subjects

Hours



14



10

continued


cont’d

FILLING MACHINES


2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A3/CompactFlex. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A3/CompactFlex.

Block

Subjects

Hours

iLine automation

• • • • •


12

Machine automation

• • • • • •


10


FILLING MACHINES

Tetra Pak® A6

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A6.

Block

Subjects

Mechanical 1*

• • • •

Mechanical 2*

• Injection Moulding Unit (IM)

18

Mechanical 3*

• Sterilisation Filling Sealing (SFS) • Cleaning

30

Automatic Splicing Unit (ASU) Ready To Fill (RTF) Sleeve forming Supply systems

Hours

30


continued


2

FILLING MACHINES

Tetra Pak® A6

cont’d

Filling machine maintenance, electrical and automation Block

Subjects

Package integrity

• • • • • •



Package evaluation Packaging material Packaging material layer function Packaging material reel label Package terminology LS-strip structure

Hours

12

8


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A6. Who is it for? Technical staff involved in the maintenance of Tetra Pak® A6.

Block

Subjects

Electrical

• Machine control • Electrical equipment • Troubleshooting

Hours

18


FILLING MACHINES

Tetra Pak® Simply 8

2

Filling machine maintenance This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® Simply 8.

Block

Subjects

Mechanical 1*


18

Mechanical 2*

• • • • • •

Drive system Jaw system Final Folder Unit (FFU) Automatic splicing unit (ASU) Strip Applicator (SA) Design control system

24

Mechanical 3*

• • • •

Sterile air system Peroxide system Step up conditions CIP and External Cleaning

16

Design correction/Package integrity



Hours

12


FILLING MACHINES

TBA/8

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of TBA/8.

Block

Subjects

Hours

Mechanical 1*

• Drive system • Jaw system • TPMS service

20

Mechanical 2*

• • • •

Final Folder Unit (FFU) Automatic splicing unit (ASU) Automatic Strip Splicing Unit (ASSU) Strip Applicator (SA)

20

Mechanical 3*

• • • •

Sterile air system Peroxide system Step up conditions Supply systems

14


continued


2

FILLING MACHINES

TBA/8

cont’d


Block

Subjects

Hours

Optional equipment PullTab

• Service and settings • Operation • Sealing evaluation

20

Optional equipment DIMC

• • • • •

Machine operation Supply systems Paper web Punch Cap forming

24



12



12

continued


FILLING MACHINES

TBA/8

cont’d

2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the TBA/8. Who is it for? Electrical: Technical staff involved in the maintenance of TBA/8. PLMS: Production supervisors and production managers. Block

Subjects

Electrical

• • • • • • •

PLMS

• PLMS ofine software

Electrical equipment Machine process instruments TMCC PLC TPIH generator Drive systems Bar code photocells

Hours

12

4


FILLING MACHINES

TBA/19

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of TBA/19.

Block

Subjects

Mechanical 1*

• Drive system • Jaw system

20

Mechanical 2*

• Final Folder Unit (FFU) • Paper tracking • Automatic Strip Splicing Unit (ASSU)

16

Mechanical 3*

• • • •

14

Sterile air system Peroxide system Step up conditions Supply systems

Hours


continued


2

FILLING MACHINES

TBA/19

cont’d


Block

Subjects

Optional equipment ASU, HI and PullTab

• Automatic Splicing Unit (ASU) • Headspace by Injection (HI) • PullTab (PT)

16


• • • •

18



Design correction Filling Control System (FCS) Package evaluation Sealing systems

Hours

14

continued


FILLING MACHINES

TBA/19

cont’d

2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the TBA/19. Who is it for? Electrical: Technical staff involved in the maintenance of TBA /19. PLMS: Production supervisors and production managers. Block

Subjects

Electrical

• • • • • • •

PLMS


Electrical equipment Machine control TPIH 2500 generator Machine process instruments TMCC Brake systems Barcode photocells

Hours

12

4


FILLING MACHINES

Tetra Pak® C3/Flex

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® C3/Flex.

Block

Subjects

Mechanical 1*


22

Mechanical 2*

• Drive system • Jaw system • Design correction

22

Mechanical 3*

• • • • •

16


Hours


continued


2

cont’d

FILLING MACHINES

Tetra Pak® C3/Flex


Block

Subjects

Hours

Optional equipment DIMC Flex

• • • •

Supply systems Paper web Punch Cap forming

22



14

continued


cont’d

FILLING MACHINES

Tetra Pak® C3/Flex

2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak ® C3/Flex. Who is it for? Electrical: Technical staff involved in the maintenance of Tetra Pak® C3/Flex. PLMS: Production supervisors and production managers. Block

Subjects

Electrical

• • • • • • •

PLMS


Electrical equipment Machine process instruments TMCC GE-Fanuc USTS Generator Drive systems Sensors

Hours

20

4


FILLING MACHINES

Tetra Rex ® /27 Extended Hygiene and Tetra Rex ® /28 Extended Hygiene Filling machine maintenance, electrical and automation Filling machine maintenance

This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Rex®/27 Extended Hygiene and Tetra Rex®/28 Extended Hygiene.

Block

Subjects

Hours

Mechanical 1*

• • • •

Documentation Supply systems Drive system Heating system

18

Mechanical 2*

• • • •

Bottom forming Magazine Carton transport Top forming

26

Mechanical 3*

• Filling system • Carton lifter • Cleaning system

14

Package integrity

• Package evaluation • Sealing systems

6


continued

2


2

FILLING MACHINES

Tetra Rex ® /27 Extended Hygiene and Tetra Rex ® /28 Extended Hygiene cont’d


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Rex®/27 Extended Hygiene and Tetra Rex®/28 Extended Hygiene. Who is it for? Technical staff involved in the maintenance of Tetra Rex®/27 Extended Hygiene and Tetra Rex®/28 Extended Hygiene.

Block

Subjects

Electrical

• • • • • •

Electrical equipment How to read the electrical manual Safety precautions Circuit diagram Mains connections Safety relays

Hours

10


FILLING MACHINES

Tetra Top® /3

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Top®/3.

Block

Subjects

Mechanical 1*

• Automatic Splicing Unit (ASU) • Carton section • Supply systems

20

Mechanical 2*

• Lid Forming Unit (LFU)

18

Mechanical 3*

• • • •

16

Package Section Extended Hygiene (XH) Filling Cleaning

Hours


continued


2

cont’d

FILLING MACHINES

Tetra Top® /3


Block

Subjects

Hours

Optional equipment Cap Applicator Unit

• Cap Applicator Unit (CAU)

18

Package integrity

• Package evaluation

12



8

continued


FILLING MACHINES

Tetra Top® /3

cont’d

2


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Top ®/3. Who is it for? Technical staff involved in the maintenance of Tetra Top®/3.

Block

Subjects

Electrical

• • • •

Electrical equipment Machine control Drive systems Troubleshooting

Hours

18


FILLING MACHINES

Tetra Pak® R1

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® R1.

Block

Subjects

Mechanical 1*

• • • • •

Documentation TPMS Supply systems Drive system Heating system

22

Mechanical 2*

• • • • •

Infeed unit Carrier transport Transversal Sealing (TS) TPOP TPMS list

26

Mechanical 3*

• Package handling (pusher and elevator unit) • Final Folder Unit (FFU) • Daily/weekly and monthly care

22

Package evaluation

• • • •

12

Tools and environment Basic – Package evaluation Extended – Package evaluation Troubleshooting – Package evaluation


Hours


FILLING MACHINES

Tetra Pak® R2

2


This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine. Who is it for? Technical staff involved in the maintenance of Tetra Pak® R2.

Block

Subjects

Mechanical 1*

• Documentation • Supply systems • Bottom ap heater

16

Mechanical 2*

• Drive system • Bottom former unit • Final Folder Unit (FFU)

24

Mechanical 3*

• • • •

Filling systems Piston ller Pocket ller Liquid ller

16

Package evaluation

• • • •

Tools and environment Basic – Package evaluation Extended – Package evaluation Troubleshooting – Package evaluation

12


Hours


FILLING MACHINES

Maintenance training on other Tetra Pak® lling machine systems We also provide maintenance training on the following Tetra Pak ® equipment:

Filling machine system

Tetra Rex®/7 Tetra Rex®/8 Tetra Rex®/18 Tetra Rex®/22 TB/19 TB/21 TBA/3 TBA/3 for Tetra Fino ® Aseptic TFA/3 TBA/9 TBA/21 TBA/22 TCA/65

For further information, please contac t your nearest Tetra Pak Technical Service representative.

2



Distribution equipment line maintenance

2

We provide maintenance training on our entire distribution equipment portfolio. This training is designed for technicians and electricians involved in the maintenance of distribution equipment. Subjects: • Safety precautions • Operation according to the OM • Machine function • Zero Setting Sequence • Settings according to Setting Sequence in the MM • Cap Positioning System (CPS)

In the table below you will find information on the duration of the DE Maintenance training block for each piece of distribution equipment in our portfolio. Distribution Equipment Accumulator Easy Ride Plus Accumulator for Tetra Wedge ® Aseptic Accumulator Helix 10 Accumulator Helix 30 Accumulator Helix 30 for Tetra Prisma ® Aseptic Cap Applicator 30 (ReCap) Cap Applicator 30 (ScrewCap) Capper 25 Cardboard Packer 30 Cardboard Packer 32 Cardboard Packer 32 Lid Cardboard Packer 78 Film Wrapper 68 Line Controller 30 Line Controller 30 Plus Multi Shrink 30 Speed Multi Shrink 62 Packag e Divider 122 Palletizer 30

Hours

8 6 4 4 6 16 20 8 16 24 22 10 26 16 18 24 20 10 8

Distribution Equipment Pallet Wrapper 30 Robot Palletizer 30 Robot Pallet Wrapper 30 Straw Applicator 1 Straw Applicator 30 Straw Applicator 30 for Tetra Classic ® Aseptic Straw Applicator 30 for Tetra Prisma ® Aseptic Straw Applicator 30 for Tetra Wedge ® Aseptic Tetra Cardboard Packer 12 Tetra Cardboard Packer 22 Tetra Cardboard Packer 70 Tetra Cardb oard Packer 71 Tetra Cardboard Packer 78 Tetra Cap Applic ator 21 Tetra Cap Applic ator 45 Tetra Cap Applic ator 47 Tetra Cap Applic ator 49 Tetra Cap Applic ator 88 Tetra Crate Packer 83

Hours

– 6 – 6 8 8 8 8 24 16 16 16 12 18 16 16 16 16 18

Distribution Equipment Tetra Easy Ride Tetra Film Wrapper 32 Tetra Film Wrappe r 66 Tetra Film Wrappe r 67 Tetra Handle Applicator 32 Tetra Helix 21 Tetra Helix 22 Tetra Roll Container Packer 85 Tetra Straw Applicator 21 Tetra Straw Applicator 22 High Speed Tetra Straw Applicator 46 Tray Shrink 30 Tray Shrink 51

Hours

12 24 22 22 6 6 6 20 6 6 6 10 20

Once your technicians and electricians have passed a DE Maintenance training block for a specific piece of distribution equipment, they can also attend the DE Line Maintenance training block.



Distribution equipment line maintenance

2

The DE line maintenance training block is designed to give participants an understanding of how to get the entire DE line to function smoothly. Who is it for? Customer maintenance staff. Prior to this training block, participants should attend the DE maintenance training block for each piece of distribution equipment include d in the DE line they will work on.

Block

Subjects

DE line maintenance

• • • • • • • • •

Safety Different ways to stop a machine Line components Conveyor lubrication Hot melt Supply of materials Package checks Care and cleaning Start up

Hours

6


Safety and hygiene

2

Safety is fundamental when it comes to packaged food and the personnel involved in operations. That’s why this training module puts extra focus on safety and hygiene. Who is it for? Package evaluation: All personnel involved in the oper ation and maintenance of the filling machine. It will also benefit laboratory and quality c ontrol personnel. We recommend that participants take part in the Filling Machine Introduction prior to this block. Safe peroxide handling: All filling machine personnel who come into contac t with peroxide.

Block

Subjects

Hours

Package evaluation This block is designed to give participants theoretical and practical knowledge of the Package Integrity checks.

• • • • • •

Aseptic production Package forming Transversal sealing Longitudinal sealing Inside layer ruptures PullTab

12

Safe peroxide handling This block is designed to train the participants in handling peroxide in a safe way.

• • • • • • • • •

Use of peroxide Safety regulations Basic properties of peroxide Risks with peroxide Protective equipment Actions at personal injuries Disposal and dilution Filling Concentration measuring

6

OUR STAFF GAINED BETTER AWARENESS OF QUALITY PROCEDURES, WHICH HELPED THEM TO DISCOVER PROBLEMS EARLIER American customer

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3

ENSURE QUALITY AND FOOD SAFETY Our Quality Assurance training helps you minimize product quality problems. We offer six targeted modules tailored specifically for senior management, middle management and operational staff, including quality assurance and quality control personnel. The modules cover the entire production process from raw material to finished product. They are conducted by skilled instructors providing best practice and expert knowledge within each area.

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3

G N I N I A R T E C N A R U S S A Y T I L A U Q

INTRODUCTION TO LONG-LIFE PRODUCTION HIGH ACID PRODUCTS LOW ACID PRODUCTS LOW ACID PRODUCTS EXTENDED HYGIENIC PROCESSING AND PACKAGING TROUBLESHOOTING Newly employed or experienced? The above training blocks help all staff in the Quality Assurance/Quality Control area acquire and maintain the skills they need to perform their duties in the best way.

QUALITY ASSURANCE TRAINING

Benefits: • Minimizing product quality problems that could damage brand value and impact sales if experienced by retailers and/or consumers • Reducing costs and waste due to quality problems • Meeting strengthened legislation for food safety and food quality • Increasing awareness and understanding of the importance of quality assurance

The following modules are included in quality assurance training:

• Introduction to long-life production • High acid products • Low acid products • Low acid products extended • Hygienic processing and packaging • Microbiological troubleshooting

3


Introduction to long-life production

3

This training module provides an introduction to long-life production. Who is it for?

Senior management. No prior experience is required.

Subjects

• Role of senior management in connection with product quality • Difference between quality assurance and quality control • Introduction to long-life production

We specify a recommended number of hours for each module.

Hours

4


High acid products

3 This training module covers aseptic processing and packaging of high acid products, quality assurance/quality control, cleaning/CIP and package integrity test methods. Who is it for? Middle management and operational staff. No prior experience is required.

Subjects

• Aseptic processing and packaging of high acid products, covering the production line from raw material to finished product • Quality control versus quality assurance • Cleaning/CIP • Package integrity checks

Hours

8


Low acid products

3 This training module covers aseptic processing and packaging of low acid products, quality assurance/quality control, cleaning/CIP and package integrity test methods. Who is it for? Middle management and operational staff. No prior experience is required.

Subjects

• Aseptic processing and packaging of low acid products, covering the production line from raw material to finished product • Quality control versus quality assurance • Cleaning/CIP • Package integrity checks

Hours

8


Low acid products extended

3 This training module covers processing and packaging from raw material to finished product, basic microbiology theory, quality assurance and quality control, troubleshooting, cleaning/CIP and package integrity test methods. Who is it for? Middle management and operational staff, including quality assurance/quality control personnel. No prior experience is required.

Subjects

• Aseptic processing and packaging of low acid products, covering the production line from raw material to finished product • Quality control versus quality assurance • Basic microbiology • Cleaning/CIP • Microbiological troubleshooting • Package integrity checks

Hours

24


Hygienic processing and packaging

3 This training module covers processing from raw material to finished product, basic microbiology theory, aseptic technology, quality assurance and quality control, critical control points concept, cleaning and package integrity. Who is it for? Operational staff including quality assurance/quality control personnel. Knowledge of dairy processing and experience from aseptic production is required.

Subjects

• • • • • • •

Equipment for aseptic processing Aseptic technology Basic microbiology Quality assurance and quality control Critical control points concept Cleaning Package integrity

Hours

40


Troubleshooting

3

This training module provides participants with a good understanding of the principles of systematic troubleshooting. Who is it for? Operational staff including quality assurance/quality control personnel. This module requires knowledge of aseptic processing and at least three years’ experience in aseptic production.

Subjects

• • • • • • • • • • •

Cases from both technical and microbiological troubleshooting General microbiology Rough identication of spoilage ora General aspects of quality control and quality assurance Critical control points Product sterilization Aseptic transfer Aseptic packaging Hazard Analysis Critical Control Points (HACCP) Concept Cleaning and CIP Package integrity

Hours

40

3

N O I T C U D O R P C I T P E S A E G A N A M

MANAGE ASEPTIC PRODUCTION

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3 Manage Aseptic Production is a three-day training programme for mid-level managers who want to increase their knowledge of aseptic production to improve performance in their plants. By analyzing real-world examples, you gain insight into the leading factors that impact aseptic product quality and production performance, and ultimately inuence operational cost.

SEVERAL YEARS AGO WE HAD DIFFICULTIES REACHING A DEFECT RATE OF 1:1,000! TODAY OUR AVERAGE DEFECT RATE BASED ON OUR INCUBATION RESULTS IS LESS THAN 1:20,000. European customer


Benefits: • Make more informed business decisions to lower operational costs • Achieve high and consistent product quality • Understand and apply best practices to prevent unsterilities • Plan production more efciently to ensure you meet your delivery deadlines

3

ALL OF US IN THE MANAGEMENT TEAM ATTENDED TRAINING ON ASEPTIC PRODUCTION WHERE WE GOT TO MEET SOME OF OUR COMPETITORS AND EXCHANGED IDEAS AND EXPERIENCES WITH THEM European customer


Manage aseptic production How does the quality of raw materials affect the end product? Are your operational costs in line with industry benchmarks? Which key factors impact performance of an aseptic filling operation? Attending the manage aseptic production course will give you answers to these questions as well as a thorough understanding of how to attain and sustain aseptic performance. Who is it for? This course is designed for plant managers, production managers, quality managers, service managers and others interested in a deeper understanding of aseptic technology. It is recommended that participants have basic knowledge of aseptic technology. Participants should have at least six months’ experience of working in a long-life production environment.

Block

Subjects

Hours

After this session, you will understand how to: A practical approach to aseptic production

• Apply Tetra Pak best practices to your own operation • Assess the impact of preventive measures to avoid quality related mishaps • Identify where in the product line the risk is major • Implement cost-efcient preventive measures

8

Quality systems, competence development and maintenance management

• Work with continuous improvement to avoid, rather than detect, uns terilities • Align competence development to match your performance ambitions • Improve maintenance routines to reduce impact on production

8

Operational cost analysis

• Start analyzing available data to identify potential improvements and “quick wins” • Investigate the need for a thorough cost mapping, improved analysis and/or changes in production planning • Evaluate the cost impact of implementing improvements

8

3

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ALWAYS CLOSE TO YOU Expertly trained and certified staff are vital for maximizing uptime, reducing costs and ensuring product quality. In addition to our dedicated competence development programmes for operators and other staff in maintenance and quality assurance/ quality control, we provide tailor-made training solutions for these key competence areas.

4

ALWAYS CLOSE TO YOU

Adapting training to your specific needs If what you’ve found so far doesn’t match your needs, get back to us, tell us what you’re looking for and we will find the best way to support you. Our global Quality Assurance Management network of approx. 100 people can support you on any food quality and food safety questions you may have. Our 17 Technical Training Centres around the world provide off-site technical training on our latest equipment as well as on older systems within the Tetra Pak equipment portfolio. Our 1,600 certied trainers Field Service Engineers provide on-the-job training at your site, tailored to your staff’s specific needs. We provide tailored competence development programmes for all members of your personnel. Please contact your nearest Tetra Pak Technical Service representative for more information about our training services.

4

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ABBREVIATIONS ASSU

Automatic Strip Splicing Unit

OM

Operation Manual

ASU

Automatic Splicing Unit

PLMS

Packaging Line Monitoring System

CAU

Cap Applicator Unit

PT

PullTab

CIP

Cleaning In Place

QA

Quality Assurance

DE

Distribution Equipment

QC

Quality Control

DIMC

Direct Injection Moulding Concept

RTF

Ready To Fill

EM

Electrical Manual

SA

Strip Applicator

FCS

Filling Control System

SFS

Sterilisation Filling Sealing

FFU

Final Folder Unit

SPC

Spare Parts Catalogue

FM

Filling Machine

TMCC

HI

Headspace by Injection

Tetra Pak Multi-purpose Compact Controller

IH

Inductive Heating

TPMS

Tetra Pak Maintenance System

IMU

Injection Moulding Unit

TPOP

Tetra Pak Operator Panel

LFU

Lid Forming Unit

TS

Transversal Sealing

MM

Maintenance Manual

XH

Extended Hygiene

5

. 1 3 1 0 2 , n e 1 6 3 9 3 S T , n e d e w S , e c i v r e S l a c i n h c e T k a P a r t e T , 3 1 0 2 ©

2

Tetra Pak®, , PROTECTS WHAT’S GOOD, Tetra Brik, Tetra Rex, Tetra Top, Tetra Fino, Tetra Classic and Tetra Recart are trademarks belonging to the Tetra Pak Group. www.tetrapak.com

We help you to build-up the competence of your personnel Our global network of trainers offers best-in-class competence training. In fact the figures speak for themselves. We have a dedicated staff of 50 global instructors specialized in the area of operation, maintenance and automation, more than 1,600 certified trainers, and a quality assurance management network of approx. 100 people operating. Our 17 Technical Training Centres around the world provide off-site technical training on our latest equipment as well as on older systems within the Tetra Pak equipment portfolio. All with one aim, to increase the competence of your staff, and the efficiency of your business.

More skilled people, in more places We’re proud to say that we deliver more than 7,800 delivered operator and maintenance training days, and 1,200 delivered quality related training days every year. For us it’s all about enhancing people’s performance, increasing their motivation, and sustaining productivity.

OPERATE

MAINTAIN

ENSURE QUALITY

YOUR EQUI PMEN T

YOUR EQUI PME NT

AND FOOD SAFETY

Tetra Pak Training Catalogue

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