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 equipment specific documentation.

Issue 3/0109 © 2001, Tetra Brik Packaging Systems AB, Technical Training Centre All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocopying, recording or otherwise, without permission in writing from 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

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Guide to the Basic Course TBA

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.

Student’s 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

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Study

Study the sections Basic Machine Introduction, Documentation 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 System and Peroxide.

Watch

Watch the video Clean Conscience referred to in the Hygiene section.

Study

Study the section: Cleaning In Place.

Discuss


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.

Discuss


Visit

Visit a production plant together with your mentor. Focus on the function of the filling machine and the operator’s 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.

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Training Document. For training purpose only.

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Study

Study the section Packaging Material.

Discuss


Perform

Perform the Package Integrity TBA Computer Based Training Program referred to in the Package Integrity section.

Discuss

Discuss the above mentioned sections with your mentor. Ask 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.

Mentor’s guide As the student’s 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 student’s 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.

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Basic Machine Introduction

Basic Machine Introduction What does the filling machine do? Starting out from a reel of packaging material, the TBA filling machine produces filled packages. The packaging material is first sterilised and then formed into a tube. The tube is filled with product and then shaped and cut into individual packages. The packaging material is formed into a tube

The packaging material is sterilised The tube is filled with product

The tube is shaped and cut into individual packages.

Reel of packaging material

The package There is a range of Tetra Pak packages, all deriving their origin from the same forming technique.

Tetra Brik, Sqare Tetra Brik, Base


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Tetra Prisma

Tetra Brik, Slim


Tetra Fino Tetra Wedge

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Package terminology Creases are the folding instructions on the packaging material, to ensure the package’s final shape. The creases are pressed into the material by the creasing tools in the converting process.

Creases

The longitudinal seal (LS) is accomplished when forming the packaging material into a tube. It seals the package along the side. A strip of laminated plastic, the LS-strip, covers the seal on the inside. The area of the overlap joint is called the longitudinal overlap.

Seals

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. The fins are the areas, at top and bottom of the package, where it is sealed and cut.

Fins

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.

Flaps

top transversal seal (TS) top flap

top flap

top fin

top flap

top flap

top crease

LS-strip

longitudinal creases

bottom flap

longitudinal overlap (L.S. overlap)

bottom flap bottom flap

bottom fin

bottom crease

bottom transversal seal (TS)

longitudinal seal (LS) bottom flap

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 Splicing Unit (ASU).

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LS-strip

longitudinal seal

Strip applicator 3

Peroxide bath 4

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.

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.

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.

shallow bath

Learn more about sterilisation in the Sterile system chapter.

Learn more about the LS-strip in the Packaging material chapter.

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PullTab unit

Aseptic chamber

Note! The PullTab unit is not shown in this example.

The packaging material will be dried with heated air.

The PullTab unit is additional equipment, providing the packaging material with a PullTab opening before it enters the peroxide bath.

In machines with deep baths, as shown in the example, an aseptic environment around the sterilised packaging material is maintained with an overpressure of heat-sterilised air. This takes place in the aseptic chamber.

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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 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. lastic

Learn more about the PullTab in the Packaging material chapter.

The packaging material will be formed into a tube and sealed longitudinally. Finally, the tube will be filled with product.

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aluminium

Learn more about sterilisation in the Sterile system chapter.

sealed

ASU Automatic splicing unit 1

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Jaw system

The automatic splicing unit splices reels of packaging material. This means that production can continue uninterrupted when one reel of packaging material comes to an end.

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During splicing though, the packaging material has to remain still in the splicing head. The magazine provides the necessary supply of material so that the machine does not have to stop.

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2

1.

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.

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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.

Learn more about packaging material in the Packaging material chapter.

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cut

Final folder 7

6

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reel of packaging material

3.

2.

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.

11 flap fin

fin

Operator panel

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Electrical cabinet

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.

operator panel


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Service unit

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In the electrical cabinet a great part of the electrical components are included, such as: • temperature regulators • control system (PLC) • contactors • IH-unit, etc.

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 the electrical components in the Electrical system chapter.

Learn more about this in the respective chapter.


flap

Drive system 11 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.

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Documentation

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.

TPMS = Tetra Pak Maintenance System


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

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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.

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Pasteurisation and UHT 4

Pasteurisation and UHT Introduction UHT = Ultra High Temperature

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.


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Milk production 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 prevent forming of layers it is homogenised. Then you divide the fat globales into smaller parts.

At pasteurisation the micro-organisms 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 storage

Raw milk

Separation

Skim milk Standardi-

sation

Homogenisation

Pasteurisation Filling machine

Cream

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.

UHT

UHT milk production When the raw milk arrives at the milk production, the cream is separated from the skim milk.

Raw 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 prevent forming of layers it is homogenised. Then you divide the fat globales into smaller parts.

At pasteurisation the micro-organisms 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 storage Separation

Skim milk Standardi-

sation

Homogenisation

Pasteurisation

UHT Filling machine

Cream

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UHT treatment kills all micro-organisms able of destroying the product.

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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. Juice production Concentrate and water are mixed.

At pasteurisation those micro-organisms able of multiplying in a high acid environment, i.e. pH value below 4.6, are killed.

The final fruit juice product is packed either immediately or stored in aseptic storing tanks before it is packed.

Juice storage

Concentrate

Mixing Water

Pasteurisation Filling machine

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 Aseptic packaging

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 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.


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Sterile System

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Sterile System Introduction Aseptic = Prevents reinfection

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 Sterilized packaging material

Sterile surrounding

Commercially sterile food

Aseptic transfer Aseptic packages

Peroxide = Hydrogen peroxide = H2O2


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 sterilised 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 sterilisation 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.

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Deep baths

Squee-gee rollers

Aseptic chamber

Heat exchanger

Air superheater

Product

Water ring compressor Peroxide bath

Water separator

Packaging material

Tight tube Peroxide tank

Air Peroxide Product Water

Filling machine with a deep bath.

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 operator´s 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.

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Machine sterilisation


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

WEAC = Work Environment Aseptic Chamber


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 concentration 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.

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Shallow baths Water ring compressor Rubber rollers

Peroxide bath

Water separator Product

Peroxide can

Air superheater Cooler

Tube heater

Tight tube

Sterile area

Packaging material

Air Peroxide Product Water

Filling machine with a shallow bath.

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.

Machine sterilisation

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.

Sterilisation of packaging material

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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.

Pneumatic = A way of producing movements by means of compressed air.


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.

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Peroxide

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Peroxide Introduction Hydrogen Oxygen

Hydrogen peroxide, H2O2, 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.

Oxygen Hydrogen

Peroxide molecule

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

ppm = parts per million = 10-6

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.

Catalysis = Change of reaction rate.

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.


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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. 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.

Personal injuries

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.

Handling

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.

Storage

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Cleaning In Place

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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? AP = Aseptic product

On a Tetra Brik machine the following parts are cleaned without dismantling • AP valve • Control valve • Upper filling pipe

AP-valve Upper filling pipe C Lower filling pipe

B A

Control valve

Cleaning device

Hot air Preheated and cooled air resp. Steam Product Detergent

The figure shows two filling machines. The upper machine is in production and the lower one is being cleaned.

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.


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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

R TE

AC ID

WA Salt and mineral

Sugar

Protein

Fat

ALK ALI 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.

7-2

TM-00072



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 actions for the daily care. Tetra Pak recommends that final cleaning takes place once per day.

C

Steam

A

Water B

Air Detergent

AP-valve, cleaned by final cleaning.

Detergent


TM-00072


7-3

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 barrier 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.

Intermediary cleaning

C

Steam

A

Product B

Water Air Detergent

7-4

AP-valve, cleaned by intermediary cleaning.

TM-00072



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. Basic function of the lubrication system

To lubrication point A

B

Dosing valve

Main line

Lubrication pump

Lubrication oil

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.


TM-00073


8-1

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. Venting pipe Filling connection

Level sensor

Main line

Level glass

Built in pump

The lubrication oil tank is equipped with filling connection, venting pipe, level sensor, level glass and a built in pump. 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.

Pressure guard

Main line

8-2

TM-00073



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. Main line

Suction pipe

Mounted locating head

Return spring Pump cylinder piston Air cylinder Air piston

Incoming air pressure

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.

Maximum level

Minimum level


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8-3

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. 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.

Oil filter

Distribution blocks are used as junctions for the hoses that distribute the oil to different dosing valves in the machine.

Distribution block

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.

Dosing valve

Lubricating pipe

Non return valve Return spring

Dosing chamber Piston

Piston housing

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.

8-4

TM-00073



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 mm3, 30 mm3, or 50 mm3, 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. Basic sketch of a central lubrication system

Dosing valves

Dosing valves

Distribution block

Lubrication oil Compressed air

Pressure guard

Main line

Filling connection

PLC Central lubrication pump


TM-00073

Button for manual lubrication


8-5

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.

Dosing chamber

Air piston


• Pressure stroke - At the pressure stroke oil is fed to the lubrication points. Lubricating pipe Main line

Non return valve Non return valve

Piston Air piston


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.

8-6

TM-00073



• Discharge pressure - At the discharge pressure, the lubrication pump and the dosing chamber in the dosing valve, will be refilled with oil.

Suction pipe

Non return valves

Non return valve

Return spring

Pump cylinder

Dosing chamber Piston Piston housing

Air piston


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.


TM-00073


8-7

There are two different lubrication cycles. The diagram below shows an example.

Lubrication cycles

Single lubrication pulse 15 min

Lubrication

10 s

Checking - oil level - pressure

8s

10 s 8s 2s

2s

Long lubrication cycle Lubrication

10 s

Checking - oil level - pressure

8s

30 s

10 s

30 s

10 s

30 s

10 s

30 s

10 s

8s 2s

2s

• 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 filled up after an interference or a service 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.

Refilling

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.

A transportable oil tank connected to the oil tank in the machine

8-8

TM-00073



• 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.

PLC

PLC

Set up for automatic refilling

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.


TM-00073


8-9

8-10

TM-00073



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. Functional principle for hydraulics Hydraulic oil

Hydraulic oil Piston

Hydraulic oil with pressure

Return spring

Hydraulic oil not under pressure Hydraulic cylinder

Hydraulic cylinder

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. Pressure reducing valve

Pressure regulator Level- and temperature transmitter

Filling connection

Pressure gauges

Hydraulic 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.


TM-00074


9-1

The hydraulic oil in the tank may be drained through a drain valve. The tank is open to the surroundings and thus not pressurised. The level transmitter can indicate two or three levels; high, low and if a third exist, soon low level.

Level transmitter and temperature transmitter

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. Hydraulic oil

Hydraulic oil

Cooling water

ooling ater

Oil cooler, length section

Oil cooler, cross section

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. A hydraulic oil pump is used in order to pressurise the hydraulic oil. The pump is a gear pump, driven by an electric motor.

Hydraulic oil pump

Outlet

Hydraulic oil with pressure Inlet

9-2

TM-00074

Hydraulic oil not under pressure



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. Indicator Overpressure valve Inlet

Outlet

Filter

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

Accumulator

Non-return valves are used in order to control the flow directions of the hydraulic system. The accumulator is used in order to keep an even pressure in the system when the various valves open and close. Pressurised nitrogen

Hydraulic oil

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.


TM-00074


9-3

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 regulator

Hydraulic oil with pressure Hydraulic oil not under pressure

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.

Pressure reducing valve

Hydraulic oil with full pressure Hydraulic oil with reduced pressur

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.

9-4

TM-00074


Throttling


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. Open valve

Closed valve

Flow inlet

Flow outlet

Cylinder

Cylinder

Hydraulic oil with pressure Hydraulic oil not under pressure

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. 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.


TM-00074


9-5

Function The working principle of a hydraulic system is shown below. 14

14

12

13 10

13 10

11

7

9

6 8 5

4

M

1 3

2

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.

9-6

TM-00074



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 connections 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 components 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.


TM-00074


9-7

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

9-8

TM-00074



Symbol

Meaning

Tank

M

Motor

Level transmitter

Temperature transmitter

Pressure gauge

Pressure indicator

Pressure regulator

Pressure reducing valve


TM-00074


9-9

9-10

TM-00074



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. Chilled unit

From cooler

Chilled unit

Cooler

Return to cooler

Drain Open cooling water system

Circulating cooling water system

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.

Open separate cooling water system

Cooler

Heat exchanger

Heat exchanger

Chilled cold water

Chilled unit

Heat exchanger

Chilled unit

Cold water

Circulating separate cooling water system

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.


TM-00075


10-1

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.

Cooling water

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 valves are opened and closed manually.

Manual valve

An electrically controlled valve receives a control signal from the machine control system when to open and close.

Electrically controlled valve

A pressure gauge displays the pressure in the cooling water system.

Pressure gauge

In order to protect the cooling water system, there might be an over-pressure valve included in the system.

Over-pressure valve

Overpressure valve

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. 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.

10-2

TM-00075


Filter


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.

3 4

1

2

• 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. Magnet field 4

4

Untreated water. The crystals gather and stick easily on surfaces.

Water tank


Magnetically treated water. The crystals do not gather and do not stick on surfaces.

There is a water tank in some machines, and it works as a reservoir for the water.

TM-00075


10-3

The accumulator is a vessel containing air. The air can be compressed, to take up any pressure variations caused by temperature variations.

Accumulator

A temperature sensor monitors the temperature and signals the control system if the temperature raises above or falls under the preset values.

Temperature sensor

The thermostat is used to keep a constant temperature by regulating the flow and thus the supply of colling water to a component.

Thermostat

A pressure guard monitors the pressure and signals the control system if the pressure raises above or falls under the preset values.

Pressure guard

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.

Heat exchanger

Cold water Hot water Plate heat exchanger

The water pump circulates cooling water, used to cool various components.

Water pump

Non-return valves are used in the cooling water system to direct the flows.

Non-return valve

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.

Throttle

The flow meter is a floating body meter used to measure small liquid flows with high accuracy.

Flow meter

10-4

TM-00075



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. Low water flow

High water flow

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 constant flow valve is designed for a fixed flow.

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 flow

High water flow

The shape of the rubber washer at low and high water pressure, respectively in a constant flow valve.

• 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.


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10-5

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.

Conductivity sensor

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.

Softening filter

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. Simplified cooling water system for a TBA/19

Separator

SERVICE UNIT Scrubber

Drain

B4

Z1

A

Compressor M (M7)

VALVE PANEL GUARD B7

Cirk. cold water inlet A4

B

Cold water

A1

Z3

Y32

M5

Z5 LIME SEPARATOR

FINAL FOLDER

C E

Cirk. cold water outlet Sealing unit

JAW SYSTEM

L

FM2

TS− sealing

FM3

(K50)

R

Cooler hydraulic system

D A2

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.

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TM-00075



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 Simplified cooling water diagram for a TBA/21

Inductor Final folder

Jaw unit TS−sealing

Pull Tab

Guide cooling

Z2 B1 Water panel

O2

Q

V

C/A

Cold water

T

B4

B3

P

P P2

Heat exchanger

O1

K2

K1

P

Heat exchanger

T B2

A2 Compressor unit

M M2

Water cooling unit M1 M

U1

B5

F1

P

P1

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.


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Symbols The table below contains the symbols that normally are used in Tetra Pak cooling water system diagrams.

Symbol

Meaning

Accumulator

C/A

Deionizing filter

Non-return valve

Electrically controlled valve

Manual valve

Filter

Throttle, adjustable

Constant flow valve

Cooler

Water pump

M

Motor

Water tank

10-8

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Symbol

Meaning

Heat exchanger

Cooling coil

Deaerator

Flow meter

Pressure gauge

Q

Conductivity sensor

T

Temperature sensor

P

Pressure guard

Pressure regulator


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10-9

10-10

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11

Pneumatic System

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.

Pressure

Shut–off

Pressure regulator Valve

Cylinder

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, up–dated, and currently valid pneumatic diagram is used when working with a particular machine.


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11-1

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 shut–off valve is built into the conditioning unit.

Pressure regulator Shut–off valve Air conditioning unit symbol

Pressure gauge

Separator Lubricator

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.

Separator

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 regulator

The pressure gauge indicates the pressure setting.

Pressure gauge

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.

Lubricator

11-2

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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 change–over force. Non–actuated

Actuated

Seat Valve head Housing Return spring

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. Non–actuated

Actuated

Housing Slide Return spring

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.


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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.

Valve symbols

The illustration shows the working principle of a slide valve, which may be in either of two positions. Outlet. Slide

Pilot air

Pilot air

Valve Inlet.

Vent.

Position 1 The valve has received pilot air on the lefthand side. The passage between inlet 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.

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. Outlet

Valve housing Pilot air

Pilot air

Inlet

Vent

Position 1 The valve symbol is shown with open passage between inlet and

11-4

Position 2 The valve symbol is shown with open passage between outlet and

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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. Outlet Active part of Pilot air Inlet Compressed air supply.

Vent Position 2 The pilot air is received on the righthand side of the symbol, which means that the righthand side of the symbol is active. The air in the cylinder can be evacuated.

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

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. 2 12 1

3

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 five–port valve with a three–position 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.

Cylinder Control signal

Outlet ports

14 Vent port

Return spring Vent port Inlet 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.

4

2

5

1 3

The control signal is discontinued, and the return spring moves the slide. The compressed air is now directed to the minus compartment of the cylinder, while its plus compartment is vented.

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.


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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.

Monostable directional valve

Electrically controlled, monostable directional

Cylinder Electrically controlled, 4

2 Seal Pilot valve Solenoid

5

1

3

14

From PLC

In those cases where the valve receives air with a reduced pressure, which is lower than the change–over 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, change–over 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 valve with separate air

Electrically controlled, monostable valve with 4

2 Seal Pilot valve Solenoid

5

1

Pressure regulator

11-6

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3

14

From PLC



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.

Electrically controlled,

4

5

2

1

3

12

14

From PLC

From PLC

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.


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11-7

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. 4

3-positioned directional valve

2

Electrically controlled, 3– positions directional valve with closed middle posi5

1

3

14

12

No control signal to ports No 12 and No 14 means that the return spring

4

5

2

1

3

14

12

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 4

5

2

1

3

14

12

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

The valve can be in three positions. In addition to the two positions of a 2–position valve, the 3–position 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.

11-8

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Soft-start valve

This type of valve is used in order to make pressurisation of the pneumatic system soft and smooth. Variable stop

1

Telescoping slide

2

3 12

Idle position. In idle position, ports No 2 and No 3 have an open connection. The pneumatic system is

1

2

3

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 opening is regulated by means of a variable stop (limit

1

2

12

3

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

12

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).


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11-9

This kind of valve is used to regulate the flow of air, which is restricted equally much in both directions.

1

Throttle valve

2

Throttle valve

Throttle fitted in directional valve

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. This kind of valve is used when the air is to be regulated in one flow direction only.

1

2

When the air flows from port No 1 to port No 2, it must pass through the throttle and can thus be regulated.

1

Throttle check valve

2

If, on the other hand, the air flows from port No 2 to port No 1, it passes through the check valve without being regulated.

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. 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.

Shut-off valve

The pressure switch triggers an alarm to the control system, if the pressure drops below a preset value. This value can be adjusted.

Pressure switch

11-10

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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. Outlet pressure Force spring

Diaphragm Inlet port Outlet port

Seat Valve plate

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 built–in accumulator.

1

3

1

3

2 Electrically controlled

2 Pneumatically controlled


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11-11

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. Plus compartment

Minus compartment Piston rod

Rear end

Connection

Piston

Cylinder housing

Connection

Front end

The piston is provided with seal–rings, 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. Minus stroke

Plus stroke

The cylinder described above is a double–action cylinder with single–side 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.

11-12

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Double-action cylinder


Single-action cylinder

In the single–action cylinder, a spring effects the minus stroke. Spring

Piston rod

Rod-less cylinder

Such a cylinder is double–acting, 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. Attachment

Connection End section

Magnetic piston sensor

Piston

Cylinder

Connection

End section

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. Magnetic piston sensor

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 switch–off delay

Magnetic piston Double–action cylinder with mag-

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.


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11-13

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. The direction of movement is controlled by directional valves..

Direction of movement

In order to control the movements of a double–action cylinder, a five–port 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. 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

11-14

Valve

Force

Cylinder

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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.

Throttle check

Throttle in valve outlet

Speed regulation by means Speed regulation by means of throttle check valves; throttles in

The reason why throttling is done on the return side of the cylinder is to make the movement smooth. Pressure Correct (vented air throttled)

Wrong (input air throttled)

Time

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.


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11-15

The movement of the piston is dampened at both end positions by built–in 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. Cylinder end

Dampening

Double-action cylinder with vari-

Adjustment Piston

The air on the vent side of the cylinder passes through

A protrusion on the piston closes the central opening in the end section, so that the vented air is forced through the narrow duct, in which the adjustment screw enables the flow, and thus dampening effect on the piston, to be regulated.

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. Piston po-

Undamped

Damped too much Correctly damped Time

11-16

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Main air supply line

Shut–off Pressure gauge Air user

Air user Condensate water

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 5–10 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 pipe–lines should be be installed so that they are easily accessible for checking that they are tight.


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11-17

Function principle This is an example of a principle diagram of a pneumatic system: Valve cabinet

Y08 1

3 2

Suction cups

U05 B06

Hot melt pump T05 U04

C4 Z04 Valve panel

T04 U03

Y03

C3

T03 Y02 4

24

2

22

3

1

5

C2

Y01 C1 YO00

U1

Pressure

Z2 A1

Z1

T1

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.

11-18

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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 3–position 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. A B C T U Y YO

manual valve cylinder cylinder pressure regulator pressure gauge electrically controlled valve pressurisation valve

Pressurisation Control line Depressurisation Vacuum line Valve panel Valve cabinet

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 soft–start valve YO00. This means that valve Y03 does not have to wait for the slow build–up of pressure via the soft–start 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)


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11-19

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 Single–action cylinder with return stroke by spring.

Double–action cylinder with single–ended piston rod.

Double–action cylinder without piston rod.

Double–action cylinder without piston rod, with variable dampening at both end positions. Double–action cylinder with variable dampening at both end positions.

Double–action cylinder with variable dampening at both end positions and magnetic piston. Torque cylinder.

2/2 directional control valve, controlled by pressure acting against return spring. 3/2 directional control valve, controlled by pressure acting against return spring. 3/2 directional control valve, controlled by solenoid with return spring.

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3/3 soft–start valve.

5/2 directional control valve, controlled by pressure acting against return spring. 5/2 directional control valve, controlled by solenoid with return spring. 5/2 directional control valve, controlled by solenoid valve with separate air supply. 5/2 directional control valve, 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.

Non–return valve with variable throttle check.

Rapid–exhaust avlve.


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11-21

Pressure regulator with relief port, spring controlled. Adjustable spring force.

Shut–off valve with exhaust port.

Silencer

Accumulator

Separator with water trap and automatic drain.

Lubricator.

Air conditioning unit, consisting of filter, pressure regulator, pressure gauge, and lubricator.

Pressure gauge.

Electric pressure switch with change–over contact and variable pressure setting. Magnetic piston sensor.

Ejector.

11-22

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12

Steam System

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. C-valve

Sterile barrier

A-valve

Steam Product Cleaning liquid

B-valve Example of a sterile barrier between 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 121˚C and all the air has been evacuated from the system.

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12-1

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 121˚C.

Steam

Steam table 160

Temperature ˚C

140 120 100 80 60 40 20 390

360

330

300

270

240

210

180

150

120

90

60

30

0

0

Absolute pressure kPa

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 µm. In this case it means that particles bigger than 1 µm 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.

12-2

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Construction The picture shows the construction of a steam system and how it works. Pressure gauge (6)

Pressure regulator (5)

Steam filter (7)

Prefilter (2) Valve (1)

Valve (4)

Steam trap (3)

Temperature transmitter (9)

Steam trap (8)

Steam trap (10)

Steam Product Detergent Water

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 condensate 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.


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12-3

12-4

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13

Electrical System

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 section 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 activated. For example, opening a safety door will cause the input channel to deactivate 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.

Example of a safety relay This relay is fulfilling the highest degree of safety relay conditions (cathegory 4).

A1 S13 S24 X2 41 13 23 33 Reset /Test 24VDC

In B

On

1

1

1

1

JOKAB SAFETY TYPE: JSBR4

In Out

In A

2

2

2

2

A2 S14 S23 X3 42 14 24 34


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13-1

Overload protection

The overload protection is used to protect, for example an electric motor, from current surges and sometimes it substitutes fuses. Example of an overload protection, front panel

Over loadprotection, function diagram

1

3

5

2

4

6

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 example in case of a short circuit. A surge filter protects the electrical equipment in the machine from overvoltage 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.

Surge filter

Example of a surge filter with indicator relay function 12 14 11

L/N

PU 4 C-R

UH : 230 V~ IN : 6 A 802 152

13-2

L/N

L/N

L/N

PU 4 C-R

PU 4 C-R

PU 4 C-R

PU 4 C-R

UH : 230 V~ Umax : 275 V~ /

UH : 230 V~ Umax : 275 V~ /

UH : 230 V~ Umax : 275 V~ /

UH : 230 V~ Umax : 275 V~ /

802 152

802 152

802 152

802 152

350 V-

350 V.

350 V-

350 V-

TM-00078



Interference filter EMC=Electro Magnetic Compatibility

Solid state relay LED = Light Emitting Diode

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. 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. Example of a solid state relay, front panel

Solid state relay, function diagram

1

4 Zero detection

Input circuit

Photo detector

And

Trigger circuit

Power circuit

+ 3

Current relay

2

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. Current relay, front panel


A1 11

E1 E2 E3

12 14 Y2

Y1 M A2

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13-3

This card is used to amplify control signals in order to drive a DC-motor.

DC - Motor Drive control

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. Example of a DC motor drive control, front panel

1

11 10 7 8 9

13-4

2 3 4 6 5

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 speed 2 is selected. 6. Internal speed 1 + 2, indicates that internal speed 3 is selected. 7. Potentiometer for setting internal speed 1. 8. Potentiometer for setting internal speed 2. 9. Potentiometer for setting internal speed 3. 10. Acc. Ramp, potentiometer for setting acceleration ramp. 11. IxR compensation. Adjustment for different motor powers. Too high settings will result in unstable motion.

TM-00078



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. Example of a brake card, front panel

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 controlled by the pulses, generated by the card. To make the motor shaft rotate correctly, 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 stepping motor driver card, front panel


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13-5

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.

Level regulator relay

Example of a level regulator relay, front panel

A1 15

A2 16 18

Function

1 Time value s

25

26 28

50 k

R-sector

5 R-value Ω

(x0.1) (x10)

R U

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 adjustable and has to be set according to the conductivity of the liquid.

13-6

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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.

Photocells

TMCC Register code

Angle decoding Angle encoder

Servomotor

PID regulation

Design Output data to DMC

Terminal

DMC

Communication with PLC and PLC Settings

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.


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13-7

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. Example of a TMCC card, frontpanel

FAULT POWER

S1 S2 S3 S4 S5 S6 S7 S8

45 23 6

CDE AB

789

• 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 according to specified application, dependent on the program used

(SW1)

F01

(Terminal)

To ensure correct package design, which means that sealing and cutting the packaging material must be performed correctly, the machine must synchronise 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 design.

Photocell

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. Printed register code and photocell

13-8

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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.

O07.06

Below is shown how racks and module positions are addressed. Example of a TPMC PLC system

Central unit Power supply unit

3

2

1

PS

7

6

5

4

Module positions 0-7 (1-7, power supply unit fitted in position 0) Main rack 0

3

2

1

0

7

6

5

4

3

2

1

0

7

6

5

4

3

2

1

0

7

6

5

4

Module positions 0-7 Expansion rack 1

Expansion rack 2

Expansion rack 3

Expansion rack 7


TM-00078

Address O07.06 is output No 06 in an output module. The module is fitted in position 7 in rack 0 (main rack)

A TPMC system can have a maximum of seven expansion racks.


13-9

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. Example of a GE Fanuc PLC system

Rack 0

PS

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

10

CPU

Rack 1

Rack 2

PS

PS

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.

13-10

TM-00078


References


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 A

B AIR DUCT

AIR DUCT

AIR DUCT X25 V001

Q001

S

K K K K K K K K K 100 101 102 103 104 105 106 107 108 Z001

X300

K K K S S S S S S 110 111 113

S

S

Z003

X001:003

S

0080

K206 K203 K200

S

K205 K202 S S

K204 K201 S S

K206 K203 K200

V001

S

E005

X010 Z002 A A A A A A S 300 301 302 303 305 307 A100 M003

M002 1

G 1 0 0

D 1 0 0

A 1 0 2

A 1 0 3

A 1 0 4

S

AIR DUCT A 1 0 5

A 1 0 6

A S S S 1 0 7

M003 B

VIEW BB

X003

X011

XL1b3

XL1b3

A101 G A 1 1 0 1 1 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

S

Q Q Q Q 013 011 010 008

S

S

Q Q Q Q Q Q Q 012 009 007 006 005 004 003

Q003

Q002

A135

S

S

S

S

FFF FFFFFF FFFFFFFFFFFFF 000 000000 1111111111111 0 0 0 S0 0 0 0 0 0 SS0 0 0 0 0 0 0 0 0 0 0 0 0 SSSSSS 1 23 59666 4 000111 2223334 AB C AB C AB C AB C AB C

F104 F007

A S S S S S S S S S 1 2 1

AIR DUCT

LEFT HAND SIDE

F008

G 1 0 2

AIR DUCT A

VIEW AA

1

MOUNTING DRAWING, EL. CABINET 5271008:07


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13-11

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

A104

M.B104

X001

X001:461 SH.45 X001:462 SH.45

X001

464

BN BU

465

X001:467 SH.56 X001:468 SH.56

X001 BK

02 /A1 I033

463

A305:15 SH.27

X001 241

M.B016A

M.X007 28

M.X007

NC

C

32

13

X001

31

242

13

M.X007 II

X001

33

157

M.B048B NO

M.B016A M.B016B

04 /A3 I035

JAW SYSTEM OVERLOAD, LEFT JAW SYSTEM OVERLOAD, RIGHT

X001 C

158

Q006

C

OVERLOAD PROTECTION COMPRESSOR PEROXIDE BATH, WATER PUMP

STERILE AIR PRESSURE

06 /A5 I037

M.B062

159

07 /A6 I038

M.B048A M.B048B

PEROXIDE BATH BOTTOM COVER, POSITION

293

08 /A7 I039

M.B045

HYDRAULIC UNIT TEMPERATURE

294

09 /A8 I040

M.B048A NO

Q012

243

P

X001

STERILE AIR PIPE POSITION

PEROXIDE BATH WATER LEVEL

05 /A4 I036

14 SH.10

M.B062 IV

M.B104

03 /A2 I034

M.X007 C

01

Q012:1

SH.10

M.X007

NC

30

Q006:1 14

M.B016B

M.X007

29

L10

L12 L11

Example of a circuit diagram

M.B045 292

1

2 t 3 4

C B

LOW LEVEL

24V 24V

0V

A

PLC−IN A104,OPERATION MONIT. 44384−41:02

13-12

TM-00078



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


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13-13

A connection diagram provides information on physical connections between, for example, components, devices, assemblies, and installations.

Connection diagram

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

259

260 2

1

254 5 6

258

253 4

257

250 251 252 1 2 3

2

249 2

1

248 1

11

246 247 1 2

X001

255 256

Example of a connection diagram

CLEANING OF PRODUCTION VALVE

1

11

5 6

W 317

2

1

2

1

8 9 10 BU BK BN

W 315

W 316

11 12 13

5 6 7

W 314 2

1

2

1

M.X014

BU BK BN

1 2 3

W 405

1 2 3 4

W 361

4

W 310

2 M

M.M018 PEROXIDE TANK FILLING

1

M.B116 MEMBRANE LEAKAGE SENSOR

M.B024 UNREELING MOTOR, CONTROL SPEED

M.B025 UNREELING MOTOR, GUARD

2

M.Y041 PULL DOWN DEVICE

1

2

M.Y042 PRESSURE DEVICE

LEAKAGE SENSOR AND SERV. UNIT 61530−25:07

13-14

TM-00078



Mains connection

A mains connection drawing shows the connection between the mains and the electrical cabinet. Example of a mains connection diagram

F001 L1 (R)

1

L2 (S)

2

L3 (T)

3

MAIN VOLTAGE 400/230V AREA TO CABLE 4x25/16 AND SETTING VALUE OF Q002 63/400

1

1

2

3

4

5

6

2

3

2

3

5

6

9

10

3

N

13

14

N

5 X003 0

N

4

4

PE

5

5

MAINS

Q001 2

X300

X300

1

2

Z002

Q002

1

1

CUSTOMER’S FUSE BOX

X011:47

FUSES (SLOW) F001 100A

Z001

FILLING MACHINE CONNECTION ACCORDING TO DIAGRAM "MAINS"

MAINS CONNECTION 61531−06:02

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. Examplel of a line summary


TM-00078


13-15

A terminal summary is a list of terminals, identified by their position number and sheet numbers.

Terminal summary

Example of a terminal summary

13-16

TM-00078



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. Example of a protecting bonding circuit diagram

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

Identification of wiring


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. Tetra Pak use wires according to a specified standard to be able to identify the different circuits, see the sign below.

TM-00078


13-17

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)

1

2

3

1 Main number 2 Sheet number 3 Version number

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.

13-18

TM-00078



Example of a mains connection diagram MAIN VOLTAGE 200−600V EXCEPT 400/230V

F001 L1 (R)

1

1

L2 (S)

2

2

L3 (T)

3

1

3

U3 1U1−1U9

W3 1W1−1W9

MAINS

5

3

2W N

5

2

2V

N PE

1

2U V3

1V1−1V9

1PE

2

4 1

2PE

5

MATCHING TRANSFORMER CONNECTION ACCORDING TO DIAGRAM 61531−07:01

CUSTOMER’S FUSE BOX

Q001

1

1

2

X300

X300

1

2

Z002

Q002

1

1

2

3

4

5

6

2

3

3

5

6

9

10

3

4

N

13

14

N

5 X003 0

5

X011:47

Z001

FILLING MACHINE CONNECTION ACCORDING TO DIAGRAM "MAINS"

MAINS CONNECTION

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.


TM-00078


13-19

Numbering systems for components

W

3

1

2

The position number is divided into three parts: • prefix (1) • function designation (2) • running number (3)

V

U

M 3 M.M007

M M 006 1

2

3

1 Prefix 2 Function designation 3 Running number

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

Prefix (1)

The function designation is indicated in accordance with international standards, see table below.

Function designation (2)

Designation

Signification in electrical diagram

A B C D E F G H K L M N P Q R S T

Assemblies, Subassemblies Transducers Capacitors Binary element, Delay devices, Storage devices Miscellaneous Protective devices Generators, Power supplies Signalling devices Relays, Contactors Inductors, Reactors Motors Analogue elements Measuring equipment, Testing equipment Switching devices for power circuits Resistors Switching devices for control circuits selectors Transformers

13-20

TM-00078



Running number (3)

Designation

Signification in electrical diagram

U V W X Y Z

Modulators, Changers Tubes, Semiconductors Transmission paths, Waveguides aerials Terminal, Plugs, Sockets Electrically operated mechanical devices Terminations, Hybrids, Filters, Equalizers, Limiters

The electrical components are given numbers in a consecutive non-logical order.

M M 006 1


TM-00078

2

3

1 Prefix 2 Function designation 3 Running number


13-21

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)

13-22

TM-00078



W

U

V

36

37

38

3

1

2

3

2

1

3

2

W W

M

39

35 2

W 301

1

3

1

2

W 308

3

34 1

3

33

29

30

2

V

32

28 1 W 304

3

1 U

31

27

26

1

2

W 5

3

25

2

1

24

23

22

21

X001

V

U

W

V

U

M

3

3

M

M

3

M.M004

2

M.M005

CLEANING SYSTEM CIRC. PUMP

3

M.M010

HYDRAULIC PUMP

M.M007

PEROXIDE PUMP

COMPRESSOR, INLET

MOTORS

61530 - 06:05 61530−06:05

XL1

L1 L2 L3

3 XL2

A

3 XL3

A 1

L1 L2 L3

3

L4 L5 L6

Sh.14

A 3

B 5

13

Q003

B 1

B 3

C 13

5

Q008

4

2

4

1

sh.35

3

2 A

5

4 A

6

D 5

HIGH SPEED

13

1

K008 sh.62

3

2

4

25

26

5 6

D 3

E 5

13

4

3

2

4

6

11

12

13

5

4

2

4

6

1

3

5

2

4

6

X001

46

47

48

M.X002

1

2

3

6 2,5mm 2 BK

5

2

E 3

14 SH.57

6 2,5mm 2 BK

1 K010 sh.62

E 1

Q013

14 SH.57 2 2,5mm 2 BK

6

D 1

Q011

6

2,5mm 2 BK

3K003

C 3

14 SH.57

6

6mm 2 BK

C 1

Q010

14 SH.57 2

LOW SPEED

1 K011 sh.62

3

5

2

4

6

14

15

16

K013 sh.63

A

X001

U

27

V

X001

W

M 3 M.M004

X001

5

CLEANING SYSTEM CIRCULATION PUMP

U 1W 1V 1U

M 3

2U 2V 2W

V

W

M 3

M.M001

M.MPLE

MAIN MOTOR

EXTERNAL CONVEYOR

4 MOTORS 44384 - 11:07 44384−11:07


TM-00078


13-23

cont´d • Go to sheet 62 in the Circuit diagrams. (7) • 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)

13-24

TM-00078



K019 15 /B4 Q012

A2

A1

12 35

K019

BENDING ROLLER

A1

11 11 11 62 62 35

K010

MAIN MOTOR LOW SPEED

11 11 11 31 62 62 35

K011

MAIN MOTOR HIGH SPEED

P002

HOUR METER

K008

CLEAN. SYSTEM CIRC. PUMP

16 /B5 Q013 C

17 /B6 Q014

A

C

18 /B7 Q015 20

K111 A 5 9 1 sh.32

K111 6 10 2 sh.32

A

K011 B K010 B 43 44

C

B K011 B 43 44

C

21

K010 22

A2

A K010 21

A 22

B

K011 A2

A1 C

10

P002 +

19 /B8 Q016

11 11 11 35

A1 0V

0V 24V

A2

9

−

8

K008

PLC−OUT A114, EMERGEN. MODULE

44384 - 62: 07 44384−62:07

7

13

11 12


TM-00078


13-25

cont‘d • 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). B55 B50

M13

B116 B51 B117 B53 B104

E1C

E1C B61 B80,1−2

E1A

E1B X71

L1

L2

X73

X72 X74

B44

X2 X8

14 M4

13-26

TM-00078




TM-00078


13-27

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) • Go to sheet 41 in the Circuit diagrams. (3) • 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)

13-28

TM-00078



466 467 468

463 464 465

460 461 462

457 458 459 BK BN BU

BK BN BU

BK BN BU

BK BN BU

6

W 454

W 455

W 456

W 413

M.B071

M.B094

M.B104

M.B117

AIR INLET VALVE POSITION

SUCTION VALVE POSITION


REGULATING VALVE OPEN POSITION

TOWER, INDUCTIVE SENSORS 61530−44:04

1

2

4

A104

M.B104

X001

X001:461 SH.45 X001:462 SH.45

5

X001

464

BN BU

465

X001:467 SH.56 X001:468 SH.56

X001 BK

02 /A1 I033

463

241

M.B016A

M.X007 28

M.X007

NC

C

29

13

13

Q006:1 14

M.X007

NC

30

M.X007 C

X001

31

242

157


M.X007 II

X001

33

M.B048B NO

PEROXIDE BATH WATER LEVEL

M.B016A M.B016B

04 /A3 I035

Q006

05 /A4 I036

14 SH.10

M.B062 IV

M.B016B

M.X007

03 /A2 I034

JAW SYSTEM OVERLOAD, LEFT JAW SYSTEM OVERLOAD, RIGHT

X001 C

158

C

OVERLOAD PROTECTION COMPRESSOR PEROXIDE BATH, WATER PUMP

STERILE AIR PRESSURE

06 /A5 I037

M.B062

159

07 /A6 I038

M.B048A M.B048B

PEROXIDE BATH BOTTOM COVER, POSITION

293

08 /A7 I039

M.B045

HYDRAULIC UNIT TEMPERATURE

294

09 /A8 I040

M.B048A NO

Q012

243

P

X001

M.B104

Q012:1

SH.10

32

01

7 A305:15 SH.27

X001

L10

L12 L11

5

M.B045 292

1

2 t 3 4

C B

LOW LEVEL

24V 24V

0V

A

PLC−IN A104,OPERATION MONIT.

44384 -41: 02 44384−41:02


TM-00078


3

13-29

cont’d • 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)

13-30

TM-00078



8

9

10


TM-00078


13-31

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 L21 is reserved for 24 V, safety circuits L30 is reserved for 0 V, safety circuits L31 is reserved for 24 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)

13-32

TM-00078



3

2

4

L30 L31

A114 11

X001

12 /B1 Q009

13 /B2 Q010

M.X034

M.X034

408

9

9−

409

10

10−

6 M.X034:8− SH.61

14 /B3 Q011

L30

1

5 K019

15 /B4 Q012

A2

A1

12 35

K019

BENDING ROLLER

A1

11 11 11 62 62 35

K010

MAIN MOTOR LOW SPEED

11 11 11 31 62 62 35

K011

MAIN MOTOR HIGH SPEED

P002

HOUR METER

K008

CLEAN. SYSTEM CIRC. PUMP

16 /B5 Q013 C

17 /B6 Q014

A

C

18 /B7 Q015

A

K111 A 5 9 1 sh.32

K111 A 6 10 2 sh.32

K011 B K010 B 43 44

C

B K011 B 43 44

C

21

K010 22

K010 21

A2

A 22

B

K011 A2

A1 C

20

P002 +

−

K008 19 /B8 Q016

11 11 11 35

A1 0V

0V 24V

A2

PLC−OUT A114, EMERGEN. MODULE

44384 - 62: 44384−62:07


TM-00078


07

13-33

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) • Go to sheet 71 in the Circuit diagrams. (7) • 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)

13-34

TM-00078



C

M.B011

CRANK POSITION

M.B012

2

M.Y022

SIDE PROTECTOR, POSITION LEFT

15 2

14 1

13 2

12 1 1

MAIN MACHINE, CLUTCH

RIGHT

2

2

1

5

2

2

2

W 107

1

BN

5 NO NC

M.B010

11

10

9

8

7

6 BU

BN

5

4 BU

BU

W 106

BN

W 011

BU

BN

W 010

BK

BU

W 102

BN

2

3 BN

1 BU

1

BK

M.X007

1

2

3

M.Y043 DRIVE UNIT, BRAKE

M.X007 BODY AND DRIVING UNIT 61530−23:02

5 4

6

L10

L10 L11

A119 01

02 /A1 Q081

10

M.Y043 X001

03 /A2 Q082

236

14

9 04 /A3 Q083

05 /A4 Q084

M.X007:13 SH.69

M.X007

M.X007 1

2

8

15

M.Y043

M.X007:16 SH.39

DRIVE UNIT, BRAKE

9

A001:26 SH.12

BENDING ROLLER ENABLE

A400:20 SH.33

DESIGN ENABLE

06 /A5 Q085

07 /A6 Q086

08 /A7 Q087

A400:22 SH.33

VOLUME ENABLE

A400:23 SH.33

VOLUME CLOCK

10 A400:24 SH.33

VOLUME DATA 0V

0V 24V

09 /A8 Q088

PLC−OUT A119

44384 44384−71:02- 71: 02


TM-00078


7

13-35

cont’d • 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)

13-36

TM-00078



B21C

B21A B47

B236

B46

M16 S4 B85 B21B B37A

B37B

B9 B112 R36 B38 B4 B48B

B108 X32 X34 Y1 Y27 Y102 Y26 Y24 Y21 Y20 Y86 Y25 Y23 Y19 Y17 Y9 Y105 Y8 Y106 Y7 Y14 Y6 Y13 Y5 Y12 Y3 Y2 X33 X35

SPLICING TABLE B14 R1

M6

Y32 Y31 B7

R5 A−B−C

Y51 Y29 B11

Y39

B2 S28 S14 M5 Y107

11

B30 Y33 B10

B6 B45

B1 X1 Y41

Y22

B15 Y109 B118

B119

B20

Y43 B16A

B13

Y42

12

10-23-96 15:21

13


TM-00078


13-37

13-38

TM-00078



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.

CIP = Cleaning In Place

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

TPMS = Tetra Pak Maintenance System


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.

TM-00079


14-1

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.

TPMS is based on a continuous reevaluation of the maintenance system based on recurrent feed back from the customers.

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.

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.

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.

14-2

TM-00079



Checklists

A checklist is a list of all the work that should be performed during one maintenance occasion.

The diagram shows the recomended maintenance intervals for various components.

• 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 checkpoints 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 valuable information for the next service.


TM-00079


14-3

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.

Reporting back

Improvement is a continous process that takes place on two different levels - national and international.

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.

Improvement

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. 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.

14-4

TM-00079


Availability


• 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.


TM-00079


14-5

Checklist - Front page

1. 2.

96.06.20

3.

Eric

4. Juice & Milk Plant J & M Plant A

5. 6.

9.

11.

10.

12.

7. 8. 13. 15. 16. 22.

14-6

17.

TM-00079

14.

18.


20.

19.

21.


1

Issued by

Name of the person who created the Maintenance Recommendations.

2

Issue date

Date when the Maintenance Recommendations 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 maintenance

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 completed

10 Completion time

The time the maintenance was completed

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 filling machine when the maintenance was started

13 Performers signature Signature from the one who performed

the maintenance, (Tetra Pak or customer) 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 recommendations 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

TM-00079


14-7

Checklist - Check items

23.

24.

25.

26.

27.

28. 29.

30. 31.

32.

34. 35.

33.

14-8

TM-00079



23 Selection/Description

Describing where on the equipment to find the item to check. Name of details selected from the SMA 3 phrase library

24 Action

Defines what to do with the check item. Check, change, clean, etc. 22 pre defined 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 define the amount of work selected for customer and Tetra Pak. 3 = Customer and 7 = Tetra Pak

26 Document Reference

Where to find 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 maintenance

28 Interval

At what interval the check item should be performed.

29 Pos No

Position number is the check item’s identity. Used when evaluating statistical results and to identify the check items when lists are printed in different languages

30 Result Code

Here is where the technician fills in the result of the maintenance. A=Satisfactory, B=Adjusted, C=Replaced, D=Remaining 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 “Rotator 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 filled 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

TM-00079


14-9

Checklist - Comment Page 36.

14-10

37.

TM-00079



36 Pos no

The position number that the comment is valid for. Note! It is also possible to make general comments about the equipment, or parts of it.

37 Comment E.g. notes about recommended rebuildings, problems on the equipment,

etc.


TM-00079


14-11

Checklist - Connected items list

38.

14-12

39.

TM-00079

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


TM-00079


14-13

14-14

TM-00079



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 product being packed. Further information is given in section Different material for different products, page 15-5. TBA = Tetra Brik Aseptic

A typical TBA material is built, from outside and inwards, as shown in the picture and description below. 1 2 3

4

5 6 7 8 Construction of the packaging material.

1. Outer coating 2. Printing 3. Paper board, 4. 5. 6. 7. 8.


protects the package against external humidity.

bleached or claycoated, offers a good printing surface. Paper board, unbleached, strengthens the package. Lamination, a plastic layer which enables the paper board to stick to the aluminium layer. Aluminium protects against oxygen and light. Internal coating 1 offers adhesion against the aluminium layer. Internal coating 2 offers tightening against the product and enables package sealing.

TM-00080


15-1

The picture below describes what type of effects the different layers in the material protects against. Moisture of water

Light

Micro-organisms

Oxygen

Odours

Outer coating Printing Paper board, bleached or claycoated

Paperboard, unbleached Lamination Aluminium Internal coating 1 Internal coating 2

Product

Flavour

The converting process The converting process is what takes place when the paper board is transformed 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 creasing tools. The creasing tools create creases, which means the folding instructions on the package, as well as opening perforations and holes for straws.

Printing press, flexography

Creasing

Printing

Opening perforation Crease pattern

Crease pattern and opening perforation on the packaging material

15-2

TM-00080



Roll = Roll of packaging material several packages wide.

• Lamination The roll will be transported to the laminator. In the laminator different layers 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.

Lamination

• 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.

Slitting

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 properties 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 substances. Negative properties are: It does not resist much heat or cold. It is fat-soluble. It does not protect the product against oxygen.


TM-00080


15-3

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.

Adhesion plastic

Paperboard is used as main support, to allow the package to stand up, to maintain its shape also with product inside, and to sustain a certain amount of physical exposure.

Paperboard

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 duplex, 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. 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 excellent printing properties.

Duplex

Unbleached

Bleached

Claycoat

Claycoated

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 aluminium layer is less than 7 µm.

Aluminium

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. Packaging material containing K-film in the innermost layer, is used when packing aggressive products and products that are sensitive to residual flavours. 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

K-film is manufactured through film blowing techniques. This method means that the plastic is stretched and oriented in length as well as transversal direction. 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 Kfilm, there is no risk of corrosion in the aluminium layer.

15-4

TM-00080



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. Outside LDPE layer, 12 g/m2 Paperboard and printing Lamination layer LDPE, 25 g/m2 Aluminium foil, 17 g/m2 Adhesive polymers, 6 g/m2 Example of TBA/j material

Inside LDPE layer, 29 g/m2

• TBA/w

k = a layer of k-film has been added on the inside

• • • • • • • • • • •

Used for wine and alcoholic drinks with less than 20% alcohol. 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 protection 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 barrier, for example pasteurised milk.


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MF has

Packaging material

Longitudinal seal strip

LDPE

LDPE

LDPE

HDPE

Primer

Primer

PET

EVOH Primer

Primer LDPE

LDPE

LDPE

LHL PPP/PPPW LHL−STRIPS PPP−STRIPS Longitudinal of LS strips. 7,5/0,1 seal and different types7,5/0,075

LSE

LSE−STRIPS 7,5/0,075

• PPP/PPPW has a core of PET, coated with primed layers of LDPE. This strip is suitable for products that require a dense oxygen barrier, 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 barrier. 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.

PullTab strip

PullTab opening

To enable this, the patch and the PullTab strip must consist of different materials. 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 PullTab is made of a laminated foil, composed of printed aluminium, which provides mechanical strength and aesthetics, and LDPE which enables sealing to the patch and the packaging material.

LDPE

Al

Primer EVOH

LDPE

Primer LDPE

TBA patch and PullTab strip

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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 Rotogravure, as described below.

Flexo Relief printing = Printing method where the cliche’ sections, which transfer the colour, are raised.

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 cliché. The cliché 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. Cliché

Anilox roller = A laser engraved roller that has a specific pattern of holes or “cups”.

Counter pressure roller

Colour transfer roller (anilox)

Roller, collecting the colour Packaging material

Function principle for Flexo CT = Continuous Tone. Like in a photograph or an illustration.

Screen pattern = small dots Yellow

Cyan

K

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 process design.

Key colour

Magenta

Line design


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Offset is used for designs with photographic pictures. Compared to flexo process, offset yields a somewhat better quality of the picture. Colour roller

Offset

Dampening roller

Printing plate

Packaging material

Rubber roller

Counter pressure roller Function principle for Offset

Offset is a flat printing method. A colour roller applies the colour on the printing plate. The colour is then transferred to a rubber roller, which applies the design onto the packaging material.

Flat printing = Printing method, where the sections which transfer the colour are in level with the plate.

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 colour 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 represent any tint. Rotogravure is a printing method that is rather rare today. It yields an extremely high printing quality and may be used for exclusive printed designs or very large series.

Rotogravure

Rotogravure is a gravure printing method. The printed design is engraved in a cliché. The cliché will collect the colour itself. Excess colour will be removed, leaving colour only in the engravings. When the packaging material is pressed against the cliché, the colour will soak into it.

Gravure printing = Printing method where the immersed sections collect the colour and transfer it to the paper.

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 Counter pressure roller

Packaging material Cliché

Scraper

Colour Function principle for Rotogravure

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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. 1

Production order label 2

3 9 4 5

6 7

10 8

Production order label

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


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Pallet label 1 2

3

2 4

5 Pallet 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 produced and delivered within specification. One condition for accepting a packaging material claim, is that the filling machine is upgraded to recommended standard and adequately maintained. Packaging material claims will not be accepted if the material has not been stored in accordance with local recommendations or recommended storage conditions 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 Manager, 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.

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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 denominations. The head group, 900 Filling machine, is intended to be used by Technical 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 precise direction of where the fault occurs on the packaging material. This to enable faster handling of the claim.

Tetra Pak Carton Packaging Division Carton Support Fault Code List Packaging Material L 009

4. Fault Code List Packaging Material

More detailed information are available from Market Companies in these documents: 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 doublewrapped. 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.


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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. 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.

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Handling


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.


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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.

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Wb_basic Course Tba

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