Tetra Alex® Homogenizers & HP Pumps

Commissioning Checklist – 2014

 Inspect Installation
 Check that the homogenizer is level
o Check to be sure locknuts on all feet are tight
o Remember to check the center leg
 Check that the piping is connected properly
o Product feed line should have as few bends as possible
o Wide-radius bend down to inlet
o Straight pipe length leading to inlet is 3-4x longer than pipe diameter
o Pipe diameter same throughout
 Dampeners are installed properly
o Drainable
o Jumper for CIP is Okay
o Customer is aware that dampers need to be drained after CIP
o Customer is aware that if CIP jumper is installed it must be removed and the stand
pipes capped off during operation
o Discuss extending pulsation dampeners
 Dampeners fill over time, after which they no longer dampen. Making
them taller extends run time
 Check the electrical connections
o Bump motors and check rotation direction
o Find hour meter
 Recommend customer install one if not currently there
o TA350/TA400
 Check alarms
 Disconnect the sensor and check that Low Oil Pressure shuts down
machine
 Move the setting on the dial and check that High Machine Temp shuts
down machine with 20 minute delay
o Tool Box
 Check to see that all required tools are there and working properly
o Check oil levels
o Let product manager know ASAP if something is missing or not working properly

Tetra Pak Inc. 101 Corporate Woods Parkway, Vernon Hills, IL, 60061, USA Tel: +1 847 955 6000 Fax: +1 847 955 6500 www.tetrapakusa.com
 Start Up Machine
 Piping should be flushed by bypassing the homogenizer to remove debris (if possible)
o If total bypass is not possible flush through the homogenizer without it running
o Check for leaks
 Check machine start-up and shutdown sequences
o See Supplemental Electrical Documentation (Chapter 11) for details
 (TA350, TA400) Check oil system
o Gearbox
 Oil pressure should be 3-8 bar (43-116 psig) positive pressure
 Adjust with bypass valve
o Crankcase
 Oil pressure should be 6-8 bar (87-116 psig) positive pressure
 Check crankcase bypass
 With just the oil lube pump running close the hand valve on top of
the pistons
 Adjust bypass valve so the pressure reads 10 bar
 Open the hand valve so the pressure is 6-8 bar (87-116 psig)
o Check for oil leaks
 Set homogenizing pressure
o Check with customer to see what pressure they are going to run
 Normal milk = 1800 psig
 Normally, anywhere from 15-25% of total product pressure on 2nd stage
o Set second stage first, then set first stage
o ONLY apply homogenizing pressure while the homogenizer has flow
o Note: Hydraulic pressure will be lower than product pressure
 Set hydraulic safety relief valves
o Relief pressure normally ~10-15% above operating pressure
o Remove cover
o To adjust safety valves:
 Adjust 2nd stage homogenizing pressure to maximum, 1st stage should
have no pressure
 Use Allen screw on top of hydraulic unit to adjust pressure to 10-15%
above operating pressures
 Adjust 1st stage homogenizing pressure to maximum
  Use Allen screw on top of hydraulic unit to adjust pressure to 10-15%
above operation pressures
o Replace cover
 Check water flow
o Feed pressure 2-4 bar (30-60 psig)
o Softened or filtered water preferred
 Hard water shortens part lifetimes (seals, pistons, etc)
o Some temperature gain across pistons
o (TA350, TA400) Set oil temp alarms
 Machine oil temp max 60°C (140°F)
 Crankcase oil temp max 55°C (131°F)
 Gearbox oil temp max 60°C (140°F)
o Adjust water flow/thermostatic valves to maintain oil temp below alarm
conditions
o Check belt tension
 Belts tight and do not slip when adding pressure
o Check product feed pressure
 Minimum 45 psig recommended at all times (60 psi for viscous product)
 If lower at any time (start up, CIP, separator shoot, production)
will cause cavitations
 Aseptic Machine
 Steam Feed pressure should be 2-4 bar (30-60 psig), 45 psi min is recommended.
 Culinary steam required
 Check water flow through condensers
o Steam condensate should be ~110°C (230°F)
 Customer Training
 Discuss operation of machine
o How product flows through
o How water flows through
o (TA350/400) How oil flow through
o How the drive system works
 Total RPM is shown in the test record of the manual
o Draining of the pulsation dampeners after CIP
o General maintenance
 Remove valves
  Explain how they work and normal maintenance
 Remove piston
 Explain normal maintenance of piston & bellows
 Remove homogenization head
 Explain general maintenance and that 1st stage will wear much
faster than 2nd stage
 Show how to change all oils
 Show how to tighten belts
 Show where to lubricate motor
 Show how to adjust water flow
 (TA350/400) Show how to change oil filter(s)
 Show how to set pressure
 2nd stage first then 1st stage
Contacts:

Keith Ortman (Homogenizers) – Office-847.955.6088; Cell-847.630.8005

Darin Dye (Homogenizers) – Office-847.955.6061; Cell-224.778.0328
John Derza (Homogenizer Starter Panels) – Office: 847.955.6334; Cell: 847.809.8725
Rockwell Drives Technical Support: 262.512.8176