Sterideal User and Maintenance Manual

STERIDEAL
USER AND MAINTENANCE

MANUAL
Client: Centrale Laitière de Mahdia (CLM)

Location: Mahdia, Tunisia
Machine: Sterideal
Type: ST 8,5 C
Year of manufacture: 2010
Order number(s): N.00352.01
Machine number(s): N.00352.01
Published by: Stork Food & Dairy Systems B.V.
Date of publication: November 12, 2010
Document version: 1.0
Machine number: N.00352.01, Centrale Laitière de Mahdia (CLM) User and maintenance manual
Copyright
Copyright © by Stork Food & Dairy Systems B.V. All rights reserved
worldwide. This publication and the software, shall not be copied,
distributed, transmitted, transcribed or translated into any human or
computer language, in any form or by any means, to any third parties,
without the express written consent of:
Stork Food & Dairy Systems B.V.,
P.O. Box 759,
1000 AT Amsterdam,
The Netherlands.
All technical and technological information along with diagrams and
technical descriptions supplied by us remain our property and cannot be
used without our previous written permission (other than for the operation
and installation), neither copied, reproduced, transmitted or communicated
to third parties.
Disclaimer notice
We reserve the right to change the construction and/or configuration of our
products at any time without being obliged to adjust earlier supplies
accordingly.
The material in this manual is believed adequate for the intended use of the
machine. If the machine, or its individual modules or procedures, are used
for purposes other than those specified herein, confirmation of their validity
and suitability must be obtained.
We have made every effort to make this manual as accurate and complete
as possible. Should you find errors or omissions, please bring them to our
attention so that we may correct them. In this way we hope to improve our
product documentation for the benefit of our customers. Please send your
corrections and comments to our Service Department.
In no event will Stork Food & Dairy Systems B.V. be liable for any damages,
direct, indirect, incidental, special, or consequential, resulting from any
defect in the information, even if it has been advised of the possibility of
such damages. Stork Food & Dairy Systems B.V. provides the publication
‘as is’ without warranty of any kind, either expressed or implied, including
but not limited to the implied warranties of merchantability or fitness for a
particular purpose. The entire risk as to the use of this information is
assumed by the user.
All mentioned values are indicative. It is the responsibility of the customer
to optimise settings on the basis of established deviations.
The information contained in this manual is based on the latest information.
It is provided subject to alterations.
2 November 12, 2010

General
Guarantee
The guarantee provisions stipulated in the delivery conditions in your
possession are applicable to the product.
Guarantee on your machine expires if:
• Service and maintenance are not carried out strictly in accordance with
the instructions.
• Repairs are not carried out by our personnel or if they are carried out
without our prior written consent.
• Changes are made to the machine without our prior written permission.
• Non-original Stork parts or non-specified lubricants are used.
• The machine is used improperly, carelessly or not in line with its nature
and/or purpose.
All parts subject to wear are excluded from guarantee.
Product liability
It must be understood that the liability of Stork Food & Dairy Systems B.V.,
whether due to breach of guarantee, negligence or otherwise, is limited to
the furnishing of such replacement parts, and Stork Food & Dairy Systems
B.V. will not be liable for any other injury, loss, damage or expenses,
whether direct or consequential, including but not limited to loss of use,
income or damage to material arising with the sale, installation, use of,
inability to use or the repair or replacement of products of Stork Food &
Dairy Systems B.V.
All mentioned values are indicative. It is the responsibility of the customer
to optimise settings on the basis or established deviations.
The product complies with all applicable CE Directives and therefore bears
a CE plate.
n Note
This machine can only be installed, adjusted or started up for the first time
by specialized staff of Stork. This remark replaces the installation
prescription (point 44 of the Committees comments 89/392/CEE).
Preface
This manual contains important information for a proper operation of the
equipment. It also contains important instructions to prevent accidents and
serious damage before commissioning and during operation of the product,
and to enable trouble-free operation in the safest possible way.
If you have any questions or need further details on specific matters
concerning the equipment, please do not hesitate to contact one of our
staff.
version 1.0 3
c Caution
Before you start using the equipment, read this manual carefully,
familiarise yourself and your employees with the functioning, operation
and safety provisions of the equipment and strictly follow the instructions.

P.O. Box 759,
1000 AT Amsterdam,
The Netherlands.
Tel.: +31(0) 20 6348911
Fax: +31(0) 20 6348790
E-mail: info.fds@sfds.eu
Website: www.fds.storkgroup.com
4 November 12, 2010

Contents
CONTENTS
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3 Theory indirect sterilization process . . . . . . . . . . . . . . . . . . . . . . 31
1.3.1 UHT sterilization process . . . . . . . . . . . . . . . . . . . . . . . 31
1.4 Summary of the modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5.1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5.2 Dimensions and connections . . . . . . . . . . . . . . . . . . . . 42
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . 46
2.3.2 Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.3 Instructions for maintenance . . . . . . . . . . . . . . . . . . . . 48
2.4 Machine decommissioned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.5 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6 Emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.7 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3 Product supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.1 Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.2 Supply valve central CIP system (module 23) . . . . . . . 62
3.3.3 Discharge pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3.4 Branch on behalf of cleaning (module 28) . . . . . . . . . . 64
3.4 Product pump (module 05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4.1 Centrifugal pump (module 05A) . . . . . . . . . . . . . . . . . . 65
version 1.0 5
3.5 Metering unit (module 03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.5.1 Dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.6 Tubular flow steriliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6.1 Filling back pressure valve (module 15) . . . . . . . . . . . . 69
3.6.2 First stage regenerative section (module 07) . . . . . . . . 70
3.6.3 Second stage regenerative (module 09) . . . . . . . . . . . 71
3.6.4 Main heater (module 10) . . . . . . . . . . . . . . . . . . . . . . . 72
3.6.5 Holding section (single tube) . . . . . . . . . . . . . . . . . . . . 75
3.6.6 Product cooler/circuit steriliser (module 12) . . . . . . . . . 76
3.6.7 System back pressure valve (module 13) . . . . . . . . . . 78
3.7 The homogeniser (module 08). . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.7.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.7.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.7.3 Pump block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.7.4 Pulsation damper and rupture disc. . . . . . . . . . . . . . . . 82
3.7.5 Pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.7.6 The pulsation dampener. . . . . . . . . . . . . . . . . . . . . . . . 85
3.7.7 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.7.8 Automatic homogenising valve actuation . . . . . . . . . . . 88
3.7.9 Cooling/lubricating water system . . . . . . . . . . . . . . . . . 91
3.7.10 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.8 Homogenising device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.8.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.8.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.9 Filling pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.9.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.9.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.10 System control cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.10.2 Functions of the operator control unit . . . . . . . . . . . . . . 96
3.11 Interaction with other machines . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.11.1 Communication between the system and
filling machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2.1 Tubular flow steriliser . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2.2 Metering unit (module 03). . . . . . . . . . . . . . . . . . . . . . 107
4.2.3 The homogeniser (module 08) . . . . . . . . . . . . . . . . . . 108
4.3 Machine environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3.2 Corrosion resistance. . . . . . . . . . . . . . . . . . . . . . . . . . 111
6 November 12, 2010

Contents
4.4 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.4.1 Mains power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.4.2 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.4.3 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.4.4 Water specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4.5 Lye (NaOH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.4.6 Acid (HNO3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.5.1 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.6 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.6.1 Ambient indoor air, general . . . . . . . . . . . . . . . . . . . . 116
4.6.2 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.6.3 Connecting the machine to the utilities. . . . . . . . . . . . 116
4.6.4 Electrical hook-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.6.5 Installing power cables . . . . . . . . . . . . . . . . . . . . . . . . 117
4.6.6 Electrical safeguards . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.6.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.7.1 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5 Operating interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

5.2 Operating mechanisms and indicating instruments . . . . . . . . . . 122
5.2.1 Stack light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.2.2 Machine control panels . . . . . . . . . . . . . . . . . . . . . . . 124
5.2.3 Pressure gauges and pressure regulators . . . . . . . . . 125
5.2.4 Siemens terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.2.5 Paperless recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.3 Operator panel Start menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.4 HMI menu layout and buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.5 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.5.1 Operator buttons and specials . . . . . . . . . . . . . . . . . . 133
5.5.2 P&ID Controller buttons . . . . . . . . . . . . . . . . . . . . . . . 133
5.6 Manual operation menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.6.1 Step control menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.6.2 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.6.3 Manual Operation - P&ID menu . . . . . . . . . . . . . . . . . 136
5.6.4 Test homogenizing system. . . . . . . . . . . . . . . . . . . . . 139
5.6.5 Main heater temperature alarm menu . . . . . . . . . . . . 140
5.7 Step menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.8 Alarm menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.9 Icon description menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.10 Help menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
version 1.0 7
5.11 Maintenance menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.11.1 Password menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.11.2 CPU menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.11.3 Variable menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.12 Program selection menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.13 Process protocol menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.14 Product return menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.15 UHT menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.16 Trending menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.17 Process temperature menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.18 Timer menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.19 System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.20 Filling pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.21 Recipe menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.22 Control components menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.22.1 Motor/pump controller. . . . . . . . . . . . . . . . . . . . . . . . . 175
5.22.2 Level controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.22.3 Cascade controller main heater . . . . . . . . . . . . . . . . . 178
5.22.4 Pressure controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.22.5 Temperature controller . . . . . . . . . . . . . . . . . . . . . . . . 180
5.22.6 Specials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6 Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.2 Machine start-up preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6.3 Machine start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.3.1 Pictographs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.4 Operator procedures during machine operation . . . . . . . . . . . . 187
6.4.1 Downloading recipe to PLC . . . . . . . . . . . . . . . . . . . . 187
6.4.2 Temporarily override main heater temperature . . . . . 187
6.5 Checks during machine operation . . . . . . . . . . . . . . . . . . . . . . 188
6.6 Machine shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.6.1 End of production run . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.6.2 Program selecting options during step 13 . . . . . . . . . 188
6.6.3 When the machine has been shut down . . . . . . . . . . 188
6.7 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.7.1 Cleaning and product control unit processes . . . . . . . 189
6.7.2 Process sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
6.8 Description of program steps of Sterideal . . . . . . . . . . . . . . . . . 192
6.8.1 Stand-by phase (Step 00 through Step 02) . . . . . . . . 195
6.8.2 Production phase (Step 03 through step 13) . . . . . . . 198
6.8.3 Intermediate CIP phase (Step 14 through step 19) . . 209
6.8.4 Main CIP phase (Step 20 through step 26) . . . . . . . . 215
6.8.5 Main cleaning 2nd loop phase. . . . . . . . . . . . . . . . . . . 220
6.9 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7 Cleaning In Place (CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
8 November 12, 2010

Contents

7.2 Intermediate Aseptic CIP program. . . . . . . . . . . . . . . . . . . . . . . 247
7.3 Main CIP program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
8.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
8.2.1 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
8.2.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
8.2.3 Aim of maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 250
8.2.4 Long term maintenance . . . . . . . . . . . . . . . . . . . . . . . 250
8.2.5 Pay attention to safety . . . . . . . . . . . . . . . . . . . . . . . . 251
8.2.6 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 253
8.3 How to order spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
8.3.1 Ordering procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 257
8.3.2 Electrical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
8.3.3 Ordering replacement parts from subcontractors. . . . 257
8.3.4 Spare part categories . . . . . . . . . . . . . . . . . . . . . . . . . 258
8.3.5 Revision sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
8.4 Preventive maintenance diagrams . . . . . . . . . . . . . . . . . . . . . . 260
8.4.1 Maintenance schedule
control cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
cleaning and supply unit. . . . . . . . . . . . . . . . . . . . . . . 263
tubular flow steriliser / cleaning and supply unit . . . . . 264
metering unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
fluid transport pump . . . . . . . . . . . . . . . . . . . . . . . . . . 266
homogeniser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
8.5 Filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8.5.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8.5.2 Cleaning the filter mats. . . . . . . . . . . . . . . . . . . . . . . . 271
8.6 Applying pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.6.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.6.2 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.6.3 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.7 Expansion tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
8.7.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
8.7.2 Checking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 273
8.8 Back pressure valve (module 13/15) . . . . . . . . . . . . . . . . . . . . . 274
8.8.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
8.8.2 Adjusting the backpressure setpoint . . . . . . . . . . . . . 274
8.9 Sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.9.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.9.2 O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
version 1.0 9
8.10 'De Haan' valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

8.10.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.10.2 Exchange the O-rings. . . . . . . . . . . . . . . . . . . . . . . . . 276
8.11 'De Haan' stainless-steel bellows valve . . . . . . . . . . . . . . . . . . . 277
8.11.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.11.2 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.11.3 Inspection procedure . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.11.4 Exchange the O-rings. . . . . . . . . . . . . . . . . . . . . . . . . 277
8.12 Checking the Pt-100 resistance bulbs . . . . . . . . . . . . . . . . . . . . 279
8.12.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
8.12.3 Measure resistance procedure . . . . . . . . . . . . . . . . . . 279
8.13 Maintenance of pump seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.14 Plungers and plunger packing . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.14.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.14.2 Disassembly and assembly plunger . . . . . . . . . . . . . . 282
8.14.3 Collar seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
8.15 Neck bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.15.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.15.2 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.15.3 Disassembly and reassembly procedure . . . . . . . . . . 286
8.16 Packing set of pump cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 288
8.16.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
8.16.2 Fitting the packing set. . . . . . . . . . . . . . . . . . . . . . . . . 288
8.16.3 O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
8.17 Valves of high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.17.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.17.2 Disassembly and assembly valves. . . . . . . . . . . . . . . 291
8.18 Hydraulic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.18.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.18.2 Refilling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.18.3 Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.19 Rupture disc protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
8.19.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
8.19.2 Replacement procedure . . . . . . . . . . . . . . . . . . . . . . . 296
8.20 The pulsation dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.20.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.21 The aseptic pulsation damper . . . . . . . . . . . . . . . . . . . . . . . . . . 299
8.21.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
8.22 Homogenisation valve P0866108 . . . . . . . . . . . . . . . . . . . . . . . 301
8.22.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
8.22.2 Disassembly and assembly procedure. . . . . . . . . . . . 301
8.22.3 Installation of homogenising valve seat . . . . . . . . . . . 303
8.22.4 Bearing bushes homogenising spindle. . . . . . . . . . . . 303
10 November 12, 2010

Contents
8.23 Tensioning the V-belts (3HL-10) . . . . . . . . . . . . . . . . . . . . . . . . 305

8.23.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8.23.3 Checking the tensioning . . . . . . . . . . . . . . . . . . . . . . . 305
8.24 Drain off water from the crankcase . . . . . . . . . . . . . . . . . . . . . . 307
8.24.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
8.24.2 Draining procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 307
8.25 Rupture disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
8.25.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
8.26 List of recommended lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 309
8.27 Oil pump of homogeniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
8.27.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
8.27.2 Change and refill the oil pomp . . . . . . . . . . . . . . . . . . 311
8.28 Electric three phase motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.28.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.28.2 Lubrication procedure. . . . . . . . . . . . . . . . . . . . . . . . . 312
8.29 Homogenising spindle in the homogenising device. . . . . . . . . . 313
8.29.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
8.29.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
8.30 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
8.30.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
8.30.2 Exchange and refill oil procedure . . . . . . . . . . . . . . . . 314
8.31 PCM dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
8.31.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
8.31.2 Change and refill procedure . . . . . . . . . . . . . . . . . . . . 316
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
version 1.0 11

List of Figures
LIST OF FIGURES
Figure 0.1 Pipe connections Stork/Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 1.1 Temperature/time diagram according to Horak . . . . . . . . . . . . . . . . . . . 36
Figure 1.2 Modular design of modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 1.3 Dimensions and connections (P0875581A). . . . . . . . . . . . . . . . . . . . . . 42
Figure 1.4 Homogeniser dimensions and specification
(P0678982-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 2.1 Placing of safety adhesives - Top view . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 3.1 Machine process flow (P0874210-B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 3.2 Product supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 3.3 Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 3.4 Supply valve central CIP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 3.5 Discharge pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 3.6 Branch on behalf of cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 3.7 Centrifugal pump (module 05A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 3.8 Metering unit with PCM dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 3.9 Tube configuration (one, two, three and multi-tubes) . . . . . . . . . . . . . . 67
Figure 3.10 Filling back pressure valve (module 15) . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 3.11 First stage regenerative (module 07) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 3.12 Second stage regenerative - fixed (module 09) . . . . . . . . . . . . . . . . . . . 71
Figure 3.13 Two heater length, serial connected . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 3.14 Time/temp diagram at different heater length . . . . . . . . . . . . . . . . . . . . 74
Figure 3.15 Holding section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 3.16 Switch board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 3.17 Product cooler/circuit steriliser (module 12). . . . . . . . . . . . . . . . . . . . . . 77
Figure 3.18 System back pressure valve (module 13) . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 3.19 Overview of the homogeniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 3.20 Pump block with separate pump cylinders. . . . . . . . . . . . . . . . . . . . . . . 81
Figure 3.21 Pulsation damper position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 3.22 Pulsation damper in suction pipe and rupture disc . . . . . . . . . . . . . . . . 83
Figure 3.23 Rupture disc incorporated in pipe running from
homogeniser to steriliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 3.24 Aseptic pulsation dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 3.25 Crankshaft with bolt-on gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 3.26 Frequency control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 3.27 Automatic activation of device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 3.28 Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 3.29 Heating element in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 3.30 Cooling/lubricating water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
version 1.0 13
Figure 3.31 Control panel in cover of homogeniser type 3HL-10 . . . . . . . . . . . . . . . 92

Figure 3.32 Seat, spindle and wearing ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 3.33 Filling pipe (customer part). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 3.34 Control cabinet of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 3.35 Operator control unit MP377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 3.36 Signals between the system and filler . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 3.37 Synchronisation between the machine and filling machine . . . . . . . . . . 99
Figure 4.1 Hoisting and adjusting of the Tubular flow steriliser. . . . . . . . . . . . . . . 106
Figure 4.2 Installation PCM dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 4.3 Lifting lugs of HL with top-mounted drive . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 4.4 Top drive homogeniser model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 4.5 Adjustable legs of the homogeniser . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 4.6 Pipe connections Stork/Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 5.1 Control cabinets with operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 5.2 Homogeniser with panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 5.3 Temperatures, pressure gauges and pressure regulators . . . . . . . . . . 126
Figure 5.4 Multipanel MP377 Human Machine Interface (HMI) . . . . . . . . . . . . . . 127
Figure 5.5 Paperless recorder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 5.6 Multipanel Start menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 5.7 Menu layout (e.g. Main menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 5.8 Numerical keyboard window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 5.9 Keyboard window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 5.10 Error message window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 5.11 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 5.12 Manual operation menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 5.13 Step control menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 5.14 Manual operation - P&ID menu
(Motor & Valve System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
(Motor & valve main drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
(Valve state) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 5.17 Test homogenizing system menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 5.18 Override main-heater temp. alarm menu . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 5.19 Step menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 5.20 Alarm menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 5.21 Icon description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 5.22 Help menu understanding step cycle . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 5.23 Maintenance menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Figure 5.24 Password menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 5.25 CPU menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 5.26 Variable menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 5.27 Program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 5.28 Process protocol menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 5.29 Product return menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 5.30 UHT menu (e.g. system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 5.31 Trending menu (UHT/DVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

List of Figures
Figure 5.32 Process temperature menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Figure 5.33 Timer menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Figure 5.34 Timer adjustment menu
(Start system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
(Rinsing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
(Balance tank system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
(Dosing system - Drain alarm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
(Sterilizing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
(Production timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
(ntermediate CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
(Main CIP 1e loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
(Main CIP 2e loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
(Final rinse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
(Final CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
(General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
(Step length (duration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Figure 5.47 System pressure menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Figure 5.48 Filling pressure menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Figure 5.49 Recipe menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Figure 5.50 PID Valuebox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Figure 5.51 PID Greenbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Figure 5.52 Dosing system menu (e.g. M0301) . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Figure 5.53 Main drive menu (e.g. M0801) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Figure 5.54 Level controller balancetank menu (e.g. LIC0102) . . . . . . . . . . . . . . . 177
Figure 5.55 Cascade controller main heater menu (e.g. TCV1001/PCV1001 . . . . 178
Figure 5.56 Pressure controller menu (e.g. PIC0805) . . . . . . . . . . . . . . . . . . . . . . 179
Figure 5.57 Pressure controller menu (e.g. PCV1001 . . . . . . . . . . . . . . . . . . . . . . 179
Figure 5.58 Temperature controller menu (e.g. TCV1001) . . . . . . . . . . . . . . . . . . . 180
Figure 5.59 Temperature controller menu (e.g. TCV1203) . . . . . . . . . . . . . . . . . . . 180
Figure 5.60 Main heater length menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Figure 5.61 Capcity adjustments menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Figure 6.1 Process steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Figure 8.1 Thermo well (TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Figure 8.2 Example of a spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Figure 8.3 Example of spare parts illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Figure 8.4 Assembly 3HL-10 homogeniser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Figure 8.5 Applying pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
version 1.0 15
Figure 8.6 Filling back-pressure valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Figure 8.7 'De Haan' valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Figure 8.8 'De Haan' bellows valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Figure 8.9 Pt-100 resistance bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Figure 8.10 Pump seals (indicated by arrows) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Figure 8.11 Removing brass plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Figure 8.12 Disassembly of plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Figure 8.13 Hydraulic tool attached to crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Figure 8.14 Position of collor seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Figure 8.15 Disassembly and reassembly neck bush . . . . . . . . . . . . . . . . . . . . . . . 286
Figure 8.16 Neck bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Figure 8.17 Dismantling pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Figure 8.18 Positions of joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Figure 8.19 Suction and delivery valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Figure 8.20 Hydraulic tool
(P0664838) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Figure 8.21 Hydraulic tool attached to crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Figure 8.22 Rupture disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Figure 8.23 Pulsation dampener (e.g mounted in suction pipe) . . . . . . . . . . . . . . . 297
Figure 8.24 Aseptic pulsation dampener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Figure 8.25 Cross-section homogenising-device . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Figure 8.26 Position of O-ring on homogenising valve seat . . . . . . . . . . . . . . . . . . 303
Figure 8.27 Assembly bearing bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Figure 8.28 Depression force (K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Figure 8.29 Cartel draining valve and sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Figure 8.30 Rupture disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Figure 8.31 Cartel draining valve and sight glass . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Figure 8.32 Lubricant sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Figure 8.33 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Figure 8.34 PCM Dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

List of tables
LIST OF TABLES
Table 0.1 Code for instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 0.2 Example: instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 0.3 Code for valves and motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 0.4 Example: valves and motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 0.5 Explanation of P&ID symbols (based on NEN 2195). . . . . . . . . . . . . . . 23
Table 1.1 Sterideal modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 1.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 1.3 Machine data, product data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 1.4 Machine data, plant data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 2.1 Location of emergency stops and stack lights . . . . . . . . . . . . . . . . . . . . 50
Table 2.2 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table 3.1 Module 10 variable Parallel connected two heater length . . . . . . . . . . . 73
Table 4.1 Mains power, general requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Table 4.2 Compressed air, general requirements . . . . . . . . . . . . . . . . . . . . . . . . 112
Table 4.3 Compressed air, instrument requirements. . . . . . . . . . . . . . . . . . . . . . 112
Table 4.4 General steam requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Table 4.5 Culinary steam requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table 4.6 General water requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table 4.7 Process water requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 4.8 Water, seal requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 4.9 Drain requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 4.10 General cooling water requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 4.11 Cooling water, chilled requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 4.12 Lye (NaOH) requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 4.13 Acid (HNO3) requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table 4.14 Lubricants requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table 4.15 Ambient indoor air, general requirements . . . . . . . . . . . . . . . . . . . . . . 116
Table 4.16 Operator panel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table 5.1 Operator panel and remote control box . . . . . . . . . . . . . . . . . . . . . . . . 122
Table 5.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Table 5.3 Explanation of Stack light signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Table 5.4 Switch panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Table 5.5 Elbow, condensate drains and pressure gauges . . . . . . . . . . . . . . . . . 125
Table 6.1 Control panel pictograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Table 8.1 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Table 8.2 Spare part categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Table 8.3 Maintenance table
control cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
version 1.0 17

cleaning and supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
tubular flow steriliser/cleaning and supply unit. . . . . . . . . . . . . . . . . . . 264
dosing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
fluid transport pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
homogeniser (3HL-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Table 8.9 Required tools homogeniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Table 8.10 Back pressure valve setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Table 8.11 Pt-100 resistance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Table 8.12 Required tools homogeniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Table 8.13 Tightening torques (in Nm) and sequence . . . . . . . . . . . . . . . . . . . . . . 293
Table 8.14 Depression force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Table 8.15 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Table 8.16 Quantity of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Table 8.17 Lubricants for dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

About this manual
ABOUT THIS MANUAL
Audience
Stork Food & Dairy Systems B.V. assumes that operators and service
engineers will:
• have sufficient technical knowledge and experience to carry out the
tasks assigned to them,
• recognize and prevent possible hazards,
• read and understand this manual,
• follow the procedures described in this manual,
• ensure that the machine will not harm personnel and/or damage its
environment.
Scope
This manual contains essential information for proper operation and
maintenance of the machine. Following the instructions contained in this
manual should assure trouble-free, safe operation and maintenance of the
machine.
c Caution
Before using or maintaining the machine, you must read this manual
carefully to become familiar with how it works. Make sure that any
operator or service engineer understands the correct operating and
maintenance procedures and all safety precautions. If you don’t
understand any part of the information in this manual, contact one of our
staff.
Operators and service engineers must be adequately trained in the correct

operation of the machine. Keep this manual in a pre-determined place near
the machine.
version 1.0 19
Document conventions
This manual uses the following text conventions:
• Actions that you should perform in a specific sequence are numbered,
for instance, “1. Press the power button.”
• Black circled numbers (e.g. 1 2 3) and numbers between brackets,
e.g. (1), refer to elements in a figure that are described by the text.
• Bold text is used for (sub)titles and for information that needs special
attention: “Read these instructions carefully”.
• Menu names in the user interface are always shown between single
quotation marks, for example: ‘Main Menu’.
• Parameter names are always shown between single quotation marks
and in red, for example: ‘Actual Low Limit’.
• Soft keys, keyboard buttons and hardware buttons are always shown
between brackets, for example: [Start], [Enter], [2].
• Messages displayed in the user interface are shown between quotation
marks and italic, for example: “Emergency stop active”.
• Cross-references to sections, tables, figures etc. are indicated as blue
text. The main purpose is easy recognition in the on-line version of the
manual (Acrobat PDF). In the on-line version, the cross-references
function as hyperlinks that can be used to navigate through the manual
by clicking on them. Example: see section Document conventions.
This manual contains Warnings, Cautions and Notes, for situations that
may endanger operators and service engineers, cause damage to
equipment or need special attention. The following text styles and symbols
are used:
n Note
Text with additional information.
c Caution
This indicates a text with indications to avoid machine damage.
w Warning
This indicates a text including indications to avoid all dangers and risks
to persons.
v Bacteriological contamination
This indicates a text with indications to avoid bacteriological
contamination of the machine and/or loss of product.
This manual contains safety symbols for situations or actions that may
endanger operators and service engineers. An overview of these safety
symbols is given in the safety chapter.
The words “upstream” and “downstream” are referring to the position of the
components in the product flow relative to the main heater. (Upstream =
before and downstream = after).

About this manual
P&ID conventions
This section lists the symbols that are used in the process diagrams (also
known as Piping and Instrumentation Diagrams, or P&ID).
The instruments in the process diagrams have a standard notation:
• The first letter indicates the measuring function.
• The following letters indicate the transfer functions.
• After the letters two numbers are given separated by a dot. The first
number indicates the group, for example, product tank (90) or CIP tank
(93). The second number indicates a sequence number.
Table 0.1 Code for instruments
CODE FUNCTION
Measuring function (the first letter)
F Flow
L Level
P Pressure, followed by subscript
• d = differential
Q Quality
T Temperature
U Mechanical displacement
Transfer function (the following letters)
I Indicating
R Recording
C Controlling
T Transmitting
version 1.0 21
Table 0.1 Code for instruments (Continued)
CODE FUNCTION
n counting revolutions per minute (rpm)
A Alarming, detection of threshold, followed by subscript
• HH = high-high
• H = high
• M = medium
• L = Low
• LL = low-low
Table 0.2 Example: instruments
SYMBOL CODE FUNCTION

TIRA90.08 Temperature sensor with Indicating and
Recording, and a Low-level Alarm
LA93.02 Level sensor with a Low-level Alarm
UA93.02 Mechanical displacement sensor with Alarm
Table 0.3 Code for valves and motors
CODE FUNCTION
L Level
T Temperature
P Pressure
C Control
R Reducing

About this manual
Table 0.3 Code for valves and motors (Continued)
CODE FUNCTION
V Valve
M Motor
Table 0.4 Example: valves and motors
SYMBOL CODE FUNCTION

V94.07 Valve
TCV93.01 Temperature Control Valve
M93.01 Motor (in this case, a pump)
Table 0.5 Explanation of P&ID symbols (based on NEN 2195)
SYMBOL FUNCTION SYMBOL FUNCTION
Non-return valve / one-way valve. Pump (an additional ’+’ sign indicates a
positive pump).
Hand valve. Coupling bend.
H
Hand valve. Steam trap.
Automatic valve, closed if not activated. Filter.
FB Automatic valve with feedback, open if Culinary steam filter.

not activated.
Rupture disc. Filter.
Valve with a hole or half open/close CIP return filter.

valve.
Butterfly valve. Sprayball.
Automatic butterfly valve, closed if not LA Level sensor with Alarm output, alarm is
activated. engaged when the level is low.
L
Spring loaded reducing valve. LICA Level sensor with local Indicator, Control
output and Alarm output.
version 1.0 23
Table 0.5 Explanation of P&ID symbols (based on NEN 2195) (Continued)
SYMBOL FUNCTION SYMBOL FUNCTION
Automatic angle valve, closed if not PICA Pressure sensor with local Indicator, Control
activated. output and Alarm output.
C Automatic three-way valve. Flow from A QIC Quality sensor with local Indicator and Control
A
to C if not activated and flow from A to B output.
B
if activated.
A C Automatic three-way valve. Flow from A QIRA Quality sensor with local Indicator, data
B
to C if not activated and flow from A to B Recorder and Alarm output.
and C if activated.
A B Automatic four-way valve. Flow from A to TIRA Temperature sensor with local Indicator, data
L
D B and D if not activated and flow from A Recorder and Alarm output on low level.
C
to B and from C to D if activated.
Critical parameter
Connections from the Stork machine to the customer’s plant are marked in
the P&ID with the symbol shown in Figure 0.1. The installation by Stork is
done up to the “S” mark, from that point on the customer is responsible for
the installation. This part of the installation is marked with a “C”.
Figure 0.1 Pipe connections Stork/Customer
C S C
OR

About this manual
Structure of this manual

• Contents
This is a list of the contents of this manual.
• List of Figures
This is a list of all figures used in this manual.
• List of tables
This is a list of all tables used in this manual.
• About this manual
• Provide general information about this manual such as audience, scope
and document conventions.
• Chapter 1 Introduction
This chapter gives a general description of the machine, a description
of the modules and the specifications.
• Chapter 2 Safety
This chapters contains advice and instructions for using your machine
in a safe manner (safety instructions on specific operations are
quoted in whole of the manual).
• Chapter 3 Description
This chapter provides the general knowledge of the machine. The
working principle and construction of the machine are explained.
• Chapter 4 Installation
This chapter details acceptance, installation, commissioning (initial
start up) and decommissioning procedures.
• Chapter 5 Operating interface
This chapter contains a description of all operating interfaces of the
machine. Placing and purpose of the operating and signalling devices
on the machine are explained. It gives a general description about the
usage of the interfaces.
• Chapter 6 Production
This chapter describes the production cycle and all related
procedures that must be performed by the operator.
• Chapter 7 Cleaning In Place (CIP)
This chapter contains general and specific instructions for manual
cleaning and disinfection of the machine.
• Chapter 8 Maintenance
This chapter contains maintenance schedules, instructions and
additional information necessary for the service engineer.
• Index
This is an alphabetical list of key-words with the corresponding pages.
version 1.0 25
Related documents
In addition to this user manual, the following documentation is available:
• DRAWINGS
It contains the Process and Identification (P&ID) drawings and the
additional drawings of the installation.
• SPARE PARTS
It contains the relevant information for identification of the spare parts.
• ELECTRICAL FILE (E-PLAN)
It contains schemes of the electrical system of the installation and
relevant information for identification of electrical parts.
• THIRD PARTY DOCUMENTATION
It gives an overview of the available documentation of third party
machine parts.
The related documentation will be included in one binder or delivered in
separate binders depending on the numbers of pages.
All the documentation related to this project is also available on the CD-
ROM.
Drawings
Some drawings used in this manual may contain blocks of text. These are
mainly intended for manufacturing purposes and initial assembly of the
parts.
Availability of this manual

Stork Food & Dairy Systems B.V. expects this manual to be available to all
operators and service engineers. The original hardcopy (paper) version
should always be available near the machine.
If the operator has the permission to perform a number of maintenance
actions or program activities, Stork Food & Dairy Systems B.V. expects that
the operator is trained according to the activities and that the appropriate
documentation is available for the operator.

About this manual
How to get help

If you need help to operate or maintain the machine, please contact:

P.O. Box 759,
1000 AT Amsterdam,
The Netherlands.
Tel.: +31(0) 20 6348911
Fax: +31(0) 20 6348790
E-mail: info.fds@sfds.eu
Website: www.fds.storkgroup.com
Installation instructions and initial start-up

This machine can only be installed, adjusted or started up for the first time
by specialized Stork staff. This remark replaces the installation prescription
(point 44 of the Committees comments 89/392/CEE).
version 1.0 27

Introduction
1 INTRODUCTION
1.1 About this chapter

This chapter gives general information about this machine. It is divided into
the following sections:
• 1.2 General on page 30,
• 1.3 Theory indirect sterilization process on page 31,
• 1.4 Summary of the modules on page 37,
• 1.5 Specifications on page 41.
version 1.0 29
1.2 General
The configuration of the installation is related closely to the following theory.
The object of the installation is to homogenise liquid products as they flow,
the UHT (Ultra High Temperature) to sterilise them with the indirect
systems, and then to supply these products sterile to the next production
machine. Homogenizing of the product takes place in the septic and/or
aseptic part of the machine with the devices mounted on the high pressure
pump.
To realize this object, high standards are set for the sterility of all the parts
of the installation which come into contact with the product directly or
indirectly. The installation is therefore sterilised with steam before the
products are admitted and cleaned with detergent and acid after removal
of the products. The PLC unit located in the control cabinets controls the
entire process.

Introduction
1.3 Theory indirect sterilization process
1.3.1 UHT sterilization process

A sterilization process is defined as a UHT (Ultra High Temperature)
process, if the product is heat treated in a continuous flow at a temperature
of not less than 135°C (280 °F) for a very short time, aseptically packaged
in sterile containers, and has undergone minimum chemical, physical and
organoleptic changes in relation to the severity of the heat treatment
required for sterilization. In other words, the product should have been
subjected to a heat treatment having a sufficiently high lethal effect so that,
after incubation at 30°C ± 1°C (86 °F ± 1,8 °F) for 5 days, no spoilage
occurs and the changes in flavour, odour, colour and nutritional value are
minimised. In addition to ensuring the destruction of micro-organisms, the
heat treatment of milk also results in a number of other reactions and
changes occurring. The main changes are:
• Inactivation of enzymes,
• Denaturation and complex formation,
• Maillard browning reactions,
• Loss of vitamins,
• Loss of amino acids.
Choosing the type of process and temperature-time combination best
suited to the handling of a range of products of widely varying initial quality
and composition should be based on the bacteriological and
physiochemical changes referred to above. The question then arises how
the effect of the heat treatment, in particular, can be measured and
assessed. Understanding the various parameters will afford an insight into
the manner in which a sterilization process should best be effected. In the
course of time, the following terms have gained general acceptance in
connection with food sterilization processes.
1.3.1.1 D-value or decimal reduction time

The D-value, which denotes the decimal reduction time, is the time
required at a specific temperature and under specified conditions to reduce
a microbial population by one decimal. The decimal reduction time is
dependent on the temperature, the type of micro-organism and the
composition of the medium containing the micro-organism.
1.3.1.2 Z-value
The Z-value is the increase or decrease in temperature required to reduce
or increase the decimal reduction time by one decimal. It is a measure of
the change in death rate with a change in temperature.
version 1.0 31
1.3.1.3 Sterilising effect or lethality

The sterilising effect, which is also called lethality or death rate, indicates
the effect of a heat treatment, expressed as the number of decimal
reductions in the number of microorganisms.
S = log ( n ⁄ s )
where:
• S = sterilising effect,
• n = number of micro-organisms (total or specific) in raw product,
• s = number of micro-organisms (total or specific) in sterilised product is
the effect of the heat treatment.
1.3.1.4 F-value or process value

The F-value indicates the effect of a heat treatment, which is governed by
the product heating temperature and the time during which the product is
held at this temperature (product holding time). An exponential function
expresses the effect's dependence on the temperature. The time and
temperature factors govern the ultimate effect, it being understood that this
effect is directly proportional to the time; triplication of the time at the
relevant temperature triplicates the effect. The effect of the heating
temperature, however, is considerably greater than that of time. The effect
of the heat treatment can be expressed by the following equation:
t T – T 0-
----------------
F = ∫ 10 z ⋅ dt
0
where:
• F is the effect of the heat treatment;
• T is the product temperature, [°C]
• T0 is the reference temperature, [°C]
• z is the z-value,
• t is the time during which the product is held at temperature T, [s].
As the effect of the heat treatment differs from micro-organism to micro-
organism and from quality attribute to quality attribute, it stands to reason
that there are a great many different F-values, each having its own values
for reference temperature T0 and Z-value.
1.3.1.5 What does the F-value represent?

The F-value can be interpreted as the time required to obtain a given
reduction in the number of micro-organisms at a temperature T = T0. Given
the effect of a heat treatment at a temperature T0 and at different treatment
times, the F-value gives an idea of the effect of the heat treatment under
review. Consequently, it follows that the value for T0 is a relatively random
choice and that the F-value depends on this choice for T0.

Introduction
An old-established F-value, commonly used in the canning industry, is the

F0-value, which is based on 12 decimal reductions for Clostridium
botulinum. The reference temperature T0 was 250 °F (121.1 °C) and the Z-
value was 18 °F (10 °C). The time was expressed in minutes, where 1
minute at 250 °F signified a lethality of 12 for Clostridium botulinum. These
parameters were subsequently adjusted to suit UHT processing
applications, the reference temperature T0 being set at 282 °F (138.9 °C),
the Z-value remaining unchanged at 18°F (10°C) and the time being
expressed in seconds. The calculated F0-value is identical for both
methods, it being understood that the former is expressed in a given
number of minutes at 121.1 °C (250 °F) and the latter is expressed in a
corresponding number of seconds at 138.9 °C (282 °F). Consequently,
both methods give an identical lethality for Clostridium botulinum.
t T – 138.9-
-----------------------
F0 = ∫ 10 10 ⋅ dt
0
1.3.1.6 Fm, Fe, Fc and Sh-values

Recent studies show that chemical and biochemical changes occurring in
milk processed in UHT systems can also be expressed as functions of
thermal destruction of micro-organisms. The various F-values developed
and defined by Professor Reuter have minimum and maximum limits
(expressed in seconds). The Fm-value was defined as the value for thermal
destruction of micro-organisms, based on the destruction of the most heat
resistant spore former occurring in milk, Bacillus stearothermophilus.
t T – 133.4-
-----------------------
Fm = ∫ 10 10.8 ⋅ dt ( F m > 15 )
0
The Fe-value was defined as the value for enzyme inactivation, based on
a 90% inactivation of proteases from Pseudomonas in milk. The requisite
Fe-value greatly depends on the enzyme content of the raw milk supplied.
Raw milk having a high enzyme content (caused, for instance, by
prolonged storage in refrigerated farm tanks) requires a more severe heat
treatment at a higher Fe-value.
t T – 140
-------------------
Fe = ∫ 10 32 ⋅ dt ( 2, 8 < F e < 14 )
0
version 1.0 33
The Fc-value is the value for heat treatment induced chemical change,
based on the loss of vitamin B1 in whole milk.
t T – 127-
------------------
Fc = ∫ 10 30 ⋅ dt ( F c < 70 )
0
The Sh-value is the value for the formation of HMF (hydroxy-methyl-

furfural). This is an intermediate product of the Maillard browning reaction.
The HMF content depends on the severity of the heat treatment.
t T – 128-
------------------
Sh = ∫ 10 24 ⋅ dt ( Sh < 33 )
0
1.3.1.7 B and C-values
Introduction
The German researcher Horak has conducted an extensive study on the
lethal effect of heat treatments on a mixed population of micro-organisms
present in good quality German milk and the effect of these heat treatments
on product quality.
B-value
On the basis of this study, he suggests a B-value for bacteriological effect,
where the minimum B-value required for a UHT process is 1.0. He bases
himself on the satisfactory destruction of the thermophilic spores present in
a mixed population of micro-organisms occurring in milk and recommends
that the thermophilic death time line (for B = 1) be used with the thermal
death value of 9, which will ensure a reduction of 109 in the number of
spores. He found a Z-value of 10.4°C and a holding time t* of 10.1 seconds
at a reference temperature T*o = 135°C.
However, if it is assumed that B = 1, this reference temperature cannot be
used in the equation, for otherwise it would be found that B* = 10.
Consequently, a reference temperature of 135 + 10.4 x log 10.1 = 145.4°C
should be used in the equation.
t T – 154.4-
-----------------------
B = ∫ 10 10 ,4 ⋅ dt (B > 1)
0
C-value
In his study, Horak used the following attributes to assess the quality of milk
which had been subjected to UHT treatment:
• changes in colour,
• formation of free HMF,

Introduction
• losses of lysine,
• losses of vitamin B1 (thiamine).
Horak introduces the C-value for chemical effect, where good quality UHT
milk should satisfy the following condition: C < 1. The C-value reflects the
degree in which the quality of the milk has suffered from the heat treatment,
i.e. the lower the C-value, the better the quality. To this end, he bases
himself on a max. 3% loss of thiamine (vitamin B1), using a holding time t*
of 30.5 seconds at a reference temperature T*o of 135°C and a Z-value of
31.4°C. Here, too, the T*o-value cannot be used as a reference
temperature in the equation, for it would be found that C = 30.5, where C
should be 1. So the reference temperature To used in the equation is equal
to:
135°C + 31.4°C × log ( 30.5 ) = 181.6°C
Consequently, the equation for the value for chemical effect suggested by
Horak and the limits for T (°C) and t (sec) recommended by him will be:
t T – 181.6-
-----------------------
C = ∫ 10 31.4 ⋅ dt (C < 1)
0
version 1.0 35
The diagram incorporated in Figure 1.1 shows the temperature/time

combinations for UHT processing and the limiting lines for the UHT region
specified by Horak.
Figure 1.1 Temperature/time diagram according to Horak
400
200
100
80
60
40
20
10
8
Equivalent holdingtme in sec.
C*=1
6
UHT area
4
1
110 120 130 140 150
Temperature in ˚C B*=1

Introduction
1.4 Summary of the modules

The Sterideal configuration is created with a modular design of modules
shown in Figure 1.2. Each module has its own function.
Figure 1.2 Modular design of modules
a
b
d Mod. 08 c
e
A D
E
B f g
h F
C G
H
Mod. 03
I
J
Mod. 07/09/10/12/13/17/18/35/36/38 Mod. 01/15/16/19/22/23/24/

25/26/27/28/29/30/30
Mod. 05
j k
Mod. 50
Mod. 37 Mod.60 Mod. 51
Mod. 39 Mod. 66 Mod. 52
Mod. 53
Mod. 33A/B Mod. 67 Mod. 54
Mod. 55
Mod. 43 Mod. 14 Mod. 56
Mod. 57
Mod. 58
Mod. 59
version 1.0 37
Modules: Utility:
a Plant A - Drain
b Sterideal B - Steam
c Control cabinets C - Drain
d Homogeniser D - Compressed air
e Air cabinet E - Product/H2O
f Tubular flow steriliser F - NaOH
g Product supply unit G - HN03
h CIP pump H- H2O
i Product pump I - Drain
j n.a. J - Product/H2O
k n.a.
The functions of the main modules used in this configuration are briefly
described in the following tables:
• Table 1.1 Sterideal modules on page 39,

Introduction
Table 1.1 Sterideal modules
MODULE LAYOUT MODULE DESCRIPTION Reference
3 Control cabinets Section 3.10

The control cabinets controls the entire process of the on page 95
installation.
4 Homogeniser (module 08) Section 3.7 on

The homogeniser is equipped with one, two or three page 79
homogenising devices to homogenise the product and
a high pressure pump to determine the capacity of the
installation.
5 Air control cabinet(s)

The air control cabinet(s) provides and controls the
compressed air to the air operating valves.
6 Tubular flow steriliser Section 3.6 on

The tubular flow steriliser comprises several heat page 67
exchangers and coolers.
7 Product supply unit Section 3.3 on

The product supply unit provides the supply and page 59
return of product/cleaning solutions to/from the
installation.
version 1.0 39
Table 1.1 Sterideal modules (Continued)
MODULE LAYOUT MODULE DESCRIPTION Reference
8 Dosing unit (module 03) Section 3.5 on

The dosing unit provides the CIP product, which page 66
cleans the machine.
9 Fluid pump (module 05) Section 3.4 on

The centrifugal pump transports the fluids from the page 65
product tank into the installation.

Introduction
1.5 Specifications
1.5.1 Machine data
1.5.1.1 Product data

Table 1.3 Machine data, product data
Product to be handled Temperature data

Milk 5-70-122-138*-88-24
* = Product sterilisation temperature
1.5.1.2 Plant data

Table 1.4 Machine data, plant data
DESCRIPTION VALUE
Machine type ST 8,5 C
Output Variable 6,600 - 8,800 l/h
System sterilisation temperature 140 °C
version 1.0 41
1.5.2 Dimensions and connections
Figure 1.3 Dimensions and connections (P0875581A)

Introduction
Figure 1.4 Homogeniser dimensions and specification

(P0678982-A)
version 1.0 43

Safety
2 SAFETY

This chapter outlines the safety precautions and the safety features of the
machine. It is divided into the following sections:
• 2.3 Safety instructions on page 46,
• 2.4 Machine decommissioned on page 49.
• 2.5 Safety devices on page 49,
• 2.6 Emergency stops on page 50,
• 2.7 Safety signs on page 51,
version 1.0 45
2.2 General
Stork Food & Dairy Systems B.V. has made all possible efforts to inform
you correctly and fully about possible dangers involved in working with this
machine. However it is your responsibility to assure that the safety rules
are actually observed.
n Note
Stork declines to put the information forward as complete and can
therefore not accept liability for possible omissions.
Maintenance or overhaul work usually needs the disassembly of one or

more components, as a result of which the original state of the machine or
part involved may undergo a change, requiring extra measures with regard
to safety. It is the responsibility of those in charge of preparing and/or
supervising such maintenance or overhaul work to take the necessary
action(s) to ensure safe working conditions.
2.3 Safety instructions
2.3.1 General safety instructions

These instructions only state a number of major personal and machine
safety precautions and lays no claim to be complete. It merely serves as a
general guide.
Those in charge of the operation and maintenance are required to ensure
continuously the maximum possible personal and machine safety.
n Note
Post these safety instructions in a prominent place near the machine so
all operators, service engineers and other persons present in the
machine area can take note of them.
• During every action, comply with all safety precautions from this
manual. If you are working on third-party parts, also consult the manual
for that part.
• Never disable or bypass safety provisions (emergency stops, guards
etc.) on the machine.
• If in doubt, or if you come across any unknown conditions, contact Stork
Food & Dairy Systems B.V. prior to proceeding.
• It is the responsibility of the customer to make sure their machine is in
accordance with applicable legislation and directives (such as FDA,
PMO, SA, OSHA).
• Nobody shall be near the machine unless accompanied by qualified
personnel.
• Machine operation, hoisting and maintenance should be done by Stork-
trained and qualified personnel only.
• Make sure that there is adequate lighting in the room accommodating
the machine.

Safety
• Always wear appropriate protective clothing when working with

chemical products. Read the supplier’s notices. Obtain safety
information (material safety data sheet) for all chemical products used,
the supplier of the chemicals is required to provide this information.
• Various places, tubes and surfaces of the machine may be very hot;
wear protective gloves if you have to touch these objects.
• Metal plating may have sharp edges. Be careful when handling the
plating.
• When the machine is in operation, do NOT approach the purge and air
vent tubes, unless you are wearing protective clothing.
• No part of your body should ever be inside the machine or near moving
parts outside the machine during operation.
• Do not walk, stand or climb on or under the machine.
• Manual cleaning of the machine should only take place when it is not in
operation.
• Never reset an ‘Emergency Stop’ (feeler switches; sensors; buttons or
cords) without ensuring a 100% safe situation for personnel and the
machine before the re-start of the machine.
• Make sure oil, chemicals and other residue materials are disposed of in
a safe and environmentally responsible way.
• Before starting the machine make sure the machine is free from lye,
acid and/or grease residue; and also free from any materials that do not
belong to the machine, such as, tools, (leather) gloves, cleaning cotton,
paper, wood, loose metal parts (iron and/or copper).
• If applicable, always pay attention to the acoustic alarm (horn), notifying
a change in the functioning of the machine; it might indicate for example
the return of the air supply with the help of a spare air key-switch; be
aware of any new operational situation, arising soon after the acoustic
alarm is heard (after about 5 seconds).
• Use hearing protection when working near noisy equipment or
environment.
2.3.2 Hygiene
Because the machine is used to process food products, it is very important
to prevent contamination of the machine and product. Take the following
precautions:
• Anyone who comes near the machine must be in a healthy condition
and may not be suffering from infectious diseases.
• Anyone with untreated injuries or wounds may not work in the aseptic
area. Treated injuries should be covered with gloves or other hygienic
protection material. A procedure must be available or developed to
cover this subject.
• Users should only use clean and preferably sanitised tools and parts.
• Every person who enters the machine area must follow the customer
procedures for personal hygiene.
version 1.0 47
2.3.3 Instructions for maintenance

For maintenance activities the following additional regulations apply:
• Always wear protective clothing such as helmet, gloves, safety shoes
and hearing protection during repair work on the machine so as to avoid
injuries and accidents with sharp edges, parts falling, chemical spills
etc.
• If the machine needs to be in operation while you are repairing it, switch
off the section you are working on.
• Once the machine has stopped, make sure of the following before
starting on maintenance work:
- the machine must be entirely decompressed and cooled off,
- the main switch must be turned off and locked,
- the main steam valve must be shut off and blocked,
- all chemical supplies (if applicable) must be shut off and blocked,
- the air supply must be shut off and blocked.
• When working on the machine, always consult this manual and the
drawings.
• Only use the tools and materials listed in this manual and the drawings.
• Never by-pass any device, component or switch supplied in the
installation. Especially safety equipment like start-up interlocking
devices, control locks, etc.
• Check that any tools used have been removed prior to starting up the
machine.
• Check that all safety equipment is present, undamaged and operational
prior to starting up the machine.
• Do not stand on guards and similar protections.
• Never use protruding beams, platforms, stairs and piping as hoisting
facilities.
• Check that stairs, platforms and the area around the machine are dry,
clean and free from grease and obstacles, in order to prevent falls.
• Do not work with a high-pressure water hose in the vicinity of the
machine, because of the machine's insulation class.
• Used lubricants, batteries, chemicals, etc. should be handled and
disposed of in a proper manner, in compliance with local anti-pollution
regulations.
• Do not modify the way the machine functions (e.g. by modifying the HMI
software) unless you have consulted Stork Food & Dairy Systems B.V.
for approval.
• Control cabinet and electrical equipment:
C If work has to be done inside the control cabinet, ensure that the power
cannot be switched on. Always consult the electrical diagrams given by
Stork and use tools giving the necessary insulation.
• Control cabinet and electrical equipment:
C Even after mains power has been switched off, a residual charge may
be present. Always check for residual charge before touching the wiring
or terminals.

Safety
• Electric motors and the parts driven by those motors:
CM Make sure that nobody can turn on the electric circuits of the motors in
question. Therefore: take out the corresponding fuses and lock the
instrument cabinet. Work switches are often provided on the machine,
but these provide insufficient security when it is impossible to have
direct control.
• Pneumatic and/or hydraulic circuits and the parts driven by them:
Mo Make sure that the circuits you work on are not under pressure and that
it is impossible to start up the compressor.
• Inspections and/or checks, along with maintenance work should be
carried out exclusively following the method described in the
maintenance chapter.
• Steam supply
G Especially with regard to the steam supply pipes, it is essential that the
main valves are shut and blocked to prevent unintended opening. This
may require the removal of the hand wheel or other steps to prevent the
main valves from being opened accidentally.
2.4 Machine decommissioned

If the machine is out of use for a longer period or if the machine is
dismantled, all the parts which could cause danger must be removed,
water, air and electricity supplies must be shut off.
2.5 Safety devices
w Warning
Never dismantle, disarm or block safety devices!
According to international standards, the machine is equipped with the

following safety devices:
• Emergency stop push buttons
Placed within easy reach of the operator.
• Lock-out system
The mains switch can be locked into OFF position.
• Stack light
The stack light contains colour indications that present the state of the
machine and includes an audible alarm to warn the operator.
version 1.0 49
2.6 Emergency stops
n Note
Activate an emergency stop button only in case of danger or potential
danger to personnel or damage to the product and/or the machine.
Do not use emergency stops as a normal stop.
An emergency stop has the following consequences:

• all pump drives and homogeniser are stopped.
• power to the control computers is not cut off,
After an emergency stop, aseptic conditions are lost.
When an emergency stop has occurred:

1 Find and solve the cause of the emergency stop.
2 Ensure a 100% safe situation for your personnel and the machine.
3 Do a sterilization cycle.
4 Restart production.
The following table shows the locations of available emergency stops.
Table 2.1 Location of emergency stops and stack lights
Control cabinet a
The homogeniser
3HL-10

Safety
a Stack light
b Emergency stop
2.7 Safety signs
The machine comes supplied with safety and protective devices.
c Caution
It is nevertheless important to be alert when carrying out operations at the
machine.
The pictograms on these pages appear on the machine and in the manual
alongside descriptions of potential dangers.
c Caution
Check regularly to see that all pictograms are in position at all times.
In case of loss or damage to pictograms, replace them. For the

replacement procedure, see section Applying pictograms in the
Maintenance chapter. For the locations of the safety pictograms, see the
spare parts list.
Table 2.2 Safety signs (Sheet 1 of 3)
PICTOGRAM/PLATE MEANING
Electrical voltage
C
Hot fluids
h
Slippery surface
f
Hot surface
G
Corrosive substances
version 1.0 51
Toxic chemical products
I
People may be locked into the machine
g (machine doors lock automatically)
Sharp objects
N
Automatic activation of machine (part)
D
Rotating parts
M
High pressure air
o
Safety helmet required
T
Protective goggles required
S
Hearing protection required.
R
Protective gloves required (no leather, but
U rubber or silicone!).
Protective shoes required. No leather
W shoes when working with H2O2. Leather

catches fire when it comes in contact with
H 2O 2!
Protective clothing required
m
Safety
Read manual before operating the
r machine
No trespassing for unauthorised persons
Y
Open flame prohibited
.
Turning direction of a motor
|
Laser
L
Hoisting instructions must be applied.
A
Lifting instructions must be applied.
B
Ultraviolet light source.
u
Figure 2.1 shows the locations of the various pictograms and safety signs.
version 1.0 53
Figure 2.1 Placing of safety adhesives - Top view
Control cabinets
C
Product supply unit
Metering unit (module 03)

C
C
J
m
Tubular flow sterilizer
G
C

Safety
Homogeniser (module 08)
RC
G
Product pump (module 05)
version 1.0 55

Description
3 DESCRIPTION

The configuration of the machine has a modular design where each
module has its own function. The construction and functioning of the
machine is divided into the following sections:
• 3.2 Installation overview on page 58,
• 3.3 Product supply unit on page 59,
• 3.4 Product pump (module 05) on page 65,
• 3.5 Metering unit (module 03) on page 66,
• 3.6 Tubular flow steriliser on page 67,
• 3.7 The homogeniser (module 08) on page 79,
• 3.8 Homogenising device on page 93,
• 3.9 Filling pipe on page 94,
• 3.10 System control cabinets on page 95,
• 3.11 Interaction with other machines on page 97.
version 1.0 57
3.2 Installation overview

The following illustration shows the process flow diagram of the installation.
Figure 3.1 Machine process flow (P0874210-B)

Description
3.3 Product supply unit
3.3.0.1 Function
The product supply unit is the first unit in the process. The product tank
(module 01) collects the fluids (product or cleaning fluids. The fluid level in
the product tank enables an uninterrupted supply of fluid, at a uniform
hydrostatic pressure to the next pump.
3.3.0.2 Components
Figure 3.2 Product supply unit
a b j
c l
m
d
e
n
f o
g
q
h
i
p
a Filling back pressure valve i Product to tubular flow steriliser

(M15) j Sparyball tube with valve
b n.a. (Module 01L)
c Product supply (from filling k n.a.
machine) l n.a.
d Product supply/retour m Supply valve central CIP system
e n.a. (M23)
f Branch on behalf of cleaning n Water
(M28) o Product pump (M05)
g Drain p Overflow
h Discharge pipe (M22&24) q CIP supply
version 1.0 59
The product supply unit is equipped with:

• Product tank (module 01) options:
- Spray ball at the top of the tank to spray cleaning agent during
cleaning.
- Two product infeed facilities for product supply and product return.
- Overflow pipe to the drain, if the product level crosses an certain
height.
- Level regulator to regulate the fluid level in the tank.
- Low-level sensor at the bottom of the tank to protect the supply
pump.
- Outfeed.
• Sight glass to observe if product/water is being transported to the drain
during the phase filling or draining.
• Water supply valve, product supply valve and drain valves.
• Circulation/drain valve, it switches between the drain and the circulation
position. During the sterilisation phase the filling circuits is subject to
high pressures.

Description
3.3.1 Switch panel
3.3.1.1 Function
The switch panel controls the product supply and return flow, but also the
circulation of the fluids (product/cleaning agents) through the installation
once more. Depending on the required process the coupling bends can be
set in production or cleaning mode (see Figure 3.3).
The sensors check the position of the coupling bends and control the
processes.
w Warning
In case the operator have to change the configuration of the coupling
bends a limited part of solution runs out the tubes.
The installation is cleaned and sterilised “stand-alone” using this switch

panel. During the pre-sterilisation of the system, the fluid tank acts as an
expansion tank.
3.3.1.2 Components
Figure 3.3 Switch panel
S01.01
S01.02
c d
a Product supply
b Product return
c Cleaning
d Production
e Production
f Intermediate/main cleaning
version 1.0 61
3.3.2 Supply valve central CIP system (module 23)
3.3.2.1 Function
This module drains the fluid between the water supply valve and the non-
return valve, when water supply valve is closed.
3.3.2.2 Components
Figure 3.4 Supply valve central CIP system
a Water
b Product
c Drain

Description
3.3.3 Discharge pipe
3.3.3.1 Function
This module collects the drains of the product supply unit. The module is
provided with a level sensor and sight glass. The sight glass enables the
operator to verify the draining fluids during the draining steps.
3.3.3.2 Components
Figure 3.5 Discharge pipe
9
1.0
V0
V03.04
V01.10
V01.01
3
1.0
V0
LA01.03
.03
01
b
a c
a Sightglass (01.03)
b Level indicator with alarm (LA01.03)
c to drain
version 1.0 63
3.3.4 Branch on behalf of cleaning (module 28)
3.3.4.1 Function
This module is used for cleaning and has the following functions:
• circulation of fluids, by-passing the product tank.
• draining of fluids when product circulation/drain valve is activated.
3.3.4.2 Components
Figure 3.6 Branch on behalf of cleaning
a Branch on behalf of cleaning

The module consists of a single pipe mounted between the V01.07 and
V01.10.

Description
3.4 Product pump (module 05)
3.4.1 Centrifugal pump (module 05A)
3.4.1.1 Function
The centrifugal pump transports product to tubular flow sterilizer and
maintains system pressure during circulation. The supply pressure must be
sufficient enough because the following pump(s) are not self-priming:
• the homogeniser (module 08),
Figure 3.7 Centrifugal pump (module 05A)
a
b
c
d
e
a Motor and protection cover

b Delivery pipe
c Centrifugal pump
d Suction pipe
e Mechanical seal
3.4.1.2 Components
The temperature transmitter measures the temperature of the product after
the fluid transport pump before it enters the tubular flow steriliser.
The pump is installed below the product supply unit to reduce the floor
space of the installation, see section 3.3 on page 59.
For further pump details consult the third-party documentation.
version 1.0 65
3.5 Metering unit (module 03)
3.5.1 Dosing pump
3.5.1.1 Function
The metering unit (module 03) ensures the appropriate solution of process
water, lye and acid solution are supplied during the various steps of the
chemical cleaning process
3.5.1.2 Components
Figure 3.8 Metering unit with PCM dosing pump
a
h f
b j k
c
d e i
a Lye (NaOH)
b Acid (HNO3)
c Process water (H2O)
d Level switch (LA03.01)
e Pneumatically actuated butterfly valve (V03.01, V03.02, V03.03)
f Pneumatically actuated valve (V03.04)
g Metering pump (M03.01)
h Drain valve (03.27)
i Pressure indicator (03.28)
j Non-return valve (03.01, 03.02, 03.02)
k Pressure control valve (PRC03.01)
The metering unit consists of a dosing pump with pneumatically actuated
butterfly valves and non return valves. The pressure reducer controls the
maximum allowable water supply pressure. The level transmitter protects
the pump from running dry. The pneumatically actuated valve separates
the metering unit from the system in the rest position by making a
connection to the drain.
To maintain and lubricate the metering unit, see section 8.4.4 Maintenance
schedule metering unit on page 265. For further details consult the
documentation of the third-party documentation.

Description
3.6 Tubular flow steriliser

The tubular flow steriliser of the installation has been designed to:
• prevent direct contact between product and heat-exchange medium,
• ensure a compact machine layout,
• permit thermal regeneration for the purpose of saving energy.
The tubular flow steriliser contains the following modules, each of which
having its own specific function:
• First stage regenerative section (module 07) on page 70,
• Second stage regenerative (module 09) on page 71,
• Main heater (module 10) on page 72,
• Holding section (single tube) on page 75,
• Product cooler/circuit steriliser (module 12) on page 76,
• System back pressure valve (module 13) on page 78.
Each tubular heat exchanger consists of concentric high-grade stainless
steel tubes wound to form a coil. The coiled concentric tubes form channels
which conduct the following media:
Figure 3.9 Tube configuration (one, two, three and multi-tubes)
a product
b water or steam
a Product
b Water or steam
version 1.0 67
In order to maximize heat-exchange efficiency, the product and steam run

in counter flow through the system. The tubular flow steriliser comprising
several heat exchangers is incorporated in an ornamental jacket, with the
connecting flanges fitted on the outside.
A satisfactory UHT sterilisation process will be ensured, if the temperature/
time combination is such that it lies inside the UHT region.
The sterilisation temperature, which is a predetermined value, is accurately
maintained and monitored in accordance with the main heater temperature
setting.
The correct process is demarcated by the limiting lines B = 1 and C = 1
shown in Figure 1.1 on page 36.
Because the system allows stepless variable outputs, it stands to reason
that machine operation at reduced outputs will also extend product
residence times and, inherently, increase heat loads. In order to ensure
that the requisite processing conditions (UHT region) are still fulfilled,
special facilities have been incorporated in a number of modules. They will
be described in the following sections.

Description
3.6.1 Filling back pressure valve (module 15)
3.6.1.1 Function
The filling back pressure valve regulates the pressure required during filling
and can be adjusted on the HMI. The valve is arranged on product supply
unit.
The pressure transmitter regulates the required filling pressure and
indicates an alarm:
• if the measured pressure < the set pressure or
• if the measured pressure > the set pressure.
On leaving the product cooler/circuit steriliser, the product is delivered to
the next production machine. Filling back pressure valve can be adjusted
to suit the pressure required at to the next production machine. The
overflow located downstream from the filling back pressure valve enables
the return of any surplus product to product tank of the product supply
control unit. The temperature transmitter secures the temperature during
the steps 3, 4 and 5.
3.6.1.2 Components
Figure 3.10 Filling back pressure valve (module 15)
a Filling back pressure valve (V15.01

b Pressure transmitter (PT15.01)
c Pressure gauge - control/alarm (PICA15.01)
d Temperature transmitter (TT15.01
e Pressure gauge (PI 15.01
f Air chamber (15.02
g PAL15.01
version 1.0 69
3.6.2 First stage regenerative section (module 07)
3.6.2.1 Function
The system incorporates a thermal regenerative which enables product to
be sterilised to absorb heat from the sterilised product to be cooled.
Thermal regeneration is done in two stages and, hence, the regenerative
consists of two heat exchanger modules (modules 07 and 09). Module 07
serves as the first-stage regenerative and module 09 serves as the
second-stage regenerative.
The temperature transmitter indicates and measures the down stream
output temperature of the 1st regenerative.
3.6.2.2 Components
Figure 3.11 First stage regenerative (module 07)
a Temperature transmitter

3.6.3 Second stage regenerative (module 09)
In common with the first-stage regenerative, the second-stage sterilizer
(module 09) regeneratively preheats the product to be sterilised by
withdrawing heat from the sterilised product and, consequently, the product
temperature will increase.
Figure 3.12 Second stage regenerative - fixed (module 09)

.
version 1.0 71
3.6.4 Main heater (module 10)
3.6.4.1 Function
The main heater is the part of the system were the product is sterilised. The
coiled heat exchangers section(s) of the main heater heats the product up
to its required sterilisation temperature by steam. The coiled heat
exchanger consists of tubes with a fixed length, the product and the steam
are running in counterflow through the system, see for details Figure 3.9 on
page 67. Controls are integrated to control the coil outlet temperature. To
calculate the temperature/time profile, volume, flow, inlet and outlet
temperature are required.
3.6.4.2 Main heater range control

The variable main heater range control serves to ensure continued aseptic
integrity and unimpaired quality of the product at reduced machine outputs.
The main heater incorporated in the installation has been divided into two
heat transfer sections, which are serial connected.
In the event of changed output conditions, these main heater steam-circuit
sections may be automatically engaged or disengaged.
Figure 3.13 Two heater length, serial connected
a c
a Product
b Steam
c Condensate
Product sterilisation is properly effected in the main heater (module 10),
this section heats the product to its required main heating temperature by
steam.
Condensate valve incorporated in the main heater steam circuit enables
adjustment of the main heater steam circuit range and, hence, variation in
heat transfer surface area.
The HMI unit incorporated in the control cabinet selects both the
homogeniser speed and the main heater steam circuit range, in conformity
with the signals emitted by the next production machine. The sterilisation
temperature is controlled with the help of a cascade control circuit.

Description
If the machine output is reduced from full capacity to half capacity on

account of the next production machines being disengaged, for instance,
the product residence time in the main heater will be doubled. In addition,
the heat load in this module will even be more than doubled, because the
thermal regeneration efficiency rate will increase at a reduced machine
output. In order to eliminate the risk of the product being subjected to an
excessive heat load, one of the main heater's steam circuit sections will be
disengaged.
Valve positions
Table 3.1 Module 10 variable Parallel connected two heater length
HEATER LENGTH V10.01

Short Energised
Full De-energised
Engagement and disengagement of the main heater steam-circuit

sections is based on the principle of closing and opening of the
condensate valves incorporated. When a condensate valve is closed, the
relevant main heater steam-circuit section will be filled with condensate,
preventing steam from entering this Main heater steam-circuit section and,
hence, reducing the heat transfer area of the product channel. The
disengaged main heater section serves as a holder, and the prevailing
product temperature is identical with that at the outlet of the second-stage
regenerative (i.e. second-stage regenerative heater). Conversely, when a
condensate valve is opened, the condensate is allowed to run off,
enabling the steam to enter the relevant main heater steam-circuit section
and, hence, to increase the heat transfer area of the product circuit.
version 1.0 73
Figure 3.14 Time/temp diagram at different heater length
c
a b
Figure 3.14 shows the temperature/time curves for a machine operating

under the following conditions:
a 100% machine output main heater in full range mode,
b 50% machine output main heater in full range mode,
c 50% machine output main heater in reduced range mode.
The temperature/time curves 1 and 2 (continuous lines) are self

explanatory. Curve 2 shows that the residence time at 50% machine
output has doubled, causing an increased heat load. Temperature/time
curve 3 largely coincides with curve 2, except for the part indicated by the
dashed line. The latter indicates the treatment in the main heater
operating in the reduced range mode, showing that the initial product
temperature in the main heater is held at a level which is lower than that
indicated by curve 2 and that the heat load is reduced. The horizontal part
of the dashed line represents the disengaged section of the main heater.

Description
3.6.5 Holding section (single tube)
3.6.5.1 Function
The holding section (holding tube) incorporated in the system is arranged
downstream from the main heater. The holding section is a single tube,
which serve to keep the product at the relevant sterilisation temperature for
a short period of time. This period ensures the destruction and/or inhibition
of any hazardous microorganisms that may be present in the product.
3.6.5.2 Components
Figure 3.15 Holding section
a Holding section 4 seconds

b Switch panel
3.6.5.3 Switch panel (module 18)

The switch panel extends the holding time of the sterilisation temperature
and decreases the capacity of the Sterideal.
The length is defined by the positions of the bending tubes. The position of
coupling bends are detected by the sensors on the holder.
Figure 3.16 Switch board
Holding time Holding time

4 sec. 7 sec.
version 1.0 75
3.6.6 Product cooler/circuit steriliser (module 12)
3.6.6.1 Function
The product cooler/circuit steriliser is arranged downstream from the
second-stage and first-stage regenerative coolers. This heat exchanger
module operates either in the product cooling mode or in the machine
sterilisation mode, depending on the process step.
Before sterilisation of the installation the cooler must be emptied by
supplying steam to the cooler by TVC12.03. During emptying the water will
be drained via valve V12.03. Purging out of the cooler will be done to save
(warming up) time and the amount of heat supplied by steam.
When operating in the product cooling mode, the product cooler/circuit
steriliser serves to remove any surplus heat from the product.
if the product leaving the regenerative is higher than the appropriate filling
temperature at TT12.01, cooling medium will be supplied by V12.01.
During production the cooling water supply valve is opened and the product
temperature decreases. The temperature control valve controls the cooling
water temperature at the outlet of the module.
If the temperature at TT12.01 is too low, the product cooler/circuit steriliser
heats the product with steam. The temperature control valve supplies
steam into the cooling leg till the temperature in the product leg is reached.
The product cooler/circuit steriliser will operate in the machine sterilisation
mode during machine sterilisation and main chemical cleaning, with the
requisite steam supply to suit the relevant heating temperatures being
branched off from the controlled steam supply to the mainheater (see
section 3.6.4 on page 72.

Description
3.6.6.2 Components
Figure 3.17 Product cooler/circuit steriliser (module 12)
c d
a Steam
b Water
c Product
d Condensate
version 1.0 77
3.6.7 System back pressure valve (module 13)
3.6.7.1 Function
The system back pressure valve is arranged at the top of the tubular flow
steriliser, downstream from the product cooler/circuit steriliser or chiller.
The back pressure valve regulates the required system pressure and
indicates an alarm, if the measured pressure is lower than the set pressure.
The system back-pressure valve is adjusted so that the pressure prevailing
in the product flow is higher than that prevailing in the water/steam
circulation loop.
On leaving the back pressure valve the product is delivered to the filling
valve in the filling pipe, see section 3.9 on page 94.
3.6.7.2 Components
Figure 3.18 System back pressure valve (module 13)
a System back pressure valve

Description
3.7 The homogeniser (module 08)
3.7.1 Function
The homogeniser has the function to transport water, product and cleaning
liquids, under high pressure through the system to the filling valve. The
motor control enables the variation in output to suite the intake capacity of
the next production machine.
The homogenisation device, attach to the pumpblock, homogenizes the
product in to smaller particles. The devices in the system are at the
locations where the optimal temperature prevails to homogenise the
product.
3.7.2 Components
The homogeniser contains the following parts:
• Crankcase (1), see section 3.7.7 on page 86.
• A forced/circulation lubricating system (2), see section 3.7.8.1 on page
89.
• A lubricating/cooling water system for the pistons (7), see section 3.7.9
on page 91.
• A single-acting piston pump with three pistons (20), see section 3.7.3
on page 81.
• The homogenising device (40), see section 3.8 on page 93.
• Hydraulic actuation system for the homogenising device (57), see
section 3.7.8 on page 88.
• A drive by means of an electric motor (70) with a V-belt transmission
(72), see section 3.7.7.1 on page 87.
• Cover and control panel, see section 3.7.10 on page 92.
version 1.0 79
Figure 3.19 Overview of the homogeniser
70
57
72 7
2
47
40
1 20
21
II

Description
3.7.3 Pump block

The pump consists of a pump block, pump-cylinders with seals and
pistons. The suction and delivery valves are fitted tightly between resp. the
pump cylinder and lower block, and the pump cylinder and upper block.
The sealing between valves and pump block is by means of o-rings. The
sealing between pistons and pump cylinders is by means of a stuffing box
packing construction.
Figure 3.20 Pump block with separate pump cylinders
version 1.0 81
3.7.4 Pulsation damper and rupture disc

The pulsation damper muffles the pressure pulses. The pulsation damper
is made up of a rubber bellows placed in stainless steel basket. This
bellows is inflated with compressed air up to roughly 60% - 80% of the
pressure in the pipe. The mounting position is mentioned in the figure
below.
Figure 3.21 Pulsation damper position
a 1ste homogenising device,

b Delivery pipe,
c Pulsation damper mounted in suction pipe.
The air pressure in the bellows can only be read from a pressure gauge on
the control panel of the homogeniser when it is not running. The pressure
switches and gives an signal alarm when the pressure is too low during
starting the homogeniser. A filling valve (tire valve) has been mounted on
this same panel so as to be able to inflate the bellows.

Description
Figure 3.22 Pulsation damper in suction pipe and rupture disc
12
11
10
9
B K
10 = Rupture disc
B = Rubber bellow
K = Stainless steel basket
To safeguard the homogeniser a rupture disc has been placed in the upper
block. When the pressure runs up too high, the rupture disc collapses.
Immediately trace the cause and cure this problem!
c Caution
Always replace the rupture disc by the correct type.
version 1.0 83
3.7.5 Pressure relief

The product circuit downstream from the homogeniser incorporates a
safety facility, which serves to prevent the tubular flow steriliser from being
subjected to pressures exceeding the maximum permissible level.
This rupture disc is set to operate at a given pressure. Under normal
machine operating conditions, this safety facility will not be actuated, but it
will if the pressure is allowed to increase beyond the permissible level,
owing to the accumulation of product deposits in the product circuit
(clogging) after inadequate CIP cleaning or after sustained operation
without intermediate aseptic CIP, or owing to the improper operation of the
back-pressure valve controlling the filling pressure.
Figure 3.23 Rupture disc incorporated in pipe running from

homogeniser to steriliser
a
b
a Rupture disc,
b Plunger pulsation damper, see section 3.7.6 on page 85.

Description
3.7.6 The pulsation dampener

The delivery pipe of the high pressure pump incorporates a pulsation
dampener. Essentially, the pulsation dampener consists of a rubber bellow,
mounted on a stainless steel piston. This piston is sealed with the help of
cup seals. The rubber bellow forces the piston downward against the
product pressure.
Figure 3.24 Aseptic pulsation dampener
c c
a Rubber bellow
b Stainless steel piston
c Product
For maintenance activities see section 8.20 on page 297.
version 1.0 85
3.7.7 Drive
The high pressure pump is driven by means of an electric motor driving an
intermediate shaft via a V-belt transmission.
Through a speed reduction gear, this intermediate shaft drives the pump
crankshaft.
The motor is mounted on an adjustable foundation plate at the top of the
frame.
Figure 3.25 Crankshaft with bolt-on gear wheel
b
c
a Drive (top-mounted) 3HL-10

b Crankshaft
c Direction of rotation
The motor is a variable speed electric motor. The pump has a variable
capacity.
The homogeniser is lubricated by means of a gear wheel type oil pump
which is driven by a separate electric motor. For a full description of the
lubricating system, see section 3.7.8.1 on page 89.

Description
3.7.7.1 Output control
Output control of the system (frequency control)

The B-version system has been configured with a homogeniser provided
with a frequency controlled three phase motor. With this AC motor the
system boasts variable capacities: either full or minimum capacity.The
output of the B-type system during the various process steps is governed
by a PLC-controlled frequency controller, which ensures automatic speed
variation of the homogeniser’s three phase motor to suit the relevant
outputs required. The system also includes a separate manual control
facility, which may serve a useful purpose during initial system adjustment
to suit the handling of new types of products. The manual/automatic mode
can be selected from the console of the PLC incorporated in the control
cabinet. The frequency controller changes the frequency of the three phase
motor, thus changing the speed and, hence, the output of the homogeniser.
Figure 3.26 Frequency control
Setpoint
Start
Reset
Frequency Fault PLC
controller Run
Line contactor
Fuse
Minor output adjustments during production can be effected by increasing

or decreasing the speed with the help of the PLC. This speed adjustment
permits an output adjustment of approx. 5% either way and serves to
control the product return flow to the product tank. The frequency controller
incorporated in the control cabinet will ensure a uniform frequency. Please
refer to chapters 8 Maintenance on page 249 and “third party
documentation” for the relevant maintenance and operating instructions.
version 1.0 87
3.7.8 Automatic homogenising valve actuation

The homogenising valve actuating system consists of a hydraulic tank unit,
tubing and a hydraulic cylinder on the homogenisation valve.
In addition, the system includes homogenisation pressure control circuit
PICA08.05, which consists of a pressure transmitter PT08.05 and a HMI
software circuit.
The hydraulic tank unit is equipped with a proportional pressure limiting
valve. The position of this pressure limiting valve is adjusted with the help
of the output signal of the PLC. It presets the oil pressure to the
homogenisation valve and, hence, the homogenisation pressure. Manual
operation is also feasible. This is effected by changing the output of the
control circuit with the help of the multipanel. The control panel of the
homogeniser incorporates a digital pressure indicator, which allows the
homogenisation pressure to be read off.
Figure 3.27 Automatic activation of device
PLC
f
a
I
b
e
d
g
e I
a Oil filter
b Level indicator
c Maximum level
d Minimum level
e Temperature in Celsius and Fahrenheit
f Oil pressure gauge
g Hydraulic cylinder
The tank unit includes an oil filter and a level/temperature indicator. The
holding capacity of the tank unit is 22.5 litres.

Description
3.7.8.1 Lubricating system

The lubricating system of the homogeniser comprises a gear pump flanged
to an electric motor and a pipe system which takes the lubricant under
pressure to the crankshaft bearings and, through the hollow centre of the
eccentric shaft, to the connecting rod bearings.
Figure 3.28 Lubricating system
5
e
4
d
1
a
2
b 3
c
a Oil cooler
b Gear pump
c Filter
d Relief valve
e flow switch
The minimum lubricating oil pressure of 3 bar required in the crankshaft
and connecting rod big-end bearings is controlled by a continuously
opened relief valve. The oil downstream from the relief valve lubricates the
crossheads in the cross head guides and the crossed pins. The line
downstream from the above relief valve incorporates a flow switch which,
via the motor starter, disengages the homogeniser, if the flow rate is lower
than 2.9 l/min. At the end of the oil pipes to the crossheads a transparent
nylon tube is fitted. Circulation of oil through the system can be checked at
this spot. If the lubricating oil level in the gearcase is too low when the
homogeniser is started, the lubricating oil pump will draw in air, causing
nondelivery of lubricating oil and thus preventing the main motor from being
started. Therefore, a daily check of the oil level is essential. The lubricating
oil pressure can be read off from a pressure gauge incorporated in the
homogeniser control panel.
The delivery pipeline of the lubricating oil pump incorporates a filter which
filters any foreign solids suspended in the lubricating oil. It stands to reason
version 1.0 89
that this filter should be replaced at regular intervals (see maintenance

schedule). The system also includes an oil cooler downstream from the oil
pump. The cooling water supply valve is opened automatically when the
drive is started.
The homogeniser is equipped with a heating element in the oil sump. This
constant-temperature heating element ensures that the lubricating oil
temperature is maintained at a uniform level in stationary state (approx. 45-
50 °C), thus preventing that condensed moisture occurs in the lubricating
oil. The heating element will be in operation as long as the main switch is
in the “on” position. Water in the oil adversely affects the lubricating film and
the viscosity of the lubricating oil and escalates the wear and tear. Consult
the maintenance schedule (Chapter 8 Maintenance on page 249)
concerning daily water drainage.
Figure 3.29 Heating element in crankcase
n Note
The scale on the thermostat is given in degrees Celsius. The ”F” on the
scale stands for “frost point” at 5 degrees Celsius. The heating has been
set by Stork at plus or minus 45 degrees Celsius.

Description
3.7.9 Cooling/lubricating water system

The homogeniser is equipped with a plunger cooling/lubricating system,
using water as a cooling medium.
The quantity of water supplied to the plungers can be adjusted with the help
of manual valve. A uniform, non-splashing flow of water is required for the
proper lubrication and cooling of the plungers and the removal of any
product residues.
The thermostatic valve allows the adjustment of the quantity of water to be
supplied to the oil cooler. The ideal lubricant operating temperature is
approx. 45-50 °C. The temperature of the lubricant is gauged downstream
from the cooler. The lubricant tube to the piston in the gear case is provided
with a flow switch and overflow valve.
The solenoid valve ensures that the water supply is interrupted
automatically when the homogeniser is disengaged and restored when the
homogeniser is started again.
Figure 3.30 Cooling/lubricating water system
B2
B1
A2
A1
a Solenoid valve A - water

b Manual valve A1 - to the plungers
c Thermostatic valve A2 - to the drain
B - lubricant
d Vent nipple
B1 - to the pistons in gear case
e Oil cooler
B2 - to the crankshaft
f Oil filter
g Lubrication pump
version 1.0 91
3.7.10 Control panel

The control panel is incorporated in the cover of the homogeniser. This
panel contains several control and monitoring instruments:
• Pressure gauge(s) to take reading of:
- the homogenisation pressure,
- the lubricating oil pressure,
- the pneumatic pressure of pulsation dampener(s),
• Filling valve for pulsation damper.
Figure 3.31 Control panel in cover of homogeniser type 3HL-10
3HL-10
a Control panel

Description
3.8 Homogenising device
3.8.1 Function
The homogenising device is automatic controlled orifice to create the shear
required to reduce the size of particles in the product.
3.8.2 Components
Figure 3.32 Seat, spindle and wearing ring
R
B
a B = Seat
b R = Ring
c S = Spindle
The homogenising device consists of a seat with a narrow passage and a
homogenising spindle pressing onto it. The spindle is hydraulically pressed
down onto its seat.
Around the pressure surfaces of the spindle and the seat a wearing ring
has been fitted. Both the spindle and the seat are made of wear-resistant
material. Actuation of the homogenising valve so that the latter is forced
down on the homogenising seat is effected hydraulically.
version 1.0 93
3.9 Filling pipe
3.9.1 Function
The filling pipe connects the output to the filling valve or to the product
return pipe. It is essential that the filling pipe running from the system to the
next production machine(s) does not include any valves which can be
closed.
w Warning
Blockages in the filling pipe may cause major damage to the heat
exchanger coils incorporated in the tubular flow steriliser!
In addition, the incorporation of valves in the filling pipe will affect the
aseptic condition of this pipe.
3.9.2 Components
Figure 3.33 Filling pipe (customer part)
a Filling valve
b Filling pipe

Description
3.10 System control cabinets

The control cabinets incorporates various components to ensure fully
automatic process control.
3.10.1 Introduction
The software of the HMI incorporates measuring and control circuits for
temperature and pressure control during automatic machine sterilization, in
place cleaning and product sterilization.
It allows output-adapted control of the homogeniser drive (applicable to B-
type systems only) and main heater range adjustment, which allows
adaptation of the machine output to suit the intake capacity of one or
several filling machines.
With the switches, you can start or stop the various components of the
machine. Safety and alarm facilities are incorporated at various critical
points in the circuit. The system also includes an emergency switch.
Figure 3.34 Control cabinet of the installation
version 1.0 95
3.10.2 Functions of the operator control unit

Functions and features of the PLC:
• Displaying options
- Displaying of process timers/counters values,
- Displaying of process steps (two digit number),
• Displaying of process pressure and temperatures,
- Displaying of alarm numbers,
- Displaying of process homogeniser capacity,
- Displaying of all internal HMI parameters (input, output, memory and
data).
• Settings options
- Setting of process timers/counters,
- Setting of homogeniser/dosing pump capacity,
- Setting of heater length,
- Setting of PID controller parameters,
- Setting of temperature and level alarm setpoints.
• Manual control options
- Manual control of homogeniser capacity,
- Manual control of heater length,
- Manual control of process steps (for maintenance only),
- Manual control of PID controller outputs.
Figure 3.35 Operator control unit MP377

Description
3.11 Interaction with other machines

The system configuration contains a control cabinet that is provided with
operator control unit. The operator control unit (Human Machine Interface)
could be connected to the filling machine and product supply machine.
3.11.1 Communication between the system and

filling machines
Description of the exchange of signals between the HMI-controlled
variable-output machine and the hooked-up filling machines, enabling their
timed operation.
A number of electrical inputs and outputs enable communication between
the machine and up to 5 filling machines.
Figure 3.36 Signals between the system and filler
RFP 1
1 PAM 1
PFM 1
RFP 2
2 PAM 2
PFM 2
RFP 3
3 PAM 3 Sterideal
PFM 3
RFP 4
4 PAM 4
PFM 4
RFP 5
5 PAM 5
PFM 5
a b
a Filling machine
b Sterideal
The signals should satisfy the following electrical requirements:
• The contacts incorporated in the machine to enable the transmission of
the output signals to the hooked-up filling machines are electrically
isolated from the rest of the system and fed from the filling machine's
24V circuit.
version 1.0 97
• The contacts incorporated in the filling machine to enable the

transmission of the input signals to the machine are electrically isolated
from the rest of the system and require connection to the machine's 24
V circuit.
Two types of signal transmitted by any of the hooked-up filling machines
may be received by the machine:
• RFP(n1) = Ready for production: which indicates that the filler (n1) is
ready to start product intake. When this filling machine is shut down, this
signal will drop off.
• PFM(n2) = Filling machine in production: which indicates that the filling
valve of filler (n1) will presently be opened, requiring the machine to
adapt its output to the intake capacity of this filler and, moreover, to
temporarily increase its output so that there is a “surplus” output in order
to facilitate initial operation of the filler.
The machine transmits one type of signal to the filling machines:
• PAM(n1) = Product at filling machine: which indicates that:
- the machine's output has been adapted to the changed demand;
and
- the product has arrived at the (n1) filling valve. The filling valve of the
(n1) filler can now be opened.
1. (n) may be any number in the series from 1 through 5. It signifies the number of the filling
machines
2. (n) may be any number in the series from 1 through 5. It signifies the number of the filling
machines

Description
3.11.1.1 Example
The example below illustrates a typical production run of a HMI-controlled
closed-circuit variable-output machine hooked up to two aseptic fillers.
Figure 3.37 Synchronisation between the machine and filling machine
Filling valve 1
RFP 1
PAM 1
PFM 1
Filling valve 2
RFP 2
PAM 2
PFM 1
I 0
operator
80%
60%
40%
20%
process phase 06 phase 07 phase 08 phase 09 phase 10 phase 11 phase12 phase 13
In Figure 3.37 on page 99, “Exchange of timing signals between machine

and two filling machines”, this example is shown graphically. In the
example, machine operation is based on the following outputs:
• circulation capacity set at 80% of rated machine output,
• product displacement phase 2 capacity set at 90% of rated machine
output,
• intake capacity of filling machine 1 set at 30% of rated machine output,
• intake capacity of filling machine 2 set at 40% of rated machine output.
3.11.1.2 Machine operation

A day's production begins with the start-up of the machine and a minimum
of 1 filling machine, thus ensuring that the preparatory steps of the two
production units are effected simultaneously. In this example, filling
machine 2 will be started up. When the machine is operating in step 06
(aseptic water circulation), filling machine 2 will transmit the RFP-2 signal,
which reports as it were that the filling machine is ready to assume its
product filling duty. When the RFP signal has been received, the light
incorporated in the start button of the machine will start to blink. The
operator in attendance at the machine may now depress the start button,
enabling the machine to start its production run.
version 1.0 99
First the product tank is drained (step 07), next the product tank is charged
with product (step 08) and, subsequently, the water displacement step
(step 09) is initiated. During the water displacement step, the machine 09
output depends on the number of RFP signals received. In this instance,
the machine output is identical to the production output for filling machine
2. If two RFP signals would have been received, the machine output would
be equal to the sum of the individual outputs required for the two filling
machines, thus offering the benefit of minimum change in output when, at
the end of the water displacement step, the production phase proper is
initiated. In the event of all RFP signals dropping off at any stage during
steps 07 and 08, the machine control system will return to step 06!
When step 09 has been completed, step 10 will be initiated, thus allowing
the machine assume its product sterilization duty. In the course of this step,
after a time that can be preset (default value of 1 minute), the PAM-2 signal
will be transmitted.
This PAM-2 signal indicates to the filling machine operator that he is
allowed to open the filling valve of the filling machine awaiting product
delivery. Just prior to the filling valve being opened, the PFM-2 signal will
be transmitted to the machine. Upon receipt of this PFM signal, the
machine will ensure that its output is increased additionally by ca. 5% for a
period of time that can be preset (default value of 2 minutes). This
additional output serves to facilitate initial product filling operation of the
filling machine.
When the next filling machine is ready to assume its product filling duty, the
relevant RFP signal will be transmitted to the machine (this is the RFP-1
signal in our example). The machine output will then be increased to suit
the intake capacity of this filling machine.After the preset time, the machine
will transmit the PAM-1 signal, which indicates to the filling machine
operator that he is allowed to open the filling valve of filling machine 1. Just
prior to the filling valve being opened, the PFM-1 signal will be transmitted
to the machine. The latter will ensure that there will again be a temporary
additional increase of 5% in machine output (default value is 2 minutes).
Next the filling valve will be opened. The Tetra Pak aseptic fillers's internal
circuitry requires a lapse of time of ca. 15 seconds between PFM signal
transmission and actual opening of the filling valve.
3.11.1.3 Machine shutdown

When a filling machine's production run is terminated, its filling valve will be
closed and the relevant PFM and RFP signals will drop off. The machine
output will then be reduced by the relevant filling machine's intake capacity.
The relevant signal will drop off. In our example, where filling machine 2 is
shut down, the PFM-2 and RFP-2 signals drop off. The PAM-2 signal is
de-energised from the machine.
A normal production run is ended when the feed product tank runs out of
product. The production run can also be terminated by depressing the
machine's 'stop production' push button. As a result, the product supply
valve will be closed, thus enabling the product tank to be drained until the
LH electrode ceases to be submersed. This allows the initiation of step 11
(product displacement phase 1). At the end of this step, all PAM signals will
be de-energised. In our example, the PAM-1 signal is de-energised, thus
causing the last filling valve to be closed.
A production run may be terminated by:
• a lack of product supply,
• all RFP signals dropping off,
100 November 12, 2010

Description
• the Main heater low-temperature cutout becoming energised,

• the breakdown of the resistance bulb in the main heater.
If, during step 10 (production) or step 11 (product displacement phase 1),
the main heater low-temperature alarm becomes energised or the Pt100
bulb becomes defective, all PAM signals will be de-energised immediately,
thus closing all filling valves.
The above description applies to a B-type machine. It also applies to an
A-type machine, which features a two-speed three-phase motor permitting
two fixed outputs only (i.e. 50% and 100%), it being understood that the
intake capacity of the two filling machines will have to be adapted to these
outputs, thus requiring that each filling machine is capable of handling 50%
of the output.
Circulation capacity will be 50% of max. machine output and product
displacement phase 2 capacity will be at max. machine output (100%).
In addition, the A-type machine does not permit a temporary additional
increase in output upon receipt of a PFM signal!
version 1.0 101

102 November 12, 2010

Installation
4 INSTALLATION

This chapter contains information about installation, commissioning and
decommissioning of the machine.
• 4.2 Transport on page 104,
• 4.3 Machine environment on page 111,
• 4.4 Utilities on page 111,
• 4.5 Maintenance on page 116
• 4.6 Environment on page 116
• 4.7 Commissioning on page 118,
• 4.8 Decommissioning on page 119.
version 1.0 103

4.2 Transport
If the machine is too large to be transported as one unit, the machine will
be delivered in parts.
c Caution
During transport, make sure not to expose the machine to severe shocks,
vibrations and shaking, in order to avoid machine damage.
n Note
A service engineer from Stork Food & Dairy Systems B.V. must be
present when the machine is assembled and installed.
w Warning
Consult the transport and hoisting guidelines before you start transport
and/or hoisting activities.
Before you install the machine:

• Make sure sufficient space is available around the machine for
operation, maintenance and cleaning.
• Make sure the operator console and the electrical cabinets are not
exposed to direct sunlight or to other heat sources (for example, steam
lines).
Take the following precautions to ensure safe working conditions:
• Study the relevant assembly drawings before you start any
(dis)assembly operations.
• Use appropriate, high-quality transport gear, and check this gear for
proper operation at regular intervals.
• Transport must be carried out by qualified, skilled personnel.
• Verify the weight of the load to be transported. The weight is listed on
the ‘Hoisting instructions’ drawing.
Use the following procedure to transport the machine or machine parts into
position:
1 Move the machine using a forklift truck or hoist, use the lifting lugs if
present.
2 Correctly position the machine on site (see the ‘Connection and
Dimensions’ drawing).
3 Level the machine and set it to the correct height by scrolling the
adjustable legs in or out, as needed. Machine parts without adjustable
legs can be levelled using shims.
4 Firmly tighten the check nuts of the adjustable legs.
104 November 12, 2010

Installation
4.2.1 Tubular flow steriliser
4.2.1.1 Hoisting
The Tubular flow steriliser must be placed with the help of hoisting
equipment. For this purpose a lifting bar with lug is mounted in the centre
of the Tubular flow steriliser to the cross frame (see Figure 4.1).
c Caution
The Tubular flow steriliser must never tilt or moved on the fork of the fork-
lift truck.
1 Demount the lid of the housing.

2 Attach the bow shackle with sling to the lifting lug.
3 Hoist the Tubular flow steriliser to its position.
4 Level the Tubular flow steriliser with the four adjusting legs beneath the
cross-frame horizontally.
c Caution
Lock the nuts of the legs!
- Loosen the lock nut and adjust the legs by putting a rod of 15 mm.
into the one of the hole of the leg.
- Secure the lock nuts.
- Remove the bow shackle with sling.
5 Mount the lid on the housing.
version 1.0 105

Figure 4.1 Hoisting and adjusting of the Tubular flow steriliser
1
2
a Lock nut
b Adjusting leg
c Lug
106 November 12, 2010

Installation
4.2.2 Metering unit (module 03)
4.2.2.1 PCM dosing pump (M03.01)

The PCM dosing pump must installed horizontally with the four adjustable
legs at each corner. Check with a spirit level if the unit is levelled correctly.
Figure 4.2 Installation PCM dosing pump
a Adjustable legs
version 1.0 107

4.2.3 The homogeniser (module 08)
4.2.3.1 Hoisting
The homogeniser should be hoisted from the lifting lugs provided for this
purpose. The illustration below shows the points where the hoisting slings
should be attached for the 3HL-10 with top-mounted drive.
Figure 4.3 Lifting lugs of HL with top-mounted drive
a a
a Lifting lugs
c Caution
Do not use the lifting lugs of the electric motor. They should be used only
for hoisting the motor.
In addition to hoisting, the homogeniser can also be moved with the help of
a fork-lift truck. Space the fork arms apart as far as possible. Lift the
homogeniser under the longitudinal girders of the frame and take care to
ensure that nothing is damaged.
c Caution
When handling the homogeniser, take care to ensure that the pipes at the
bottom of the frame are not damaged during transport!
108 November 12, 2010

Installation
Consult the drawing P0678982 to install the homogeniser, which indicates

the measurements and specification.
4.2.3.2 Levelling
Figure 4.4 Top drive homogeniser model
d
e
a Pump block
b Left
c Rear
d Right
e Front
For proper operation, it is essential that the homogeniser is properly
levelled. If the homogeniser is to be relocated, take care to ensure that it is
moved in accordance with the instructions given below
1 Place a spirit level on the machine, top surface of the pump block, and
level the pump block with the help of the four adjustable legs.
c Caution
Loosen the four lock nuts on the adjustable legs prior to adjust them.
Retighten them after adjustment!
version 1.0 109

2 Now tighten the four lock nuts.
Figure 4.5 Adjustable legs of the homogeniser
a Lock nut
110 November 12, 2010

Installation
4.3 Machine environment
4.3.1 General
The environment of the machine must be as clean as possible. This implies
that the machine and its surroundings must at least be cleaned regularly.
Ventilation is of vital importance. Adequate ventilation reduces the air
humidity and can thus counteract condensation.
4.3.2 Corrosion resistance
4.3.2.1 Stainless steel parts

The machine contains stainless steel parts. This metal may show corrosion
when exposed to chlorides (such as common salt). Corrosion develops
very quickly if the temperature rises and the solution containing the
chlorides evaporates. This means you must not use that liquids with a
unduly high concentration of chloride in the machine.
Other metals, such as unalloyed steel used for hoisting equipment, must
also be prevented from coming into contact with stainless steel machine
parts. Damage due to such contact may cause corrosion. If contact is
inevitable, wooden parts must be used to protect the machine.
The machine environment must be free of metallic particles. These
particles may cause rust.
c Caution
Do not perform work in the vicinity of the machine that disseminates
metallic particles into the air, such as steel grinding.
If you do need to do this type of work near the machine, make sure to
protect the machine using a tarpaulin. When you remove this tarpaulin,
take extreme care to avoid dirt and metallic particles migrating to the
machine.
4.4 Utilities
4.4.1 Mains power
Table 4.1 Mains power, general requirements
Application mains electrical power to the power distribution

panel
Standard IEC
Voltage, frequency 3-phase, neutral, ground, 380-420 V, 50 Hz
Continuity no microcuts (UPS for PLC/PC only)
version 1.0 111

4.4.2 Air supply
4.4.2.1 Compressed air, general
Table 4.2 Compressed air, general requirements
Application general application

Pressure 750-850 kPa overpressure
Temperature ambient
Quality standard min. ISO8573.1 (1991), class 4.4.4
must be suitable for food application: must not
contain odour, flavour, colour additives.
4.4.2.2 Compressed air, instruments
Table 4.3 Compressed air, instrument requirements
Application pneumatic control instruments / controlled

positioners
Basic specifications see General compressed air
Quality standard min. ISO 8573.1 (1991, class 3.4.3)
n Note
It is recommended to clean the air-tube system with air before
connection.
4.4.3 Steam
4.4.3.1 Steam, general
Table 4.4 General steam requirements
Application non-food contact heating

Quality min. 99 % steam
Condensate pH 6.5-8
Solids, rust none
Boiler carry-over none
Health properties no health risk
Pressure 800-1000 kPa, max. 20 kPa variation during stable
process conditions
Oxygen max. 0.5 mg/kg
Carbon dioxide max. 5 mg/kg
112 November 12, 2010

Installation
Table 4.4 General steam requirements (Continued)
Additives no volatile substances

Corrosivity non corrosive to AIS316L, DIN 1.4404
Condensate max. 30 kPa at floor level
discharge pressure
4.4.3.2 Steam, culinary
Table 4.5 Culinary steam requirements
Application food contact and food contact surface heating

Basic specification see General steam
Quality dry,
Steam source generated from potable water acc. 98/83/EG or
FDA21CFR173.310
Particles filtered 0.2 μm, >95%, full stainless circuit
Other must be suitable for food application: must not
contain odour, flavour, colour additives.
4.4.4 Water specification
4.4.4.1 General water
Table 4.6 General water requirements
Application any water in contact with the equipment

Supply pressure 400-600 kPa
Health standard potable water standard 98/83/Eg, WHO1971
Microbiology Total plate count < 100/mL; no pathogenic or
faecal coli
Corrosivity non-corrosive to stainless steel AISI 316L / 1.4404
Non-dissolved solids none, no substances like oil, sand, clay, etc.
Hardness (tot. max. 100 mg/L
CaCO3)
Chloride (Cl-) max. 60 mg/L
Free chloride/biocide max. 0.1 mg/L
(as Cl, DPD)
Sulphate (SO4=) max. 100 mg/L
Iron (tot. Fe) max. 0.1 mg/L
Manganese (tot. Mn) max. 0.05 mg/L
Copper (Cu) max. 0.1 mg/L
pH 7-8
version 1.0 113

4.4.4.2 Process water
Table 4.7 Process water requirements
Application water for product contact and closed loop heat

exchanger circuits
Basic specification see General water
Hardness, (bi)- max. 1 mg/L
carbonate
4.4.4.3 Seal water
Table 4.8 Water, seal requirements
Application cooling / lubrication of seals

Supply, discharge 270-330 kPa
pressure
Supply temperature 20-40 °C
4.4.4.4 Drain, fluids & waste
Table 4.9 Drain requirements
Application all waste water, condensate and other fluids

Suitable to receive hot fluids, product, chemicals, condensate, steam/
air (incidental)
Pressure max. 0 kPa at floor level
4.4.4.5 Cooling water, general
Table 4.10 General cooling water requirements
Application general cooling

Supply pressure 400-600 kPa
Available pressure min. 400 kPa
difference in/out
114 November 12, 2010

Installation
Table 4.10 General cooling water requirements
Supply temperature max. 28 °C

CaCO3 hardness max. 50 mg/kg (frequent descaling needed)
max. 5 mg/kg in any other case
4.4.4.6 Cooling water, chilled
Table 4.11 Cooling water, chilled requirements
Application low temperature cooling

Basic specifications see General cooling water
Temperature max. 1 °C
4.4.5 Lye (NaOH)
Table 4.12 Lye (NaOH) requirements
Application cleaning
Quality Sodium Hydroxide (NaOH)*, food grade,
commercial concentration 30 %-40 %
w/w
* Lye is also known as alkaline, or caustic soda
4.4.6 Acid (HNO3)
Table 4.13 Acid (HNO3) requirements
Application cleaning
Quality nitric acid (HNO3) food grade
commercial concentration 45 %-55 %
w/w
version 1.0 115

4.5 Maintenance
4.5.1 Lubricants
Table 4.14 Lubricants requirements
See the maintenance chapter of this manual
4.6 Environment
4.6.1 Ambient indoor air, general
Table 4.15 Ambient indoor air, general requirements
Application general equipment environment

Quality non-condensing, non-corrosive, dust
free, odour free, no metallic particles,
well ventilated
Temperature 1-35 °C
4.6.2 Operator Panel
Table 4.16 Operator panel requirements
Application ambient conditions for power, control

and instruments panels
Basic specifications see section “Ambient indoor air” of this
chapter.
4.6.3 Connecting the machine to the utilities

Thoroughly flush the supply lines before connecting them to the machine.
This is to prevent any dirt getting into the machine.
See the utility connection drawing for location of all utility connections.
4.6.4 Electrical hook-up

Only authorised electricians are allowed to do the electrical hook-up.
The terminals for the mains connection are located in the control cabinet.
For further details, please refer to the set of electrical engineering
drawings.
116 November 12, 2010

Installation
4.6.5 Installing power cables

The power supply and motor cables must never be routed through the
program control section of the control cabinet. The high-power signals in
these cables can interfere with the low-power control signals.
4.6.6 Electrical safeguards

The machine has a main switch that can be locked in the OFF position
using a padlock.
The mains supply must have a proper earth lead.
The appropriate control voltage for each machine is shown in the wiring
diagram. The required alternating current comes from a transformer.
n Note
The machine is controlled electronically. A constant voltage is required to
ensure proper functioning.
w Warning
It is absolutely necessary to turn off and lock the main switch before you
carry out any repair jobs on the machine.
w Warning
Before connecting the power besure all switched, valves are in OFF
position to prevent that functions can be started accidentally.
4.6.7 Motors
It is recommended to check if the motors are fed with the correct voltage
(compare with the motor rating plate) and the current value is not
exceeded.
Changing the direction of rotation of the electric motor is allowed only if the
supplier’s instructions are observed. Never change the direction of rotation
by reversing the armature and field windings.
Never allow the machine to run in reverse. Once the machine has been
hooked up to the mains, test its direction of rotation. This can best be
checked by pressing the start button in manual mode and immediately
thereafter the emergency stop button. By observing the machine after this
short start-up, you can check the direction of rotation.
version 1.0 117

4.7 Commissioning
n Note
Before connecting the machine or parts like switches and valves, make
sure that they are in the OFF position, to prevent the machine from
starting to run unintentionally.
Procedure for commissioning the machine:

1 Check that all guards have been fitted.
2 Check the fuses and energise the control cabinet.
3 Connect the main compressed air line.
4 If the machine has been transported in parts and arranged, check all
cable connections and test the machine I/O.
4.7.1 Piping
Connections from the Stork machine to the customer’s plant are marked in
the P&ID with the symbol shown in Figure 4.6. The installation by Stork is
done up to the “S” mark, from that point on the customer is responsible for
the installation. This part of the installation is marked with a “C”.
Figure 4.6 Pipe connections Stork/Customer
C S C
OR
118 November 12, 2010

Installation
4.8 Decommissioning
At the end of the service life of the machine, the following instructions for
dismantling the machine must be observed.
Always follow the safety instructions, see the Safety chapter.
1 Disconnect all power cables supplying the machine so that all
components are dead.
2 Disconnect the compressed air supply line, and make sure that there is
not any residual pressure left in the machine.
3 Block all moving parts in order to avoid accidental movements of
components.
4 Bleed all liquids, including coolant, lubricants, hydraulic oils, etc.
Correctly dispose of these liquids.
5 Take off all sheets and guarding.
6 Remove all electric cabling and pneumatic lines.
7 Dismantle the internal units, proceeding top down.
8 Sort the scrap parts by type of material, whenever possible, so they can
be disposed of in line with national environmental standards.
version 1.0 119

120 November 12, 2010

Operating interface
5 OPERATING INTERFACE

This chapter gives details about the operating features and principles of the
machine.
• 5.2 Operating mechanisms and indicating instruments on page 122,
• 5.3 Operator panel Start menu on page 118.
version 1.0 121

5.2 Operating mechanisms and indicating instruments

During the processes, the operator uses the operator panels to control the
machine. The operator panels in this configuration are:
• the human machine interface on the control cabinets, Figure 5.1 on
page 122.
• the panel to control the homogeniser, pulse dampers and homogenising
devices, see Figure 5.2 on page 123.
The control cabinets contains the motor control instruments and process
control instruments. The other controls on the machine (gauges, indicators,
manual valves) are used for maintenance and troubleshooting.
Figure 5.1 Control cabinets with operator panel
1 2
6
5 7
C
B
A
Table 5.1 Operator panel and remote control box
Nº DESCRIPTION
a Main switch
b Emergency stop button
c Temperature recorder TIR
d Touch screen
e 220 V AC control circuit on (white)
f 24 V AC control circuit on (white)
g Reset emergency button
h Control circuit switch
122 November 12, 2010

Operating interface
Table 5.1 Operator panel and remote control box (Continued)
Nº DESCRIPTION
i Stack light including siren
j Water heat exchanger
A = Power cabinet,
B = Frequentcy controlers,
C = Terminal blocks
Figure 5.2 Homogeniser with panel
1 2 3
0000
I I
Table 5.2 Control panel
Nº DESCRIPTION
a Lubrication pressure
b Homogeniser pressure (device 1)
c Oil pressure (device 1)
version 1.0 123

5.2.1 Stack light

The installation is equipped with a stack light to indicate the status of the
machine. The stack light is positioned on top of the control cabinets. Table
5.3 shows the stack light and gives an explanation of the indications.
Table 5.3 Explanation of Stack light signals
ILLUMINATION (1) SIGNALLING

Continuous red • Alarm active, acknowledged and no new alarm.
Flashing red • Alarm active, not acknowledged or new alarm.
Continuous yellow • Pre-heating steps 304, 305 and 306.
• Sterilization step 400.
• System and aseptic cooling.
• CIP (all steps).
Flashing yellow • Product return.
• Starting system step 100 and 101.
• Run down main drive.
• Start pre-heating step 301, 302 and 304.
Continuous green • Production steps 7 through 13.
• Rinsing system with water.
• Aseptic water circulation step 6.
Black (2) • Buzzer/alarm
5.2.2 Machine control panels

The machine is equipped with switching panels, which can be set manually.
These switching panels will only be used to set-up an initial installation of
the machine.
5.2.2.1 Switching panels
Table 5.4 Switch panels
Switch panel (see section 3.3.1 on page 61).

Function:
To select production or cleaning method (S.01.01/02/03).
Module 18 - Switch panel section (see Figure 3.16 on page 75)

Function:
To select the required holding time of 4 sec. or 7 sec. at a capacity of ST
8,5 C l/h.
124 November 12, 2010

Operating interface
5.2.3 Pressure gauges and pressure regulators

Table 5.5 gives an overview of gauges, inspection elbow and condensate
drains on the tubular flow steriliser. See also Figure 5.3 on page 126.
Table 5.5 gives an overview of gauges and condensate drains on the
aseptic tank. See also Figure 5.3 on page 126.
Table 5.5 Elbow, condensate drains and pressure gauges
ITEM FUNCTION SETTING

Condensate drains:
• 10.02, 10.05 and 10.09 • Mainheater
• 12.03 • Cooler.heater
Pressure gauges: To check the pressure...
• 03.28 • at the water inlet of the dosing
unit.
• 10.03 and 10.04 • before and after the control
valve (TCV10.01) of the main
heater
• 12.11 • Product cooler/heater
• 15.01 • Back pressure valve
Inspection elbow Located near:
• the 1st homogeniser device
• module 09
• TT10.01
• V13.01
In the figure on the next page all items are shown.
version 1.0 125

Figure 5.3 Temperatures, pressure gauges and pressure regulators
P0875441A
126 November 12, 2010

Operating interface
5.2.4 Siemens terminal

The terminal of the HMI is mounted on the control cabinets. This terminal
is MP377 Simatic touch screen with a Windows CE running an interface
application - WinccFlex Pachage.
The display is a touch screen to serve as an alternative to a computer
mouse for interaction with the graphic interface. The operator buttons are
below the terminal.
Figure 5.4 Multipanel MP377 Human Machine Interface (HMI)
5.2.5 Paperless recorder

The applications for the device are practically limitless, from recording and
visualisation, to data acquisition and elementary control.
Figure 5.5 Paperless recorder
For detailed information about the recorder see the third party
documentation.
version 1.0 127

5.3 Operator panel Start menu
Figure 5.6 Multipanel Start menu
The Start menu, see Figure 5.6, is the first operating screen of the
Sterideal, if both the main switch and the control current switch are on. The
Start menu shows the project data below the title “STORK Food & Dairy
Systems B.V.”:
• The first line contains the Project information.
• The other lines represent the technical data of the machine:
- The Sterideal capacity,
- The order number.
The year and time of the running system are shown at the right bottom of
the window.
The Main menu can be activated by a single press in any area of the
screen.
n Note
When a window is active for some minutes, defined in the operating
system screensaver, the light intensity is reduced to 30%.
Standard icons are used in various screens. the meaning of the icons are
described in section 5.9 Icon description menu on page 143.
128 " November 12, 2010

Operating interface
5.4 HMI menu layout and buttons

The Human Machine Interface (HMI) has a similar layout for all the menus
and contains the following frames:
Figure 5.7 Menu layout (e.g. Main menu)
a
f
e d c
a an Event bar which shows the event messages during operation of the
machine at the top of the menu.
b a Main frame can contains buttons and/or value boxes.
The value boxes on the mainframe of the menus has the following
function:
- Editable value, but password protected
- Value defined by the recipe.
c the right area shows the timing of the process and if activated a button
to switch between the available languages.
d An Operator bar contains the following buttons:
- [reset alarm] to acknowledge an alarm
- [ I ] to start and the [ 0 ] to stop the program steps.
version 1.0 " 129

e A Navigation bar at the left with the following navigation buttons:
to return to the main menu of the indirect heating process

(see Main menu on page 132),
displays/hides the tag indicators of the instrument on
menu,
to switch between the available the languages
Navigates to the section 5.15 UHT menu on page 154
f If an alarm is active the alarm indication icon appears somewhere in the

screen.
During the selection of the buttons and value boxes the interface could be
showing the following additional windows:
• Numerical keyboard window on page 131,
• Keyboard window on page 131,
• Error message window on page 131.
130 " November 12, 2010

Operating interface
5.4.0.1 Numerical keyboard window

The numerical keyboard window appears after an editable parameter value
box selection, the user must enter a new value or press [ESC] to return to
the menu.
Figure 5.8 Numerical keyboard window
5.4.0.2 Keyboard window

The keyboard window can appear after a button selection, the user can
enter a textual code, a message on the keyboard or press [ESC] to return
to the menu. The window acts as a normal keyboard, but the combination
of keys is not allowed. This is done by pressing the single keys touch after
each other.
Figure 5.9 Keyboard window
5.4.0.3 Error message window

If the selection of an action is not allowed the error message window of
Figure 5.10 appears on the screen. The text message is a brief explanation
of the fault message and the colour shows the type of warning.
Figure 5.10 Error message window
version 1.0 " 131

5.5 Main menu

The Main menu presents the operating buttons to control the Sterideal
processes.
Figure 5.11 Main menu
a b
The Main menu can be divided in the following functional parts:

a Operator buttons and specials,
The first three columns of the main menu represents the operating
buttons and specials to activate the menus that control the activated
program/process.
b P&ID Controller buttons,
The last column of each main menu contains the buttons that activate
the controller menus of the configuration.
c Caution
Certain menus or settings are password
protected. The maintenance engineer or STORK User
engineer with the correct login level can modify Password
these settings. The user and password will be

active for some time defined in the password
menu, see “Password menu” on page 146.
132 " November 12, 2010

Operating interface
5.5.1 Operator buttons and specials

The operating buttons and specials of the first three columns are described
in the following sections:
• [Manual operation], see section 5.6 Manual operation menu on page
134,
• [Step], see section 5.7 Step menu on page 141,
• [Alarm], see section 5.8 Alarm menu on page 142,
• [Icon description], see section 5.9 Icon description menu on page 143,
• [Help], see section 5.10 Help menu on page 144,
• [Maintenance], see section 5.11 Maintenance menu on page 145,
• [Program selection], see section 5.12 Program selection menu on page
150,
• [Process protocol], see section 5.13 Process protocol menu on page
152,
• [Selection product retour], see section 5.14 Product return menu on
page 153,
• [UHT], see section 5.15 UHT menu on page 154,
• [Trending], see section 5.16 Trending menu on page 155.
• [Process temperature adjustment], see section 5.17 Process
temperature menu on page 156,
• [Timer adjustments], see section 5.18 Timer menu on page 157,
• [System pressure], see section 5.19 System pressure on page 171
• [Filling pressure], see section 5.20 Filling pressure on page 172
• [Recipe], see section 5.21 Recipe menu on page 173,
5.5.2 P&ID Controller buttons

The controller buttons [grey] open the appropriate menu indicated on the
button. The operator can view the setting and trending of the controller. The
details of the menus are described in section 5.22 Control components
menus on page 174.
version 1.0 " 133

5.6 Manual operation menu

This Manual operation menu presents the components of the Sterideal,
which could be set manually during step 0000.
Figure 5.12 Manual operation menu
The functional descriptions of the available buttons are described in the

following section:
• 5.6.1 Step control menu on page 135
• 5.6.2 Lamp test on page 135
• 5.6.3 Manual Operation - P&ID menu on page 136
• 5.6.4 Test homogenizing system on page 139
• 5.6.5 Main heater temperature alarm menu on page 140
134 " November 12, 2010

Operating interface
5.6.1 Step control menu

The 'Step control menu' enables the operator to operate the step manually.
The operator has to enter the correct phase number for manual operation.
If the machine is in manual operation the operator must acknowledged
each single step or can enter a correct 'Enter code' to reset the manual
operation. The reset code will put the machine in stand-by (phase 0000)
The [Step control] opens the Manual step control menu. On this menu you
are able to select a step manually, after you have typed in the correct code
to operate the step.
Figure 5.13 Step control menu
5.6.2 Lamp test

The causes a test to be carried out on lamps in the buttons of the
control cabinets below the multipanel.
version 1.0 " 135

5.6.3 Manual Operation - P&ID menu

The Manual operation - P&ID menu show the related part of the P&ID. The
manual operation of the process components can be operated by means
of the function bar at the bottom of the menu. The available P&ID parts are:
• Motor & valve System, see Figure 5.14 on page 136.
• Motor & valves main drive (homogeniser), see Figure 5.15 on page 137.
• Valve state, see Figure 5.16 on page 138.

(Motor & Valve System)
a b
a Valve value box

b Motor value box
To activate a valve or motor manually, proceed with the following steps:
VALVE MANUAL OPERATION: MOTOR MANUAL OPERATION:

1 Select the valve value box 1 Select the motor value box
2 Type in the item number of the valve (without prefix 2 Type in the item number of the motor (without
letter) prefix letter)
3 After entering the valve item number the valve will 3 To start the motor press the stop button without
automatically open en close every few seconds. release
4 To stop the manual control enter 0 into the valve 4 Release the stop button to stop manual control.
value box.
5 Enter 0 into the motor value box to reset manual
control.
136 " November 12, 2010

Operating interface

(Motor & valve main drive)
a b
a Valve value box

b Motor value box
To activate a valve or motor manually, proceed with the following steps:
VALVE MANUAL OPERATION: MOTOR MANUAL OPERATION:

1 Select the valve value box 1 Select the motor value box
2 Type in the item number of the valve (without prefix 2 Type in the item number of the motor (without
letter) prefix letter)
3 After entering the valve item number the valve will 3 To start the motor press the stop button without
automatically open en close every few seconds. release
4 To stop the manual control enter 0 into the valve 4 Release the stop button to stop manual control.
value box.
5 Enter 0 into the motor value box to reset manual
control.
version 1.0 " 137


(Valve state)
The menu shows the state of the valves and feedback:
Valve activated
Valve not activated
Two way valve
Two way valve with feedback signals
Three way valve
Three way valve with feedback signals
= Closed
= Open
= Open
138 " November 12, 2010

Operating interface
5.6.4 Test homogenizing system

The [Test homogeniser system] tests the pressure of the homogeniser with
water during step 0103. This feature is password protected and used for
STORK engineers and maintenance engineers during the initial installation
of the Sterideal.
Figure 5.17 Test homogenizing system menu
version 1.0 " 139

5.6.5 Main heater temperature alarm menu

The Main heater temp alarm menu enables you to reset the alarms if
TT10.01 falls down (temperature too low) during production phase 04 and
19.
The activation button overrides this alarm temporarily, but needs a
password code. The status of this feature is displayed in the menu.
n Note
The customer is entirely responsible and STORK can not stand surety
for the integrity of the product.
Figure 5.18 Override main-heater temp. alarm menu
a Password code,
b Activation button,
c Status.
140 " November 12, 2010

Operating interface
5.7 Step menu

The Step menu shows all the steps of the selected process. The following
information is stored: time, date, status, and the description of the step. The
menu is meant for maintenance purposes.
Figure 5.19 Step menu
version 1.0 " 141

5.8 Alarm menu

The Alarm menu lists the actual alarms of the process. These alarms will
be stored in the menu and shows the Time, data, status and description.
The history of the alarms are stored on the HMI memory card, that can be
viewed with the [Alarl Log] button.
Figure 5.20 Alarm menu
142 " November 12, 2010

Operating interface
5.9 Icon description menu

The Icon description menu explains the used icons of this interface.
Figure 5.21 Icon description
version 1.0 " 143

5.10 Help menu

The Step overview menu (Help menu) gives an overview of the available
steps. The actual step is highlighted in green. On the operator bar the
operator is able to start [ I ] and stop [ 0 ] the program step.
Figure 5.22 Help menu understanding step cycle
The steps mentioned in this menu are described in chapter 6.4
144 " November 12, 2010

Operating interface
5.11 Maintenance menu

The Maintenance menu is password protected and a login window pops-
up. After typing the correct password level, select [Maintenance] again to
activate the Maintenance menu. This menu contains the settings of the
HMI. All submenus activated by the buttons are password protected.
Figure 5.23 Maintenance menu
The operating functions of the buttons listed in the menu are:

• [Language selection] allows you to select one of the available
languages of the interface.
• [TEST Language selection] shows/hides the Switch language button at
the button bar.
• [Password], see section 5.11.1 Password menu on page 146,
• [Exit Screen runtime] closes the interface (Protool) and opens the
operating system of the HMI.
• [Delete Event Buffer] deletes the history of the events,
• [Display system Message] presents the current system messages.
• [CPU], see section 5.11.2 CPU menu on page 148,
• [Variable], see section 5.11.3 Variable menu on page 149,
• [Cleaning screen] activates a time bar on the screen. During the time
the time bar is presented you are allowed to clean the screen.
• [Touch Screen Calibration] calibrates the touch screen,
• [dd/mm/yyyy] adjusts the date of the HMI.
• [hh:mm:ss AM/PM] adjusts the time of the HMI.
version 1.0 " 145

5.11.1 Password menu

The parameters on the menus are password protected. This is done to
prevent unauthorized access and damage to the machine. There are two
levels predefined and the customer can add seven additional levels:
• The user Admin and STORK are restricted for STORK engineers only,
• The Operator user is defined for the customer.
During the installation of the system the Stork representative creates the
authorization levels and passwords for the customer.
w Warning
There is no service available to warn you, if you need to change the
password.
Figure 5.24 Password menu
<password STORK only>

<password customer>
<password STORK only>
Password modification procedure:
n Note
When leaving the password menu the system logs off.
1 Press the password icon on the main menu

2 Type in the password on the pop-up window with the help of the
keyboard window and acknowledged with the enter key.
3 Press the password icon again
146 " November 12, 2010

Operating interface
4 Within the password menu press on cell you want to modify:

- Password to modify the password string,
- Group to modify the access level,
- Logoff time to adjust the timer.
version 1.0 " 147

5.11.2 CPU menu

The CPU menu lists the state of PLC events (CPU = Central Processing
Unit). The PLC report disconnected cables, power shut-off and on, battery
interruption etc. These events will be stored in the menu and shows the
date and time of interruption.
Figure 5.25 CPU menu
148 " November 12, 2010

Operating interface
5.11.3 Variable menu

The Variable menu is used to define the values for I/O tests, this menu is
not applicable for customer or maintenance engineers.
Figure 5.26 Variable menu
version 1.0 " 149

5.12 Program selection menu

The program selection menu presents the programs designed for this
configuration of the Sterideal.
This menu can be activated by the buttons in the following menus:
• [Program Selection] in section:
- 5.5 Main menu on page 132
• [Production] in section:
- 5.15 UHT menu on page 154,
Figure 5.27 Program selection
OR
The selected program can be operated by a touch on the [ I ] to start or [ 0 ]

to stop the program. The program selections are:
• [Production], see the steps 7-12 described in Chapter 6,
• [Intermediate CIP], see the steps 14-19, it cleans the installation during
the production under aseptic conditions within a short period,
• [Main CIP], see the steps 20-35 described in Chapter 6. The main CIP
program can be activated twice. Therefore the main CIP program have
to be selected, but also the number of loops for [Caustic] and [Acid],
150 " November 12, 2010

Operating interface
• [Final CIP] is only be selected in Main step 2 (Inspection stop). It is a

short cleaning cycle which can not replaced the functionality of the main
CIP. When the CIP is finished, the cycle goes back to step 0.
n Note
For all CIP programs, automatic or manual dosing of lye can be selected.
This selection has to be made before the start of CIP. During CIP the
selection can not be altered.
version 1.0 " 151

5.13 Process protocol menu

The Process protocol menu shows the components or modules you able to
operate during the selected program of section 5.12.
Figure 5.28 Process protocol menu
a b
a The activates/deactivates the process followed by the start “I” or

stop “0” button.
b The opens the recipe menu after given the correct password to
change the recipe settings, see section 5.21 on page 173.
152 " November 12, 2010

Operating interface
5.14 Product return menu

The Product return menu is used to return the product from the UHT into
the product buffer tank. This feature can be activated after given the correct
password with the start button “I” in the following steps:
• Step:0001, water rinsing,
• Step:0108, from UHT to product storage tank.
Figure 5.29 Product return menu
version 1.0 " 153

5.15 UHT menu

The UHT menu presents the heating system of the complete system. For
some components the P&ID could not contain the detailed information,
therefore the screen is divided into selectable areas as mentioned in the
Figure 5.30.
Figure 5.30 UHT menu (e.g. system)
The P&ID is project dependent and has the following selectable areas:
The P&ID is project dependent and has the following selectable areas:
a Selectable detail areas open a submenu to zoom in on the selected
component/module for more detailed information:
b The selectable areas opens the process component menu described in
section 5.22 Control components menus on page 174.
c The selectable areas opens the overview of process temperatures
menu described in section 5.17 Process temperature menu on page
156.
d When the switchboards are blinking red, then the coupling bends are
mounted in the wrong position.
154 " November 12, 2010

Operating interface
5.16 Trending menu

The measurement of the critical components of the system are displayed
in the Trending menu to get an overview of the machine.
Figure 5.31 Trending menu (UHT/DVS)
version 1.0 " 155

5.17 Process temperature menu

The process temperature menu shows the temperatures of the system and
the activation value of the transmitters. The transmitter setpoints can be
adjusted, but are password protected.
Figure 5.32 Process temperature menu
a b c
a Setting of the setpoint

b positive/negative hysteresis of the setpoint
c Actual value of the transmitter
156 " November 12, 2010

Operating interface
5.18 Timer menu

The Timer menu shows the buttons to adjust the process timer(s). Each
Figure 5.33 Timer menu
The following sections are the timer adjustment menus. If you have the
correct authorization code, you can click on the current value and type in
the new value on the key-board in the pop-up window. The new value must
acknowledged by pressing the return key. The parameters of the
production timers are in seconds and the parameters of process timers are
in pulses.
version 1.0 " 157

5.18.0.1 Start system

This menu sets the timers of the product supply pump

(Start system)
158 " November 12, 2010

Operating interface
5.18.0.2 Rinsing
This menu sets the timers to rinse out or to drain the system.

(Rinsing)
version 1.0 " 159

5.18.0.3 Balance tank system

This menu sets the timers to supply water to the spray-ball or top inlet

(Balance tank system)
160 " November 12, 2010

Operating interface
5.18.0.4 Dosing system - Drain alarm

This menu sets the timers to rinse out the system en to detect the lost of
solution to the drain.

(Dosing system - Drain alarm)
version 1.0 " 161

5.18.0.5 Sterilising
This menu sets the timers of the sterilisation process.

(Sterilizing)
162 " November 12, 2010

Operating interface
5.18.0.6 Production
The production adjustment menu sets the timers to fill/drain the balance
tank and displacement of product/water.

(Production timer)
version 1.0 " 163

5.18.0.7 Intermediate CIP

This menu defines the timers of the cleaning agents during the
intermediate CIP process.

(ntermediate CIP)
164 " November 12, 2010

Operating interface
5.18.0.8 Main CIP 1e loop

This menu defines the timers of the cleaning agents during the main CIP
process of the 1ste loop.

(Main CIP 1e loop)
version 1.0 " 165

5.18.0.9 Main CIP 2e loop

This menu defines the timers of the cleaning agents during the main CIP
process of the 2nd loop.

(Main CIP 2e loop)
166 " November 12, 2010

Operating interface
5.18.0.10 Final Rinse

(Final rinse)
version 1.0 " 167

5.18.0.11 Final CIP

(Final CIP)
168 " November 12, 2010

Operating interface
5.18.0.12 General
This menu defines the general timers parameters of the indirect heating
systemt.

(General)
version 1.0 " 169

5.18.0.13 Step length (duration)

This menu defines the timer values of module 09, 12 and the adjustment of
the CIP temperature.

(Step length (duration)
170 " November 12, 2010

Operating interface
5.19 System pressure

The system pressure is defined by the capacity of the filling machine/tank.
If the filling capacity changes, the main drive and the back pressure valve
parameters can be manually/automatically adjusted on this menu
Figure 5.47 System pressure menu
a b
a Capacity settings
b Actual value and diagram
version 1.0 " 171

5.20 Filling pressure

The filling pressure menu displays the actual capacity output values of the
system and the predefined closing precentage of the backpressure valve.
The backpressure valve controls the product flow to the next production
machine depending on the capacity of the homogeniser.
The backpressure valve is active during the phases 5 till 13, but not in the
following phases:
• 1002: Production,
• 1100: Displacement product with water up to the tank,
• 1302: Cooling tank bottom with aseptic water/aseptic rinse,
• 1308: Aseptic water circulation (Prepare for aseptic rinse),
• 1309: Rinsing aseptic tank.
Figure 5.48 Filling pressure menu
b
c
a Actual capacity output values of the system

b Actual backpressure setting durring curent step.
c Predefined closing percentage of the backpressure.
172 " November 12, 2010

Operating interface
5.21 Recipe menu

The Recipe menu enables you to handle recipes and process data quickly.
The actual recipe is displayed at the top of the screen. The customer can
define up to 255 recipes in the ‘Recipe selection box’. The operating unit
(HMI) stores the recipe data on a memory medium (FLASH memory). The
recipe contains the process component values both are password
protected.
Figure 5.49 Recipe menu
The modifications of the recipe starts to give the correct password level.
Then the user is allowed to change the name, number and process
components values. If the modifications are time consuming the interface
closes the password level after a number of minutes defined in the
software. The buttons in the recipe selection box proceed the following
actions with the selected recipe:
Creates a new recipe and set each component value to

“0”.
Saves the current values of the recipe in the data on the
the flash card.
Changing the current data record name or selecting an
existing data record name.
Deletes the selected recipe.
Downloads the current data record from the tags to the

PLC.
version 1.0 " 173

On changing screen, the recipe view retains its present contents. If the
recipe view contains unsaved values at the time the screen is changed, you
are prompted to save them. The recipe concerned and the data record are
displayed for guidance. If you return to the recipe view, its contents are
updated automatically.
5.22 Control components menus

The control components of the Sterideal have a trending and setting menu
to control or view the settings. These menus can be activated by the
buttons on the last column of the Main menu, but also by the selectable
areas of the controlled components in the UHT menu.
The menus in this section show the following parts:
1 PID Value box
Figure 5.50 PID Valuebox
a
b
c
d
e
The actual values of the diagram are:

- a A process value is the actual value of the measured controller.
- b A pre-setpoint is the step value to achieve the setpoint value
- c A setpoint is the desired value to achieve.
- d A output value is the actual output percentage of the controller.
- e A output manual value is the desired output value of the controller.
2 The green box contains the values of the following valves which can be
tuned by Stork personnel or qualified control engineers:
Figure 5.51 PID Greenbox
a
b
c
- a P = Proportional valve,
- b I = Integral valve,
- c D = Differential valve.
174 " November 12, 2010

Operating interface
5.22.1 Motor/pump controller
5.22.1.1 Dosing system (M0301)

The dosing system menu displays the actual capacity of the metering unit,
the parameters to control the pump and the parameters to define the
amount of cleaning solutions.
Figure 5.52 Dosing system menu (e.g. M0301)
version 1.0 " 175

5.22.1.2 Main drive (M0801)

The main drive menu displays the actual capacity of the homogenizer, the
parameters to control the main drive and homogenisation valve.
Figure 5.53 Main drive menu (e.g. M0801)
176 " November 12, 2010

Operating interface
5.22.2 Level controller
Figure 5.54 Level controller balancetank menu (e.g. LIC0102)
version 1.0 " 177

5.22.3 Cascade controller main heater

The cascade control uses the output of the primary controller to manipulate
the setpoint of the secondary controller as if it were the final controller.
The control of the mainheater outlet temperature using the pressure as a
secondary loop.
Figure 5.55 Cascade controller main heater menu (e.g. TCV1001/

PCV1001
a b
a Opens the temperature controller menu, see Temperature controller on

page 180.
b Opens the Pressure controller menu, see Pressure controller on page
179.
178 " November 12, 2010

Operating interface
5.22.4 Pressure controller
Figure 5.56 Pressure controller menu (e.g. PIC0805)
Figure 5.57 Pressure controller menu (e.g. PCV1001
version 1.0 " 179

5.22.5 Temperature controller
Figure 5.58 Temperature controller menu (e.g. TCV1001)
Figure 5.59 Temperature controller menu (e.g. TCV1203)
180 " November 12, 2010

Operating interface
5.22.6 Specials
5.22.6.1 Main heater length menu

The heater length of the mainheater is depending on the capacity of the
maindrive. This menu defines the parameter settings of the mainheater
manually or automatically.
Figure 5.60 Main heater length menu
version 1.0 " 181

5.22.6.2 Capacity adjustments menu
Figure 5.61 Capcity adjustments menu
OR
The detailed area on the UHT menu shows the PAM, RFP and PFM
signals:
• Signal PAM (product at filling machine), the valve 2 below the filling
machine 1 is lighted,
• Signal RFP (ready for production), the filling machine 1 is blinking,
• Signal PFM (filling machine in production), the filling machine 1 is
ligthed.
182 " November 12, 2010

Production
6 PRODUCTION

This chapter contains a number of operating procedures and has the
following sections:
• 6.2 Machine start-up preparation on page 184,
• 6.3 Machine start-up on page 185,
• 6.4 Operator procedures during machine operation on page 187,
• 6.5 Checks during machine operation on page 188,
• 6.6 Machine shut down on page 188,
• 6.7 Process on page 189,
• 6.8 Description of program steps of Sterideal on page 192
• 6.9 Alarm messages on page 230
c Caution
Before starting the sterilization process make sure the machine is free
from lye, acid and/or grease residue; and also free from any materials
that do not belong to the machine, such as, tools, (leather) gloves,
cleaning cotton, paper, wood, loose metal parts (iron and/or copper).
version 1.0 183

6.2 Machine start-up preparation

The machine start-up preparations include all those technical preparations
which are required to enable the machine to be put into operation.
Prior to machine start-up, carefully check that if:
1 The requisite media, i.e. steam, water, compressed air and power, are
available in conformity with the machine data and environment
specified in chapters 1 and 4 of this manual.
2 Product can be continuously supplied from the storage tanks to the feed
product tank; in the event of a drastic drop in product level in the feed
product tank, the machine will automatically initiate product
displacement phase 11.
3 All other maintenance operations have been performed.
4 The indicators and alarms operate properly.
5 The timers and counters have been set properly; see HMI.
6 The outputs and capacities have been set properly; see HMI.
7 The main heater low-temperature cutout is stand-by.
8 homogenising device(s) is/are not activated.
184 November 12, 2010

Production
6.3 Machine start-up

Prior to machine start-up, make sure that the instructions given under 6.2
Machine start-up preparation on page 6-184 have been complied with.
1 Switch the control circuit on with the help of the control switch. The main
switch should always be in the “on” position.
2 Open the main air valve.
3 Open the main water valve.
4 Gradually open the main steam valve after having drained the
condensate from the tubular flow steriliser with the help of the
condensate drain valve at the bottom of the tubular flow steriliser.
5 Choose the correct recipe. Upload recipe in PLC. And meanwhile
connect the bending tubes into the right position (module 18). Inspect if
there is contact between the sensors and the holding section.
6 Put the program in the “Production” position. The lamp in the start
button will now start to blink, if the level in the product tank is adequate.
When the start button is pressed, the machine will initiate step 01 ‘Water
rinsing’. When timer 1 has run down, the program will step through step
02 ‘Inspection stop’.
7 Clean the expansion vessels and/or check the air pressure in the
pulsation dampeners incorporated in the connecting tubes running to
the homogeniser and, upon completion,
Press the start button again to restart the program. When started, the
program will step through step 06 ‘Aseptic water circulation’ and the
machine will then wait for the RFP signal from the filling machine.
8 During step 09, the water is displaced from the tubular flow steriliser.
9 Adjust the correct homogenising pressure.
n Note
From phase 2:
- Pressing start button [1] will initiate step 03, if the program is in the
“Production” position (input 3.1).
- Pressing start button [1] will initiate step 14, if the program is in the
“Intermediate CIP” position (input 3.2).
- Pressing start button [1] will initiate step 20, if the program is in the “Main
CIP” position (input 3.3).
- Pressing start button [1] will initiate step 01, if the program is in the “Main
CIP and machine shutdown” position (input 3.4).
version 1.0 185

6.3.1 Pictographs
The control panel of the high-pressure pump includes several control
pictographs. The pictographs are shown below and have the following
designations:
Table 6.1 Control panel pictograph
PICTOGRAPH DESCRIPTION
Lubricating oil pressure.
Homogenisation pressure, first-stage homogenisation valve.
Oil pressure, first-stage homogenisation valve.
Pneumatic pressure at suction side of pulsation dampener.
Pneumatic pressure at delivery side of pulsation dampener.
No chlorine in detergents.
Delivery pressure of high-pressure pump.
186 November 12, 2010

Production
6.4 Operator procedures during machine operation
6.4.1 Downloading recipe to PLC

A new data record (variables set) can downloaded only in step 0, 2 and 6.
1 Stand-by main step 0.
2 Stand-by main step 2 (inspection stop).
3 Aseptic water circulation main step 6.
After downloading edited records a warning will be generated in order to
alerting the operator.
n Note
- New data records are active only if the are downloaded successfully to
PLC.
- Program cycle proceed (in above 3 steps) if both recipes are equal (PLC
and OP).
- Data records of an actual value can be edited and downloaded in all
cycle steps.
6.4.2 Temporarily override main heater temperature

When temperature transmitter of module 10 falls down below production
temperature alarm setpoint (see recipe parameter).
In this case the UHT loose its sterility status and product is not sterile any
more. Product supply valve will close and product can be either returned
back to storage tank or to the drain.
All interface signals to the fillings machine will be retracted.
There is a possibility to override this alarm temporarily by resetting this
alarm 27:
n Note
The responsibility is entirely to the customer and Stork can not stand
surety for the integrity of product.
1 Alarm 27 can not be reset manually by pressing Reset Alarm push

button.
2 Obviously this alarm is reset by PLC logic when fully CIP cycle is done.
3 The program equipped with a functionality to override this alarm for
emptying at the product tank or go on proceeding production.
4 From Manual menu press button ‘Reset main temp. Alarm’ (see section
Main heater temperature alarm menu of chapter 5 Operating interface
on page 121).
version 1.0 187

6.5 Checks during machine operation

With the machine in operation, check the following at regular intervals:
• Lubricating oil pressure,
• Cooling/lubricating water supply to pistons,
• homogenising pressure,
• Piston seal for leaking,
• Filling pressure (15.01),
• Main heater steam pressure.
The pressure will gradually rise as the main heater fouls.
• Check the colour of the cooling water:
- Clear, it is only water.
- Not clear, the water is mixed with product.
6.6 Machine shut down
6.6.1 End of production run

Proceed the following steps to end a production run.
1 Press the stop button on the touch screen, which will close the product
supply valve V01.02. When the LLL level transmitter is no longer
submerged, step 11 “Product displacement phase 1" will be initiated.
2 After step 11, the program will step through step 12 (product
displacement). The interface of product and water has now passed the
valve of the filling machine and will be discharged to the drain or too the
return tank depending on the position of the valve V0106.
3 When timer 12 has run down, step 13 will be initiated.
6.6.2 Program selecting options during step 13

Step 13 allows the selection of one of four programs:
• Production, resuming the production run if the system is no badly soiled,
• Intermediate CIP,
• Main CIP,
• Step 27 from step 02: injection of 0,2% lye (NaOH).
6.6.3 When the machine has been shut down

1 Close the main steam supply valve,
2 Close the main water supply valves,
3 Switch the control circuit off.
w Warning
The main switch should remain in the “on” position for purposes of control
cabinet and motor heating.
188 November 12, 2010

Production
6.7 Process
The entire process effected by the system is subdivided into 28 different
steps. These steps form part of the following main process cycles:
• System rinsing,
• Production,
• Intermediate CIP,
• Main CIP,
• machine shutdown after 0.2% lye-solution injection.
6.7.1 Cleaning and product control unit processes
6.7.1.1 Rinsing
The installation is rinsed in the following sequence in step 01 and steps 14/
17/19/20/23/30/26/33:
1 Rinsing of installation via system drain.
- The timing of the first step should be set at approximately 1 cycle. To
rinse the product supply pipeline, there will have to be “clean” water
at valve V01.06.
2 Rinsing of product supply pipeline via the switch panel .
- When rinsing the product supply pipeline, the product is drained via
valve V01.09.
3 Rinsing of product tank via V01.03 (only during steps 23,30,33 and 26).
- When rinsing the installation in steps 23/30/33 the drain valve
V01.03 is open to the drain.
6.7.1.2 Production
Before moving on to further steps, it is necessary to wait for a low level in
the fluid tank.
6.7.1.3 Intermediate chemical cleaning, steps 14 through 19

During the intermediate chemical cleaning, the product tank and the
product supply pipeline are only cleaned with an lye solution. During the
acid cleaning the product tank and the product supply pipeline are not
cleaned.
With the coupling bends of the switching panel the cleaning and product
control unit is isolated from the product supply of the installation.
The product supply piping can be independently cleaned from the CIP
system of the installation.
With sensors on the switch panel. The PLC is checking during the various
steps of the process the correct position of the coupling bends of the
following switch panels:
• Switchpanel on product supply unit, see section 3.3.1 on page 61.
version 1.0 189

6.7.1.4 Main chemical cleaning

During the main chemical cleaning, the product supply pipe and the
product tank are automatically cleaned. To this end, there are three circuits
which are cleaned step by step. Cleaning is done in the following
sequence:
1 Via the spray product tank inlet,
2 Via the product intake,
3 Via the closed system,
The cleaning times per circuit are determined by timers which can be set.
During the main chemical cleaning, the product supply pipe and the buffer/
water tanks are automatically cleaned. To this end, there are three circuits
which are cleaned step by step. Cleaning is done in the following
sequence:
4 Via the product intake,
5 Via the closed system,
The cleaning times per circuit are determined by timers which can be set.
6.7.2 Process sequence

The complete Sterideal process consists of 28 phases. The phases can be
classified in the following main groups:
• Sterideal rinse
• Production
• Intermediate cleaning
• Main cleaning
• Final cleaning
System process steps:
n Note
The specified step numbers will not be displayed.
190 November 12, 2010

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Figure 6.1 Process steps
Flowchart
00
System
Stand-by
start
button
Operator
Selec-
No tion product yes
return
0100-0106 0107-0108
Water rinsing Product return
02
Stop
Inspections-
button
stop
Operator
05
Aseptic cooling Selection
(or directly 02) Production, inter. CIP, Main CIP, final
CIP, filler regenerative
yes
Stop
button Start
Operator button
Operator
14-19 20-25 20
03-05 27-28
Intermediate 30-35 Filler
Sterilisation Final CIP
CIP Main CIP regenerative
no alarm 27
06
RFP Aseptic 26 26
circulation Rinsing system Rinsing system
alarm 27
Start Stop Stop Stop Stop

button button button button button
Operator Operator Operator Operator Operator
selection 26 03 04 26 02 00 02 02
Production
yes
07-12
No Production
13
Aseptic
circulation
version 1.0 191

6.8 Description of program steps of Sterideal

Standby phase (Step 00 through Step 02)
• Step 00: System stand-by.
- Step 0000: System stand-by.
• Step 01: Water rinsing (Step 01 and 02).
- Step 0100: Start M0501.
• Step 02: Inspection stop
- Step 0200: System run-down M0801.
Production phase (Step 03 through step 13).

• Step 03: Preheating.
- Step 0300: Ready to start sterilising.
• Step 04: Sterilization.
- Step 0400: Sterilization.
• Step 05: Aseptic cooling.
- Step 0500: Forcing condensate out of product cooler.
• Step 06: Aseptic cooling.
- Step 0600: Waiting for main heater temperature.
• Step 07: Draining balance tank.
- Step 0700: Draining product supply pipe via valve V0109.
• Step 08: Filling balance tank with product.
- Step 0800: Filling balance tank up to LL.
• Step 09: Water displacement.
- Step 0900: Water displacement up to filling machine or aseptic tank.
• Step 10: Production.
- Step 1000: Product circulation (no RFP).
• Step 11: Product displacement 1
- Step 1100: Displacement product with water.
• Step 12: Displacement product with water up to valve V0106.
- Step 1200: Displacement product with water up to valve V0106.
• Step 13: Aseptic water circulation.
- Step 1300: Rinsing out system up to valve V0110.
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Intermediate CIP phase (Step 14 through Step 19)

• Step 14: Rinsing the system with water.
- Step 1400: Rinsing the system with water.
• Step 15: Lye solution dispensing.
- Step 1500: Lye solution dispensing.
• Step 16: Lye solution circulation.
- Step 1600: Waiting for main heater setpoint.
• Step 18: Acid solution dispensing.
- Step 1800: Acid solution dispensing.
After step 19 the program returns to step 0611, in case of a
temperature alarm the program returns to step 0306.
Main CIP phase (Step 20 through Step 26)

• Step 25: Acid solution circulation.
- Step 2500: Acid solution circulation via the top balance tank.
version 1.0 193

Main cleaning 2nd loop phase

• Step 35: Acid solution circulation.
- Step 3500: Acid solution circulation via top balance tank.
• Step 26: Rinsing the system with water
Final cleaning phase (step 27 and step 28)

• Step 27: Final CIP (Selection 0.2% dosing lye)
- Step 2700: Filling balance tank
• Step 28: System run down
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6.8.1 Stand-by phase (Step 00 through Step 02)
6.8.1.1 Step 00
Step 0000: System Stand-by

This step serves to ensure that the non-operative plant is ready for start-
up. During this step, the various valves and motors can be operated and
checked for correct functioning manually. Depending on the previous step
the pumps will run down.
Step 00 will be initiated, if:
• Control switch is turned to "on".
• Stop button on the operator panel is pressed during step 01 or step 02.
• The emergency stop button is pressed during any given step.
• The fan of M0801 is defect.
• The motor temperature M0801 is too high.
• The flow of lubricant in M0801 is too low.
• The main drive alarm occurs.
• If the run-dry protection electrode in the balance tank is reached.
Effects:
The control cabinet cooling fan starts to run.
When run-dry protection electrode in the balance tank is not reached and
if high level in the balance tank has not been reached water will be supplied
to the balance tank.
The start button on the operator panel will start to blink if the balance tank
has been charged with water and fault 07 has not been generated.
Finishing Step 0000
As soon as the low level electrode has been activated and there is sufficient liquid in the tank, Step 0100
HL is reached and control air pressure prevails, the lamp in the start button will burn. If the start
button on the operator panel is pressed, the program will move on to the next step.
Selection of product return , the coupling bends must be in the right position, a code should be Step 0107
entered in the operator panel and the start button must be pressed.
version 1.0 195

6.8.1.2 Step 01: Water rinsing
Step 0100: Start product supply pump M0501

This step serves to rinse the product circuit with fresh, cold water for a
given period
Water rinsing is effected in order to displace any lye solution present in the
system (after main chemical cleaning it is possible to shut down the plant
with a 0.2% lye solution to prevent the stainless steel being corroded).
This water rinsing step is also important if the emergency stop button has
been pressed during any given step and the program returns to step 00.
The product or chemical solution present in the circuit at that moment
should be discharged from the system before the plant is started up. The
product can be returned to the buffer tank if the selection "Product return"
is activated.
The rinsing time should be equal to the time required to make one pass
(optional time per loop is depending of the installed holding section; relation
holding section and extra required loop time is programmed automatically)
plus approx. 1 minute so as to ensure that the interface of lye is discharged
from the system.
Circulation takes place by the homogeniser and product supply pump
M0501.
Finishing Step 0100
After the run-down of timers the program moves on to the next step Step 0200
Pressing the stop button on the operator panel resets the program returns to step Step 0002
Pressing the stop button on the operator panel during draining of the balance tank, the program Step 0000
returns to step
If the emergency button on the operator panel is pressed the program returns to step Step 0000
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6.8.1.3 Step 02: Inspection stop
Step 0200: System run-down M0801.

During this step the pumps run down and the operator is given the
opportunity to check/inspect the following before production starts. An
acoustic signal warns the operator that the plant is ready for inspection:
• Is the balance tank clean and free from parts (select drain balance tank
manually)
• Are all pipes and couplings free from leakage.
• Check if the pressure in the pulsation dampeners is correct.
• Fit the coupling bends properly (for module 01 and 18).
• Is the air pressure for the homogenisation pressure set at zero; the air
pressure should be zero so as to allow the homogenisation pressure to
be set during step 09.
• Open the main coolant supply valve.
• Open the main steam supply.
• Find and eliminate faults if an alarm message is displayed.
Select one of the following programs on the operator panel:
• Production (Step 03)
• Intermediate CIP (Step 14)
• Main CIP (Step 20)
• Final CIP (Step 27), this step can only be selected in step 0200.
Fit the coupling bends properly (for module 01 and optional 18)
Final CIP or "Main CIP and plant shutdown (after 0.2% lye solution
dispensing)" is selected if the production run is to be ended and the plant
to be shut down.
Finishing Step 0200
When the above operations have been performed, the operator may press the blinking start Step 0300,
button on the operator panel, thus allowing the system to initiate 1408,
2004, 2700
If in step 0204 till 0209 no utilities are available the program moves to step Step 0203
Pressing the stop button on the operator panel resets the program returns to step Step 0000
version 1.0 197

6.8.2 Production phase (Step 03 through step 13)
6.8.2.1 Step 03: Preheating
Step 0300: Ready to start sterilising.

During this step, the plant is heated to the appropriate plant sterilization
temperature. The system is rinsed with water for a period of time to the
drain, thus purging any air that may have entered the circuit at the filling
valves during the inspection stop. Next the circuit is closed and will go into
internal circulation (by-passing the balance tank), and the plant is heated
to the appropriate sterilization temperature.
The main heater steam supply is controlled by the main heater outlet
temperature transmitter (TT10.01).
The main heater steam supply is directly connected to the steam supply of
the circuit steriliser/product cooler, thus ensuring that the outlet
temperature of the circuit steriliser/product cooler is identical with that of
the main heater. With the circuit steriliser/product cooler operating in the
plant sterilization mode, the system's effective heat transfer surface area is
increased, thus reducing the time required to reach the appropriate plant
sterilization temperature.
Circulation takes place by the homogeniser, the product supply pump
M0501 will keep the system on the required pressure.
Finishing step 0300
The program will move on to step 04 as soon as the appropriate plant sterilization temperature Step 0400
has been reached and is being hold for a specific time.
If the program is in step 0300, filling balance tank, and the stop button on the operator panel is Step 0203
activated the program returns to step
If the program is in step 0301, Start product supply pump, and the stop button on the operator Step 0201
panel is activated the program returns to step
If the program is in step 0302, Ramp up main drive, and the stop button on the operator panel Step 0200
is activated the program returns to step
If the program is in step 0303, Rinse system, and the stop button on the operator panel is Step 0200
activated the program returns to step
If the program is in step 0304, Preheating, and the stop button on the operator panel is activated Step 0200
the program returns to step (Production is possible)
If the program is in step 0305, Preheating and cooling product supply pump, and the stop button Step 0508
on the operator panel is activated the program will move on to step (Production is no longer
possible)
If in step 0306 the sterilization temperature set value is not reached the program will return to Step 0304
step
If the program is in step 0306 and the stop button on the operator panel is activated the program Step 0508
will move on to step
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6.8.2.2 Step 04: Sterilization
Step 0400: Sterilization.

During this step, the entire product circuit (all product-contact parts) is
sterilised for a minimum of 15 minutes by circulating hot water having a
temperature of 138°C-140°C.
Circulation is done by the homogenisator in closed cicuit, the product
supply pump M0501 will keep the system on the required pressure.
This will ensure a high level of sterility, thus eliminating the risk of plant-
induced product infection.
Finishing Step 0400
At the end of sterilization time, the program will move on to step. Step 0500
As soon as any of the sterilization temperatures becomes lower than its setting, the program Step 0304
returns to Step.
If the stop button on the operator panel is pressed, the program moves on to step (production is Step 0508
no longer possible).
If the emergency button on the operator panel is pressed the program returns to step. Step 0000
version 1.0 199

6.8.2.3 Step 05 Aseptic Cooling
Step 0500: Forcing condensate out of product cooler.

During this step, the system is cooled, by the product steriliser/ cooler, to
the appropriate operating temperature. The main heater will continue to
operate at the sterilization temperature, the steam supply valve to the
circuit steriliser/ product cooler will be closed and, if the plant incorporates
a product preheater, the latter will change over to the temperature setpoint
for production.
After a given period of time, cold water will be supplied to the circuit
steriliser/product cooler. The time delay is required to prevent pipe
hammering caused by sudden drops in system temperature and pressure.
Circulation is done by the homogeniser in closed circuit, the product supply
pump M0501 will keep the system on the required pressure.
Finishing Step 0500
As soon as the monitored cooling temperatures are lower than the relevant pre-set values, the Step 0600
program will initiate step
As soon as the main heater temperature becomes lower than the setting the program returns to Step 0304
step
If during step 0500 the stop button is used the program returns to step Step 0508
200 November 12, 2010

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6.8.2.4 Step 06: Aseptic water circulation
Step 0600: Waiting for main heater temperature.

The main heater temperature controller's production temperature setpoint
will become active during this step
In order to allow the production to be started, the system should receive a
"Ready For Production" (RFP) signal from the filling machine(s) or sterile
tank. The program will not exit from this step as long as this signal has not
been received. When the signal has been transmitted and the coupling
bends are in the right position (sensor of the coupling bends “S0102” is
active) the start button in the operator panel will start to blink.
Circulation is done by the homogenisator in closed cicuit, the product
supply pump M0501 will keep the system on the required pressure.
Finishing step 0600
When the RFP signal has been transmitted and the coupling bends are in the right position, no Step 0700
signal "request Empty Sterideal" is received, the start button on the operator panel will start to
blink. Pressing the blinking start button will initiate step
If in step 0601 the selection CIP is activated in the program the start button blinks to indicate that Step 1301
it is possible to move on to step
As soon as the main heater temperature becomes lower than the temperature alarm setting the Step 0304
program moves to step
If the stop button on the operator panel is pressed the program moves to step Step 2600
If the emergency button on the operator panel is pressed the program moves to step Step 0000
version 1.0 201

6.8.2.5 Step 07: Draining balance tank
Step 0700: Draining product supply pipe via valve V0109.

During this step the water present in the product supply pipe to the balance
tank will be drained, in order to minimise the interface of water and product.
The water in the balance tank is drained, in order to minimize the interface
of water and product.
During this step, the water present in the product circuit circulates by the
homogeniser and product supply pump M0501.
Finishing step 0700
After the timer to drain the water in the balance tank is finished and the RFP signal is active Step 0800
If in step 700, Draining product supply pipe, the stop button is pressed, the RFP signal stops, Step 0601
the "Request empty Sterideal"comes or there is a main heater temperature alarm, then the
program moves to step
If in step 701 & 702, Draining balance tank, the stop button is pressed, the RFP signal stops, the Step 0604
"Request empty Sterideal"comes or there is a main heater temperature alarm. then the program
moves to step
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6.8.2.6 Step 08: Filling balance tank

- Step 0800: Filling balance tank up to LL.
During this step, the balance tank is filled with product to the production
level. The balance tank is filled in two steps, first it is filled to the low level
setting, after that to the production level.
M0501.
Finishing step 0800
As soon as the production level has been reached, the program will move on to step Step 0900
If the timer of step 0800 has run down and the low level has not yet been reached the stop button Step 0604
is pressed, the RFP signal stops, the "Request empty Sterideal" comes or there is a main heater
temperature alarm, valve V0102 is closed, the program returns to step
If the timer of step 0801 has run down and the production level is not reached, the stop button Step 1100
is pressed, the RFP signal stops, the "Request empty Sterideal" comes or there is a main heater
temperature alarm, valve V0102 closes, the program moves to step
version 1.0 203

6.8.2.7 Step 09: Water displacement
Step 0900: Water displacement up to filling machine or aseptic tank.

During this step, the water present in the system is displaced by the
incoming product. The water is displaced to the drain.
At the start of the water displacement, a counter starts which runs to the
moment the Sterideal is filled with product up to the filling valves. The
required time to fill the Sterideal is depending of the selected product circuit
as well as stabilisator/ holder selection. If the timer is broken counter stops
working, alarm 50 comes up and the start button in the operator panel will
start to blink. The operator can activate the start button when product is
observed in sight glass 01.03. To avoid that too much product is spilled to
the drain, which can happen when no operator is present, a timer runs
down. The length of the timer is the maximum time necessary for one
production circulation loop.
When the counter has completed its run-down or the start button is
activated or the timer runs down, the PAM signal will be activated and the
filling valves will be opened and the program will initiate step 10.
During this step, as well as during steps 10 and 11, the plant capacity is
governed by the RFP signals from the filling machines. During water
displacement, the homogenisation pressure is set to production setpoint
(pressure setting is product depending and optional). Both during this step
and step 10, the production will be active.
Displacement takes place by the homogeniser and product supply pump
M0501.
Finishing step 0900
After run-down of the counter or when alarm 50 is active after pressing the start button or after Step 1000
run-down of the timer, the program moves in to the next step
If the stop button on the operator panel is pressed, valve V0102 close, the program moves to Step 1100
step
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6.8.2.8 Step 10: Production
Step 1000: Product circulation (no RFP).

During this step, after the exchange of the timing signals between the
Sterideal plant and the filling machine(s), the filling valve(s) will be opened
after the PAM signal is given.
This PAM signal indicates to the filling machine operator that he is allowed
to open the filling valve of the filling machine awaiting product delivery. Just
prior to the filling valve being opened, the PFM (Production of Filling
Machine) signal is transmitted to the Sterideal plant.
Upon receipt of this signal, the Sterideal plant will increase its output, with
the homogeniser, by an additional 5% for a given period of time. This
temporary increase in output serves to facilitate the filling machine's initial
product filling operation. The product will now be subjected to in-flow
homogenisation and UHT sterilization, followed by aseptic filling and
packaging.
PI1501 shows the back-pressure required for the filling machines.
Remember to check and, if required, adjust this back-pressure.
PI1301 creates the back pressure for the system.
The PAM signal will cease:
• if a main heater low-temperature fault (alarm 27) is generated,
• if a main heater Pt-100 fault is generated,
• if the filling machine's intake capacity is lower than the minimum
production output,
• if the filling machine's RFP (Ready For Production) signal ceases.
If the PAM signal ceases, the filling valve(s) will be closed.
If the main heater temperature drops below the pre-set main heater low-
temperature cut-out value, alarm 27 will be generated and product supply
valve V0102 will be closed; if the product level in the balance tank drops to
below the run dry level of the product supply pump, step 11 will be initiated.
The fault condition (fault 27) can be disabled by the overrule main heater
temperature button on the operator panel. If this is effected before the
product in the balance tank has reached run dry level of the product supply
pump, valve V0102 will be opened again. When the disable switch is
turned, fault 37 will be generated. After alarm 27, plant sterilization is
mandatory.
Displacement during production takes place by the homogeniser and
product supply pump M0501.
Finishing step 1000
If the main heater temperature drops below the pre-set value, the product supply valve will close. Step 1100
Plant sterilization will be required. (If this temperature fault indication is overruled by entering a
code, it is possible to continue with the processing of the current batch of product)
As soon as the product level in the balance tank reaches run dry level of the product supply Step 1100
pump, the program moves on to the next step (with a fault indication that the level is too low)
If during production step 1002 the stop button is activated the program moves on to step Step 1100
version 1.0 205

6.8.2.9 Step 11: Product displacement 1
Step 1100: Displacement product with water up balance tank.

When the product in the balance tank reaches the run dry level of the
product supply pump, water will be supplied to the balance tank, the
incoming water displacing the product present in the product circuit.
At the start of product displacement, a counter starts. The Sterideal is filled
with water up to the filling valves. The required time to fill the Sterideal is
depending of the selected product circuit as well as stabilisator/ holder
selection. If the counter stops working, alarm 50 comes up, the start button
in the operator panel will start to blink. The operator can activate the start
button when no more product is observed in sight glass 01.03. The process
moves on to the next step. To avoid that the program stays too long in step
11 when no operator is present a timer runs down from the start of alarm
50. When this is run down the process moves on to the next step.
When the counter has completed its run-down, the PAM signal drops and
the filling valves will be closed and the program will initiate step 12.
If the main heater temperature drops to below the pre-set main heater low-
temperature cut-out value, alarm 27 will be generated and the PAM signal
will cease. Plant sterilization will be required.
The PAM signal will also cease if the filling machine intake capacity is lower
than the minimum production capacity or if the RFP signal ceases. After the
PAM signal has been interrupted, product filling will stop.
M0501.
Finishing step 1100
After run down of the counter, the program moves on to step Step 1200
If the counter is not activated the timer of this step will be active. If the timer has run down the Step 1200
program moves on to step
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6.8.2.10 Step 12: Product displacement 2
Step 1200: Displacement product with water up to valve V0106.

Having reached a point just upstream from the (first) filling valve, the
interface of product and water now displaces, the product present in the
product pipe running from the (first) filling valve to the drain.
The product-displacement counter time starts to run when step 12 is
initiated and counts off. If the counter stops working, alarm 50 comes up,
the start button in the operator panel will start to blink. The operator can
activate the start button when no more product is observed in sight glass
01.03. The process moves on to the next step. To avoid that the program
stays too long in step 11 when no operator is present a timer runs down
from the start of alarm 50. When this is run down the process moves on to
the next step.
If the main heater temperature drops below the fault value setting, alarm 27
will be generated. Plant sterilization will be required.
M0501.
Finishing Step 1200
After run down of the timer, the program moves on to step. Step 1300
If the counter is not activated the timer of this step will be active. If the timer has run down the Step 1300
program moves on to step.
If the emergency button on the operator panel is pressed the program returns to step. Step 0000
version 1.0 207

6.8.2.11 Step 13: (Aseptic) water circulation
Step 1300: Rinsing out system up to valve V0110.

During this step, the water present in the closed circuit will be circulated
under aseptic conditions or otherwise, depending on the previous step from
which the program has exited.
If the program returns from step 12 the system will be rinsed with water
during the timer before changing over from balance tank to the closed
circuit. Four different programs can now be selected in the operator panel:
• Production =>Step 06 or Step 03
• Intermediate CIP => Step 14
• Main CIP => Step 20
• Final CIP => Step27
"Production" should be selected if the production run is to be resumed
without effecting chemical cleaning of the plant. The program will initiate
step 03 (Plant sterilization) if the main heater temperature has dropped to
below the main heater low-temperature cut-out value during any of the
steps 06 to 13.
If there has not been main heater low-temperature fault, the program will
immediately initiate step 06 (aseptic water circulation).
“Intermediate CIP" can be selected if a different type of product is to be
handled and the plant does not yet require a Main CIP cycle.
"Main CIP" is selected if the specified period of sustained plant operation
has been reached.
M0501.
Finishing step 1300
As soon as the main heater temperature becomes lower than the setting (in step 06 to 13) and Step 0304
the start button is pressed, the program returns to step
If the start button on the operator panel is pressed and the coupling bends are in the right Step
position the program moves to one of the following steps. 0601, 1400,
2000.
If the stop button is pressed the program will move to step Step 2600
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6.8.3 Intermediate CIP phase (Step 14 through step 19)
6.8.3.1 Step 14: Water rinsing (Intermediate aseptic CIP)
Step 1400: Rinsing the system with water.

A short rinsing time will suffice, considering the fact that after the production
run was ended water was already made to flow through the system to
displace the product (steps 11 and 12 - product displacement steps 1 and
2), thereby rinsing the system and the water being drained. After the timer
the product supply pipe will be rinsed.
If the main heater temperature drops below the fault value setting, alarm 27
will be generated. Plant sterilization will be required.
If the program starts from step 02 the balance tank is filled with water and
the product supply pumps start up and circulation takes place by the
homogeniser and product supply pump M0501.
Finishing step 1400
After run down of the timer, the program moves on to step Step 1500
If the stop button on the operator panel is pressed the program will move to step Step 2600
version 1.0 209

6.8.3.2 Step 15: Lye solution dispensing

(Intermediate aseptic CIP)
Step 1500: Lye solution dispensing.

Lye solution is now supplied at a rate and concentration so that the circuit
will contain a 2% lye solution when timer has completed its run-down.
The lye solution dispensing time should be set at a value which is equal to
the time required to make one pass and additional timer to take in to
account the amount of fresh water in the balance tankplus 2 minutes. Lye
solution is dispensed for an additional two minutes, because the lye
solution front (entraining a comparatively large amount of deposits which
should not be returned to the system is drained for the first two minutes.
After the lye solution has been dispensed, the pipe of the metering pump is
rinsed with water for a pre-set period of time, in order to force the lye
solution still present in the pipe of the metering pump into the system via
V0304.
M0501.
Finishing step 1500
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6.8.3.3 Step 16: Lye solution circulation

Step 1600: Waiting for main heater setpoint.

During this step, the closed circuit is cleaned with a 2% lye solution. During
this step, the pipe after the metering pump is is rinsed, with water for a pre-
set period of time, in order to eliminate the risk of the metering pump seal
being attacked by lye solution. The rinsings are drained. When the main
heater reached its cleaning setpoint the following circuits will be cleaned:
• via the top inlet of the balance tank (timer starts)
• via the sprayball of the balance tank (timer starts)
• via the product supply pipe of the balance tank (timer starts)
If the liquid level in the balance tank drops to below the ML level, fault 40
will be generated. Fault 40 indicates that there is a loss of lye solution.
If the main heater temperature drops below the pre-set value, alarm 27 will
be generated and plant sterilization is required.
M0501.
Finishing step 1600
version 1.0 211


During this step, fresh water is pumped into the circuit, thereby displacing
the lye solution. The rinsing time should be set so that the risk of the acid
solution (to be dispensed during step 18) becoming mixed with the lye
solution is eliminated. A rinsing time of approx. 2 minute will suffice.
If the main heater temperature drops below the preset value, alarm 27 will
M0501.
Finishing Step 1700
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6.8.3.5 Step 18: Acid solution dispensing

Step 1800: Acid solution dispensing.

Acid solution is now dispensed, for a maximum of 2 minutes, at a rate and
concentration so that the circuit will contain a 1% acid solution "block" when
the has completed its run-down. The dispensing time and acid solution
concentration are less than those during the Main CIP, because the main
heater temperature setpoint remains unchanged during this step (during
the Main CIP the main heater temperature setpoint is reduced to 80°C. On
account of the increased temperature, the aggressiveness of the acid
solution is considerably greater, thus allowing reductions in concentration
and dispensing time during Intermediate Aseptic CIP cleaning.
After the acid solution has been dispensed, the pipe of the metering pump
is rinsed with water for a pre-set period of time, in order to force the acid
V0304.
M0501.
Finishing step 1800
version 1.0 213


The product circuit now contains acid solution, water and acid solution (in
order of introduction). The contents are displaced by the incoming water
and thereby discharged.
The rinsing time should be equal to the time required to make one pass
plus approx. 1 minute so as to ensure that the interface of acid solution and
water is also discharged from the system.
At the end of this step, the product circuit should not contain any cleansing
agent anymore, because the system will then resume its closed-circuit
operating mode. During this step, the pipe after the metering pump is rinsed
with water for a pre-set period of time, in order to eliminate the risk of the
metering pump seal being attacked by cleaning liquid. The rinsings are
drained.
M0501.
Finishing step 1900
After run down of the timer and as soon as the main heater temperature becomes lower than the Step 0304
setting the program returns to step
After run down of the timer and the main heater temperature alarm fault is not generated the Step 0601
program returns to step
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6.8.4 Main CIP phase (Step 20 through step 26)
6.8.4.1 Step 20: Water rinsing (Main CIP, 1st loop)

Before this step can be initiated, the coupling bend should be connected in
the proper positions so that proximity switches S0102 are covered by the
coupling bend.
The product circuit is now rinsed with fresh water in order to remove any
dirt that has not yet caked on the product contact surfaces. If main CIP is
selected from step 02, first the balance tank is filled with water.
A short rinsing time will suffice, considering the fact that after the production
run was ended water was already made to flow through the system to
displace the product (steps 11 and 12 product displacement steps 1 and 2),
thereby rinsing the system and the water being drained. During this step
the product supply pipe is rinsed.
Module 7 can be cleaned in process or counter process flow. For counter
process flow the coupling bends S43.01 and S43.02 need to be changed
(See P&ID for correct position of coupling blends).
If selected the plant can be cleaned by a counter flow CIP. This type of CIP
is required to remove all fibres in the 3 pipes heat exchangers. For counter
flow CIP the coupling bends need to be changed to its required positions
(see P&ID). Temperature transmitter TT0901 secures the temperature of
the system.
M0501.
Finishing step 2000
After run down of the timer and the 1st lye cleaning loop is selected the program moves on to step Step 2100
After run down of the timer and the 1st acid cleaning loop is not selected the program moves on Step 2301
to step
version 1.0 215


(Main CIP, 1st loop)

will contain a 2% lye solution when the timer has completed its run-down.
Lye solution is dispensed for an additional two minutes, because the lye-
should not be returned to the system) is drained for the first two minutes.
rinsed with water for a pre-set period of time, in order to force the lye
V0304.
During the lye solution dispensing, acid solution dispensing, lye solution
circulation and acid solution circulation steps forming part of the Main CIP
program, the temperature of the return water is controlled between 70°C
and 90°C. This is effected by supplying steam or water to the circuit
steriliser/ product cooler, thus ensuring the proper CIP temperature in the
heating and cooling sections.
M0501.
Finishing step 2100
After run down of the timer the program moves on to step Step 2200
If the stop button is pressed the program will move to step Step 2603
216 November 12, 2010

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During this step, the closed circuit is cleaned with a 2% lye solution. When
the main heater reached its cleaning setpoint the following circuits will be
cleaned:
During this step, the pipe after the metering pump is rinsed with water for a
pre-set period of time, in order to eliminate the risk of the metering pump
seal being attacked by lye solution. The rinsings are drained.
M0501.
Finishing step 2200
After run down of the timer, the program moves on to step See text
version 1.0 217

6.8.4.4 Step 23: Water rinsing (Main CIP, 1st loop)

the lye solution.
The rinsing time should be set so that the risk of the lye solution becoming
mixed with acid solution dispensed after this step is eliminated. A rinsing
time of approx. 1 minute will suffice.
If acid solution circulation is to be effected after this step, the main heater
temperature controller setting is reduced to 80°C. Acid solution circulation
is effected at a lower temperature than that used for lye solution circulation,
because acid solution cleaning at a high temperature yields no effective
improvement.
M0501.
Finishing step 2300
After run down of the timer and the main heater has reached its cleaning temperature, the
program moves on to step Step 2400
218 November 12, 2010

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Acid solution is now supplied at a rate and concentration so that the circuit
will contain a 2% acid solution when timer has completed its run-down.
Acid solution is dispensed for an additional two minutes, because the acid-
After the acid solution has been dispensed, the pipe of the metering pump
is rinsed with water for a pre-set period of time, in order to force the acid
solution still present in the metering pipe into the system via V0304.
M0501.
Finishing step 2400
version 1.0 219

6.8.5 Main cleaning 2nd loop phase
6.8.5.1 Step 25: Acid solution circulation

(main CIP, 1st loop)
Step 2500: Acid solution circulation via the top balance tank.
During this step, the closed circuit is cleaned with a 2% acid solution. When
cleaned:
During this step, the pipe of the metering pump is rinsed with water for a
preset period of time, in order to eliminate the risk of the metering pump
seal being attacked by acid solution. The rinsings are drained.
M0501.
Finishing step 2500
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6.8.5.2 Step 30: Water rinsing (Main CIP, 2nd loop)

The product circuit is now rinsed with fresh water in order to remove the
cleaning solution. The rinsing time should be set so that the risk of the acid
solution becoming mixed with lye solution dispensed after this step is
eliminated.
M0501.
Finishing step 3000
version 1.0 221


(main CIP, 2nd loop)

will contain a 2% lye solution when the timer has completed its run-down.
The lye solution dispensing time should be set at a value which is equal to
the time required to make one pass and additional timer to take in to
account the amount of fresh water in the balance tank plus 2 minutes. Lye
solution is dispensed for an additional two minutes, because the lye-
rinsed with water for a preset period of time, in order to force the lye
V0304.
During the lye solution dispensing, acid solution dispensing, lye solution
circulation and acid solution circulation steps forming part of the Main CIP
program, the temperature of the return water is controlled between 70°C
and 90°C. This is effected by supplying steam or water to the circuit
sterilizer/ product cooler, thus ensuring the proper CIP temperature in the
heating and cooling sections.
M0501.
Finishing step 3100
222 November 12, 2010

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(Main CIP, 2nd loop)

During this step, the closed circuit is cleaned with a 2% lye solution. When
the main heater temperature is reached its cleaning setpoint the following
circuits will be cleaned:
• via the top inlet of the balance tank (timer starts),
• via the sprayball of the balance tank (timer starts),
• via the product supply pipe of the balance tank (timer starts).
preset period of time, in order to eliminate the risk of the metering pump
seal being attacked by lye solution. The rinsings are drained.
After run down of the timer, depending on the selected program, the
program moves on to step:
• Step 2600 => selection only lye cleaning 2nd loop,
• Step 3300 => selection acid cleaning 2nd loop.
M0501.
Finishing step 3200
version 1.0 223

6.8.5.5 Step 33: Water rinsing (Main CIP, 2nd loop)

the lye solution.
The rinsing time should be set so that the risk of the lye solution becoming
mixed with acid solution dispensed after this step is eliminated. A rinsing
time of approx. 1 minute will be sufficient.
If acid solution circulation is to be effected after this step, the main heater
temperature controller setting is reduced to 80°C. Acid solution circulation
is effected at a lower temperature than that used for lye solution circulation,
because acid solution cleaning at a high temperature yields no effective
improvement.
M0501.
Finishing step 3300
224 November 12, 2010

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(Main CIP, 2nd loop)

Acid solution is now supplied at a rate and concentration so that the circuit
will contain a 2% acid solution when timer has completed its run-down.
Acid solution is dispensed for an additional two minutes, because the acid-
After the acid solution has been dispensed, the metering pipe is rinsed with
water for a preset period of time, in order to force the acid solution still
present in the pipe of the metering pump into the system via V0304.
M0501.
Finishing step 3400
version 1.0 225

6.8.5.7 Step 35: Acid solution circulation (main CIP, 2nd loop)
Step 3500: Acid solution circulation via top balance tank.

During this step, the closed circuit is cleaned with a 2% acid solution. When
cleaned:
• via the top inlet of the balance tank,
• via the sprayball of the balance tank,
• via the product supply pipe of the balance tank.
The temperature of the return water is controlled between 70°C and 90°C.
This is effected by supplying steam or water to the circuit steriliser/ product
cooler via V1201 or TCV1203, thus ensuring the proper CIP temperature
in the heating and cooling sections.
pre-set period of time, in order to eliminate the risk of the metering pump
seal being attacked by acid solution. The rinsings are drained.
M0501.
Finishing step 3500
After run down of the timer, or the stop button on the operator panel is activated the program Step 2600
moves on to step
226 November 12, 2010

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6.8.5.8 Step 26: Water rinsing (Main CIP)

During this step, the acid solution is displaced by the incoming water and
thereby discharged. The rinsing time should be equal to the time required
to make one pass plus approx. 1 minute so as to ensure that the interface
of acid solution and water is also discharged from the system. After the
timer the product supply pipe is also cleaned and drained.
At the end of this step, the product circuit should not contain any cleansing
agent anymore. If the program returns from a dosing step, the pipe of the
metering pump is rinsed with water for a pre-set period of time, in order to
force the lye solution still present in the metering pipe into the system via
V0304. In this step the main heater temperature controller is de-energised.
Rinsing takes place via:
• via the top inlet of the balance tank,
• via the sprayball of the balance tank,
• via the product supply pipe of the balance tank.
M0501.
Finishing step 2600
version 1.0 227

6.8.5.9 Step 27: Final CIP, 0.2% Lye solution

dispensing
Step 2700: Filling balance tank

During this step first the balance tank is filled with water then lye solution is
dispensed intermittently so that the product circuit will contain a 0.2% lye
solution at the end of this step.
This lye solution dispensing is effected to bind any free chloride ions with
the lye, thus eliminating the risk of hypochlorite-induced corrosion. During
this step, the metering pump continues to run, but lye solution supply valve
and water supply valve are energised and de-energised alternately.
rinsed with water for a pre-set period of time, in order to force the acid
solution still present in the metering pipe into the system via V0304.
Finishing step 2700
If the stop button on the operator panel is pressed before lye solution dispensing has started, Step 0200
the program returns to step
If the lye solution dispensing has started (step 2703 or 2704) and the stop button on the operator Step 2603
panel is activated, the program moves to step
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6.8.5.10 Step 28: System run down
Step 2800: Run down M0801; rinsing dosing system to drain.

In this step the pumps run down.
When the homogeniser and product supply pump M0501 run down the
pipe of the metering pump is rinsed with water for a pre-set period of time,
in order to eliminate the risk of the metering pump seal being effected by
lye solution. The rinsings are drained.
Finishing step 2800
version 1.0 229

6.9 Alarm messages

ALARM001: M0301 No response (cont.feedb), Metering pump
Active When dosing pump runs

Energised When dosing pump runs and if there is no feedback from motor switch within 2 seconds.
Effect Dosing pump is disengaged and message is displayed on the operator panel
Action • Check output of the dosing pump. The fault relay is energised if the controller is too hot
or after tripping. It is also possible that there is some physical dragging or seizure of
the dosing pump.
• Check the control unit of the dosing pump.
ALARM002: LA0301 Stator empty, M0301 Metering pump
Active When dosing pump runs

Energised When dosing pump runs and if level electrode LA0301 is exposed longer than 3 seconds
Effect Dosing pump is disengaged and message is displayed on the operator panel
Action • Check that water supply is opened.
• Check that acid solution and alkaline solution are available and that the supply is
opened.
• Check that valves V0301, V0302 and V0303 operate; it is possible that the air supply
to one of these valves has failed.
[Critical] ALARM003: M0501 No response (cont.feedb), Product supply

pump
Active When centrifugal pump runs

Energised When centrifugal pump runs and if there is no feedback signal from the motor switch within
2 seconds
Effect System returns to step 00 and message is displayed on the operator panel
Action • Check circuit breaker.
• Check feedback contact of the pump.
ALARM004: LT0102 Level transmitter fault
Active During all steps.

Energised If current lower than 2.5 mA or higher than 25 mA is transmitted to analogue input.
Effect Step 00 cannot be started and message is displayed on the operator panel during all other
steps.
Action Check current at analogue input by connecting a mA meter in series with input level
amplifier.
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ALARM005: M0803 No response (cont.feedb), Maindrive hydraulic unit
Active From step 09 through 11

Energised When homogenizer runs and if there has been no feedback from pressure switch of the
hydraulic unit
Effect Homogenization pressure cannot be set. Message is displayed on the operator panel
Action Set pressure reducing valve at zero and, if fault persists, check the hydraulic unit
[Critical] ALARM006: M0804 No response (cont.feedb), Maindrive

lubricating oilpump
Active During steps 01, 03 through 34.

Energised When oil pump runs, a contact of magnetic switch gives feedback within 3 seconds
Effect System returns to step 00 (stops) and message is displayed on the operator panel
• Check feedback contact of magnetic switch.
[Critical] ALARM007: FS0801 Oilflow fault, Maindrive lubricating
Active In step 01, step 03 through 34, If flow switch FA0801 is not energised
Energised If homogenizer is engaged, the flow switch FA0801 should be energised within 10
seconds. If homogenizer and oil pump are disengaged, the flow switch FA0801 should be
de-energised within 20 seconds.
Effect System returns to step 00 (stops) and message is displayed on the operator panel
Action Check connections of flow switch LA0801. If fault occurs when system is shut down,
contact of flow switch sticks.
ALARM008: M0802 No response (cont.feedb), Maindrive cooling fan
Active During all steps

Energised When the cooling fan is running and there is no contactor feedback within 6 seconds
Effect A message is displayed on the Multipanel.
When the motor of M0801 becomes overheated the system will return to step 00.
• Check feedback contact of the motor.
[Critical] ALARM009: M0801 Temperature too high, Maindrive motor
Active During all steps and when control switch is on.

Energised The temperature is measured in the winding of the thermistor of the DC motor or the three
phase motor. If the temperature of the windings > 150°C.
Effect System returns to step 00 and message is displayed on the operator panel
Action Check whether motor is very hot; if so, check cooling fan or check power consumption
after motor has cooled down. It is also possible that klixon thermostat is defective.
version 1.0 " 231

[Critical] ALARM010: M0801 No response (cont.feedb), Maindrive motor
Active During steps 01, 03, 14 and 20 after run-down of timer after start-up, and 04 through 27
and 28.
Energised When homogenizer has been started and if there is no feedback from current relay within
10 seconds.
Effect System returns to step 00 and message is displayed on operator panel.
Action • Check whether there is field voltage on motor.
• Check the connection to current relay. If field voltage and current relay setting are in
order, then current relay is defective.
[Critical] ALARM011: M0801 Speed controller unit fault, Maindrive control
Active During steps 01, 03, 14 and 20 after run-down of timer after start, and during steps 04
through 27 and 29 through 34.
Energised When homogenizer has been started and if there is no feedback from thyristor unit within
5 seconds.
Effect System returns to step 00 and message is displayed on operator panel.
Action Establish the cause of the fault with the help of the thyristor unit manual (see chapter 8)
ALARM013: TT0701 Temperature transmitter fault
Active When control switch is on.

Energised When Temperature transmitter is out of range longer then 2 seconds
Effect Message is displayed on the operator panel
Action • Check resistance of Pt-100 with ohmmeter; resistance of Pt-100 will lie between 100
and 157.3 Ohm (0°C and 150°C.
• Check the connection of the wires of the Pt-100. If the fault is still active replace the Pt-
100

Effect During steps 04 through 08, system returns to step 03. During steps 09 and 10, product
supply valve V0102 is closed. The product supply valve to the filler/aseptic tank is closed
immediately.
During steps 14 through 19, system returns to step 03 after finishing of step 19. Message
is displayed on the operator panel
and 157.3 Ohm (0°C and 150°C.
100
232 " November 12, 2010

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Energised When Temperature transmitter is out of range longer then 2 seconds
and 157.3 Ohm (0°C and 150°C.
100
ALARM016: No control air supply

Energised When control switch is on and if there is no feed back from the pressure switch and the
pressure is lower than 3.5 bar.
Effect Message is displayed on the operator panel.
Action The air pressure should be higher than 3.5 bar.
Check pressure switch and wiring to the input of PLC
ALARM017: LL0101 No product supply, Balance tank level too low
Active During steps 09 and 10.

Energised If level is 10% below pre-set value of level controller.
Effect Message is displayed on operator panel.
Action Check product supply. If fault 17 is generated in conjunction with fault 18, fault is due to
wrong level controller setting.
ALARM018: LL0101 Level too high, Balance tank is overcharged
Active During steps 09 and 10.

Energised If level is 8% above pre-set value of level controller.
Action Check pressure of product supply. If fault 17 is generated in conjunction with fault 18, fault
is due to wrong level controller setting.
ALARM019: High control cabinet temperature

Energised When control switch is on and if thermostat does not give signal to the PLC.
Action • Check fans of control cabinet.
• Check filters of these fans. If ambient temperature is too high, make sure that cold air
is supplied.
version 1.0 " 233

ALARM020: LA0103 Product loss to the drain
Active During step 10

Energised If LA0103 is active
Action Check position of the valve V0107 + V0101 + V0110.
ALARM021: PS1301 No system backpressure
Active During steps 05 through 19.

Energised If, during steps 05 through 19, there is no feedback in 5 seconds from pressure switch
PS1301 to the PLC.
Action Check the input and output; the outputs energise the solenoid valves for back-: pressure
valve V1301.
ALARM022: No fillingmachine available
Active During the phases 07 through 11 (production).

Energised The last filler that is still in operation, is turned off.
Effect An alarm indication follows. The program will go to another step as follows:
• from 0700 through 0601
• from 0702/0701/0800 through 0604
• from 0801/0900 through 1100
• from 10.01 through 10.00
• from 10.02 through 10.00
Action Turn off the horn by means of the pressure button.
[Critical] ALARM023: LA0101 OR System without water
Active During all steps, except 00, 02, 0300, 0604, 07, 0800, 1408, 2004, 2700.
Energised During step 00 and when control switch is on, if level electrode (LALL0101) is exposed.
During steps 03, 06, 14 and 20 when control switch is on, if level electrode (LL0101) is
exposed after 10 seconds. During other steps, if level electrode (LL0101) is exposed after
2 seconds.
Effect System returns to step 00 and message is displayed on the operator panel.
Action Check whether water supply is opened. Check whether water supply is sufficient during
rinsing step. Check air supply to water supply valve V0101. The signal for this fault will be
energised, if the level electrode (LALL0101) has not been energised. If the feed balance
tank contains water, check all connections and level amplifier.
234 " November 12, 2010

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Active When main switch is on.

and 157.3 Ohm (0°C and 150°C).
100
ALARM027: TT1001 LOW TEMPERATURE ALARM, Mainheater

Energised If main heater temperature drops to below pre-set value.
If the pressure difference of the legal transmitters between the different sections is too low,
or the flow of the legal flow transmitter is too high (in case of FDA)
Effect During steps 04 through 08, system returns to step 03.
During steps 09 and 10, product supply valve V0102 is closed. The product supply valve
to filler/aseptic tank is closed immediately.
During steps 14 through 19, system returns to step 03 after completion of step 19.
Message is displayed on the operator panel.
Action Check steam supply and steam trap 10.06.
ALARM030: TIC1001 Temperature controller in manual mode, Mainheater

Energised If temperature controller is energised and if temperature 1001 has been set in manual
mode by entering a figure 1.
Action If automatic control mode is to be restored, 0 should be entered.
ALARM031: PIC1001 Pressure controller in manual mode, Mainheater

Energised If pressure controller is energised and if pressure controller PIC1001 has been set in
manual mode by entering a figure 1.
ALARM032: LIC0102 Level controller in manual mode, Balance tank

Energised If level controller is energised and if level controller LIC0101 has been set in manual mode
by entering a figure 1.
version 1.0 " 235

ALARM034: Wrong fillingmachine connected capacity

Energised If the sum of the hooked-up fillers, exceeds the output entered.
If, during production, the total filler capacity exceeds the value entered, the penultimate
capacity will remain in force.
Action Select the number of filling machines so that the maximum plant output is not exceeded.
It is possible that too high a value has been entered.
ALARM035: PT1001 Pressure transmitter fault, Mainheater

Energised If current at analogue input from PT1001 is lower than 2.5 mA or higher than 25 mA.
Action • Check current at analogue input by connecting mA meter in series with input and PT
1001 pressure transmitter.
• Check the wires and connections of the pressure transmitter.
If the fault is still active replace the pressure sensor
ALARM036: Program control in manual mode (only reset by phase-0000)
Active When the code 3120 is entered on the operator panel and the system is in manual
operation mode.
Energised Phases in manual operation mode.
Effect The program can be controlled manually, without fulfilling the program conditions in a
certain phase. The internal conditions concerned are not active. Production is not possible
in this situation. No signals are sent to the filler.
Action In order to neutralize alarm 45, the program has to be returned to phase 00 and the code
has to be reset.
ALARM037: Mainheater temperature alarm overrride
Active During steps 09 through 19

Energised If main heater temperature has dropped to below preset value and if the code has
energised, this memory is reset. The memory is automatically reset during step 03.
Action When the code is reset, plant requires sterilization. If intermediate aseptic chemical
cleaning has been selected, system will automatically initiate step 03 at the end of step 19.
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ALARM038: Phase duration fault (phase lenght too long)
Active When the main drive M0801 is running.

Energised During steps 0304, 0305, 0400, 0501, 0509, 2302 or 3302.
Effect Message is displayed on the operator panel during:
• step 0304, 0305, 0400 after run-down of the preheating step timer.
• step 0501, 0509 after run-down of the cooling step timer.
• step 2302, 3302 after run-down of the CIP warm up step timer.
Action • Check why step duration has exceeded pre-set value.
• Check the steam and water supply.
ALARM039: M0801 In manual mode, Maindrive

Energised If, with the help of the operator panel a number 1 is entered..
Action If automatic homogenizer output control is to be restored, '0' should be entered.
ALARM040: Loss of cip solution from ballance tank
Active When the control switch is on M0801 is running and M0301 is NOT running and V0301 is
not active.
Energised If, during phase 16, 22, 25, 32 and 35 the level LA0103 has been energised for more than
10 seconds. Or when V0101 opens in the circulation phase.
Action Check system for leakage.
[Critical] ALARM041: Emergency stop activated
Active When main power is on.

Energised When emergency button is pressed.
Effect When main switch is on and if there has been no feedback from emergency stop button
to the PLC. Message is displayed on the operator panel
Action Unlock emergency stop button and/or check the connections from emergency stop button
to input of PLC (reset alarm).
ALARM042: PIC0805 Pressure controller in manual mode, First stage

homogenizer
Energised When control switch is on.

Energised When control switch is on and if pressure controller of first-stage homogenizing valve is
set in manual mode (manual output > 0%).
Action If the automatic control mode is to be restored, '0' should be entered.
version 1.0 " 237

ALARM043: PT0805 Pressure transmitter fault, First stage homogenizer

Energised If the current at analogue input of PT0805 (pressure sensor of first-stage homogenizing
valve) is lower than 2.5 mA or higher than 25 mA
Action Check current at analogue input of PT0805 by connecting mA meter in series with input
and PT0805 pressure sensor.
ALARM046: PIC1301 Pressure controller in manual mode, System

backpressure

Energised If the control switch is on and if the system backpressure controller is set
in manual mode (manual output > 0%).
Action If the automatic control mode is to be restored, "0" should be entered.
ALARM047: PIC1501 Pressure controller in manual mode, Filling pressure
Active When the control switch is on.

Energised If the controller is energised and if pressure controller PIC1501 has been set in manual
mode by entering "0"
Action If the automatic control mode is to be restored, "0" should be entered.
ALARM048: TIC1203 Temperature controller in manual mode

Energised If temperature controller is energised and if temperature controller has been set in manual
mode.
Action Put the controller in automatic control mode.
ALARM050: M0801 Maindrive counter input fault (switch over to 1 sec

pulse)
Active During steps 09, 11 and 12.

Energised During steps 09, 11 and 12, if no counter pulse is transmitted from sensor to the PLC. And
if the pre-set timer rundown.
Effect During steps 09, 11 and 12 a timer will replace the counter. Message is displayed on the
operator panel.
Action Check the input of the counter pulse and/or wiring from counter sensor (S0801) to the
input
238 " November 12, 2010

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ALARM051: PIC1001 High steampressure, during production

Energised During steps 09 through 11, if main heater steam pressure exceeds the alarm setting.
Action Check main heater condensate drain valve(s). Increased steam pressure may also be
caused by main heater pullution, requiring chemical cleaning.
ALARM052: PIC1001 Steampressure too high for start production
Active During step 06.

Energised During step 06, if main heater steam pressure exceeds the alarm setting.
Action Check main heater condensate drain valve(s). Increased steam pressure may also be
caused by main heater soiling, requiring chemical cleaning.
ALARM053: PIC0805 Pressure too low, First stage homogenizer

Energised During steps 09 through 11, if homogenization pressure is lower than the alarm setting,
the message is displayed on the operator panel after 5 seconds.
Effect Message is displayed on operator panel
Action Check the oil pressure of the hydraulic-unit.
ALARM054: PIC0805 Pressure too high, First stage homogenizer

Energised During steps 09 through 11, if homogenization pressure is higher than the alarm setting,
the message is displayed on the operator panel after 5 seconds.
Effect Message is displayed on operator panel
Action Check the oil pressure of the hydraulic-unit.
ALARM055: No Homogenizing system selected

Energised During steps 09 through 11, If no homogenization pressure has been selected.
Action Set homogenization pressure on OP.
[Critical] ALARM060: No controlswitch available
Active In all phases.

Energised In every phase of the program and when the control switch breaks down.
Effect The program goes to phase 0000. Indication on the operator panel.
Action Turn on the control switch.
version 1.0 " 239

Waiting for operator action
Active When the lamp incorporated in the start button blinks.

Energised In phase 2, 6 and 13
Action Press the start button and select "production" or "CIP", if required.
ALARM070: V0103 Valve in wrong position

Energised If this valve is energised and there is no feedback (+ sensor), or if this valve is not
energised and there is a feedback (- sensor).
Action Check the inputs of sensors FB0103 (+ sensor) and FB0103 (- sensor), the pneumatic
tubing and that the stems of the sensors are not bent.



240 " November 12, 2010

Production

ALARM077: M0801 Pulsation pressure too low, Maindrive
Active When the control switch is on.

Energised If it is not energised.
Action Check whether the air pressure is adequate and whether the wires have been connected
properly. Increase the air pressure in the air bladder of the pulsation dampener, if so
required.

ALARM080: S0101 Coupling bend fault, Product retour selection error
Active In step 0107, 0108

Energised If in step 0107, 0108 the proximity switch S0101 is not activated or S0102 is activated the
alarm is activated
Action Check the position of the coupling bends

Energised When transmitter input signal is too low or too high (delay 2 seconds)
Action • Check the resistance of the Pt-100 bulb with the help of an Ohmmeter. The resistance
of the Pt-100 bulb will lie between 100 and 157.3 Ohm (0°C and 150°C).
100
version 1.0 " 241

ALARM082: PS1501 No filling backpressure available, Fillingmachine OFF

Energised If in phase 10 or step 1308, 1308 there is no feedback from the pressure switch PS1501.
Action Check the input and output; the outputs energise the solenoid valves for back-pressure
valve V1501.
ALARM083: S0101/0102 Coupling bends wrong position, Product supply

system
Active During steps 0001, 0007, 0601, 0107, 0108, 1303, 1304, 1313, 1314, phase group 02, 07,
12, 14 through 26, 30 through 35.
Energised During step 01, when code product return is entered. During step 02, 1303, 1304, 1313,
1314 and the start button is activated and S0102 is not activated. In step 20 through 35
and S0102 is not activated. In step 0007, 0601 and the start button is activated or in steps
07 through 12 and S0101 is not activated and S0102 is activated.
Action Check position of proximity switch and the coupling bends.
ALARM086: S0102 In wrong position, Product supply pipe rinse or cip not
posible
Active During steps:

• Active during rinse phases, Intermediate CIP and main CIP.
Energised If in one of the following situations S0102 is not activated:
• step 207
• step 14xx or 19xx
• step 2000 or 2202 or 2501 or 2600
• step 3202 or 3501
Action Check position of proximity switch and the coupling bends.
ALARM087: M0301 Speed controller unit fault, Dosing pump

Energised The PLC receives an error from the frequency controller of the pump.
Effect A message is displayed on the operator panel.
Action Check the manual of the frequency-controller to find the cause of the failure.
[Critical] ALARM088: M0501 Speed controller unit fault, Product supply

pump
Active Control current switched ON.

Energised When the circuit breaker of the motor shuts down.
Effect A message is displayed on the operator panel.
Action Check circuit breaker.
242 " November 12, 2010

Production
ALARM089: FS0802 Water flow fault, Maindrive
Active When the main power in active.

Energised When the oil pump (M0804) is running and there is no water flow (FA0802) within 15
seconds.
Action • Check the water supply.
• Check the sensor FA0802
• Check the cables.
ALARM091: Error config module 18
Active In all step

Energised If sensor combination does not match an actual recipe
Effect Blocking start up from step 2 through 3 and step 6 through 7
Action Check sensor combination
ALARM096: TT1001 High temperature, Mainheater
Active When controller is active

Energised If main heater is higher than pre set deviation value
during phases: 4, 6.01, 6.02, 7, 8, 9, 10, 11, 12, 13, 16, 17, 18, 19
Effect Message displayed on the operator panel
Action Check steam supply
ALARM097: TT1001 Low temperature, Mainheater
Active When controller is active

Energised If main heater is lower than pre set deviation value
during phases: 4, 6.01, 6.02, 7, 8, 9, 10, 11, 12, 13, 16, 17, 18, 19
Effect Message displayed on the operator panel
Action Check steam supply
ALARM099: M0301 Motor temperature too high, Dosing pump
Active When control switch is on

Energised If pump is energised
Effect Message displayed on operator panel/ pump stops
Action Check motor temperature. Action when motor is warm: check product in- and outlet pump.
And in case motor is cold: check thermal relay
version 1.0 " 243

ALARM103: M0301 In manual mode, Dosing pump
Active If the dosing pump is energised

Energised If pump is energised and pump has been set in manual mode
Effect Message displayed on operator panel
Action If the automatic mode is to be restored, 0 should be entered
ALARM123: TT1001 Main temperature, higher than 100 °C

Energised When pasteurising mode is selected and the main heater temperature is higher then
100°C.
Action • Check temperature controller settings of the main heater.
• Check pasteurisation setpoint.
• Check steam supply of main heater and pasteurisation set.
ALARM124: TT1201 Low temperature
Active When controller is active.

Energised When the temperature is lower than pre-set low deviation value during phase: 10
Action Check hot water supply.
ALARM125: TT1201 High temperature
Active When controller is active.

Energised When the temperature is higher than pre-set high deviation value during phase: 10
Effect Message displayed on the operator panel.
Action Check hot water supply.2.
ALARM131: M0803 Speed controller unit fault, Maindrive homogenizing

system
Active In all steps

Energised When motor runs and if there is no feedback from motor switch within 2 seconds.
Effect Motor is disengaged and message is displayed on the operator panel
Action The fault relay is energised if the motor is too hot or after tripping.
It is also possible that there is some physical dragging or seizure of the motor.
Check the control unit of the motor.
244 " November 12, 2010

Production
[Critical] ALARM132: M0804 No response (cont.feedb), Maindrive

lubricating oilpump
Active In all steps

Energised switch within 2 seconds.
Effect Motor is disengaged and message is displayed on the operator panel
Action The fault relay is energised if the motor is too hot or after tripping.
It is also possible that there is some physical dragging or seizure of the motor.
Check the control unit of the motor.
ALARM133: CIP programma loop sequens selection wrong
Active In step 02, 13, 20 through 25, 30 through 35

Energised If only the second loop of the CIP steps is selected.
Effect It is not possible to start up the cleaning program
Action Select the first loop of the CIP step
ALARM135: H0801 No response (cont.feedb), Maindrive carter heating
Active In all steps

Energised When the safety relay is activated
Effect Check the output of the casing heating The safety relay is activated, if the casing is too hot.
Action Check the safety settings of the crankcase heating with the manual of the casing.
ALARM136: H0801 controller unit fault, Maindrive carter heating
Active In all steps when the control circuit is activated

Energised If the case is active and there is no feed back in 2 seconds
Effect A message is displayed on the operator panel
Action Check the control unit of the crankcase heating
ALARM138: Wrong adjusted timer (adjusting equal to zero sec)
Active During process steps

Energised One of the timers is 0
Effect Message displayed on operator panel/ continuation to next step
Action Put the right value into the timer
ALARM152: Recipe download not posible, not equal to data in PLC
Active In all steps except Inspection stop

Message Recipe download not possible, not equal
Effect Actual recipe stays active.
Action Wait till step 2 or 6 (inspection stop).
version 1.0 " 245

ALARM169: Empty sterilizer in aseptic tank (tank on high level)
Active In step 10.

Energised If the level in the aseptic tank reached the level to empty sterilizer to aseptic tank
Effect The sterilizer moves to step 1100 displacing product with water.
Action Not applicable.
ALARM170: Homogenizer pressure below Stop Production Level
Active The control current is ON and the pump has started.

Energised The pump is functioning but the commutator of the motor does not send a feedback signal
within 3 seconds.
Effect The installation switches to phase 00 and outputs a message on the operator panel.
Action Check the starting of the pump (M0801).
ALARM178: Fillingvalve filler still open
Active Step 10, through 12.

Energised Handshaking from filling machines.
This is only a message to operator
Action Check filling machine if product flow is ok.
ALARM185: M0501 In manual mode, Product supply pump

Energised If control switch is on and the stated pump has been set in manual control mode.
Action Set the stated pump in automatic control on the operator panel.
246 " November 12, 2010

Cleaning In Place (CIP)
7 CLEANING IN PLACE (CIP)

At the end of the production run, either of two Cleaning-In-Place programs
may be selected:
• 7.2 Intermediate Aseptic CIP program on page 247, or
• 7.3 Main CIP program on page 247,
7.2 Intermediate Aseptic CIP program

The Intermediate Aseptic CIP program serves to clean the machine
between two production runs without necessitating machine sterilization.
During the entire Intermediate Aseptic CIP program, the temperatures
prevailing in the system are identical with those under normal production
conditions, thus ensuring that machine sterility remains unimpaired. Upon
completion of the Intermediate Aseptic CIP program, the system will
resume the production run. Intermediate Aseptic CIP is a fixed program,
comprising the following main steps:
1 Prerinse.
2 Lye-solution cleaning (2% lye-solution dispensing, lye-solution
circulation, water rinsing).
3 1% acid-solution injection for 2 minutes.
4 Final rinse.
7.3 Main CIP program

The Main CIP program is effected when the machine is shut down or when
the machine has reached the specified period of sustained operation (i.e.
maximum production time). During the Main CIP program, the filling pipes,
the supply pipes to the feed product tank and the feed product tank proper
are also cleaned. Upon completion of the Main CIP program, the machine
requires sterilization prior to allowing the production run to be started.
The Main CIP program comprises a number of steps, which may be
executed in a predetermined order.
The main steps are:
1 Prerinse,
2 Lye-solution cleaning (2% lye-solution dispensing, lye-solution
circulation, water rinsing),
version 1.0 247

3 Acid-solution cleaning (2% acid-solution dispensing, acid-solution

circulation, water rinsing),
4 Final rinse.
The prerinse serves to remove the majority of unincrusted residues and
water-soluble compounds such as milk sugar and salts.
During lye-solution cleaning, the proteins are solubilised and the fats
saponified, thus allowing them to be readily discharged with the lye
solution.
Acid-solution cleaning serves to solubilize and remove milkstone. The Main
CIP program can be specifically configured to suit the processor's
requirements. To this end various values should be entered under function
key F5. It is recommended that the general Main CIP program includes
both lye-solution cleaning and acid-solution cleaning. If dictated otherwise
by operating practice, a different CIP program may be performed.
n Note
You may check the cleaning results by loosening and removing the
inspection elbow situated direct after the main heater and subsequently
inspect it on the inside. Always replace the O-rings prior to re-installing
this bend. The inspection elbow has been mounted at the outside top of
the jacket of the flow unit
248 November 12, 2010

Maintenance
8 MAINTENANCE

This chapter describes the maintenance aspects of the installation. It is
divided into the following sections:
• 8.3 How to order spare parts on page 257,
• 8.4 Preventive maintenance diagrams on page 260.
8.2 General
In this chapter we present you our advises; procedures and methods for
executing proper cleaning and maintenance of the equipment, from which
we think they are the best to have and hold the sterility conditions as
required.
All data given in advises, procedure and methods hereafter, must be read
as “indicative only” and could be otherwise if circumstances and practical
experiences do require.
n Note
When in doubt, always follow the suppliers subscriptions, where
maintenance work is to be done, and oblige the security measures as
advised! If still in doubt, please consult Stork or the specialists in
question.
n Note
As a rule of good manufacturing practice, performed inspections,
cleaning and maintenance operations must be noted and filed in a
machine maintenance log.
One of the main responsibilities of the operator is to perform regular

continuity tests of all critical process parameters, such as times;
temperatures; pressures etcetera. Many of these data, are written down by
the technical writer, which data also requires a regular check, to ensure the
proper functioning of all machine processes.
version 1.0 249

8.2.1 Required tools

For performing the maintenance procedures you will need the following
tools a.o.:
Table 8.1 Required tools
TOOL CODE - DESCRIPTION NAME

Grease gun
Hook spanner
8.2.2 Consumables
You will have to use the following consumables in a number of
maintenance procedures:
• Loctite,
• Silicone grease,
• Grease for screwed connections (STORK B0204243)
8.2.3 Aim of maintenance

All activities related to recommended maintenance here have a common
factor: regularity. In order to facilitate the practical carrying out,
maintenance work is divided into periodical diagrams.
Where the maintenance actions make it necessary, special instructions
have been drawn up, to which the diagrams refer to.
If the manufacturers instructions are referred to, you should consult the
referred documentation.
8.2.4 Long term maintenance

The period of time over which preventive maintenance spreads in the
diagrams is one year maximum.
Over a longer period, work could become necessary which has not been
foreseen in this manual, either because of the age of the material, or
because the latter has reached the limit of working hours.
250 November 12, 2010

Maintenance
In this respect, the first drawings mentioned are those which appear in the
spare parts manual. In the case where certain revision work can be carried
out by the local maintenance department, the drawings can supply the
necessary information for dismantling and mounting of parts.
8.2.5 Pay attention to safety

Working with machinery and equipment, even if they comply with safety
codes and regulations, can only be safe if:
• The instructions relative to such machinery and equipment are strictly
observed. All provisions serving to ensure protection are left
unimpaired.
• Maintenance or overhaul work usually necessitates the disassembly of
one or more components, as a result of which the original state of the
machine or the piece of equipment involved will undergo a change
requiring extra measures in regard to safety.
w Warning
It is the responsibility of those in charge of preparing or surveying this
work, to take the necessary steps to guarantee safe working conditions.
Concerning this, it is helpful to recall certain essential points:

• Control cabinet and electrical equipment
C In the case of work in the cabinet, make sure that the voltage has been
switched off. Attention must be paid to the positions of the main switch
and the control switch. If the main switch is in the “on” position, the
heating element in the operator panel will be energised, if the control
switch is turned off. In that case the control circuit will be dead. If the
control switch is turned on, the heating element will be de-energised.
n Note
The white control current signal lamps remain lit when the control switch
is in the “off” position. The main switch must be turned “off” only during
maintenance works inside the control panel.
w Warning
Always consult the electric diagrams provided by Stork Food & Dairy
Systems B.V. and use tools of the requisite insulation class.
• Controls:
Make sure that nobody can turn on the electric circuits of the motors in
question. Therefore: take out the corresponding fuses and lock the
instrument cabinet. Work switches are often provided on the machine;
but these provide insufficient security when it is impossible to have
direct control.
• Compressed air tubes:
Make sure that the tubes of circuits implied are not under pressure and
that it is impossible to start up the compressors.
• Steam supply:
Especially with regard to the steam supply pipes, it is essential that the
main valves are shut and blocked to prevent unintended opening. This
may require the removal of the hand wheel or other steps to prevent
from being opened accidentally.
version 1.0 251

• Drive units:
Ensure, that nobody can start the motor of a drive unit requiring
servicing. For this purpose remove the fuses and seal off the distribution
box involved. Often safety switches have been provided at certain
points but they do not offer adequate protection if not within direct view.
• Piping:
Especially with regard to the steam supply pipes it is essential to ensure
that the main valves are not only shut but also blocked. This may require
the removal of the hand-wheel or other steps to prevent the valves from
being opened.
• Compressed-air and hydraulic-oil ducts:
Prior to maintenance or overhaul, these ducts must be made
pressureless, whilst the compressors and the hydraulic pumps
operating the circuits in question must be interlocked to prevent them
from being started.
• Guards of V-belt transmissions:
M As a rule, these guards serve to prevent accidents. Therefore, always

put them back in place before engaging the transmission.
The above summary only states a number of important points and lays
no claim to being complete. It is up to those in charge of maintenance
and overhaul to take account of every aspect associated with safety and
to assume full responsibility to ensure the protection of the people
carrying out the work involved.
• Thermo well:
These thermo well (TW) have been installed at various places in the
pipelines of the installation. The purpose of these TWs is to examine the
proper functioning of a Pt-100 element while in operation. When test
measuring, be sure to always wear protective clothing to avoid any
burns.
Figure 8.1 Thermo well (TW)
TW
b
a Glass thermometer
b Silicone oil
w Warning
During both the installation’s sterilization process and during the
production and cleaning process the pipelines get hot to very hot (60° -
140°C).
252 November 12, 2010

Maintenance
• Chemicals:
J We advise the users of our machines for the treatment of chemicals to

set up safe procedures and provide the appropriate aids and protective
equipment to ensure the personal safety of employees. The observance
of many safety regulations is influenced by factors over which Stork has
little or no control e.g. installation, layout, acoustics, materials used in
the process, process and safety procedures, maintenance, training and
production management. In this connection Stork offers no guarantee
that the goods come up to standards in force locally. The client is
responsible for ensuring that before commencement of production,
goods are inspected by the authorities responsible at local level for
safety and working conditions.
8.2.6 General instructions
8.2.6.1 Dismantling and mounting of parts

Dismantling and mounting of parts can only be carried out correctly if the
Y corresponding drawings have been studied:

• in order to determine the order of dismantling and mounting
• because the drawings can contain useful indications
This is why we remind you that there are drawings which are part of the
spare part manual.
Remove and dispose in a correct manner lubricating agents, batteries,
used chemical products and other such matter. On this subject, the local
environmental recommendations should be respected.
8.2.6.2 Adjustment of V-belt transmissions

• Grooves of pulleys carrying belts are in one plane (with machine
running).
• More detailed instruction for tensioning the V belts are given in the
special instructions after the maintenance schedules in paragraph 8.23.
8.2.6.3 Electrical equipment

Always make sure to keep electrical equipment free from moisture. For this
purpose, pay attention to the following points:
• Access doors to switch gear fitted in switch boxes and control panels
must be kept closed and properly sealed at the edges. The switch boxes
are equipped with a heating element, which is energised when the
master switch has been given the proper position (refer to the operating
instructions).
• Condensate that has formed in motors and limit switches must be able
to run off without obstruction. In other words, the point of discharge must
be cleared by removing any plug that has been fitted. All the equipment
mounted at or near the machine must be thoroughly sealed against
penetration of moisture.
• Cable conduits must be carefully protected against moisture by means
of a suitable socket and/or sealing compound.
version 1.0 253

• Otherwise, maintenance is limited to the following points:

- Fuses: make sure these are screwed firmly in position and check
position of fuse keys at bottom of fuse holders.
- Contacts: the contact material is subject to burning but never file or
grind down any contact. Always replace the contacts belonging to a
given switch simultaneously.
- Thermal overload relays: max. position should derived from the
indication on the motor type shield. During the trial run the thermal
relays receive a provisional setting which should be checked and
where necessary corrected on start-up. The throw-over time for the
star-delta starter should be set in such a manner, that the motor has
enough time to attain its proper speed. If the starting time is too
short, the fuses will out the circuit; if it is too long the motor may
suffer damage. Check maximum relay setting at regular intervals,
because experience has shown, that there is a tendency to exceed
max. permissible value if failure develops.
- If a thermal overload relay is cut out, the cause will rarely lie in the
relay itself. Locate the source of the failure before setting the relay to
a higher value. This will prevent even greater trouble.It should be
noted, that the value of a given fuse in the system depends on the
thermal relay employed. Consequently, any increase in this value
should go hand in hand with a higher relay setting.
- Moving parts: as a rule these do not require any lubrication. Isolators
and contacts must be kept free from oil and grease.
- Photocells/light sources: check for proper performance at regular
intervals. Keep lenses free from dust and condensate. Replace
lamps as soon as their light intensity decreases.
- Connections: check at regular intervals.
- Pilot lamps: check for proper performances.
- Limit switches: check at regular intervals, particularly those which
rarely come into action (safety switches).
- Carbon brushes of electric motor: check for wear, contact pressure,
type and position.
8.2.6.4 Pneumatic equipment

Given the various uses to which this is put, the following instructions should
be observed:
• Measuring and control gear: The air required for this equipment must be
dry and free of oil and dust. Check and drain the water separators
included in the pneumatic circuit at regular times.
Pneumatically actuated valves

In the third-part documentation you will find comprehensive information
concerning the parts of the air-operated valves that we use in the cleaning
and product control unit, the metering unit and the tubular flow steriliser.
8.2.6.5 Welding
During electric welding operations on site, special care should be taken to
ensure that the machine component to be welded is properly earthed. In
the event of inadequate earthing, the earth current may run through the
earth conductor of an other (undersized) electric cable, which may cause
the latter to become damaged beyond repair.
254 November 12, 2010

Maintenance
During argon arc welding, a high concentration of UV radiation is released.

If EPROMs are exposed to this radiation, these EPROMs may be erased.
Shield all electrical equipment from the UV radiation.
8.2.6.6 Handling stainless steel

It is necessary to keep other metals (such as unalloyed steel hoisting
systems are sometimes made of) from contacting the stainless steel
installation and piping. Any damage caused by such contact may trigger
corrosion of the installation. Where contact is unavoidable, wooden parts
should be employed instead of metal ones.
Make sure the environment is free from metal particles, since they may
cause extraneous rust and attack the installation. To obviate the risk
involved, the stainless steel parts should be treated with acid-free vaseline
from time to time.
8.2.6.7 Chemical cleaning

The machine cleaning procedure has been discussed in some detail in
“Description of program steps” of chapter 6 Production on page 183.
The lye detergent referred to in this section is lye, commercially available
J as a solution with a strength of 33 %.

The purpose served by the lye (NaOH) is to dissolve proteins, emulsify fats
and attack the deposit that has formed in the heat exchange unit. The
concentration to be adopted is approx. 2 % at a temperature of 140 °C
(280 °F).
Acid cleaning should be done with nitric acid (HNO3), commercially
available as a solution with a strength of 53 % (36Bé). This detergent has
the purpose of removing any deposit that remains in the system after the
lye detergent run. The concentration to be used is approx. 2% at a
temperature of 80 °C (180 °F.
For the application of detergents other than those prescribed above we
cannot accept responsibility, unless a sample of any such detergent is
submitted to us for prior analysis and you have received a written statement
from us to the effect that the detergent in question is suitable for use in the
equipment supplied. The nature and extent of the deposition on the
system's heated surface depend on the product and operating conditions.
It follows that in some cases it may be desirable, or indeed necessary, to
depart from the detergent concentrations specified above.
The re-use of detergent solutions employed earlier in plant cleaning must
be advised against. Although the acidity or alkalinity of such solutions
may still be adequate, we have found that in practice their cleaning effect
is unsatisfactory.
The use of detergents in the form of flakes dissolved on the spot by the
personnel in attendance is inadvisable, because this may clog the metering
equipment.
c Caution
Furthermore, the detergents and the water employed in cleaning the
plant may not contain any Chlorine, because the type of stainless steel
our equipment is manufactured from cannot withstand this element,
whether in free or combined state.
version 1.0 255

It is pointed out with emphasis that:

Cleaning should be carried out as soon as possible after machine has been
emptied of product. No prolonged period of time may intervene between
these process phases.
• The cleaning program must be implemented in full, and the cleaning
times in the software of the HMI strictly adhered to.
• The cleaning procedure established relative to the product involved and
recorded in the HMI software is aimed at removing all product deposits
from the circuit. Neglecting any part of this procedure will affect proper
machine performance.
To establish with some degree of reliability whether machine cleaning has
had the desired result, it is recommended to proceed as follows:
• After the machine has been cleaned and has received the last water
rinse, remove and inspect the inspection-bend connecting the main
heater to the regenerative section. The condition of this bend reflects
the condition of the heater itself, so that if the bend contains any deposit,
the same will apply to the heater.
• When starting production, check the steam pressure on the gauge
located after the heater steam control valve. The gauge reading should
normally be 2.8 to 3 bar in excess of atmospheric pressure.
A higher reading may mean that more steam pressure is needed to give
the product the requisite sterilising temperature, because the heater is not
clean. Please note, however, that the gauge will also give a higher reading
if the activated heater section should be shorter than required for the preset
machine output.
8.2.6.8 Third party devices

Wherever necessary, subcontractors documentation is included in this
manual. For the maintenance of this material, one should consequently
refer to instructions given by the manufacturer.
256 November 12, 2010

Maintenance
8.3 How to order spare parts
When ordering spare parts, please adhere to this ordering procedure to

ensure fast execution of your orders.
8.3.1 Ordering procedure

The spare parts are listed in the spare parts binder. Figure 8.2 shows an
example of a page from this binder. When ordering a spare part, you must
supply the following information:
a Machine number or order number (see the cover of this manual),
b Assembly number,
c Position number,
d Identification number,
e Required quantity,
f Description,
g Tag number (if present).
You can also copy the relevant pages from the spare parts binder. In the
squares 8, enter how many examples of this part you want to order.
Provide at least the following information about yourself:
• Company name,
• Name of the contact person in your company,
• E-mail address of the contact person,
• Telephone number of the contact person.
Figure 8.2 Example of a spare part list
1 N.00100.01 Dairy Factory International Spare parts list
Description: PARISON KNIFE

2 Item number: P0656014
Drawing number: 1P.0656.014-B
3 4 5 6 6 7 9
Pos Item no. Quantity Unit Description Drawing no./DIN no. Tag nr. Length R Doc Page
Description Remark (mm)
1 PB638592 1 ST PARISONMES SAM. 2P.B638.592-E Z 1-11
PARISON KNIFE P0656014 1P.0656.014-B
8 ENS.PARISON KNIFE
2 P0617879 1 ST BESCHERMBEUGEL 2P.0617.879-E Z
PROTECTIVE BRACKET
8.3.2 Electrical parts

Electrical components like sensors and safety switches may be shown on
the mechanical drawings but they are not always included in the
corresponding parts lists. For identification and ordering of those parts,
please refer to the ’Material lists’ included in the electrical plans.
8.3.3 Ordering replacement parts from subcontractors

If no Stork part number is available, please follow the subcontractor’s
instructions for ordering replacement parts.
version 1.0 257

In this case please state all data (such as serial number, type, year of
construction) shown on identification plates, if available.
8.3.4 Spare part categories

The spare parts list tells you when to expect replacement for each part. The
letter code column (9, marked R in the spare parts list) indicates the
replacement interval. These letter codes are explained in Table 8.2.
Table 8.2 Spare part categories
CODE DESCRIPTION EXAMPLES

A Consumable • Oil
Articles that are used up during production. • Grease
B Breakable parts • CIP sprayer • Sensor
These parts do not wear down predictably, but can • Valve • Spring
break without warning. • Drive belt • Air hose
• Fuse
D Wear parts • O-ring • Filter
These parts are subject to increased wear for • V-ring
example, due to calibrating the machine. Most of • Seal
these parts come into contact with the product.
E Wear parts class E (minor overhaul) • Hinge • Slide bearing
During 3000-hour maintenance, check these parts • Universal joint
and replace them if necessary.
F Wear parts class F (major overhaul) • Pulley • Ball bearing

During 6000-hour maintenance, check these parts • Chain sprocket • Change parts
and replace them if necessary. • Gears
G Third-party parts • Air filter • Reject unit
• Pump • Hydraulics
• Air cylinder • Motor
H Non-wearing parts. • Reductor • Fan
These should last the lifetime of the machine • Product feed hose
S Wear parts class S (sterilisation) • O-rings in the product circuit, SIP circuit and
After 100 CIP or sterilisation cycles, replace these HPV circuit
parts. • Sterile filters
Z Parts not considered to be spares • Frame • Fasteners
• Wiring
258 November 12, 2010

Maintenance
8.3.5 Revision sets

In these illustrations “revision sets” and “recommended spare parts”
may be displayed in colour. The item numbers of the revision sets are
coloured red or orange and the item numbers of recommended spare parts
are coloured green. It is highly recommended to keep these parts in stock.
Figure 8.3 Example of spare parts illustration
version 1.0 259

8.4 Preventive maintenance diagrams
c Caution
The frequency of maintenance operations is given as an indication. It
could be necessary for some maintenance activities to be carried out
more or less frequently according to the real production situation.
The maintenance procedure described below, and all the operations and
activities involved have one common denominator: regularity. To help
ensure proper and regular maintenance we have laid down all
maintenance operations in schedules. The following symbols indicate the
inspection frequency (i.freq.), with which the various operations should be
repeated:
• D daily or after 10 hours of operation,

• W weekly or after 60 hours of operation,
• ½M twice a month or after 120 hours of operation,
• M monthly or after 250 hours of operation,
• 3M once every three months or after 750 hours of operation,
• ½Y once every six months or after 1500 hours of operation,
• Y once a year or after 3000 hours of operation.
Where necessary special maintenance instructions are provided. They are

incorporated in the relevant maintenance schedules. In the area of
maintenance instructions, lubrication constitutes a subject apart. Given the
frequency required for lubricating jobs as compared with other
maintenance operations, we have devoted a separate column for the
lubricating frequency (lub. freq.). If reference is made to the manufacturer's
instructions, please refer to the third party documentation.
The maximum period of preventive maintenance covered by the schedules
is 12 months. After that period certain maintenance or overhaul operations
may prove necessary, because of components having aged or attained the
limit of their working life. These corrective maintenance operations fall
outside the scope of the present manual. In this context, reference is made
to the drawings included in the spare parts. They provide the data required
for the disassembly and reassembly of components and so enable the
client's maintenance staff to perform given jobs without outside assistance.
Some types of overhaul work, however, call for specialized skill. In the
event you apply to Stork Food & Dairy Systems B.V.’s Service department,
whose task it is to help customers whenever the need arises, the
department's services are subject to certain terms and conditions.
Another aspect requiring attention is the bacteriological conditions
prevailing in the machine. Expert advice on the subject is available from
Stork’s Research and Development Laboratory (Technocentre) at our
premises.
260 November 12, 2010

Maintenance
Explication of the abbreviations used in the attached maintenance table(s):

• Per. Personnel (S = Stork engineer, O = Operator and
M = Maintenance/service engineer,
• Pos. no. Part number on enclosed drawing,
• Item. Description of the part number,
• I. freq. Inspection frequency,
• Lub. freq. Lubricating frequency,
• Lub. no. Lubricant number.
version 1.0 261


control cabinets

control cabinets
SPECIAL
POS. LUB.
PER. ITEM. OPERATIONS I FREQ. LUB. NO. INSTRUC-
NO. FREQ.
TIONS
O Compressed Check water separators and D Third

air system drain. party
document
ation
O Temperature Clean the touch screen D Third
recorder party
M Replace battery 3Y
document
ation
M Measure and Check connection and functioning M
control of the Pt-100 thermocouples
system
Replace all Pt-100 thermocouples 2Y 8.12
O Signal/alarm Check pilot lamps, replace if D
system necessary.
M Fan with filter Clean the air filter mats. M 8.5
M Switch gear For general maintenance, see W 8.2.6.3
general instructions
M Air equipment For general maintenance, see 6M 8.2.6.4
general instructions
262 November 12, 2010

Maintenance

cleaning and supply unit

cleaning and supply unit
SPECIAL
POS. LUB.
NO. FREQ.
TIONS

system
O Steam traps Check functioning M Third
party
document
ation
M Steam piping • Clean steam traps/steam filter
M Switch gear General maintenance (Electrical 8.2.6.3
equipment)
M Compressed General maintenance (Pneumatic 8.2.6.4
air system equipment)
M Air operated Check sealings/collar and M Third
valves diaphragms/rolling type party
diaphragms document
ation
Replace if necessary 8.10
version 1.0 263


tubular flow steriliser / cleaning and supply unit

tubular flow steriliser/cleaning and supply unit
SPECIAL
POS. LUB.
NO. FREQ.
TIONS
M Tubular flow Chemical cleaning D 8.2.6.7

steriliser
Renew sealing rings of tubular Y 8.9
heat-exchanger
system
O Steam traps Check functioning M Third
party
document
ation
M Steam piping • Clean steam traps/steam filter
M Switch gear General maintenance (Electrical 8.2.6.3
equipment)
M Compressed General maintenance (Pneumatic 8.2.6.4
air system equipment)
M Air operated Check sealings/collar and M Third
valves diaphragms/rolling type party
diaphragms document
ation
Replace if necessary 8.10
M Steam See documentation of Third
control/ valve manufacturer. party
positioner document
ation
M Condensate Check functioning, repair or renew W
valves if necessary
264 November 12, 2010

Maintenance

metering unit

dosing unit
SPECIAL
POS. LUB.
NO. FREQ.
TIONS
M PCM dosing See documentation of D Third

pump manufacturer. party
(M03.01) document
ation
• Check the piston seal, D
• Drain oil and refill after a break 200 - 300 8.31
in period, h.
• Drain oil and refill each 2000 h. or
crankcase with three litre. 6M
version 1.0 265


fluid transport pump

fluid transport pump
SPECIAL
POS. LUB.
NO. FREQ.
TIONS
M Pako pump See documentation of Third

manufacturer. party
document
ation
greasing the bearings:
• > 22 kW 3000 rpm
• = 18,5 kW 1500 rpm
266 November 12, 2010

Maintenance

homogeniser
Figure 8.4 Assembly 3HL-10 homogeniser
70
57
4
3 72 2 7
A 47
40
21
20
II
version 1.0 267

w Warning
Pump-cylinders and the crankshaft cannot be disassembled with the help
of ordinary hand tools. Their disassembly requires the application of
special Stork hydraulic tools. Non-application of these tools will cause
serious damage

homogeniser (3HL-10)
SPECIAL
POS. LUB.
NO. FREQ.
TIONS
O 1 Crankcase Drain condensate by means of D 8.24

drain cock in drain pipe.
(Drainage should be effected after
a period of downtime)
M 1 Crankcase Drain oil when warm, remove oil- 6M/ 2 8.27
sump and clean crankcase and oil 1,500 h.
passages thoroughly. Refit sump
and refill to required oil level.
(initial after 200 operating hours)
M 2 Oil filter Replace filter cartridge. 6M Third
party
document
ation
M 2 Flow switch in Check for proper operation and W
lubricating renew if required.
system
S 3 Pinion shaftr Replace both double-row 20,000 Contact
spherical roller bearings. hours STORK
S 4 Crankshaftr Replace main bearing shells and 40,000
connecting rod shells. hours
Replace double row spherical 20,000
roller bearing. hours
M 20 Plunger sealsr In case of leaky piston seals, 8.13
replace the packing. 8.14
(Frequency depends on operating
conditions)
O-ring/back- During production under pressure W 8.14
up ring check for product leakage by
sealing means of leakage indication
(small hole) in bronze nut.
In case of leakage, replacement is
required at next production stop.
(Always replace when removing
the bronze nut)
268 November 12, 2010

Maintenance

homogeniser (3HL-10) (Continued)
SPECIAL
POS. LUB.
NO. FREQ.
TIONS
M 40/47 Homogen- Check homogenising spindle, W

ising devicer seat and wearing ring, replace if
necessary.
Device types:
• P866108 8.22
Lubricate the spindle and bearing W 8.29
bushes with silicone grease.
(Silicone grease must be allowed
for dairy industry)
M 57 Hydraulic Check for absence of leakage and 3M Third
system repair leaks, if required. party
Check oil-level in hydraulic unit. W
Change the oil and renew the filter 2W/Y 107
element.
(Initial after the 200 operating
hours)
M 70 Electric motor See documentation of 18 Third
manufacturer. party
document
ation
M 72 V-belts Check belt tension. 3M 8.23
r = Overhaul kit available
8.4.6.1 Required tools

For performing the maintenance procedures you will need the following
tools:
Table 8.9 Required tools homogeniser

B02.04.243 - Silicone kit
Kluber Paraliq GTE 703 (Stork Ident. no. B0204243, approved for use in
food industry)
P0573539 - Brass plug tool
version 1.0 269


P0573698 - Neck bush tool
P0856824 - Tool attachment
P0678913 - Hydraulic tool, see Figure 8.20
P0402161 - Packing ring extractor
Hook spanner -
Torque wrench and sockets -

P0664070
270 November 12, 2010

Maintenance
8.5 Filter cleaning
8.5.1 Purpose
The fan of the control cabinets contains an air filter mat. This air filter mat
has to be cleaned at regular intervals, depending on the level of
contamination.
8.5.2 Cleaning the filter mats

Air filter mats of the fan can be cleaned as follows:
• Type SK 3170-3173
Wash them in water (of up to approx. 40 °C, with commercial fine
detergent added if necessary). You can also vacuum-clean or blow
them out with compressed air. In case of fatty or greasy substances:
wash them in naphtha, trichloroethylene or warm water with fat solvent
added.
• Type SK 3181-3183
Wash them in water (of up to approx. 40 °C, with commercial fine
detergent added if necessary). In case of fatty or greasy substances:
Wash them in water with fat solvent added.
Do not wring them out. When spraying them with water, do not use a
sharp jet.
version 1.0 271

8.6 Applying pictograms
8.6.1 Purpose
This procedure tells you how to replace the pictograms (safety stickers) on
the machine.

You need the following tools and consumables for this procedure:
• detergent,
• degreasing non-corrosive agent (e.g. methanol),
• scraper,
• new pictogram sticker.
8.6.3 Procedure
When the pictograms become illegible following deterioration or when they
become unstuck, stick new pictograms in the appropriate places as
indicated in chapter 2 Safety.
Sticking instructions:
1 Using detergent and a degreasing non-corrosive agent (e.g. methanol),
clean carefully the surface to which the pictogram is to be applied.
2 Take off the protective film from the back of the pictogram and apply to
the cleaned surface.
3 Position the pictogram and fix it by using a scraper to insure perfect
adherence and eliminate any air bubbles.
4 After applying, let the pictogram harden for 24 hours before any contact
with water and/or detergent.
Figure 8.5 Applying pictograms
1 2
3 4
272 November 12, 2010

Maintenance
8.7 Expansion tanks
8.7.1 Purpose
Check the operation condition of the expansion tank(s).

Tyre pressure gauge.
8.7.2 Checking procedure

The intermediate-medium circulating system of the second-stage barrier
regenerator incorporates a number of expansion tanks. These tanks serve
to permit the expansion of water following an increase in temperature. The
number of expansion tanks depends on the required expansion volume.
With the system under no-load conditions, the air pressure prevailing in the
expansion tanks is 2 - 2.5 bar. A spring-loaded safety valve is incorporated,
which serves to prevent the system from being subjected to excessive
pressures. During standstill of the cold Sterideal system, the circulating
system is pressurized automatically to a pressure of 2.5 - 3 bar.
Check the initial pressure in the expansion tank(s):
1 Depressurize the system.
2 Check the pressure in the expansion tank(s) with the help of a tyre
pressure gauge.
- If the pressure is lower than 2 bar, then it should be increased to a
maximum of 2.5 bar.
- If, owing to leakage of the rubber diaphragm, it is not possible to
build up the pressure, the relevant expansion tank should be
renewed!
version 1.0 273

8.8 Back pressure valve (module 13/15)
8.8.1 Purpose
Adjust the setpoint of the back pressure valve in relation to the operating
phase.
8.8.2 Adjusting the backpressure setpoint

The valid setpoints of the back pressure valve are:
Table 8.10 Back pressure valve setpoints
SETPOINT
DESCRIPTION
MODULE 15
1 During product circulation of phase 10

2 During the production
Figure 8.6 Filling back-pressure valve
274 November 12, 2010

Maintenance
8.9 Sealing rings
8.9.1 Purpose
Renew sealing rings of the tubular heat exchanger.
8.9.2 O-rings
Carefully check all O-rings prior to re-assembly. Always replace damaged
O-rings immediately.Make sure O-ring grooves are perfectly clean. Rings
should be resistant to acid, alkali and water and should have a hardness of
80° Sh. When fitting new O-rings, they should be greased with Klüber
Paraliq GTE 703 (Stork Ident. nr. B0204243).
version 1.0 275

8.10 'De Haan' valves
8.10.1 Purpose
The purpose is to prevent the new rings (11) for the ‘De Haan’ valves from
becoming damaged during assembly
8.10.2 Exchange the O-rings

Replace the O-rings described in the following steps:
1 Disassemble the valve according the sequence drawn in the Figure 8.7.
2 New rings (11) can be made more flexible by immersing them in hot
water (approx. 80°C) for approx. 5 min.
3 Fit them immediately and make sure that the edge in the valve is clean
and undamaged.
4 Assemble the valve in reverse order.
Figure 8.7 'De Haan' valves
5 11
12
3
6
12
10
7
10
276 November 12, 2010

Maintenance
8.11 'De Haan' stainless-steel bellows valve
8.11.1 Purpose
Check and maintain the stainless steel bellows of the valve.

• Open-end spanner of 19 mm to hold the upper rod (13),
• Ring/open-end spanner 13 mm to fix the cover (19) with bolt M8
beneath the cover.
8.11.3 Inspection procedure

Inspect the valve:
1 Check for visual cracks and/or dents that can be caused during
transport.
2 Check the bellows. Make sure the bellows is not damaged with the
mounting tools or stretched:
- An undamaged bellows has a life span of 50.000 strokes.
- A damaged bellows would be leaking quickly.
8.11.4 Exchange the O-rings

Exchange the O-rings described in the following steps (see Figure 8.8):
Disassembly procedure:
1 Put the air-operated engine in the upper position.
2 Release clamp (18).
3 Remove the air-operated engine from the casing (20).
4 Put the air-operated engine in the lower position.
5 Unscrew the cover (19) of the upper rod (13). Use open-end spanner 19
and ring spanner 13.
Mounting procedure:
6 Exchange the O-rings (10 and 12) and if neccessary the guiding ring
(11).
7 Proceed the disassembly in reverse order.
c Caution
Do not damage the bellows of the valve.
version 1.0 277

Figure 8.8 'De Haan' bellows valve
10 -O-ring
11 - Guiding ring
12 - O-ring
13 - Upper rod
18 - Clamp
19 - Valve cover
20 - Casing
278 November 12, 2010

Maintenance
8.12 Checking the Pt-100 resistance bulbs
8.12.1 Purpose
Check and control the Pt-100 at the intervals specified in flow scheme.

• Thermometer
• Ohmmeter (analog type, with mirror behind pointer)
n Note
Disconnection of one of the resistance bulbs will result in the system not
reaching its preset temperature.
Check if the Pt-100 resistance bulbs are properly connected and operate
properly. If the Pt-100 does not work properly perform the procedure in
section 8.12.3.
8.12.3 Measure resistance procedure
n Note
It is recommended that the resistance bulbs be renewed every two years.
Measure the resistance of the Pt-100 with an accurate Ohmmeter between

the white and black wires if the bulb is immersed in melting ice (0°C).The
ohmmeter should measure a resistance of 100.
Figure 8.9 Pt-100 resistance bulb
Black
black
Black
black
100 Ohm/0
Ohm/°CC
White
white
White
white
The resistance bulb can also be immersed in a medium whose temperature

is known precisely. The resistance related to this temperature can be read
off from the Pt-100 Table 8.11.
version 1.0 279

Table 8.11 Pt-100 resistance table
T °C 0 1 2 3 4 5 6 7 8 9 10
-10.00 96.09 96.48 96.87 97.26 97.65 98.04 98.44 98.83 99.22 99.61 100.00
0.00 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51 103.90
10.0 103.90 104.29 104.68 105.07 105.46 105.85 106.24 106.63 107.02 107.40 107.79
20.00 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.29 111.67
30.00 111.67 112.06 112.45 112.83 113.22 113.61 114.00 114.38 114.77 115.15 115.54
40.00 115.54 115.93 116.31 116.70 117.08 117.47 117.86 118.24 118.63 119.01 119.40
50.00 119.40 119.78 120.17 120.55 120.94 121.32 121.71 122.09 122.47 122.86 123.24
60.00 123.24 123.63 124.01 124.39 124.78 125.16 125.54 125.93 126.31 126.69 127.08
70.00 127.08 127.46 127.84 128.22 128.61 128.99 129.37 129,75 130.13 130.52 130.90
80.00 130.90 131.28 131.66 132.04 132.42 132.80 133.18 133.57 133.95 134.33 134.71
90.00 134.71 135.09 135.47 135.85 136.23 136.61 136.99 137.37 137.75 138.13 138.51
100.00 138.51 138.88 139.26 139,64 140.02 140.40 140.78 141.16 141.54 141.91 142.29
110.00 142.29 142.67 143.05 143.43 143.80 144.18 144.56 144.94 145.31 145.69 146.07
120.00 146.07 146.44 146.82 147.20 147.57 147.95 148.33 148.70 149.08 149.46 149.83
130.00 149,83 150.21 150.58 150.96 151.33 151.71 152.08 152.46 152.83 153.21 153.58
140.00 153.58 153.96 154.33 154.71 155.08 155.46 155.83 156.20 156.58 156.95 157.33
150.00 157.33 157.70 158.07 158.45 158.82 159.19 159.56 159,94 160.31 160.68 161.05
160.00 161.05 161.43 161.80 162,17 162.54 162,91 163.29 163.66 164.03 164.40 164.77
280 November 12, 2010

Maintenance
8.13 Maintenance of pump seals

The homogeniser 3HL-10 contains 3 types of seals (Figure 8.10), namely:
a collar seals (pistons in gear case).
b stuffing boxes (pistons in pump cylinders),
c O-rings (pump cylinders and valves),
For these seals the following instructions should be observed.
c Caution
Homogenising will be done under high pressure. Consequently replace
during maintenance always the O-rings! Be sure of the correct size and
type.
c Caution
The hydraulic tank unit must be shut off during maintenance of the
homogenising device!
Figure 8.10 Pump seals (indicated by arrows)
version 1.0 281

8.14 Plungers and plunger packing
8.14.1 Purpose
To maintain the plunger and plunger packing of the pump cylinder at the
intervals defined in the maintenance table, because they are subject to
excessive wear.
8.14.2 Disassembly and assembly plunger

Disassembly of the plungers and plunger seals is as follows:
w Warning
If work is to be performed on the plungers and plunger seals, make sure
that the main switch is in the off position and locked, thus eliminating the
risk of the drive motor being started accidentally
Disassembly:
1 Remove brass plugs located in front of the pump cylinders with the
special Stork tool (P0573539).
2 Check if the small hole of the leak detection is open!
282 November 12, 2010

Maintenance
Figure 8.11 Removing brass plugs
2
b
1
a
a Brass plug
b Pull cap
c Special Stork tool P0573539 for HL 05/10/15/25
3 Pull caps from the pump cylinders.
n Note
After disassembly of caps always replace the O-ring and the back-up ring
by new rings
4 Remove plugs in top of crosshead guides of the homogeniser by hand

in order to align the oil-hole in crosshead with the hole in crosshead
guide.
5 Loosen the gland nut at back of pump cylinder a few turns. Use a piece
of pipe or a steel rod with outside diameter of 10 mm, see figure 8.12
6 Prepare the hydraulic tool, see procedure and instructions as described
in section 8.18.
version 1.0 283

Figure 8.12 Disassembly of plunger
d
4
c
3
6
f
e
5
h
g
b
a
a Brass plug e Plunger packing

b Pull cap f Gland
c Gland nut g Neck bush
d Splash ring h Thrust ring
7 Screw the hydraulic tool into the crosshead, passing it through the hole
in the crosshead guide.
Figure 8.13 Hydraulic tool attached to crosshead
8 Screw the sleeve further onto the cylinder of the hydraulic tool, forcing
the oil between the plunger and the crosshead and thus releasing the
plunger.
284 November 12, 2010

Maintenance
9 Move rubber splash ring backward and pull the plunger from the pump
cylinder.
10 Renew directly the plunger packing if necessary.
a Loosen gland nuts and remove glands.
b Remove packing rings, using the packing removing tool. Take care
to ensure that the stuffing boxes are not damaged.
c Thoroughly clean the stuffing boxes in the pump cylinders.
d Fit the new sets of packing rings in accordance with the
instructions described in section 8.13.
Assembly:
11 Reassembly of the plungers is in the reversed order of disassembly.
Thoroughly degrease the cones of the crossheads and the plungers
prior to reassembly. Fit the plungers in the crossheads, tapping them
home with the help of a soft mallet.
8.14.3 Collar seals

The collar seal which form the seals at the gearcase end may now be
renewed, if required.
When fitting collar seals, make sure that they are fitted in the glands with
their backs facing outward (lugs of packing rings on lubricating oil side).
Figure 8.14 Position of collor seals
3
2
1
7
i
4
7
i
5
6
i Collar seal
version 1.0 285

8.15 Neck bush
8.15.1 Purpose
Exchange the neck bush if necessary.

P0573698 - Neck bush tool
8.15.3 Disassembly and reassembly procedure
n Note
Use only special Stork tool for this procedure.
The following illustration shows how to use the neck bush tool during the
removing/fitting procedure of neck bush!
Figure 8.15 Disassembly and reassembly neck bush
a Fitting
b Removing
During reassembly, make sure that stainless steel thrust ring is fitted on the
gearcase side of the pump cylinder. In addition also make sure that the gap
between the two ends of the liner is located at the top, this gap should have
a width of min. 4 mm. Finally, the four flushing slots located on the outside
of the neck bush should be clean and permit the free flow of liquid.
286 November 12, 2010

Maintenance
Figure 8.16 Neck bush
8
7
10
5 - Packing set
7 - Stainless steel thrust ring
8 - Neck bush
10 - Gearcase side of the pump cylinder
version 1.0 287

8.16 Packing set of pump cylinders
8.16.1 Purpose
Fitting the packing set, O-ring and collar seals of the pomp cylinder at the
interval defined in the maintenance table.
Figure 8.17 Dismantling pistons
8
7
10
5 - Packing set, 8 - Neck bush,

7 - Stainless steel thrust ring, 10 - Pump cylinder.
8.16.2 Fitting the packing set

The neck bushes, gland nuts and plungers should be in optimum condition
before the packingset is fitted. It is recommended that new neck bushes
and glands be fitted and, if the plungers are scoured, they should be
restored or renewed. The packingset should be slightly greased and the
packing rings should be staggered 120° relative to each other.
1 Check whether the diameter of the plunger is the same in the centre, at
the top and at the bottom. This can be done with the help of a new neck
bush.
Slide this neck bush up and down over the plunger. This will allow you
to establish whether or not the clearance is the same at all points. If
there is hardly any sensible difference, the plunger is still suitable for
operating service. The stuffing box in the pump cylinder should be
100% clean and smooth.
2 Fit the neck bush so that the opening of the liner faces upward (see
maintenance procedure 8.15).
3 Apply a little silicone grease1 on the circumference of the packing rings,
taking care to ensure that the packing rings are not deformed.
1. Klüber Paraliq GTE 703 (Stork Ident. nr. B0204243)
288 November 12, 2010

Maintenance
4 Fit the first ring with the slot facing upward.
Figure 8.18 Positions of joints
6
5
4
3
2
1
6 4
60°
3 2
5 Fit the second and third rings so that their joints slots are each
staggered by 120°.
6 Fit the fourth ring so that its joint is staggered by 180° in relation to the
first ring.
7 Fit the fifth and sixth rings to that their joints are staggered by 120° in
relation to the slot of fourth ring.
8 Fit the gland follower and the nut so that the nut contacts the gland
follower, with the gland follower being positioned in the pumping
cylinder to a depth of at least 10 mm.
Care should be taken to ensure that the gland follower just does not
contact the packing ring. Otherwise it will be more difficult to fit the
plunger.
9 Fit the plunger.
10 After all plungers have been fitted, tighten the glands with an additional
attachment (P0856824) and a torque wrench:
- 3HL-10 90 Nm.
11 After a few minutes, compress the packing slightly more. Keep the
packing under pressure for a minimum of 20 minutes. This will ensure
that the packing rings are made to form one complete package, which
assumes the shape of the plunger and the pumping cylinder. Thanks to
the rings having been greased, they help ensure maximum
compression and ensure better sliding in the pumping cylinder. Failure
to grease the rings will cause the rings to leak between the pumping
cylinder and packing.
n Note
The crankshaft must not be turned when the packing is being tightened.
It can easily be checked whether the packings have been fitted properly.
Properly fitted packings are characterised by the fact that their outside
edges are sharp, especially those of the front ring.
version 1.0 289

12 After the packing rings have been under pressure for 20 minutes, it will
depend on the type of homogeniser how to proceed.
Subsequently, it should be loosened one full turn 360°, thus ensuring
that the packing has sufficient clearance to permit slight leakage. This
leakage is minimal so that it cannot be detected in the plunger cooling
water. If there is not sufficient clearance, the centre packing rings of
the packing will run dry, causing excessive wear of the packing and
plungers.
- After the plant has been started up to handle product, a newly fitted
packing will not leak.
- After a CIP cycle, the plunger cooling water may be slightly
discoloured during the first twenty minutes; thereafter it should not
show any discolouration.
- If, after a given period of time, the plunger cooling water is
permanently discoloured, re-tighten the gland follower by turning the
nut 1 to a maximum of 3 holes (½ turn). However, it must be
assumed that the packing is worn.
- If the gland follower is tightened hard so that there is no leakage, the
plunger will be subject to excessive wear, i.e. scoring at the points
where the packing is rubbing dry on the plunger.
8.16.3 O-rings
Carefully check all O-rings prior to re-assembly. Always replace damaged
O-rings immediately.Make sure O-ring grooves are perfectly clean. Rings
should be resistant to acid, alkali and water and should have a hardness of
80° Sh. When fitting new O-rings, they should be greased with Klüber
Paraliq GTE 703 (Stork Ident. nr. B0204243).
290 November 12, 2010

Maintenance
8.17 Valves of high-pressure pump
8.17.1 Purpose
Maintain the suction and delivery valves of the pomp cylinder at the
intervals defined in the maintenance table, because they are subject to
excessive wear.
8.17.2 Disassembly and assembly valves

Exchange the suction and delivery valves:
w Warning
Make sure that the homogeniser cannot be started during these
operations. Also take care to ensure that no parts are damaged and
prevent foreign matter from entering the cylinder block.
Disassembly:
1 Disconnect the connecting pipelines from the front of pump block.
2 Unscrew the 8 stainless steel nuts from the studs and allow the lower
block to be suspended from the two outer studs.
3 The 3 suction valves can be removed laterally.
4 Remove the lower block and the upper block from the pump cylinders.
5 The 3 delivery valves can be removed now.
w Warning
Always renew the O-rings when performing maintenance work, make
sure that O-rings of the proper type and size are used!
6 Inspect the valves on wear and replace if necessary.
version 1.0 291

Figure 8.19 Suction and delivery valves
a O-ring 63,09x3,53
b Back-up ring
c O-ring 53,57x3,53
d Clip
e Compression spring
f Valve disc
g Valve seat
h Casing
Assembly:
w Warning
When assembling the valves, pay attention to the correct assembly
position of the valves housing/body. All valves open in upwards direction.
Three arrows are marked on the exterior of the valve body. The arrows
must point upwards
7 Assembly is in the reversed order of disassembly.
292 November 12, 2010

Maintenance
Tighten the individual nuts according the values and sequence given
in Table 8.13:
Table 8.13 Tightening torques (in Nm) and sequence
NUTS TORQUE
6 4 2 8
5, 6, 7, 8 154 Nm
1, 2, 3, 4 290 Nm 7 1 3 5
8 When reassembling the valves, make sure that the valves are in the
appropriate assembly positions.
9 Connect the connecting pipelines to the front of pump block.
version 1.0 293

8.18 Hydraulic tool
8.18.1 Purpose
Prepare the hydraulic tool for the removal of plungers. The hydraulic tool
comes standard with the set of tools supplied with the homogeniser.
8.18.2 Refilling procedure

Perform the following steps to fill the hydraulic tool:
Figure 8.20 Hydraulic tool

(P0664838)
d
4
3
c
b
2
a
1
a Threaded rod
b Ring
c Piston
d Tommy bar with cylinder
1 Attach the threaded rod to the crosshead and fill it with mineral oil
having a viscosity of 40 cSt at 50°C (SAE 20).
2 Insert the cylindrical pin into cylinder.
3 Screw the cylinder onto the threaded rod with the help of the tommy bar.
n Note
Take care to ensure that the hydraulic tool is undamaged and thoroughly
cleaned prior to utilisation!
4 The hydraulic tool is now ready for utilisation.
294 November 12, 2010

Maintenance
8.18.3 Usage
It is used for the removal of the plungers during the “disassembly and
reassembly of the plungers and plunger packings”.
The illustration below clearly shows how the hydraulic tool is attached to
the crosshead.
Figure 8.21 Hydraulic tool attached to crosshead
The cylinder has right-hand internal screw thread to connect it to the

externally threaded rod. With a hooked-up hydraulic tool filled with oil,
clockwise rotation of the cylinder with the help of the tommy bar will cause
the piston to move forward, increasing the oil pressure in the joint between
the piston and the crosshead. If, in practice, situations should occur where
the plunger cannot be released with the help of oil, the hydraulic tool should
be packed with grease (instead of oil).
version 1.0 295

8.19 Rupture disc protection
8.19.1 Purpose
The rupture disc in the upper-block is fitted below the homogenising device
and protects the homogeniser for high pressures. If the rupture disc (red
dot) collapses, the entire output of the homogeniser is blown-off and must
be replaced.
8.19.2 Replacement procedure

Replace the collapsed rupture disc:
1 Trace and solve the cause.
2 Replace the rupture disc with a correct one.
n Note
Do not forget to replace the O-ring above seat.
Figure 8.22 Rupture disc
296 November 12, 2010

Maintenance
8.20 The pulsation dampener
8.20.1 Purpose
Check the pressure in the rubber bellows of the pulsation damper.

A pulsation dampener is fitted in the suction and/or delivery pipeline. In this
dampener a rubber bellow (7) is fitted inside a stainless steel strainer (24).
The bellow is pressurised with compressed air to a pressure of approx.
70% of the infeed pressure during not operating. This pressure can be read
from a pressure gauge on the operating panel. During operation of the unit
the pressure is fluctuating, due to the pressure fluctuation in the suction
and/or delivery pipe-line. When the pressure is decreasing, this means that
the bellow is leaking. The bellow has to be replaced at once (see 8.20.3
Replacement procedure).
Figure 8.23 Pulsation dampener (e.g mounted in suction pipe)
1
6
24
8 10
9 2

Perform the following steps to renew the bellows:
1 Disassemble the pulsation damper as shown in the Figure 8.23
Assembly:
2 Fit O-ring (6) in the groove of item (1).
5 Slide bellows (7) over item (8) so that the raised edge slips behind it.
Do not use any grease or lubricant/slip additive.
6 Slide flange (4) over (8) so that it contacts bellows 7.
version 1.0 297

7 Hand-tighten nut (10) so that it contacts item (4), but do not yet screw
it down.
8 Next slip the sub-assembly, consisting of items (4), (5), (7), (8), (9) and
(10), into perforated screen (24).
taking care to ensure that no grease or lubricant/slip additive is used.
9 Slip this assembly into the housing (1) of the pulsation dampener.
10 Gradually tighten the four bolts (2) crosswise.
11 Next firmly tighten nut (10) against flange (4).
12 Finally, put the pulsation dampener under the appropriate pressure:
- Suction side: between 1.5 and 2 bar.
- Delivery side: between 5 and 6 bar.
298 November 12, 2010

Maintenance
8.21 The aseptic pulsation damper
8.21.1 Purpose
Verify that the working pressure of the pressure gauge is within the design
tolerances.
8.21.1.1 Specifications
• Maximum product pressure 50 bar.
• Maximum compressed air pressure in the air cylinder xx bar.
8.21.1.2 Procedure
When the pressure tolerance is out of range compensate the pressure with
compressed air.
c Caution
Stop the production process and the put the machine in maintenace.
Release the air pressure of the air cylinder and close the condensate
valve before disassembly the aseptic pulsdamper.
If a leak is detected disassemble the aseptic pulsation damper according

Figure 8.24 Aseptic pulsation dampener on page 300.
Inspect the following assembly parts on wear and replace if necessary:
1 the rubber bellow.
2 the steam barrier.
3 the stainless steel piston.
version 1.0 299

Figure 8.24 Aseptic pulsation dampener
d
10
f
23
g
18 e
21
a Compressed air nipple

b Pressure gauge (Manometer)
c Air cylinder
d Rubber bellow
e Stainless steel piston
f Cup seal
g Steam barrier
300 November 12, 2010

Maintenance
8.22 Homogenisation valve P0866108
8.22.1 Purpose
In order to enable the weekly lubrication of the homogenising valve with
silicone grease1 and the inspection of the homogenising spindle (24) and
valve seat surfaces (26) and wear ring (25), the homogenisation valve
requires disassembly.
8.22.2 Disassembly and assembly procedure
w Warning
Homogenisation is effected at very high pressures. Always renew the O-
rings when performing maintenance work, making sure that O-rings of
the proper type and size are used!
Disassembly procedure:
1 Make sure that the hydraulic system is switched off.
2 Loosen the two stainless steel nuts at the top of the homogenisation
valve and remove the hydraulic cylinder and piston assembly (3+7).
c Caution
Do not disconnect the hydraulic high-pressure tubing!).
3 Disassemble the bottom section of the homogenisation valve (9+11).

4 Next remove the valve seat (24) and impact ring (25).
5 Press the spring retainer (5) down and remove the lock pin (4), thus
releasing the spring retainer, spring and homogenising valve.
n Note
Make sure that worn or damaged o-rings and sealing rings are renewed
immediately.
Assembly procedure:
1 Reassembly is in the reversed order of disassembly.
2 Make sure that the hydraulic system is vented properly. Venting can be
effected by putting the cylinder under pressure and allowing any air to
escape via the vent screw (1) on top of the device.Repeat these
operations a few times.
1. Approved for use in food industry.
version 1.0 301

Figure 8.25 Cross-section homogenising-device
1 - Vent screw 11 - Housing (bottom section)

2 - Sealing ring 12 - O-ring
3 - Hydraulic cylinder 16 - O-ring
4 - Locking pin 20 - Spring
5 - Spring retainer 21 - O-ring
6 - O-ring 22 - shamban seal
7 - Piston 23 -
8 - Glacier bearing bushes 24 - Spindle
9 - Guide bushing (bottom section) 25 - wearring
10 - O-ring 26 - Valve seat
302 November 12, 2010

Maintenance
8.22.3 Installation of homogenising valve seat

Stork employs two types of homogenising valve seats:
• Stellite-coated homogenising valve seat (S) features a circumferential
groove to house the O-ring.
• Tungsten carbide-faced homogenising valve seat (H) features a
bevelled edge at the top of the valve seat to house the O-ring.
Figure 8.26 Position of O-ring on homogenising valve seat
S H
n Note
Hard metal parts are brittle and fragile and may easily be damaged by
jolting them against hard surfaces. Therefore treat the parts carefully and
leave them in the original packaging as long as possible. Unpack them
on a wooden or plastic table surface. While assembling them do not exert
any force: use soft hammers.
8.22.4 Bearing bushes homogenising spindle

When clearance between the homogenising spindle and the two Glacier
bearing bushes has become too large, these bearing bushes must be
replaced. With new bearing bushes the clearance between bushes and
spindle is barely perceptible. Carefully tap the worn out bushes out of the
guide bushing.
• By means of an old modified homogenising spindle first mount a new
bearing bush at the bottom of the guide bushing. See situation A in the
illustration below.
version 1.0 303

• Subsequently mount the top bearing bush with the spindle. See
situation B in the illustration.
Figure 8.27 Assembly bearing bushes
10
B
18 11
A C
8 - Glacier bearing bushes,
10 - Guide bushing,
18 - Shamban-seal.
Modify a used homogenising spindle as shown in situation C in Figure 8.27.
n Note
After mounting new bearing bushes always mount a new O-ring and
Shamban-seal on the spindle. Thoroughly lubricate bearing bushes and
spindle with silicone grease (Klüber Paraliq GTE 703).
304 November 12, 2010

Maintenance
8.23 Tensioning the V-belts (3HL-10)
8.23.1 Purpose
Replace the v-belt and check the tension at the intervals defined in the
maintenance table.
w Warning
Never remove guards and protections when the homogeniser is in
operation!
If work is to be performed on the drive mechanism, make sure that the
main switch is in the off position and locked, thus eliminating the risk of
the motor being started accidentally

Replace the ravelled, cracked or damaged V-Belt:
1 Release the tension of the belts by loosen the clamping bolts
2 Replace the belts. Always replace the belts per set. New and used V
belts must never be fitted together on the same drive.
w Warning
Keep the belts and the disc grooves thoroughly clean and free of grease.
3 The V-belts of the top drive are tensioned by adjusting the motor with
the motor support with the help of the four adjusting nuts.
4 Check the tension of the belt (see 8.23.3), if necessary adjust the motor
till the belt is properly tensioned.
8.23.3 Checking the tensioning

Proof of a properly tensioned V-belt is the ability to press the belt with a
certain force a number of mm's in the middle of the centre distance of drive.
The extent of being able depress the belt depends on the diameter of the
smallest belt pulley, the centre distance and the belt profile.
The depression must amount to 15 mm per 1000 mm centre distance. For
instance:
At a centre distance of 900 mm the depression amounts to:
900 ⁄ 1000 × 15 = 13.5 mm
version 1.0 305

When using new belts Stork recommends to multiply K min. and K max.
with factor 1.3.
Figure 8.28 Depression force (K)
l deflection
Dd
With the belt profiles shown below the depression force K (in N) is
applicable in the middle of and perpendicular to the centre distance of the
drive.
Table 8.14 Depression force
DD (MM) PROFILE XPB PROFILE XPC

K min. (N) K max. (N) K min. (N) K max. (N)
100 29 39
112 34 45
125 38 51
140
42 56
160 46 62 56 75
180 49 66 63 84
200 52 69 69 92
224
54 72 75 100
250 57 75 80 106
280 59 78 85 112
315 61 80 90 118
355
63 82 94 123
400 99 127
450 103 132
306 November 12, 2010

Maintenance
8.24 Drain off water from the crankcase
8.24.1 Purpose
To prevent damage to the drive of the homogeniser drain off water from the
crankcase daily.
The illustration below clearly shows the locations of the draining valve and
oil level sight glass.
Figure 8.29 Cartel draining valve and sight glass
a Draining valve
b Sight glass
c Maximum
d Minimum
8.24.2 Draining procedure

Water will sink to the bottom of the tank by means of specific gravity, this
process makes it easily drainable from the tank. Perform the following step
to drain the water:
1 Put a measuring glass below the draining valve.
2 Open the draining valve.
3 If you observe a small oil film on the water surface, close the draining
valve.
4 Check the oil level in the oil level sight glass of the crankcase.
5 If the oil level is below its maximum, perform the refilling procedure, see
section 8.27.
version 1.0 307

8.25 Rupture disc
8.25.1 Purpose
A rupture disc device is a non-reclosing pressure relief device actuated by
inlet static pressure and designed to function by the bursting of a pressure
containing disc. The disc may be made of metal and housed in a suitable
holder, If the rupture disc collapses the product in the system is
contaminated and flows around the floor to the drain. The installation must
shutdown and the rupture disc must be replaced.
Figure 8.30 Rupture disc
1
2
a Rupture disc
b Identification plate

Replace the collapsed rupture disc:
1 Shutdown the installation.
2 Trace and solve the cause.
3 Replace the rupture disc with a correct one mentioned on the
identification plate, see third party documentation
4 Restart the installation.
308 November 12, 2010

Maintenance
8.26 List of recommended lubricants

Please find detailed in the table below the lubricants recommended by
Stork Food & Dairy Systems B.V..
Table 8.15 Lubricants
NO .
2 Degol BG 150 Energol GR-XP 150 Spartan EP 150

18 Aralube HL 3 Energrease LS-EP 2 Beacon 2/3
57 Teresso 150
107 Energol HLP 32
NO .
2 Mobilgear 629 Omala oil 150 Meropa 150

18 Mobilplex EP 46 Alvania grease EP 2 Multifak EP 2
57 DTE Extra heavy Tellus C 150 Regal 150 (R&O)
107 DTE FM 32 Tellus Oil 27 Rando oil HD 32
n Note
To lubricate the homogenizing spindle and to grease the O-rings during
the assembly, Klüber Paraliq 703 lubricant should be used.
version 1.0 309

8.27 Oil pump of homogeniser
8.27.1 Purpose
If the oil level is below the centre of the sight glass the oil pump must be
refilled or changed at the specified intervals in the maintenance table.The
illustration below clearly shows the locations of the draining valve and oil
level sight glass.
Figure 8.31 Cartel draining valve and sight glass
a Draining valve
b Sight glass
c Minimum
d Maximum
8.27.1.1 Required tools/lubricants

• Filter element
• Oil number 2 (see § 8.26).
To effect the oil change, the following quantities of oil are required for the
different types of homogenisers:
310 November 12, 2010

Maintenance
Table 8.16 Quantity of oil
TYPE QUANTITY OF OIL

3HL - 10 ca. 45 l
Figure 8.32 Lubricant sticker
70
70
MAX
MAX
mineral oil
FILTER
FILTER
MAX 1500 h + FILTRE
FILTRO
ISO VG-CLASS 150 mineral oil
CHEVRON - NL Gear compound 150

ESSO - Spartan EP 150
MOBIL - Mobilgear 629
SHELL - Omala oil 150
TEXACO - Meropa 150
8.27.2 Change and refill the oil pomp

The lubrication oil is pumped round by an electric driven gear wheel
pump.
1 Drain all the oil directly after the machine has been put out of operation.
2 Remove welded stainless steel oil-sump of frame and clean thoroughly.
3 Replace the filter element and clean the magnet mounted in the filter.
4 Next fill the machine with one of the products listed in section 8.27.1.1 ,
until the oil-level is visible halfway the sight glass.
w Warning
Waste lubricants should be drained and disposed of in a proper manner.
Observe the relevant local anti-pollution regulations.
5 Once the machine has been put into service, make certain the oil level
is still correct: it should come halfway the sight glass.
c Caution
Drain off condensation/water daily prior to going into operation, see
section 8.24.
version 1.0 311

8.28 Electric three phase motors
8.28.1 Purpose
The used bearings must lubricated at the defined time intervals in the
maintenance table.
8.28.1.1 Required lubricant/tool

• Lubrication grease lubricant no. 18 (see § 8.26).
• Greased gun.
8.28.1.2 Interval
Roller bearings have to be greased twice as often as ball bearings. The
grease durability and the mandatory quantity of grease for the bearings of
the electric motor are mentioned in the documentation of the sub-supplier.
8.28.2 Lubrication procedure

The Electric three phase motors (squirrel cage armature motors) are
furnished at:
• the drive end (D.E.) with roller bearings.
• the non-driving end (N.D.E.) with ball bearings.
Apply lubricant no. 18 (see section 8.26 List of recommended lubricants) to
the grease nipple of the bearings with a grease gun. As a rule of thumb 30 –
50% of the bearing space in the bearing should be filled with grease.
312 November 12, 2010

Maintenance
8.29 Homogenising spindle in the homogenising device
8.29.1 Purpose
The homogenising spindle is subject to wear, therefore the spindle must be
lubricated at the defined time intervals in the maintenance table.
8.29.1.1 Required lubricant

• Silicone lubricant that complies with the food regulations,
• Klüber Paraliq GTE 703.
8.29.2 Procedure
1 Remove the spindle, see section “Homogenisation valve P0866108” on
page 301.
2 Apply a silicone lubricant that complies with the food regulations.
n Note
During production and assembly Stork applies Klüber Paraliq GTE 703.
c Caution
Stork Food & Dairy Systems B.V. shall not assume liability for any
damage caused by lubricants other than those specified by us.
3 Reassemble the spindle.
version 1.0 313

8.30 Hydraulic system
8.30.1 Purpose
If the oil level is below the centre of the gauge glass the hydraulic unit must
be refilled.
8.30.1.1 Required lubricants/tools

• Texaco Rando Oil HD 32 (Lub. nr. 107).
Maximum content of unit is 22,5 l.
• Oil filter.
8.30.2 Exchange and refill oil procedure

1 Open the filling cap at the top of the tank.
2 Refill the hydraulic unit with lub. nr. 107 through the filling cap.
3 Renew the filter (See third-part documentation).
4 Check for absence of leakage and repair leaks, see third party
documentation.
Figure 8.33 Hydraulic unit
Maximum level
Minimum level
Temperature in
Celsius and
Fahrenheit
57
a Oil level indicator.
314 November 12, 2010

Maintenance
8.31 PCM dosing pump
8.31.1 Purpose
To change or refill the lubrication oil of the pump at the defined time
intervals for maintenance.
8.31.1.1 Required lubricants

For this purpose use lubricants as stated in the following table.
Table 8.17 Lubricants for dosing pump
PRODUCT MAKE ISO GRADE

Reductelf SP100 Elf 100
Dynam SP100 Igol 100
Renep 100GL- Fuchs 100
Unil SP100 Unil 100
Cygnus hydraulic PAO Texaco 100
n Note
Do not mix lubricants from different manufacturers.
If a change to another type or brand of oil is made, the existing lubricant

should be drained and the gear case flushed with a small quantity of the
new lubricant before refilling with the new lubricant.
8.31.1.2 Interval
After a break-in period of 200 - 300 hours and subsequently every 2000
operating hours or after half a year.
version 1.0 315

8.31.2 Change and refill procedure
Figure 8.34 PCM Dosing pump
a Drain cock,
b Filling plug.
To Change lubrication oil of the gear box:
1 Attach a hose to the drain cock furnished with 3/8 gas thread at the
bottom of the pump gear box.
2 Drain the lubrication oil from the gear box by opening first the drain cock
and then the filling plug.
3 After draining close the drain cock.
4 Fill the gear box (cap. 3 litres) via the filling plug located on top of the
gear box next to the stroke adjustment.
Ensure that the oil level is between the max. and min. level indicated on
the gauge glass.
5 Close the filling plug.
To check and refill the lubrication oil of the gearbox:

1 Check the oil level in the gauge glass.
2 If necessary, refill the gear box via the filling plug located on top of the
gear box.
3 Ensure that the oil level is between the max. and min. level indicated on
the gauge glass.
4 Close the filling plug.
316 November 12, 2010

Index
INDEX
corrosion
A chlorides. . . . . . . . . . . . . . . . . . . . . . . . . 111
acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 common salt. . . . . . . . . . . . . . . . . . . . . . 111
additional binders . . . . . . . . . . . . . . . . . . . . . .26 resistance. . . . . . . . . . . . . . . . . . . . . . . . 111
air unalloyed steel . . . . . . . . . . . . . . . . . . . . 111
supply . . . . . . . . . . . . . . . . . . . . . . .111, 112 crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
alkaline . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
ambient air . . . . . . . . . . . . . . . . . . . . . .111, 112
argon arc welding . . . . . . . . . . . . . . . . . . . . .255 D
aseptic pulsation damper De Haan stainless-steel bellows valve
maintenance . . . . . . . . . . . . . . . . . . . . . .299 maintenance . . . . . . . . . . . . . . . . . . . . . 277
De Haan valves
maintenance . . . . . . . . . . . . . . . . . . . . . 276
B decommissioning . . . . . . . . . . . . . . . . . . . . 119
back pressure valve . . . . . . . . . . . . . . . . .69, 78
maintenance . . . . . . . . . . . . . . . . . . . . . .274
bearing bushes
maintenance . . . . . . . . . . . . . . . . . . . . . .303
black circled numbers . . . . . . . . . . . . . . . . . . .20
branch on behalf of cleaning. . . . . . . . . . . . . .64
C
carter
maintenance . . . . . . . . . . . . . . . . . . . . . .307
caustic soda . . . . . . . . . . . . . . . . . . . . . . . . .115
centrifugal pump
description . . . . . . . . . . . . . . . . . . . . . . . . .65
chemical cleaning . . . . . . . . . . . . . . . . . . . . .255
CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
intermediate (aseptic) . . . . . . . . . . . . . . .247
main . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
cleaning in place . . . . . . . . . . . . . . . . . . . . . .247
cleaning process
product control process . . . . . . . . . . . . . .189
commissioning . . . . . . . . . . . . . . . . . . . . . . .118
dosing unit . . . . . . . . . . . . . . . . . . . . . . . .107
homogeniser . . . . . . . . . . . . . . . . . . . . . .108
tubular flow steriliser . . . . . . . . . . . . . . . .105
communication . . . . . . . . . . . . . . . . . . . . . . . .97
control cabinets. . . . . . . . . . . . . . . . . . . . . . . .95
description . . . . . . . . . . . . . . . . . . . . . . . . .95
cooling water. . . . . . . . . . . . . . . . . . . . .114, 115
cooling water system . . . . . . . . . . . . . . . . . . .91
version 1.0 317

description filter cleaning

automatic valve maintenance. . . . . . . . . . . . . . . . . . . . . . 271
actuation . . . . . . . . . . . . . . . . . . . . . . . 88 first stage regenerative section . . . . . . . . . . . 70
back pressure valve . . . . . . . . . . . . . . 69, 78 forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . 104
branch on behalf of cleaning . . . . . . . . . . 64 functions PLC . . . . . . . . . . . . . . . . . . . . . . . . 96
centrifugal pump . . . . . . . . . . . . . . . . . . . 65
dosing pump . . . . . . . . . . . . . . . . . . . . . . 66
filling pipe . . . . . . . . . . . . . . . . . . . . . . . . . 94
G
first regenerative section . . . . . . . . . . . . . 70
general
high-pressure pump
instructions . . . . . . . . . . . . . . . . . . . . . . . 253
pressure relief . . . . . . . . . . . . . . . . . . . 84
gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
holders (pipe) . . . . . . . . . . . . . . . . . . . . . . 75
homogeniser
aseptic pulse damper . . . . . . . . . . . . 299 H
control panel . . . . . . . . . . . . . . . . . . . . 92 handling stainless steel . . . . . . . . . . . . . . . . 255
cooling water system . . . . . . . . . . . . . 91 hearing protection . . . . . . . . . . . . . . . . . . . . . 48
device . . . . . . . . . . . . . . . . . . . . . . . . . 93 heating element. . . . . . . . . . . . . . . . . . . . . . . 90
drive . . . . . . . . . . . . . . . . . . . . . . . . . . 86 helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
first device. . . . . . . . . . . . . . . . . . . . . . 93 high-pressure pump
lubricating system . . . . . . . . . . . . . 89, 91 maintenance. . . . . . . . . . . . . . . . . . . . . . 291
pulsation damper . . . . . . . . . . . . . . . . 82 pressure relief . . . . . . . . . . . . . . . . . . . . . 84
pulse damper (aseptic) . . . . . . . . . . . . 85 HNO3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
rupture disc . . . . . . . . . . . . . . . . . . . . . 82 hoisting instructions. . . . . . . . . . . . . . . . 46, 104
second device . . . . . . . . . . . . . . . . . . . 93 holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
main heater . . . . . . . . . . . . . . . . . . . . . . . 72 holders (pipe) . . . . . . . . . . . . . . . . . . . . . . . . 75
metering unit . . . . . . . . . . . . . . . . . . . . . . 66 homogenisation valve
output control maintenance. . . . . . . . . . . . . . . . . . . . . . 301
frequency . . . . . . . . . . . . . . . . . . . . . . 87 homogeniser
product cooler/circuit steriliser . . . . . . . . . 76 aseptic pulse damper . . . . . . . . . . . . . . . 299
product pump . . . . . . . . . . . . . . . . . . . . . . 65 automatic valve
product supply unit. . . . . . . . . . . . . . . . . . 59 actuation . . . . . . . . . . . . . . . . . . . . . . . 88
program steps . . . . . . . . . . . . . . . . . . . . 230 commissioning . . . . . . . . . . . . . . . . . . . . 108
supply valve central CIP system . . . . . . . 62 control panel. . . . . . . . . . . . . . . . . . . . . . . 92
tubular flow steriliser . . . . . . . . . . . . . . . . 67 cooling water system . . . . . . . . . . . . . . . . 91
directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 device. . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . 66 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 first device . . . . . . . . . . . . . . . . . . . . . . . . 93
lubricating system . . . . . . . . . . . . . . . 89, 91
output control
frequency . . . . . . . . . . . . . . . . . . . . . . 87
E
pictographs. . . . . . . . . . . . . . . . . . . . . . . 186
electric
pulsation damper . . . . . . . . . . . . . . . . . . . 82
welding. . . . . . . . . . . . . . . . . . . . . . . . . . 254
pulse damper (aseptic). . . . . . . . . . . . . . . 85
emergency stop
rupture disc . . . . . . . . . . . . . . . . . . . . . . . 82
push-buttons . . . . . . . . . . . . . . . . . . . . . . 49
second device . . . . . . . . . . . . . . . . . . . . . 93
emergency stops. . . . . . . . . . . . . . . . . . . . . . 50
hosting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
locations. . . . . . . . . . . . . . . . . . . . . . . . . . 50
hydraulic system
E-plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
lubrication. . . . . . . . . . . . . . . . . . . . . . . . 314
equipment control panels . . . . . . . . . . . . . . 124
hydraulic tool
expansion tanks
maintenance. . . . . . . . . . . . . . . . . . . . . . 294
maintenance . . . . . . . . . . . . . . . . . . . . . 273
F I
indicating instruments . . . . . . . . . . . . . . . . . 122
filling machine in production . . . . . . . . . . . . . 98
filling pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
318 November 12, 2010

Index
installation . . . . . . . . . . . . . . . . . . . . . . . . . . .103 maintenance . . . . . . . . . . . . . . . . . . . . . . . . 249

machine environment . . . . . . . . . . . . . . .111 aseptic pulsation damper . . . . . . . . . . . . 299
utilities . . . . . . . . . . . . . . . . . . . . . . . . . . .111 back pressure valve . . . . . . . . . . . . . . . . 274
instrument air . . . . . . . . . . . . . . . . . . . . . . . .112 bearing bushes . . . . . . . . . . . . . . . . . . . 303
interaction of machines . . . . . . . . . . . . . . . . . .97 carter . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
interface De Haan stainless-steel bellows valve. . 277
alarm menu . . . . . . . . . . . . . . . . . . . . . . .142 De Haan valves . . . . . . . . . . . . . . . . . . . 276
CPU menu . . . . . . . . . . . . . . . . . . . . . . . .148 expansion tanks . . . . . . . . . . . . . . . . . . . 273
help menu . . . . . . . . . . . . . . . . . . . . . . . .144 filter cleaning . . . . . . . . . . . . . . . . . . . . . 271
icon description menu . . . . . . . . . . . . . . .143 high-pressure pump . . . . . . . . . . . . . . . . 291
main menu . . . . . . . . . . . . . . . . . . . . . . . .132 homogenisation valve . . . . . . . . . . . . . . 301
maintenance menu . . . . . . . . . . . . . . . . .145 hydraulic tool . . . . . . . . . . . . . . . . . . . . . 294
manual operationt menu . . . . . . . . . . . . .134 neck bush. . . . . . . . . . . . . . . . . . . . . . . . 286
password menu . . . . . . . . . . . . . . . . . . . .146 personnel . . . . . . . . . . . . . . . . . . . . . . . . . 48
product return menu . . . . . . . . . . . . . . . .153 plunger . . . . . . . . . . . . . . . . . . . . . . . . . . 282
program selection menu . . . . . . . . . . . . .150 plunger packing . . . . . . . . . . . . . . . . . . . 282
recipe menu . . . . . . . . . . . . . . . . . . . . . . .173 preventive diagrams. . . . . . . . . . . . . . . . 260
start menu . . . . . . . . . . . . . . . . . . . . . . . .128 pt-100 resistance bulbs . . . . . . . . . . . . . 279
step menu . . . . . . . . . . . . . . . . . . . . . . . .141 pulsation damper . . . . . . . . . . . . . . . . . . 297
trending menu . . . . . . . . . . . . . . . . . . . . .155 pump cylinder. . . . . . . . . . . . . . . . . . . . . 288
UHT menu . . . . . . . . . . . . . . . . . . . . . . . .154 pump seals. . . . . . . . . . . . . . . . . . . . . . . 281
variable menu . . . . . . . . . . . . . . . . . . . . .149 rupture disc . . . . . . . . . . . . . . . . . . . . . . 308
intermediate cleaning shear plate . . . . . . . . . . . . . . . . . . . . . . . 296
process V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . 305
intermediate cleaning . . . . . . . . . . . . .189 manual structure . . . . . . . . . . . . . . . . . . . . . . 25
metering unit . . . . . . . . . . . . . . . . . . . . . . . . . 66
modules
01A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
L
03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
location of emergency stops . . . . . . . . . . . . . .50
05A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
lock-out system . . . . . . . . . . . . . . . . . . . . . . . .49
07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
lubricant
08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
lubrication . . . . . . . . . . . . . . . . . . . . . . . .309
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
lubricating system . . . . . . . . . . . . . . . . . . . . . .89
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
lubricating water system . . . . . . . . . . . . . . . . .91
12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
lubrication
13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
hydraulic system . . . . . . . . . . . . . . . . . . .314
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
lubricant . . . . . . . . . . . . . . . . . . . . . . . . . .309
18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
oil pump . . . . . . . . . . . . . . . . . . . . . . . . . .310
23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PCM dosing pump . . . . . . . . . . . . . . . . . .315
28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
spindle . . . . . . . . . . . . . . . . . . . . . . . . . . .313
H# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
three phase motors . . . . . . . . . . . . . . . . .312
MP377. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
lye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
N
M
NaOH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
machine environment . . . . . . . . . . . . . . . . . .111
neck bush
machine shut down . . . . . . . . . . . . . . . . . . . .188
maintenance . . . . . . . . . . . . . . . . . . . . . 286
main cleaning . . . . . . . . . . . . . . . . . . . . . . . .190
nitric acid . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
main heater . . . . . . . . . . . . . . . . . . . . . . . . . . .72
main heater range control . . . . . . . . . . . . . . . .72
O
oil pump
lubrication. . . . . . . . . . . . . . . . . . . . . . . . 310
operating . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
version 1.0 319

operating interface . . . . . . . . . . . . . . . . . . . 121

operating mechanisms . . . . . . . . . . . . . . . . 122 R
operation ready for production . . . . . . . . . . . . . . . . . . . 98
checks . . . . . . . . . . . . . . . . . . . . . . . . . . 188 resistance
process . . . . . . . . . . . . . . . . . . . . . . . . . 189 corrosion . . . . . . . . . . . . . . . . . . . . . . . . 111
shut down. . . . . . . . . . . . . . . . . . . . . . . . 188 RFP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
ordering spare parts . . . . . . . . . . . . . . . . . . 257 rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
rupture disc
maintenance. . . . . . . . . . . . . . . . . . 296, 308
P
PAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 S
PCM dosing pump safety. . . . . . . . . . . . . . . . . . . . . . . . . . . 45, 251
lubrication. . . . . . . . . . . . . . . . . . . . . . . . 315 devices and protection devices . . . . . . . . 49
PFM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 general instructions . . . . . . . . . . . . . . . . . 46
pictograms. . . . . . . . . . . . . . . . . . . . . . . . . . 272 hoisting instructions . . . . . . . . . . . . . . . . 104
piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 regulations . . . . . . . . . . . . . . . . . . . . . . . . 46
PLC shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
functions. . . . . . . . . . . . . . . . . . . . . . . . . . 96 transport instructions . . . . . . . . . . . . . . . 104
plunger shut down . . . . . . . . . . . . . . . . . . . . . . . . . . 188
maintenance . . . . . . . . . . . . . . . . . . . . . 282 end production . . . . . . . . . . . . . . . . . . . . 188
plunger packing step 13 . . . . . . . . . . . . . . . . . . . . . . . . . . 188
maintenance . . . . . . . . . . . . . . . . . . . . . 282 Siemens MP377 . . . . . . . . . . . . . . . . . . . . . 127
plungers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 sodium hydroxide . . . . . . . . . . . . . . . . . . . . 115
pressure spare parts . . . . . . . . . . . . . . . . . . . . . . 26, 257
gauges and pressure-regulators . . . . . . 125 spindle
preventive maintenance diagrams . . . . . . . 260 lubrication. . . . . . . . . . . . . . . . . . . . . . . . 313
process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 spray ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
main cleaning. . . . . . . . . . . . . . . . . . . . . 190 stack light . . . . . . . . . . . . . . . . . . . . . . . 49, 124
production . . . . . . . . . . . . . . . . . . . . . . . 189 start-up preparations . . . . . . . . . . . . . . . . . . 184
rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . 189 steam . . . . . . . . . . . . . . . . . . . . . . . . . 112, 113
sequence . . . . . . . . . . . . . . . . . . . . . . . . 190 step 14 - 19 . . . . . . . . . . . . . . . . . . . . . . . . . 209
process water . . . . . . . . . . . . . . . . . . . 113, 114 step 20 - 26 . . . . . . . . . . . . . . . . . . . . . . . . . 215
product at filling machine . . . . . . . . . . . . . . . 98 supply valve central CIP system . . . . . . . . . . 62
product cooler/circuit steriliser. . . . . . . . . . . . 76 system holding time . . . . . . . . . . . . . . . . . . . 75
product pump . . . . . . . . . . . . . . . . . . . . . . . . 65
product supply unit . . . . . . . . . . . . . . . . . . . . 59
product tank . . . . . . . . . . . . . . . . . . . . . . . . . 59
production . . . . . . . . . . . . . . . . . . . . . . . . . . 189 T
checks . . . . . . . . . . . . . . . . . . . . . . . . . . 188 thermo well . . . . . . . . . . . . . . . . . . . . . . . . . 252
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 third party documentation . . . . . . . . . . . . . . . 26
start-up. . . . . . . . . . . . . . . . . . . . . . . . . . 185 three phase motors
start-up preparations . . . . . . . . . . . . . . . 184 lubrication. . . . . . . . . . . . . . . . . . . . . . . . 312
program steps . . . . . . . . . . . . . . . . . . . . . . . 230 transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
14 - 19 . . . . . . . . . . . . . . . . . . . . . . . . . . 209 transporting the machine. . . . . . . . . . . . . . . 104
20 - 26 . . . . . . . . . . . . . . . . . . . . . . . . . . 215 tubular flow steriliser . . . . . . . . . . . . . . . . . . . 67
main cleaning 2nd loop . . . . . . . . . . . . . 220 commissioning . . . . . . . . . . . . . . . . . . . . 105
protective clothing . . . . . . . . . . . . . . . . . . 47, 48
pt-100 resistance bulbs
maintenance . . . . . . . . . . . . . . . . . . . . . 279 U
pulsation damper UHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
maintenance . . . . . . . . . . . . . . . . . . . . . 297 ultra high temperature . . . . . . . . . . . . . . . . . . 31
pump block . . . . . . . . . . . . . . . . . . . . . . . . . . 81 utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
pump cylinder
maintenance . . . . . . . . . . . . . . . . . . . . . 288
pump seals
maintenance . . . . . . . . . . . . . . . . . . . . . 281
320 November 12, 2010

Index
V
V-belt transmissions . . . . . . . . . . . . . . . . . . .253
V-belts
maintenance . . . . . . . . . . . . . . . . . . . . . .305
ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . .111
W
water
specification . . . . . . . . . . . . . . . . . . . . . . .113
wearing ring . . . . . . . . . . . . . . . . . . . . . . . . . .93
welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
WinccFlex Pakket . . . . . . . . . . . . . . . . . . . . .127
version 1.0 321

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Sterideal User and Maintenance Manual

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Copyright:

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STERIDEAL

USER AND MAINTENANCE

Client: Centrale Laitière de Mahdia (CLM)

2 November 12, 2010

Stork Food & Dairy Systems B.V.,

4 November 12, 2010

About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5 Metering unit (module 03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6 November 12, 2010

4.4 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5 Operating interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

5.11 Maintenance menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

7 Cleaning In Place (CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

8 November 12, 2010

7.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

8.10 'De Haan' valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

10 November 12, 2010

8.23 Tensioning the V-belts (3HL-10) . . . . . . . . . . . . . . . . . . . . . . . . 305

12 November 12, 2010

Figure 0.1 Pipe connections Stork/Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 3.31 Control panel in cover of homogeniser type 3HL-10 . . . . . . . . . . . . . . . 92

14 November 12, 2010

Figure 5.32 Process temperature menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Figure 8.6 Filling back-pressure valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

16 November 12, 2010

Table 0.1 Code for instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 8.4 Maintenance table

18 November 12, 2010

ABOUT THIS MANUAL

Operators and service engineers must be adequately trained in the correct

20 November 12, 2010

Table 0.1 Code for instruments

Measuring function (the first letter)

P Pressure, followed by subscript

Transfer function (the following letters)

Table 0.1 Code for instruments (Continued)

n counting revolutions per minute (rpm)

A Alarming, detection of threshold, followed by subscript

Table 0.2 Example: instruments

SYMBOL CODE FUNCTION

LA93.02 Level sensor with a Low-level Alarm

UA93.02 Mechanical displacement sensor with Alarm

Table 0.3 Code for valves and motors

22 November 12, 2010

Table 0.3 Code for valves and motors (Continued)

Table 0.4 Example: valves and motors

SYMBOL CODE FUNCTION

TCV93.01 Temperature Control Valve

M93.01 Motor (in this case, a pump)

Table 0.5 Explanation of P&ID symbols (based on NEN 2195)

SYMBOL FUNCTION SYMBOL FUNCTION

Automatic valve, closed if not activated. Filter.

FB Automatic valve with feedback, open if Culinary steam filter.

Rupture disc. Filter.

Valve with a hole or half open/close CIP return filter.

Table 0.5 Explanation of P&ID symbols (based on NEN 2195) (Continued)

SYMBOL FUNCTION SYMBOL FUNCTION

Figure 0.1 Pipe connections Stork/Customer

24 November 12, 2010

Structure of this manual

Availability of this manual

26 November 12, 2010

How to get help