Om 81841 0103

OM
Operation Manual
TBA/21 050V
648570-0500
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WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.
Doc. No. OM-81841-0103

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Copyright © 2005 Tetra Pak Group
All rights reserved. No part of this document may be reproduced or copied in any form or by any means
without written permission from Tetra Pak Carton Ambient S.p.A..
and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
The content of this manual is in accordance with the design and construction of the machine or
equipment at the time of publishing. Tetra Pak reserves the right to introduce design modifications
without prior notice.
This document was produced by:
Tetra Pak Carton Ambient S.p.A.
Via Delfini, 1
41100 Modena
Italy
Additional copies can be ordered from Tetra Pak Parts or the nearest Tetra Pak office. When ordering
additional copies, always provide the document number. This can be found in the machine specification
document. It is also printed on the front cover and in the footer on each page of the manual.
Doc. No. OM-81841-0103
Issue 2005-06
This manual is valid for: i Introduction
Series No./ Machine No. Sign.

ii Safety Precautions
1 General Description
OM
Operation Manual
2
3
TPOP
Preparation
4 Start
TBA/21 050V
648570-0500 5 Checks
6 Supplies of Materials
7 Stop
8 Care and Cleaning

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9 Sterilisation Liquid
10 Technical Data
A list of all optional equipment, optional

kits, and rebuilding kits that this manual is
valid for is found on the next page.
Doc. No. OM-81841-0103
Issue 2005-06

Valid for:
PullTab Unit PT21 050V
648508-0500
Headspace by Injection HI
1296061-0200
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Update Log for Doc. No. OM-81841-0103
This table shows all changes made to this manual, such as kits installed
and pages added or removed.
Date Installed Kit Added Pages Removed Pages Signature

(Doc. No.)
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Date Installed Kit Added Pages Removed Pages Signature
(Doc. No.)
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i Introduction
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Doc. No. OM-81841-0103 i - 1 (14)

i Introduction
This chapter contains basic information about this manual

and related Tetra Pak equipment.
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i - 2 (14) Doc. No. OM-81841-0103

i Introduction Table of Contents
Manual Information . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Typographical Conventions . . . . . . . . . . . . . . . . . . i - 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Machine Introduction . . . . . . . . . . . . . . . . . . . . . . i - 8
Intended Use of the Equipment . . . . . . . . . . . . . . . i - 8
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
CE Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
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Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 10
Hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 11
Abbreviations and Terminology . . . . . . . . . . . . . i - 12
How to Use This Operation Manual . . . . . . . . . . i - 13

Purpose of the Operation Manual. . . . . . . . . . . . . i - 13
Operator Workflow. . . . . . . . . . . . . . . . . . . . . . . . . i - 14
A: General Information. . . . . . . . . . . . . . . . . . . . . . . . . i - 14
B: Machine Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 14
C: Supplies and Checks. . . . . . . . . . . . . . . . . . . . . . . . i - 14
Doc. No. OM-81841-0103 i - 3 (14)

i Introduction
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i - 4 (14) Doc. No. OM-81841-0103

i Introduction Manual Information
Manual Information
Tetra Pak recommends reading all delivered manuals carefully. Make sure
that the delivered manuals are available to personnel who operate or
maintain the equipment.
It is important to keep this manual for the lifetime of the equipment and to
pass the manual on to any subsequent holder or user.
Tetra Pak will not be held responsible for any damage to the equipment
caused by not following the instructions given in this manual.
Delivered Manuals
The manuals delivered with this equipment include
• Electrical Manual (EM)
This manual provides technicians with information about the
equipment’s electrical system
• Installation Manual (IM)
This manual provides technicians with information required to safely
install the equipment
• Maintenance Manual (MM)
This manual provides technicians with information on maintaining the
equipment
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• Operation Manual (OM)

This manual provides the operator with information on handling and
operating the equipment before, during, and after production
• Spare Parts Catalogue (SPC)
This manual provides the information necessary to order spare parts
from Tetra Pak.
Doc. No. OM-81841-0103 i - 5 (14)

Manual Information i Introduction
Page Layout
Every main page in a manual contains a header and a footer. The page header
contains the section name (1) and the chapter name (2). The page footer
contains the manual’s document number (3), and the page number (4). See
also the Page Numbering section.
1 2
3.4 Motor 3 Drive
(Cont'd)
a) Remove the banjo connections (2).
b) Loosen the cable to the micro switch.
c) Remove the cross bar (3) and separate the disconnection link. Lower the
link arm.
d) Remove the screws (4), apply the extractor, and pull out the shaft.
e) Remove the screws (5) and the washer.
f) Change the bearing.
g) Repeat steps g) and h) for the upper bearing.
4
2
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5
1 Banjo connection
2 Cross abr
3 Screw
4 Screw
(Cont'd)
Doc. No. MM-123457-0108 3 - 15 (102)
3 4
1 Section name
2 Chapter name
3 Document number
4 Page number
i - 6 (14) Doc. No. OM-81841-0103

i Introduction Manual Information
Page Numbering
A page number has three parts:
• chapter number (1)
• consecutive page number (2) within the chapter
• total number of pages (3) in the chapter.
4 - 11 (18)
1 Chapter number
2 Consecutive page number
1 2 3 3 Total number of pages
Typographical Conventions
Controls on the operator panel, emergency stop devices, and program steps
are printed in CAPITAL LETTERS.
Cross-references are underlined.
Symbols
The following symbols are used in illustrations:
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• A pointer arrow (1) indicates the position of an object.

• A zoom arrow (2) indicates that an object view is enlarged. The arrow
points towards the enlarged view of the object.
• A rotation movement arrow (3) indicates rotational movement of an
object. The arrow points in the direction of rotation.
• A straight movement arrow (4) indicates movement of an object.
The arrow points in the direction of movement.
1 2 3 4
1 Pointer arrow
2 Zoom arrow
3 Rotation movement arrow
4 Straight movement arrow
Doc. No. OM-81841-0103 i - 7 (14)

Machine Introduction i Introduction
Machine Introduction
Intended Use of the Equipment
The intended use of this Tetra Pak equipment is to pack liquid food products.
All other use is prohibited. Tetra Pak will not be held responsible for injury
or damage if the equipment is used for any other purpose.
Manufacturer
This Tetra Pak equipment has been manufactured by
Via Delfini, 1
41100 Modena
Italy
Service
If you encounter problems when operating this equipment, contact the
nearest Tetra Pak office.
Contact the Liaison with other inquiries, comments, or suggestions for
improvement regarding the equipment and its documentation.
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i - 8 (14) Doc. No. OM-81841-0103

i Introduction Identification
Identification
CE Classification
This equipment complies with the basic health and safety regulations of
the European Economic Area (EEA).
Machine Plate
The illustration below shows an example of the machine plate and its
location on the equipment. The machine plate carries data needed when
contacting Tetra Pak concerning this specific equipment.
Make sure that the equipment data in the front pages of this manual
corresponds to the machine plate data and the machine specification.
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Tetra Pak
2
Machine type 3
Drawing Spec.
Machine No. 4
Designed by
5 1 Machine type
2 Volume
Manufactured by 6
3 Drawing specifications
4 Machine serial number
Year of manufacture 5 Designed by
6 Manufacturer by
7 Year of manufacture
7 8 8 CE mark
Doc. No. OM-81841-0103 i - 9 (14)

Orientation i Introduction
Orientation
The illustration below shows the orientation of the equipment. This
orientation information will be used throughout this manual.
A D
B
A Front
B Right-hand side
C Left-hand side
D Back
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i - 10 (14) Doc. No. OM-81841-0103

i Introduction Hygiene
Hygiene
Avoid microbiological pollution of the packaging material:
• Always keep the doors to the filling room (area) closed. To prevent
contamination via air streams, never open a window when the equipment
is in production.
• Never clean the floors or the equipment in the filling room (area) when
the equipment is in production.
• Compressed air used for cleaning purposes is to be used only for
cleaning filters and should only be used outside of the filling room (area)
or in the final folder compartment of the filling machine.
• Prepare the splicing of the packaging material as late as possible.
• Disinfect your hands before touching anything that may come into
contact with the product. Use disinfectant code H. See the Technical
Data chapter.
• Keep your hands and gloves clean.
• Always wear some type of hair protection (cap or hairnet) and clean
clothes (preferably white).
• Do not wear a watch, ring, necklace, earrings, or any other exposed
jewellery.
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Doc. No. OM-81841-0103 i - 11 (14)

Abbreviations and Terminology i Introduction
Abbreviations and Terminology

Abbreviation/ Meaning Translation
Terminology
AN Analog -
ASSU Automatic Strip Splicing Unit -
ASU Automatic Splicing Unit -
B Base (package shape) -
CIP Cleaning In Place -
HI Headspace by Injection -
IH Induction Heating -
IS Inner Strip -
LH Left Hand -
LS Longitudinal Sealing -
min Minimum -
max Maximum -
OK Optional Kit -
OE Optional Equipment -
PE Polyethylene -
PT PullTab -
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RH Right Hand -
S Slim (package shape) -
SA Strip Applicator -
Sq Square (package shape) -
TBA Tetra Brik Aseptic -
TPA Tetra Prisma Aseptic -
TMCC Tetra Pak Multi-purpose Compact Controller -
TPOP Tetra Pak Operator Panel -
TS Transversal Sealing -
TPIH Tetra Pak Induction Heating -
i - 12 (14) Doc. No. OM-81841-0103

i Introduction How to Use This Operation Manual
How to Use This Operation Manual

Purpose of the Operation Manual
The Operation Manual provides the operator of this equipment with
information on the handling and operating of the equipment before, during,
and after production.
(Cont'd)
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Doc. No. OM-81841-0103 i - 13 (14)

How to Use This Operation Manual i Introduction
(Cont'd)
Operator Workflow
The content of this Operation Manual is divided into three main groups and
is structured to follow the operator’s work flow. The three main groups are
described below.
Safety General A: General Information

A Precautions Description These chapters provide important safety
Technical information, a description of the
TPOP
Data equipment describing the location of key
components and the information needed
to enable the operator to control and
maintain the equipment.
These chapters include:
B Preparation Preparation • Safety Precautions
After Weekly After Daily
Care Care • General Description
• TPOP
• Technical Data.
Weekly
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Start
Care B: Machine Cycle
These chapters provide the operator with
a sequence of work instructions that
Yes follow the order of the machine’s cycles.
Weekly No
Care Stop These chapters include:
needed?
• Preparation
• Start
• Conversion
Care &
Daily Care Cleaning • Stop
• Care and Cleaning.
C: Supplies and Checks

C These chapters describe what actions to
Supplies of
take when supplies for the machine have
Checks to be provided and the checks that must
materials
be performed to keep the machine in
production.
These chapters include:
• Supply of Materials
• Checks.
i - 14 (14) Doc. No. OM-81841-0103

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Doc. No. OM-81841-0103 ii - 1 (36)

Read the Safety Precautions
WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.
Definitions
Energy Isolating Device. A mechanical device that physically prevents
transmission or release of energy.
Power Supply Disconnector. The energy isolating device for the electrical
power supply to the equipment.
Lockout. The use of a device, such as a padlock, to make sure that an energy
isolating device, such as a power supply disconnector, cannot be operated.
Lockout Procedure. A procedure to put each necessary energy isolating
device in its safe position to prevent the energising of the equipment, such as
when a maintenance procedure should be carried out.
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ii - 2 (36) Doc. No. OM-81841-0103

ii Safety Precautions Table of Contents
Safety Messages Description. . . . . . . . . . . . . . . ii - 5
Personnel Requirements . . . . . . . . . . . . . . . . . . ii - 6
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Instructed Person. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Locations of Safety Signs . . . . . . . . . . . . . . . . . . . ii - 9
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 13
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 13
EMERGENCY STOP Push-Buttons . . . . . . . . . . . ii - 14
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 15
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 17
Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 17
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Personal Protection. . . . . . . . . . . . . . . . . . . . . . ii - 18
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 18
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . ii - 18
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . ii - 19
Hydrogen Peroxide (H2O2) . . . . . . . . . . . . . . . . . ii - 20
Emergency Procedures. . . . . . . . . . . . . . . . . . . . . ii - 20
Personal Protective Equipment . . . . . . . . . . . . . . ii - 21
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 22
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 23
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 24
Nitrogen (N2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 25
Handling and Storage of Nitrogen
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 25
Disposal of Nitrogen Gas . . . . . . . . . . . . . . . . . . . ii - 25
Cooling Media R134a . . . . . . . . . . . . . . . . . . . . . . ii - 26
Doc. No. OM-81841-0103 ii - 3 (36)

Table of Contents ii Safety Precautions
Handling and Storage of Cooling

Media R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 26
Disposal of Cooling Media R134a. . . . . . . . . . . . . ii - 26
Supply Systems . . . . . . . . . . . . . . . . . . . . . . . . . ii - 27
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . ii - 27
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 28
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 30
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 31
Steam Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 32
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 34
Equipment for Lifting and Moving Loads . . . . ii - 35
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ii - 4 (36) Doc. No. OM-81841-0103

ii Safety Precautions Safety Messages Description
Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.
This is the safety alert symbol. It is used to alert about potential personal
injury hazards. To avoid hazards, obey all safety messages that follow this
symbol.
The following safety alert symbols and signal words are used in this manual
to inform the user of hazards.
DANGER
Danger indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Warning indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
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CAUTION
Caution indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be
used to alert against unsafe practices.
CAUTION
Caution without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property
damage.
Doc. No. OM-81841-0103 ii - 5 (36)

Personnel Requirements ii Safety Precautions
Personnel Requirements
Note! Personnel includes all persons working on or near this
equipment.
Only skilled or instructed persons are allowed to work with this equipment.
Skilled Person
A skilled person must have relevant education and experience to enable him
or her to identify hazards, analyse risks, and avoid hazards which electricity,
machinery, chemicals, other energies, and supply systems on this equipment
can create.
Skilled persons must meet local regulations, such as certifications and
qualifications for working with electricity, mechanical systems, and so on.
Instructed Person
An instructed person must be adequately advised or supervised by a skilled
person. The skilled person enables the instructed person to identify hazards,
analyse risks, and avoid hazards which electricity, machinery, chemicals,
other energies, and supply systems on this equipment can create.
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ii - 6 (36) Doc. No. OM-81841-0103

ii Safety Precautions Safety Signs
Safety Signs
WARNING
Damaged or missing safety signs increase the risk of death or
serious injury.
Replace all missing or damaged safety signs immediately.
There are two types of safety sign

• ISO signs are used worldwide
• ANSI signs are used in the United States only
The table shows all safety signs that are located on this equipment.
Note! The position numbers (Pos.) in the table refer to the positions in
the illustration(s) in the Locations of Safety Signs section.
Pos. ISO sign ANSI sign

1
WARNING
Rotating blade
can crush and cut.
Do not operate with
guard removed.
Follow lockout procedure
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before maintenance.
Rotating blade can crush and cut.

Do not operate with guard removed.
Follow lockout procedure before maintenance.
2
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
before maintenance.
Hazardous voltage.
3
WARNING
Hazardous voltage could be
present with power supply
disconnector switched off.
Can shock, burn, or cause death.
Orange conductors supplied from
an external source. Follow lockout
procedure before maintenance.
Hazardous voltage could be present with power supply

disconnector switched off.
Orange conductors supplied from an external source.
Doc. No. OM-81841-0103 ii - 7 (36)

Safety Signs ii Safety Precautions
Pos. ISO sign ANSI sign

4
WARNING
Chemical burn hazard.
Wear personal protective
equipment.
Chemical burn hazard.

Wear personal protective equipment.
5
WARNING
Hot surface.
Do not touch.
before maintenance.
Hot surface.
Do not touch.
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ii - 8 (36) Doc. No. OM-81841-0103

Locations of Safety Signs

Note! Make sure that each safety sign is undamaged and in its
correct position after installation and maintenance. Replace all
missing or damaged safety signs immediately.
The illustration shows where the safety signs are located. The position
numbers refer to the table in the Safety Signs section.
Note! Sign (2a) belongs to machines equipped with Headspace by
Injection.
Note! Sign (2b) belongs to machines equipped with Last point DE.
2 2 2 2
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2a
2b
(Cont'd)
Doc. No. OM-81841-0103 ii - 9 (36)

(Cont'd)
2 5
2
2
2
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2
2
2
2
2
2
(Cont'd)
ii - 10 (36) Doc. No. OM-81841-0103

(Cont'd)
2 2
5
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(Cont'd)
Doc. No. OM-81841-0103 ii - 11 (36)

(Cont'd)
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5
ii - 12 (36) Doc. No. OM-81841-0103

ii Safety Precautions Safety Devices
Safety Devices
WARNING
Unshielded hazards.
Never inch or run this equipment if any safety device is inoperative.
Change inoperative components of the safety system immediately.
WARNING
Hazardous Voltage.
Activating a safety device, such as pressing an EMERGENCY STOP
push-button or opening a door, does not disconnect the power supply
from this equipment.
Emergency Stop
Emergency stop devices are used to stop this equipment immediately in an
emergency. Learn the positions of all emergency stop devices and how to use
them.
Instructions for a normal production stop are included in the Stop chapter of
the Operation Manual.
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Doc. No. OM-81841-0103 ii - 13 (36)

Safety Devices ii Safety Precautions
EMERGENCY STOP Push-Buttons

Push one of the EMERGENCY STOP push-buttons to stop this equipment
immediately.
The illustration shows an EMERGENCY STOP push-button. The location of
each EMERGENCY STOP push-button is shown by an arrow.
Note! The EMERGENCY STOP push-buttons for the filling machine
control also the PullTab unit.
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LH side
RH side
ii - 14 (36) Doc. No. OM-81841-0103

Safeguards
WARNING
Moving machinery.
Never defeat or bypass the interlocking devices.
All movable guards, such as doors and covers, leading to hazardous areas are
fitted with interlocking devices, usually electric safety switches. These
devices are part of the safety system and must never be defeated, bypassed,
or otherwise made inoperative.
CAUTION
Burn hazard.
Parts of this equipment protected by safeguards may be thermally hot
after operation.
After installation and maintenance, and before this equipment is inched or

run, check that all safeguards are in place and that they operate correctly.
CAUTION
Equipment damage.
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Never stop this equipment by opening a movable guard.
The location of each movable guard on the filling machine is shown by an

arrow.
LH side RH side
(Cont'd)
Doc. No. OM-81841-0103 ii - 15 (36)

Safety Devices ii Safety Precautions
(Cont'd)
The location of each movable guard on the PullTab unit is shown by an
arrow.
LH side RH side
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ii - 16 (36) Doc. No. OM-81841-0103

Warning Lamp
A warning lamp is a column of warning lights:
• A red light (1) indicates a hazardous condition. This is an emergency
situation that requires immediate action.
• A yellow light (2) indicates an abnormal condition. This is an impending
critical condition calling for action by the operator.
• A blue light (3) indicates that operator action is required.
3
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1 Red light
2 Yellow light
3 Blue light
A warning light flashes when operator action is required. The light stops
flashing and remains lit when the alarm is acknowledged. After the fault is
corrected or the operator takes the appropriate action, the warning light goes
off.
Audible Alarm
The audible alarm produces a warning signal every time this equipment is
about to start. The warning signal sounds for approximately three seconds
prior to starting to alert personnel.
Doc. No. OM-81841-0103 ii - 17 (36)

Personal Protection ii Safety Precautions
Personal Protection
This section applies to all personnel at all times when this equipment is in
operation. For special personal protection required when handling hazardous
materials, see the Hazardous Materials section.
Noise Hazard
CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.
Entanglement Hazard
WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this
equipment. Long hair may not be loose.
TechPub_2614345_0104 - 81841013sp.fm
ii - 18 (36) Doc. No. OM-81841-0103

ii Safety Precautions Hazardous Materials
Hazardous Materials
WARNING
Contact with chemicals can cause death, serious injury, and
illness.
Always follow the chemical manufacturer’s instructions when handling
chemicals.
Make sure that

• the showers work
• an eyewash device, movable or wall-mounted, is available and
operational
• additional washing facilities are nearby
Note! Learn the locations of all washing facilities in order to act

immediately in case of an accident.
TechPub_2614345_0104 - 81841013sp.fm
Doc. No. OM-81841-0103 ii - 19 (36)

Hazardous Materials ii Safety Precautions
Hydrogen Peroxide (H2O2)
WARNING
Corrosive chemical.
Wear personal protective equipment.
In both liquid and gas states, hydrogen peroxide may cause irritation or
damage if it comes into contact with skin, mucous membranes, eyes, or
clothes. Call for medical attention immediately if there is an accident.
Liquid hydrogen peroxide in concentrations of less than 1% is generally
considered harmless to humans.
Consult the instructions on the label of the tank or container.
Emergency Procedures
If there is an accident involving hydrogen peroxide, rinse the affected area as
soon as possible with large amounts of water.
If hydrogen peroxide is swallowed
• do not attempt to cause vomiting
• drink large amounts of lukewarm water to dilute the peroxide
TechPub_2614345_0104 - 81841013sp.fm
• call for medical attention immediately
If splashes or vapour from hydrogen peroxide come in contact with the eyes
• wash the eyes thoroughly with lukewarm water for 15 minutes (keep
eyelids wide apart)
• call for medical attention immediately
If hydrogen peroxide comes into contact with skin or clothes

• rinse immediately with plenty of water
• call for medical attention immediately if skin burns appear
• thoroughly wash the clothes before wearing them again
If irritation or pain is experienced due to having inhaled hydrogen peroxide

vapour
• leave the affected area and get some fresh air
• call for medical attention if the symptoms get worse
ii - 20 (36) Doc. No. OM-81841-0103

Personal Protective Equipment

The personal protective equipment for hydrogen peroxide is
• safety goggles (TP No 90303-11)
• protective gloves made of neoprene (TP No.90303-12)
• apron (TP No. 90303-13)
• shoes made of PVC, PE plastic, or rubber
TechPub_2614345_0104 - 81841013sp.fm
Doc. No. OM-81841-0103 ii - 21 (36)

Handling
WARNING
Sudden and violent chemical reaction.
Avoid any contamination of hydrogen peroxide.
Hydrogen peroxide reacts suddenly and violently with many compounds or

if it is contaminated. The reaction is a violent decomposition liberating
oxygen and heat, with a big increase in volume due to the oxygen produced
by the peroxide decomposition.
Never pour surplus hydrogen peroxide back into the original container if it
contains fresh hydrogen peroxide. There is a risk of explosion when
hydrogen peroxide is in a closed container.
Ensure that equipment used for handling and diluting hydrogen peroxide is
clean before it comes in contact with hydrogen peroxide. Pumps or other
equipment used for handling hydrogen peroxide must be used for this
purpose only and must be manufactured from appropriate materials, such as
stainless steel 316 L, glass, polyethylene, or teflon. After use, make sure that
all peroxide residue is rinsed away.
If hydrogen peroxide is spilled, dilute it with large amounts of water and
TechPub_2614345_0104 - 81841013sp.fm
flush it into a drain.
WARNING
Self-ignition.
Never wipe up hydrogen peroxide with materials such as rags or
paper as these may self-ignite several hours after contact.
If there is a fire, spray with large quantities of water.
ii - 22 (36) Doc. No. OM-81841-0103

Storage
DANGER
Containers will explode if not properly ventilated.
Keep the container upright and fitted with its proper ventilation cap. If
there is a fire, cool all containers by spraying them with large
quantities of water.
Hydrogen peroxide decomposes much faster with increasing temperature.

There is a risk of explosion at high temperatures, since the ventilation cap
cannot release the gases produced quickly enough.
Hydrogen peroxide must be stored in the original container delivered by the
supplier. Keep the container upright and fitted with its proper ventilation cap,
which allows oxygen to escape. Otherwise, there can be an explosion if
decomposition of the peroxide occurs violently.
TechPub_2614345_0104 - 81841013sp.fm
Make sure that the container is always properly closed.

(Cont'd)
Doc. No. OM-81841-0103 ii - 23 (36)

(Cont'd)
Commercial food-grade hydrogen peroxide has been stabilized to inhibit the
catalytic decomposition effects of metals and other impurities, but it can
decompose into oxygen and water if it is exposed to heat or contaminated.
Make sure that the area used for storage of hydrogen peroxide is
• cool, clean, and well ventilated
• shielded from direct sunlight
• kept free from combustible materials
Disposal
Hydrogen peroxide should be sent to an approved facility for destruction.
Some countries allow it to be diluted with water to a concentration of less
than 1% and poured into the drain.
TechPub_2614345_0104 - 81841013sp.fm
ii - 24 (36) Doc. No. OM-81841-0103

Nitrogen (N2)
WARNING
High pressure gas.
Nitrogen gas in high concentration can cause rapid suffocation. Make
sure that the areas for storing and using this gas are adequately
ventilated.
WARNING
Extremely cold high pressure gas.
Rapidly expanding nitrogen gas can cause frostbite injuries. Always
wear personal protective equipment.
Nitrogen gas in high concentrations can cause an oxygen deficient
environment. Rapidly expanding nitrogen gas can cause frostbite injuries.
In the case of an accidental release of this gas:
• leave the affected area immediately
• never attempt to rescue victims of exposure to this gas without the
TechPub_2614345_0104 - 81841013sp.fm
proper personal protective equipment

• remove victims to fresh air and if necessary administer expired air
resuscitation and/or cardiopulmonary resuscitation. Call for immediate
medical attention
• in case of contact with eyes or skin, soak the exposed areas with luke
warm water, not hot or cold. Call for immediate medical attention.
• allow the gas to dissipate, use auxiliary ventilation if available.
Handling and Storage of Nitrogen Gas

When handling nitrogen gas cylinders, make sure that:
• the areas used for the storage and handling of this gas are adequately
ventilated (min. 19.5% oxygen)
• the cylinders are transported with the valves closed and with the valve
protection caps securely in place
• the gas cylinders are connected only to connections marked for this gas
• the cylinder valves are opened slowly
Disposal of Nitrogen Gas

When returning nitrogen gas cylinders, make sure that:
• the cylinder valves are closed and the valve protection caps are securely
in place
• there is still some gas in the cylinder.
Doc. No. OM-81841-0103 ii - 25 (36)

Cooling Media R134a

WARNING
Refrigerant gas.
High concentration of cooling media R134a vapour can cause
dizziness, headache, confusion and unconsciousness. In liquid form
R134a can cause frostbite injuries on contact with skin. Always wear
personal protective equipment.
Inhaling large quantities of cooling media R134a vapour can cause dizziness,
headache, confusion and unconsciousness. In liquid form cooling media
R134a can cause frostbite injuries on contact with skin.
In the case of an accidental release of this refrigerant:
• leave the affected area immediately
• remove victims to fresh air and if necessary administer expired air
resuscitation and/or cardiopulmonary resuscitation. Call for immediate
medical attention
• in case of contact with eyes or skin, soak the exposed areas with luke
warm water, not hot or cold. Call for immediate medical attention
TechPub_2614345_0104 - 81841013sp.fm
• allow the vapour to dissipate, use auxiliary ventilation if available.
Handling and Storage of Cooling Media R134a

When handling cooling media R134a, make sure that:
• the cylinders are stored in a cool dry place away from direct sunlight or
sources of heat
• the areas used for the storage and handling of this refrigerant are
adequately ventilated
• the cylinders are transported carefully
• the cylinder valves are opened slowly.
Disposal of Cooling Media R134a

Cooling media R134a should whenever possible be reprocessed or recycled.
Contact the manufacturer or supplier for information on authorised
refrigerant reclamation and recycling programs.
ii - 26 (36) Doc. No. OM-81841-0103

ii Safety Precautions Supply Systems
Supply Systems
Electrical Cabinet
DANGER
Hazardous voltage.
The power supply disconnector must be switched off and secured
with a lock before maintenance inside the electrical cabinet.
Note! The key to the lock must be removed by the technician and
retained in his/her possession until all work is completed.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with lock must be locked.
The location of each electrical cabinet on the filling machine and on the
PullTab unit is shown by an arrow.
TechPub_2614345_0104 - 81841013sp.fm
LH side
TetraPak
LH side
RH side
Doc. No. OM-81841-0103 ii - 27 (36)

Supply Systems ii Safety Precautions
Socket Outlet
WARNING
Hazardous voltage.
Read the Maintenance Manual before using this socket outlet.
The illustrations show the socket outlet (1) and the residual current
device (2). Their locations in the electrical cabinet (3) of the filling machine
are shown by arrows.
2
1
TechPub_2614345_0104 - 81841013sp.fm
3
1 Socket outlet
2 Residual current device F029
3 Electrical cabinet
(Cont'd)
ii - 28 (36) Doc. No. OM-81841-0103

(Cont'd)
The illustrations show the socket outlet (1) and the residual current
device (2). Their locations in the electrical cabinet (3) of the PullTab unit are
shown by arrows.
2
1
3
TechPub_2614345_0104 - 81841013sp.fm
1 Socket outlet
2 Residual current device F029
Doc. No. OM-81841-0103 ii - 29 (36)

Power Supply
DANGER
Hazardous voltage and moving machinery.
The power supply disconnector must be switched off and secured
with a lock before any maintenance.
Certain maintenance procedures may require power supply systems to be on.

These exceptions are clearly stated in the Maintenance Manual.
The illustration shows the power supply disconnector. The arrow shows its
location on this equipment.
‘
TechPub_2614345_0104 - 81841013sp.fm
ii - 30 (36) Doc. No. OM-81841-0103

Air Supply
WARNING
Compressed air and moving machinery.
Close the main air valve and secure it with a lock before any
maintenance.
Certain maintenance procedures may require air supply systems to be on.

The illustrations show the main air valve (1) and the lock (2). Their locations
are shown by arrows.
1
2
TechPub_2614345_0104 - 81841013sp.fm
1 Main air valve

2 Padlock
Doc. No. OM-81841-0103 ii - 31 (36)

Steam Supply
WARNING
Hot steam can cause scalds.
Pressurized steam can be discharged unexpectedly.
Close the steam supply valve and secure it with a lock, depressurize
and vent all steam safely before any maintenance on parts with
steam, such as pipes and valves.
Certain maintenance procedures may require steam supply systems to be on.

The illustration shows the steam supply valve (1) and its location.
TechPub_2614345_0104 - 81841013sp.fm
1
1 Steam supply valve
(Cont'd)
ii - 32 (36) Doc. No. OM-81841-0103

(Cont'd)
WARNING
Hot parts can cause severe burns.
Pipes, valves, and other parts containing steam can be extremely hot.
Do not touch hot parts.
Arrows in the illustration below shows hot parts of this equipment.

TechPub_2614345_0104 - 81841013sp.fm
Doc. No. OM-81841-0103 ii - 33 (36)

Water Supply
WARNING
Water under pressure.
Close the water supply valves before any maintenance.
Certain maintenance procedures may require water supply systems to be on.

The illustration shows the water supply valves (1) and their locations.
Closed valve Open valve
TechPub_2614345_0104 - 81841013sp.fm
1
1 Water supply valve
ii - 34 (36) Doc. No. OM-81841-0103

Equipment for Lifting and Moving
ii Safety Precautions Loads
Equipment for Lifting and Moving Loads

WARNING
Risk of crushing injury.
Make sure that the capacity of the lifting equipment is adequate and
that the equipment itself is in proper working order.
If lifting tackle must be joined to make up the necessary lengths, make sure
that the joints are secure and have the same lifting capacity as the rest of the
lifting tackle.
Always engage safety clips fitted to lifting hooks to prevent the lifting tackle
from slipping off.
Use ropes or poles to steady and manoeuvre suspended loads. Do not use
hands or feet.
Make sure that the route and destination are free from obstacles before
moving a suspended load. It must always be possible to quickly and safely
lower the load to the floor in an emergency.
When depositing loads, keep lifting tackle in place until the stability of the
load has been substantiated.
TechPub_2614345_0104 - 81841013sp.fm
Doc. No. OM-81841-0103 ii - 35 (36)

Equipment for Lifting and Moving
Loads ii Safety Precautions
TechPub_2614345_0104 - 81841013sp.fm
ii - 36 (36) Doc. No. OM-81841-0103

TechPub_2614345_0104 - TB048413en.fm
Doc. No. OM-81841-0103 1 - 1 (20)

This chapter describes the main parts of the machine and

the terminology.
Note! To ensure maximum safety, always read this section and the
Safety Precautions carefully before doing any work on the equipment
or making any adjustments.
TechPub_2614345_0104 - TB048413en.fm
1 - 2 (20) Doc. No. OM-81841-0103

1 General Description Table of Contents
Main Groups of the Equipment . . . . . . . . . . . . . 1 - 5

Filling Machine, LH Side . . . . . . . . . . . . . . . . . . . . 1 - 5
Service Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Valve Panel, Machine Body . . . . . . . . . . . . . . . . . . 1 - 7
Valve Panel, Superstructure . . . . . . . . . . . . . . . . . 1 - 7
PullTab Unit, LH Side . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Filling Machine, RH Side . . . . . . . . . . . . . . . . . . . 1 - 10
PullTab Unit, RH Side. . . . . . . . . . . . . . . . . . . . . . 1 - 11
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
HI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Machine Symbols . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
TechPub_2614345_0104 - TB048413en.fm
Valve Panels, Symbols . . . . . . . . . . . . . . . . . . . . 1 - 14

Service Unit, Symbols . . . . . . . . . . . . . . . . . . . . . 1 - 15
Electrical Cabinet, Symbols . . . . . . . . . . . . . . . . 1 - 16
Equipment, Symbols . . . . . . . . . . . . . . . . . . . . . . 1 - 16
ASU, Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
PullTab Unit, Symbols . . . . . . . . . . . . . . . . . . . . . 1 - 17
Packaging Material Web Path. . . . . . . . . . . . . . 1 - 18
Alarm Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
Doc. No. OM-81841-0103 1 - 3 (20)

TechPub_2614345_0104 - TB048413en.fm
1 - 4 (20) Doc. No. OM-81841-0103

1 General Description Main Groups of the Equipment
Main Groups of the Equipment

Filling Machine, LH Side
1 2 3 4 5 6 7 8 9
10
11
11
12
8
TechPub_2614345_0104 - TB048413en.fm
23
8
22
21 20 19 18 17 16 8 15 14 13
1 Electrical cabinet 13 Final folder

2 Valve panel, superstructure 14 Jaw system
3 Lower, peroxide bath hatch 15 Volume adjustment
4 Tab folding device 16 Tube flushing
5 Upper, aseptic chamber door 17 Central lubrication container
6 HI Nozzle 18 Detergent container
7 Knob, tube adjustment 19 Valve panel, machine body
8 EMERGENCY STOP button 20 PullTab unit
9 Lower, aseptic chamber door 21 Packaging material carriage
10 Service unit 22 Material holder
11 Warning beacon 23 MATERIAL LOCKING button
12 Control panel
Doc. No. OM-81841-0103 1 - 5 (20)

Main Groups of the Equipment 1 General Description
Service Unit
1 2 3 4 5
6 7 8 9 10 11 12
TechPub_2614345_0104 - TB048413en.fm
16 15 14 13
1 Cooling water flowmeter, jaw system, TS right 9 Water filter
2 Cooling water flowmeter, jaw system, TS left 10 Air pressure gauge
3 Cooling water flowmeter, final folder 11 Air supply switch
4 Cooling water flowmeter, hydraulic system 12 Mains power switch
and LS transformer 13 External cleaning pressure gauge
5 De-ionizing circuit flowmeter 14 External cleaning handle
6 Cooling water pressure gauge 15 Mains water supply valve
7 Foaming pressure regulator external cleaning 16 Cooling water refilling valve
8 Mains water pressure gauge
1 - 6 (20) Doc. No. OM-81841-0103

Valve Panel, Machine Body
1
2
3
4
5 7
6
1 Air pressure, hold down device

2 Air pressure, flap blowing
3 Air pressure, design correction photocells
4 Overpressure, final folder
5 Air pressure, flap heating top left and right
6 Air pressure, flap heating bottom left and right
7 Air valve
TechPub_2614345_0104 - TB048413en.fm
Valve Panel, Superstructure
1
2
1 Air pressure, feed packaging material
3 2 Air pressure, calender rollers
4 3 Air pressure, peroxide spray
4 Tab folder
Doc. No. OM-81841-0103 1 - 7 (20)

PullTab Unit, LH Side
1 2 3 4 5 6
12
13
14
TechPub_2614345_0104 - TB048413en.fm
15
8
10
11
1 Upper photocell, infeed 10 Upper photocell, outfeed

2 Infeed unit 11 Lower photocell, outfeed
3 Bypass roller 12 Hour counter
4 Tension unit 13 Service key
5 Bypass roller 14 Selector switch PullTab functions
6 Bypass sensor - left pos. = PREPARATION
7 Patch magazine - straight pos. = PRODUCTION WITHOUT PT
- right pos. = PRODUCTION WITH PT
8 Roller assembly
15 SINGLE CYCLE button
9 Drive unit
1 - 8 (20) Doc. No. OM-81841-0103

Electrical Cabinet
5 9
4 8
7 1
6 2
3
TechPub_2614345_0104 - TB048413en.fm
1 Hour counter
2 Package counter
3 TPOP PC
4 Process recorder Honeywell
5 CIP recorder Honeywell
6 Cleaning steam barrier space, key switch
7 Service switch
8 Process recorder JUMO
9 CIP recorder JUMO
Doc. No. OM-81841-0103 1 - 9 (20)

Filling Machine, RH Side
1 2 3 4 5 6 2
7
8
TechPub_2614345_0104 - TB048413en.fm
3
15 2 14 13 12 11 10 9
1 Steam valve 9 Strip applicator

2 EMERGENCY STOP button 10 ASSU
3 SHORT STOP button 11 Rope, magazine roller
4 Top, aseptic chamber door 12 PullTab unit
5 Upper, peroxide bath hatch 13 Hydrogen peroxide tank and dilution tank
6 Top cover 14 Hydrogen peroxide container
7 MANUAL WEB SPLICE button 15 HI control panel
8 MANUAL STRIP SPLICE button
1 - 10 (20) Doc. No. OM-81841-0103

PullTab Unit, RH Side

1 11
2 12
3 13
4 14
5 15
6 16
7 17
TechPub_2614345_0104 - TB048413en.fm
9 18
10
19
1 Hole punch unit 11 Cap blowing

2 Bar code reader 12 Waste blowing
3 IS patch station 13 Tension unit, pressure roller
4 Missing patch detector 14 Drive unit, pressure roller
5 Reseal station 15 IS patch counter jaw
6 Tab station 16 Reseal counter jaw
7 IS strip magazine 17 Tab counter jaw
8 Missing tab detector 18 Vacuum, strip suction
9 Tab strip magazine 19 Main air valve
10 Waste box
Doc. No. OM-81841-0103 1 - 11 (20)

Control Panel
12
11
10
1 9
2 8
TechPub_2614345_0104 - TB048413en.fm
3 4 5 6 7
1 TPOP RESET 9 JAW SYSTEM INCHING

- flashing light = restart the TPOP flashes when inching is possible
- constant light = warm-up mode 10 FINAL FOLDER INCHING
- general software reset and alarm reset flashes when inching is possible
2 LAMP TEST 11 SELECTOR SWITCH
3 EMERGENCY STOP - RH position: high speed inching, RH jaw pair
4 MANUAL FLUSHING opened in Short Stop
final folder and jaw system - LH position: low speed inching, LH jaw pair
5 PACKAGE EJECTOR opened in Short Stop.
6 SHORT STOP 12 TPOP DISPLAY (see chapter 2 TPOP)
7 PROGRAM DOWN
8 PROGRAM UP
1 - 12 (20) Doc. No. OM-81841-0103

HI Control Panel
4 5 6 7
3 AIR IN
NITROGEN IN
AIR/NITROGEN OUT
2
1
1 Out nitrogen
2 In nitrogen
TechPub_2614345_0104 - TB048413en.fm
3 In air
4 Proportional valve
5 Flow meter
6 Absolute filter
7 Filter/separator
8 Pressure switch
8 9 Solenoid valve
Doc. No. OM-81841-0103 1 - 13 (20)

Machine Symbols 1 General Description
Machine Symbols
Valve Panels, Symbols
Pendulum roller Calender rollers
Air pressure, peroxide Flap sealing top left and

spray right
Flap sealing bottom left Flap blowing

and right
Overpressure final folder Air pressure, design

correction photocells
TechPub_2614345_0104 - TB048413en.fm
Hold down device Tab folder
1 - 14 (20) Doc. No. OM-81841-0103

1 General Description Machine Symbols
Service Unit, Symbols

Cold water (blue) Foaming
Cooling water Warm water (red)
Air De-ionizing circuit
Cold water flow, TS left Cold water flow, TS right

TechPub_2614345_0104 - TB048413en.fm
Cold water flow, final folder Cold water flow,

hydraulics/ IH- LS
transformer
Main switch
(on/off)
1 0
Doc. No. OM-81841-0103 1 - 15 (20)

Machine Symbols 1 General Description
Electrical Cabinet, Symbols

Service switch Cleaning steam barrier
A space
C
B
Hour counter Package counter
Equipment, Symbols
Hydraulic draining Hydraulic emptying
ASU, Symbols
TechPub_2614345_0104 - TB048413en.fm
Short stop Manual web splice
Manual strip splice Material holder
1 - 16 (20) Doc. No. OM-81841-0103

1 General Description Machine Symbols
PullTab Unit, Symbols

Cap blowing Tension roller, pressure
tension
Drive unit, pressure roller IS patch counter jaw
Outer patch counter jaw Tab counter jaw
Waste blowing Air

TechPub_2614345_0104 - TB048413en.fm
Hour counter Single cycle
Service key Selector switch

- Preparation
- Production without PT
- Production with PT
Doc. No. OM-81841-0103 1 - 17 (20)

Packaging Material Web Path 1 General Description
Packaging Material Web Path

9
10
8
11
12
4
5
3
6 13
2 7 14
15
TechPub_2614345_0104 - TB048413en.fm
16
17
18
20
19
1 Packaging material reel 11 Edge roller

2 Material holder 12 Upper tube support
3 Movable splicing device 13 Filling pipe
4 Inner frame 14 Upper forming ring
5 Drive unit front 15 LS inductor
6 Rope magazine roller 16 Lower forming ring
7 Packaging material by-pass position 17 Outlet rubber seal, aseptic chamber
8 Tab folding device 18 Photocells, design correction
9 Crankhandle peroxide bath 19 Material lock
10 Tunnel 20 PullTab applicators
1 - 18 (20) Doc. No. OM-81841-0103

1 General Description Alarm Beacon
Alarm Beacon
The warning beacon lights up when a machine fault occurs.
When a machine fault occurs, the

warning beacons (1) light up.
2
The warning beacon (1) colours are:
• RED lamp (2) On means an
3 Emergency Stop or an open door,
therefore hazardous condition
4 • YELLOW lamp (3) On means
machine alarms for any reason other
1 than Emergency Stop
• BLUE lamp (4) On requires an
1 operators action.
The lamp colours are prioritised from the

top to the bottom.
In case of multiple alarms occurring
simultaneously, the alarm with the
highest priority will override the others.
TechPub_2614345_0104 - TB048413en.fm
When the highest level alarm goes Off,

the next level alarm appears.
When a machine alarm is present the
red (2) and yellow lamp (3) continue to
1 Warning beacon flash until the operator acknowledges the
2 Red lamp alarm.
3 Yellow lamp When an alarm persists and the
4 Blue lamp beacon (3) is acknowledged, the light
becomes fixed. When the alarm stops, the
related alarm beacon (3) goes Off.
If the blue lamp (4) is On, it will be
switched Off only when the cause of the
alarm is solved.
By pressing the ALARM RESET button
the signal lamp on the control panel
changes from flashing to fixed light.
Doc. No. OM-81841-0103 1 - 19 (20)

Alarm Beacon 1 General Description
TechPub_2614345_0104 - TB048413en.fm
1 - 20 (20) Doc. No. OM-81841-0103

2 TPOP
TechPub_2614345_0104 - TB058413en.fm
Doc. No. OM-81841-0103 2 - 1 (60)

2 TPOP
This chapter describes how to navigate through the TPOP,

what to do when alarms occur and how to make machine
settings.
Note! This chapter contains instructions for making machine settings.
These settings must only be performed by a TPOP trained operator.
TechPub_2614345_0104 - TB058413en.fm
2 - 2 (60) Doc. No. OM-81841-0103

2 TPOP Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
TPOP Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Selection of an Event Cause . . . . . . . . . . . . . . . . . . . . .2 - 9
Common Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10
Common Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Changing the Values . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
System Communication Fault Reset . . . . . . . . . . . . .2 - 12
Production Program Step . . . . . . . . . . . . . . . . . 2 - 13

Before and During Production . . . . . . . . . . . . . . . . . .2 - 13
TechPub_2614345_0104 - TB058413en.fm
After Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 13
Cleaning Program Step . . . . . . . . . . . . . . . . . . . 2 - 14

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 14
Cleaning CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
External Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
System Settings. . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Language Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 17
Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 18
Production Shift Setting. . . . . . . . . . . . . . . . . . . . . . . .2 - 19
Alarm System. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20
Alarm Group Buttons . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 20
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 21
Alarm Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 21
Doc. No. OM-81841-0103 2 - 3 (60)

Table of Contents 2 TPOP
Alarm Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22
Collect System . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 23
Conditions for a Manually Registered Event. . . . . . . 2 - 23
PREPARATION Phase . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24
PRODUCTION Phase . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24
After PRODUCTION Phase . . . . . . . . . . . . . . . . . . . . . 2 - 24
Planned Maintenance Phase. . . . . . . . . . . . . . . . . . . . 2 - 24
Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24
Delay in the Preparation Phase . . . . . . . . . . . . . . . . . 2 - 25
Jump to Step Zero during the Preparation

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 27
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Manual Recording of the Production Stop
Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 28
Check or Change the Production Stop Causes . . . . 2 - 31
Jump to Step Zero during the Production

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 33
Jump to Step Venting during the Production

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 33
Record Customised Events . . . . . . . . . . . . . . . . . . . . 2 - 34
Record Package Waste for a Quality Check . . . . . . . 2 - 36
Record Maintenance Time . . . . . . . . . . . . . . . . . . . . . 2 - 38
Recorded Data Copying . . . . . . . . . . . . . . . . . . . . . . . 2 - 39
Manoeuvre System . . . . . . . . . . . . . . . . . . . . . . 2 - 40
Manoeuvre System Buttons . . . . . . . . . . . . . . . . . . . . 2 - 40
Filling System Window . . . . . . . . . . . . . . . . . . . . . . . . 2 - 41
Peroxide Concentration Meter . . . . . . . . . . . . . . . . . . 2 - 43
2 - 4 (60) Doc. No. OM-81841-0103

2 TPOP Table of Contents
Overview Temperature . . . . . . . . . . . . . . . . . . . . . . . . .2 - 45
PullTab Overview Temperature . . . . . . . . . . . . . . . . . .2 - 47
TS IH Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 48
LS IH Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 49
SA IH Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 50
Package Counter Window . . . . . . . . . . . . . . . . . . . . . .2 - 51
Waste Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 52
Hydrogen peroxide bath waste setting. . . . . . . . . . . .2 - 53
Package Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 53
Tight Tube Function . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 54
Packages per Tray Setting . . . . . . . . . . . . . . . . . . . . . .2 - 54

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Production Overview . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 55
Parameter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 56
Production Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 58
Line Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 59
Doc. No. OM-81841-0103 2 - 5 (60)

2 TPOP
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2 - 6 (60) Doc. No. OM-81841-0103

2 TPOP Description
Description
The TPOP display is touch-sensitive. The buttons allow the operator to
communicate with the system.
1 2 3 4 5 TPOP Main Window

The TPOP main window displays the
buttons and icons used identify the status
Alarms Drive Unit
of the machine and to access the different
sections of the filling machine control
system.
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11 10 9 8 7 6
1 Headspace by Injection status

2 Current time
3 Alarm group (if any activated)
4 Program step icon
5 Program step name
6 EXTERNAL CLEANING button
7 CIP button
8 MANOEUVRE SYSTEM button
9 SYSTEM SETTING button
10 ALARM SYSTEM button
11 COLLECT SYSTEM button
Doc. No. OM-81841-0103 2 - 7 (60)

Navigation 2 TPOP
Navigation
This section describes how to navigate into the TPOP windows.
Touch the OK button to record the data

OK
entry and close the active window.
Touch the CANCEL button to close the

active window without recording any
Cancel data.
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If the entry number is incorrect, touch the
Clear
CLEAR button and enter the correct
number.
2 - 8 (60) Doc. No. OM-81841-0103

2 TPOP Navigation
Touch the EXIT button to close the active

window.
PLANT
PROCESSING EQUIPMENT Selection of an Event Cause
FILLING MACHINE
CONVEYOR / TP DISTRIBUTION EQ When a selection of a specific cause is
MACHINE IDLE TIME
PLANNED TIME needed, it is possible to select the cause
with different levels.
The first window gives the list of the
main level causes.
Detail
To find the specific cause, use the arrows
to select its main group, and then touch
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the DETAIL button. Repeat until the

specific cause is found.
General
To move back one level, touch the
GENERAL button.
SAFETY Note! Specific cause selection can
DRIVE UNIT / JAW SYSTEM
FINAL FOLDER be also made by pressing the alarm
FILLING
SERVICE UNIT group button and selecting the alarm
STERILE SYSTEM
PEROXIDE SYSTEM symbol.
ASU
SUPERSTRUCTURE
CIP/EXTERNAL CLEANING
SA/MAGAZINE UNIT
Detail
General
Jaw system, hold down device

Left jaw overload
Right jaw overload
Left jaw sealing
Right jaw sealing
Main motor servo system fault
Jaw system, angle encoder
Left jaw pressure, hydraulic valve
Right jaw pressure, hydraulic valve
No volume values
Tube support roller position
Doc. No. OM-81841-0103 2 - 9 (60)

Navigation 2 TPOP
Common Buttons
• Factory - touch and hold for at least
three seconds to reset values to
Factory factory settings. The button changes
to white to indicate that the value has
been reset.
Note! Some settings have more than
one factory value (such as the setting
Inductor for the tab sealing pad heater that
changes with the hole type). For
these settings, the factory button only
provides an approximate value.
Temperature monitor
or • Inductor - touch to display the
Temperature regulator current value(s) for the inductor
• Temperature monitor or temperature
regulator - touch to display the
current value(s) for the monitor or
regulator
Trend • Trend - touch to display statistical
information.
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When an item shown in white is touched:
• the START/STOP buttons are
displayed, or
• a dialogue window is displayed.
START/STOP button is used for

automatic processes and also to turn on
the light inside the machine.
2 - 10 (60) Doc. No. OM-81841-0103

2 TPOP Navigation
Common Symbols
Lower Limit • Lower limit - temperatures below
this value activates an alarm
• Output - percentage of time the
heater is on
Output
• Process - actual value
• Set point - value that has been set for
the particular function
Process
• Upper limit - temperatures above this
value activates an alarm.
Set point
Upper limit
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Changing the Values

If the dialogue window has arrow keys,
the values can be changed in increments
of 10 (double-arrow keys) or in
increments of 1 (single-arrow keys).
Note! After a single-arrow key has
been continuously touched for 10
increments of 1, the values will
change by 10 instead of 1.
Doc. No. OM-81841-0103 2 - 11 (60)

Navigation 2 TPOP
System Communication Fault

Reset
If a communication fault occurs, a
dialogue window is displayed on the
TPOP display.
The TPOP RESET button also flashes to
show that an error has occurred.
Press the TPOP RESET button to reset
the TPOP.
Note! If the communication fault
remains, call a technician to check
the communication cable between
the PLC and the flexbox.
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2 - 12 (60) Doc. No. OM-81841-0103

2 TPOP Production Program Step
Production Program Step

This section describes the program steps displayed on the TPOP to indicate
the machine status before, during and after PRODUCTION.
During PRODUCTION After PRODUCTION

Before and During Production
1 No light = STEP ZERO
Light = PREPARATION
12 2 TIGHT TUBE
3 HEAT STERILISATION
4 SPRAYING
5 DRYING
11 6 SIGNAL TO STERILISER
7 SIGNAL FROM STERILISER
8 MOTOR START
15
9 PRODUCTION
10 10 PRODUCTION ENDED
11 EXTERNAL CLEANING
9 14 12 CLEANING - CIP
After Production
13 PRODUCTION ENDED, TIME OUT
14 VENTING ASEPTIC CHAMBER
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8 13 15 DOORS ASEPTIC CHAMBER

A fixed light indicates the current
program step.
6 A flashing light indicates when the

7 machine is ready to begin a program step.
5
4
2 3
Doc. No. OM-81841-0103 2 - 13 (60)

Cleaning Program Step 2 TPOP
Cleaning Program Step

This section describes the program steps displayed by the TPOP to indicate
the machine status during and after Cleaning CIP.
Cleaning
Cleaning
16 EXTERNAL CLEANING
17 18
17 CLEANING - CIP
18 CIP DRYING
A fixed light indicates the current
program step.
16 A flashing light indicates when the
machine is ready to begin a program step.
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2 - 14 (60) Doc. No. OM-81841-0103

2 TPOP Cleaning CIP
Cleaning CIP
This section describes how to start and stop the cleaning of the product line
system with the Internal Cleaning Unit.
1
To start the CLEANING - CIP program:
– touch the CIP button.
– when the PROGRAM UP button
begins to flash, press it to start the
cleaning.
2
To stop the CLEANING - CIP program:
– touch the STOP button
– when the PROGRAM DOWN
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button begins to flash, press it to

stop the cleaning.
Doc. No. OM-81841-0103 2 - 15 (60)

External Cleaning 2 TPOP
External Cleaning
This section describes how to start and stop the cleaning of the exposed
mechanical parts of the machine.
1
To start the EXTERNAL CLEANING
program:
– touch the EXTERNAL
CLEANING button.
– when the PROGRAM UP button
begins to flash, press it to start the
cleaning.
2
To stop the EXTERNAL CLEANING
program:
– touch the STOP button
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– when the PROGRAM DOWN
button begins to flash, press it to
stop the External cleaning.
2 - 16 (60) Doc. No. OM-81841-0103

2 TPOP System Settings
System Settings
This section describes how to set the language used by the TPOP, the time on
the TPOP and the Production Shift Setting.
Language Setting
1
Touch the SYSTEM SETTING button.
2
Touch the required language button. Wait
a few seconds.
Note! If the TPOP RESET button
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starts flashing, do not press it.
Touch the EXIT button.
Doc. No. OM-81841-0103 2 - 17 (60)

System Settings 2 TPOP
Time Setting
1
Note! Setting the time can only be
done in the program STEP ZERO
and with the PREPARATION phase
and the PRODUCTION phase
closed.
Touch the SYSTEM SETTING button.
2
Touch the CLOCK button.
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3
Touch the thick arrows to set the hours
and the thin arrow to set the minutes.
Touch the OK button.
OK
4
Touch the EXIT button.
2 - 18 (60) Doc. No. OM-81841-0103

2 TPOP System Settings
Production Shift Setting

Note! Setting the Production shift can
only be done in STEP ZERO and with
the PREPARATION phase and the
PRODUCTION phase closed.
Note! If the filling machine is not in

STEP ZERO, the SHIFT button is
displayed as an icon showing the
shift number and the shift time
setting.
1
Touch the COLLECT SYSTEM button.
Touch the SHIFT button.
Planned Maintenance Waste Close

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COPYLOG
1 2 2
Touch the required SHIFT button.
OK
Input a start time (1) and an end time (2)
for each shift as required.
CANCEL Set the shift time if necessary and touch
the OK button.
Repeat for the other shifts if necessary.
Note! Do not overlap the shift time
otherwise an error will be displayed.
OK
CANCEL
Doc. No. OM-81841-0103 2 - 19 (60)

Alarm System 2 TPOP
Alarm System
This section describes the machine alarms and how to handle alarms with the
TPOP.
Alarm Group Buttons

If no alarms appear, touch the ALARM
SYSTEM button.
The ALARM SYSTEM window appears
showing the alarm groups. Each button
opens the corresponding alarm window.
3 7 11
4 8 12
1 5 9 13 15
10
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2 6 14 16
1 SA/Magazine 9 Design correction

2 ASU 10 Drive unit/Jaw system
3 Superstructure 11 External cleaning and CIP
4 Peroxide system 12 Service unit, right
5 PullTab, right 13 Service unit, left
6 PullTab, left 14 Final folder
7 Sterile system 15 Safety, right
8 Filling 16 Safety, left
2 - 20 (60) Doc. No. OM-81841-0103

2 TPOP Alarm System
General Information
When the MULTIPLE ALARM button is
displayed, other alarm groups are also
activated. Touch the button to display
these groups.
A triangle in the symbol for an alarm
group, indicates that an alarm has not
been acknowledged.
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Alarm Colour Code

The alarms are colour-coded:
• Red = hazardous condition
• Yellow = abnormal condition
• Blue = information or operator action
All red or yellow alarms must be
acknowledged.
There is no need to acknowledge blue
alarms, they disappear when the cause is
corrected.
Note! If the alarm window does not
close after pressing the
ACKNOWLEDGE button, the alarm
still exists.
Doc. No. OM-81841-0103 2 - 21 (60)

Alarm System 2 TPOP
Alarm Handling
1
When the alarm window opens, the alarm
that was activated is lit up. Touch the lit
symbol to open the instruction
window (1).
Follow the instructions in the order
given.
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2
Touch the flashing ACKNOWLEDGE
button to acknowledge the alarm.
3
Touch the EXIT button to return to the
main window.
2 - 22 (60) Doc. No. OM-81841-0103

2 TPOP Collect System
Collect System
This section describes how to manually register reasons in the TPOP for
stops or delays in the PREPARATION and PRODUCTION phases of the
machine and for other generic tasks.
Conditions for a Manually

Registered Event
The machine automatically records the
causes of the events in the
PREPARATION phase and the
PRODUCTION phase.
The TPOP prompts the operator to enter
the cause for some events.
See Record Customised Events for
information on how to record event
causes.
PREPARATION phase:
• Delay in the Preparation Phase
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• Jump to Step Zero during the

Preparation Phase
PRODUCTION phase:
• Manual Recording of the Production
Stop Cause
• Check or Change the Production
Stop Causes
• Jump to Step Zero during the
Production Phase
• Jump to Step Venting during the
Production Phase
Generic tasks:
• Record Customised Events
• Record Package Waste for a Quality
Check
• Record Maintenance Time
• Recorded Data Copying
Doc. No. OM-81841-0103 2 - 23 (60)

Collect System 2 TPOP
Phases
Machine
Steps Planned
PREPARATION PRODUCTION After PRODUCTION Maintenance
Phase Phase Phase Phase
1 2 3 4 5 6 7 8
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Time
1 PREPARATION
PREPARATION Phase
2 Jump to STEP ZERO during PREPARATION This phase starts with the first attempt to
(Only if occurs) prepare the equipment for planned
3 MOTOR START production (4 minutes after the machine
4 SHORT STOP steps to step Preparation or as soon as it
(Only if occurs) steps to TIGHT TUBE) and ends when
5 Jump to STEP ZERO during PRODUCTION the Production Phase starts.
(Only if occurs, Cleaning and Preparation follow)
6 VENTING PRODUCTION Phase
7 CLEANING - CIP Starts with the first attempt to produce
8 EXTERNAL CLEANING packages and ends when the planned
production is done or when a production
interruption is decided.
After PRODUCTION Phase
Starts with the first attempt to run the
after production program and ends when
intended tasks in After Production Phase
have been completed.
Planned Maintenance Phase
Starts at the beginning of the first
preventive action and ends when the
planned maintenance has been carried
out.
2 - 24 (60) Doc. No. OM-81841-0103

Delay in the Preparation

Phase
1
If the PREPARATION phase is too long
(more than 30 minutes), the COLLECT
SYSTEM button starts to flash at the first
attempt to produce packages.
Why so much pre-production delay? 2

The TPOP prompts the following
NO WORKFORCE
MISSING OPERATOR INPUT question:
MANAGEMENT
MEAL
NO PAPER
Why so much pre-production delay?
NO PRODUCT
OPERATOR ERROR Select the correct cause for the event, see
FILLING MACHINE IDLE TIME
DE IDLE TIME
Selection of an Event Cause on page 2-9
for details.
If no answer is given within 10 minutes,
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a MISSING OPERATOR INPUT will be

assigned automatically as a stop reason.
3
00:44:00 The CLOCK button shows the exceeding
PREPARATION time. The system
allows a split up of the exceeding
PREPARATION time and allocates it to
the different causes.
Doc. No. OM-81841-0103 2 - 25 (60)

4
00:20:00
Enter the time allocated to the selected
cause.
Touch the OK button to accept the entry
and return to the previous window.
00:00:00 23:59:59
OK
5
The CLOCK button shows the stop time
00:44:00
which has been allocated.
Touch the OK button to record the causes
and return to the main window.
OK
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6
If the stop time is not fully allocated, the
COLLECT SYSTEM button keeps
flashing.
Touch the COLLECT SYSTEM button
and repeat the whole procedure to fully
allocate the remaining stop time.
2 - 26 (60) Doc. No. OM-81841-0103

Jump to Step Zero during the

Do you want to continue the Preparation Phase?
Preparation Phase
When the machine steps down to STEP
ZERO during the PREPARATION phase
YES NO the TPOP prompts the following
question:
Do you want to continue the
PREPARATION phase?
If the answer is NO the TPOP closes the
PREPARATION phase.
If the answer is YES the TPOP keeps the
PREPARATION phase open. After 10
minutes in STEP ZERO the TPOP
prompts again the same question. If the
answer is YES again the
PREPARATION phase is closed
automatically after 10 minutes.
If no answer is given within 20 minutes
the TPOP closes the PREPARATION
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phase.
Doc. No. OM-81841-0103 2 - 27 (60)

Manual Recording of the

Production Stop Cause
1
During the PRODUCTION phase, the
machine may stop due to:
• conveyor congestion
• manual Motor Start interruption
• manual Short Stop
• manual Emergency stop
• step out from PRODUCTION (Step
up or Step down)
• opening of a door.
The COLLECT SYSTEM button starts to

flash.
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2
The TPOP prompts one of the following
questions:
- Reason for conveyor congestion?
- Why did you interrupt Motor Start?
- Why did you press Short Stop?
- Why did you press Emergency Stop?
- Why did you Step out from Production?
- Why did you open the door?
Note! The TPOP prompts the
question “Why did you interrupt Motor
Start?” only at the first manual
MOTOR START interruption after the
PREPARATION phase.
Note! If the automatic catch of

distribution equipment stops function
is enabled, the TPOP button will flash
after a conveyor congestion only if a
distribution equipment stop has not
been detected.
2 - 28 (60) Doc. No. OM-81841-0103

3
Note! Answer by selecting the
NO LABOR
MISSING OPERATOR INPUT correct cause for the event, see
MANAGEMENT
MEALS Selection of an Event Cause on page
NO PAPER
NO PRODUCT
2-9 for details.
OPERATOR ERROR
FILLING MACHINE IDLE TIME
DE IDLE TIME Note! If no answer is given within 10
minutes after the restart, a MISSING
OPERATOR INPUT will be assigned
automatically as a stop reason.
Note! If the stop is due to a

CONVEYOR CONGESTION, and no
cause is manually selected within 10
minutes after the restart, A GENERIC
CONVEYOR CONGESTION will be
assigned automatically as a stop
reason.
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4
00:00:27
The CLOCK symbol displays the total
time taken for the stop.
5
0 When there is a manual waste, touch the
WASTE NUMBER button.
Note! Manual waste means
packages removed by the operator.
Doc. No. OM-81841-0103 2 - 29 (60)

6
3 Use the ARROW buttons or the numeric
keypad to enter the number of packages
taken.
and return to the previous window.
OK
7
Touch the OK button to record the stop
OK
cause, the waste and return to the main
window.
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2 - 30 (60) Doc. No. OM-81841-0103

Check or Change the

Production Stop Causes
1
During a production stop, it is possible to
check or change production stop causes
which have been automatically assigned
by the system.
Note! This button is only available
during the stop and during the first 10
minutes after the restart.
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2
Touch the SEESTOP button to check if
the recorded stop cause is correct.
SeeStop
PLANT
PROCESSING EQUIPMENT
3
FILLING MACHINE If the cause is not correct, select the
TP DISTRIBUTION EQ
IDLE TIME correct cause in the scroll lists, see
ANCILLARY TIME
Selection of an Event Cause on page 2-9
for details.
Doc. No. OM-81841-0103 2 - 31 (60)

4
When there is a manual waste, touch the
WASTE NUMBER button.
Note! Manual waste means
0
packages removed by the operator.
5
3 Use the ARROW buttons or the numeric
keypad to enter the number of packages
taken.
for package numbers and return to the
previous window.
OK
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6
Touch the OK button to record the
entered data and return to the main
OK
window.
2 - 32 (60) Doc. No. OM-81841-0103

Jump to Step Zero during the

Is this the end of Production?
Production Phase
YES = End of production
NO = Machine failure-Prepare for a new production
When the machine steps to STEP ZERO
during the PRODUCTION phase the
TPOP prompts the following question:
YES NO
• If the answer is YES the TPOP
closes the PRODUCTION phase
• If the answer is NO the TPOP keeps
the PRODUCTION phase open and
the period of time until the next
PRODUCTION is recorded as a
PRODUCTION stop.
If the machine keeps staying in STEP
ZERO, the question appears again 10
minutes after the first reply. If the
answer is NO again, the system
allows 10 additional minutes in
STEP ZERO, then closes the
PRODUCTION phase automatically
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• If no answer is given within 20

minutes, the PRODUCTION phase
closes automatically.

YES = End of production
NO = Machine failure-Prepare for a new production
Jump to Step Venting during
the Production Phase
When the machine steps to VENTING
YES NO
during the PRODUCTION phase the
TPOP prompts a question.
• If the answer is YES the TPOP
closes the PRODUCTION phase
• If the answer is NO the TPOP keeps
the PRODUCTION phase open and
the period of time until the next
PRODUCTION is recorded as
PRODUCTION stop
• If no answer is given within 4
minutes the TPOP assigns it as
default NO.
Doc. No. OM-81841-0103 2 - 33 (60)

Record Customised Events

1
Planned Maintenance Customised Waste Close The customised events list must be
utilised to record local customer
configured events. Time duration and an
additional text can be assigned to each
event.
CopyLog
Touch the CUSTOMISED button.
Note! Scroll and select the required
event from the list.
LS
TS
PAPER SLICE General OK
STRIP SLICE
DESIGN
Customised Cancel
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2
To record a time duration touch the
CLOCK button.
Set the time, then touch the OK button.
OK
CANCEL
2 - 34 (60) Doc. No. OM-81841-0103

3
Customised To log a text entry touch the
KEYBOARD button.
Type the required text, then touch OK
button.
Correct
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4
Touch the OK button to record the data
LS
entry, time duration and text entry.
TS
PAPER General OK Touch the LIST button to show the list of
SLICE custom events for the last 24 hours.
STRIP
Customised Cancel
Planned Customised Waste Close
CopyLog
Doc. No. OM-81841-0103 2 - 35 (60)

Record Package Waste for a

Quality Check
1
Note! Remember to record the
number of packages taken whenever
packages are collected for quality
checks.
2
Waste
Touch the WASTE button.
TechPub_2614345_0104 - TB058413en.fm
PLANT 3
PROCESSING EQUIPMENT
FILLING MACHINE Use the arrow keys to select PLANNED
TP DISTRIBUTION EQ
MACHINE IDLE TIME TIME.
PLANNED TIME
Touch the DETAIL button.
Detail
PLANNED PRODUCT CHANGE 4

PLANNED PAPER CHANGE
PLANNED MAINTENANCE Use the arrow keys to select PACKAGE
PLANNED STRIP CHANGE
PREPRODUCTION WARMUP QUALITY CHECKS.
PACKAGE QUALITY CHECKS
Touch the WASTE NUMBER button.
2 - 36 (60) Doc. No. OM-81841-0103

5
3
Use the ARROW buttons or the numeric
key pad to enter the number of packages
taken.
for package numbers and return to the
previous window.
OK
6
OK Touch the OK button to record the data
entry and return to the main window.
TechPub_2614345_0104 - TB058413en.fm
Doc. No. OM-81841-0103 2 - 37 (60)

Record Maintenance Time

1
Touch the PLANNED MAINTENANCE
button.
Plann. Maint. Note! This button is only available in
STEP ZERO, and with the
PREPARATION phase and the
PRODUCTION phase closed.
PREPARATION AFTER DAILY CARE

PREPARATION AFTER WEEKLY CARE
2
PLANNED MAINTENANCE 250 HOUR Select the correct item, see Selection of
PLANNED MAINTENANCE 1000 HOUR
an Event Cause for details.
00:44:00
TechPub_2614345_0104 - TB058413en.fm
3
00:20:00
Use the ARROW buttons or the numeric
key pad to enter the time used.
Touch the OK button to accept the time
entry and return to the previous window.
00:00:00 23:59:59
OK
4
OK Touch the OK button to record the data
entry and return to the main window.
2 - 38 (60) Doc. No. OM-81841-0103

Recorded Data Copying

CopyLog The COPYLOG button is used to copy
the data from the TPOP flexbox to a
floppy disk.
Note! To analyse the data collected
by the system, the data must be
copied to an office PC and analysed
utilising the appropriate software.
TechPub_2614345_0104 - TB058413en.fm
Doc. No. OM-81841-0103 2 - 39 (60)

Manoeuvre System 2 TPOP
Manoeuvre System
This section describes how to use the TPOP to make machine settings, view
the number of packages wasted, reset counters and to set the number of
packages per tray/unit.
Manoeuvre System Buttons

Touch the MANOEUVRE SYSTEM
button to view the buttons corresponding
to the various manoeuvre functions.
Touch a MANOEUVRE button to open
the associated manoeuvre window.
3 7 11 15
1 4 8 12 16
2 5 9 13 17
TechPub_2614345_0104 - TB058413en.fm
6 10 14 18
19
1 Parameters storage 12 Service unit, right

2 SA/Magazine 13 Service unit, left
3 Superstructure 14 Final folder
4 Peroxide system 15 PT21 temperatures
5 PullTab, right 16 Package counter
6 PullTab, left 17 Production overview by
7 Sterile system volume - total produced
8 Filling system and total time
9 Design correction 18 Production recorder
10 Drive unit 19 Line configuration
11 Overview of temperature
monitors/regulators
2 - 40 (60) Doc. No. OM-81841-0103

2 TPOP Manoeuvre System
Filling System Window

1
button.
2
Touch the FILLING SYSTEM button.
TechPub_2614345_0104 - TB058413en.fm
3
1 2 Touch the START FLOW (1) button. The
colour of the icon becomes blue and the
SETTING WINDOW (2) will be
displayed.
Doc. No. OM-81841-0103 2 - 41 (60)

4
Touch the SINGLE ARROW button (1)
to increase or the button (2) to decrease
5
the value in steps of 1. Touch the
DOUBLE ARROW button (3) to
increase or the button (4) to decrease the
value in steps of 10. Touch the LOAD
FACTORY SETTINGS button (5) to
3 1 2 4 load the factory default values.
Note! The start flow value is
adjustable in this window and can be
recalculated from the TMCC during
production.
TechPub_2614345_0104 - TB058413en.fm
1 2 5
Touch the TUBE (1) button and the
PRODUCT LEVEL METER (2) is
displayed.
main window.
2 - 42 (60) Doc. No. OM-81841-0103

Peroxide Concentration Meter

1
button.
Touch the PEROXIDE SYSTEM button.
2
The PEROXIDE SYSTEM window
appears.
Touch the PEROXIDE
CONCENTRATION METER button.
TechPub_2614345_0104 - TB058413en.fm
Doc. No. OM-81841-0103 2 - 43 (60)

3
The PEROXIDE CONCENTRATION
1 2 3 METER window appears.
The box (2) displays the hydrogen
peroxide concentration in real time:
• for the first ten minutes when the
machine is in step PREPARATION
• continuously from step HEAT
STERILISATION to step
PRODUCTION.
The box (1) displays the hydrogen

peroxide temperature inside the peroxide
concentration meter.
Touch the button (3) to display the chart
of the hydrogen peroxide concentration
during the last 8 hours.
Note! The chart may show “missing
information blocks” due to the
TechPub_2614345_0104 - TB058413en.fm
machine steps, see above.
4
MANOEUVRE SYSTEM window.
button to return to the main window.
2 - 44 (60) Doc. No. OM-81841-0103

Overview Temperature
1
Touch the OVERVIEW
TEMPERATURE button.
2
The window SETTING AND
INFORMATION TEMPERATURES is
1 2 3 4 displayed.
5 6 7
TechPub_2614345_0104 - TB058413en.fm
8 9 10 11 12
13 14
1 Top left flap heater

2 Top right flap heater
3 Bottom flaps heater
4 Air super heater
5 Peroxide tank
6 Peroxide bath
7 Water bath
8 Pre-sterilisation
9 Water heat exchanger
10 Water circulating
12 Headspace by Injection
13 Aseptic chamber
14 Steam
Doc. No. OM-81841-0103 2 - 45 (60)

3
Touch the TOP LEFT FLAP HEATER
button.
The SETTING WINDOW (1) is
displayed.
Touch the SINGLE ARROW buttons to
increase or to decrease the value in steps
1 of 1. Touch the DOUBLE ARROW
buttons to increase or to decrease the
value in steps of 10. Touch the LOAD
FACTORY SETTINGS button to load
the factory default values.
main window.
TechPub_2614345_0104 - TB058413en.fm
2 - 46 (60) Doc. No. OM-81841-0103

PullTab Overview
Temperature
1
Touch the OVERVIEW
TEMPERATURE button.
2
1 2 3 The window SETTING AND
INFORMATION TEMPERATURES
PT21 is displayed.
Touch either the buttons (1) or (2) or (3)
to access the setting window (4).
Note! The button (1) is available only
if the outer patch is present.
TechPub_2614345_0104 - TB058413en.fm
Doc. No. OM-81841-0103 2 - 47 (60)

TS IH Power Setting
1
Touch the DRIVE UNIT button.
2
The DRIVE UNIT WINDOW (1) with
1 2 5 the regulator window (2) is displayed.
Touch the symbol (3) to access the
settings window for the LH TS IH
generator. Touch the symbol (4) to access
the settings window for the RH TS IH
generator.
TechPub_2614345_0104 - TB058413en.fm
The selected value becomes blue. Use the
ARROW buttons to set the value, or
touch the FACTORY button (5) to load
3 4
2 - 48 (60) Doc. No. OM-81841-0103

LS IH Power Setting
1
Touch the SUPERSTRUCTURE button.
2
The SUPERSTRUCTURE window (1) is
displayed with the regulator window (2).
1 4 3 5 2 6 Three settings are available:
• power during the tight tube (3)
• power during production (4)
• power during service (5).
TechPub_2614345_0104 - TB058413en.fm
Touch the required setting. The selected

value becomes blue. Use the ARROW
buttons to set the value, or touch the
FACTORY button (6) to load the factory
default values.
Doc. No. OM-81841-0103 2 - 49 (60)

SA IH Power Setting
1
Touch the SA MAGAZINE button.
2
The SA MAGAZINE window (1) is
1 3 2 4 displayed with the regulator window (2).
Touch the display box (3) to access the
settings for the SA IH generator. The
selected value becomes blue. Use the
ARROW buttons to set the value, or
touch the FACTORY button (4) to load
TechPub_2614345_0104 - TB058413en.fm
2 - 50 (60) Doc. No. OM-81841-0103

Package Counter Window

1
In the main TPOP window, touch the
MANOEUVRE SYSTEM button.
TechPub_2614345_0104 - TB058413en.fm
2
Touch the PACKAGE COUNTER
button.
Doc. No. OM-81841-0103 2 - 51 (60)

Waste Counters
The waste counters can be observed to
18 PLMS EVENTS 18 know which part of the machine is
causing the waste.
1 1
Press the TECHNICAL WASTE
2 2
button (9) and the events counters
3 3 appears. Events counters count all the
reasons why a package is wasted.
4 4
5 5 PLMS counters count the number of
packages wasted during PRODUCTION
6 10 or because of a stop.
7 11 Their sum is the total waste, see item
8 12 Package Counters on page 2-53.
9 13 Keep the button (10) pressed to reset all

the events counters.
1 Waste paper splice

14
2 Waste strip applicator splice
15 16 17 3 Waste strip applicator stop
TechPub_2614345_0104 - TB058413en.fm
4 Tab waste
5 Waste filling system
6 Design correction waste
7 Manual waste
8 Stop caused waste
9 TECHNICAL WASTE button
10 RESET button
11 Top forming ring waste
12 LS waste
13 Hydrogen peroxide bath waste setting
14 Hydrogen peroxide bath waste
15 Jaw waste
16 Motor start
17 HI waste
18 Latest reason for waste
2 - 52 (60) Doc. No. OM-81841-0103

Hydrogen peroxide bath

waste setting
Touch the hydrogen peroxide bath waste
setting symbol (13) and the BATH
WASTE window appears.
13 Select the range of packages (19) to
waste in the hydrogen peroxide bath
when the machine restarts, by touching
21 the buttons (20) to change the values.
The values must be inside the minimum-
23 maximum value (21) range.
Note! Touch the NO WASTE
button (22) to save all the packages
in the hydrogen peroxide bath.
19
Note! Touch the FACTORY
button (23) to load the factory default
values.
22 20
TechPub_2614345_0104 - TB058413en.fm
24 25 Package Counters
The counter (25) displays the incoming
26 packages going into the filling machine.
27 The counter (27) displays the total waste
28 of packages.
29 The counter (28) displays the number of
30 packages coming out from the final
folder.
31
The counter (31) displays the number of
packages passing the last point counting
photocell on the packaging line or
coming out from the cardboard packer,
according to the configuration.
Keep the buttons (24),(26), (29) and (31)
pressed to reset the respective
counters (25), (27), (28) and (31).
Note! The button (24) resets also all
the PLMS counters.
Doc. No. OM-81841-0103 2 - 53 (60)

Tight Tube Function

TIGHT TUBE TO STRIP
APPLICATOR FUNCTION icon (32)
choose to run the TIGHT TUBE wasting
the packages up to the inlet of the
peroxide bath or to waste the packages up
to the strip applicator.
The first choice is automatically select.
To select the second choice press the
TIGHT TUBE TO STRIP
APPLICATOR icon (32) in the
32 33 PACKAGE COUNTERS window and
then press 1 (33).
The green light (34) displays that the
34 packages up to the strip applicator are
wasted during TIGHT TUBE.
TechPub_2614345_0104 - TB058413en.fm
Packages per Tray Setting
The counter (35) displays the number of
packages per tray/unit.
35 Touch the buttons (36) to change the
value.
36
Note! The counter (35) value ranges
are from 1 to 200 packages.
Note! This setting is not available if

the cardboard packer is the last point
counting configured unless the
machine is in STEP ZERO and the
production is ended after one hour.
2 - 54 (60) Doc. No. OM-81841-0103

Production Overview
1
Touch the PRODUCTION OVERVIEW
button
2
2 1 3 The PRODUCTION OVERVIEW
window (1) is displayed.
The window displays the total production
quantities (2) and the total time (3).
TechPub_2614345_0104 - TB058413en.fm
3
main window.
Doc. No. OM-81841-0103 2 - 55 (60)

Parameter Storage
1
Touch the PARAMETER STORAGE
button.
2
The PARAMETERS window is
1 4 8 12 13 displayed.
Ten different parameter sets can be
2 5 9 14 loaded (18) and saved (19).
Note! The actual parameter set name
3 6 10 15 is displayed only if none of the
parameters have been changed
TechPub_2614345_0104 - TB058413en.fm
7 11 16 since the last load or the last save
operation.
17
18 19
1 Flap top left

2 Flap top right
3 Flaps bottom
4 SA power
5 LS power during tight tube
6 LS power during production
7 Strip splice power
8 TS left
9 Design correction offset
10 Filling start sector
11 Filling start flow
12 TS right
13 Design correction offset
14 Outer Patch power
15 Patch power
16 Tab power
17 Actual parameter set
18 Load
19 Save
2 - 56 (60) Doc. No. OM-81841-0103

3
Touch the SAVE button to save all
current parameters, or touch the LOAD
button to load a previous saved set of
parameters.
4
Select which set to save or load and press
the OK button for a few seconds.
Note! Before saving, it is possible to
change the set name, by keeping the
parameters set button pressed for a
few seconds.
TechPub_2614345_0104 - TB058413en.fm
Doc. No. OM-81841-0103 2 - 57 (60)

Production Data
1
Touch the PRODUCTION RECORDER
button.
2
1 The production data window is
displayed.
2
3
TechPub_2614345_0104 - TB058413en.fm
4 5 6 7 8
1 CIP drying
2 CIP
3 Production
4 Backwards
5 Zoom in
6 Zoom out
7 Forward
8 Set end of diagram to actual time
2 - 58 (60) Doc. No. OM-81841-0103

Line Overview
1
The overview window gives the status of
the configured distribution equipment.
button.
2
Touch the LINE OVERVIEW button.
The line overview is shown.The colours
of the distribution equipment are:
• Yellow = Alarm
• White = Preparation
• Green = Production
TechPub_2614345_0104 - TB058413en.fm
• Grey = OFF
• Cross = No data communication with
distribution equipment.
Note! Communication with

distribution equipment is active only
from the PREPARATION phase until
one hour after the end of the
Production Phase.
Note! The TPOP configuration may

display the line overview window
automatically in case of new alarms.

main window.
Doc. No. OM-81841-0103 2 - 59 (60)

TechPub_2614345_0104 - TB058413en.fm
2 - 60 (60) Doc. No. OM-81841-0103

3 Preparation
TechPub_2614345_0104 - TB068413en.fm
Doc. No. OM-81841-0103 3 - 1 (44)

3 Preparation
This chapter describes how to prepare the machine for

PRODUCTION after Care and Cleaning has been
performed.
TechPub_2614345_0104 - TB068413en.fm
3 - 2 (44) Doc. No. OM-81841-0103

3 Preparation Table of Contents
Preparing After Weekly Care . . . . . . . . . . . . . . . 3 - 5

Threading inside ASU Compartment . . . . . . . . . . . . . .3 - 6
Threading inside ASSU Compartment . . . . . . . . . . . . .3 - 9
Production without PullTab . . . . . . . . . . . . . . . . . . . . .3 - 14
Production with PullTab. . . . . . . . . . . . . . . . . . . . . . . .3 - 15
Threading up to Hydrogen Peroxide Bath (With

Crease Wheel Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 17
Threading up to Hydrogen Peroxide Bath

(Without Crease Wheel Unit) . . . . . . . . . . . . . . . . . . . .3 - 17
Threading through Hydrogen Peroxide Bath. . . . . . .3 - 18
Preparing after Daily Care. . . . . . . . . . . . . . . . . 3 - 23

TechPub_2614345_0104 - TB068413en.fm
Honeywell Recorders . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 24
Chart Paper Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 24
Ink Wheel Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 26
JUMO Recorders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 28
Chart Paper Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 28
Print Head Change . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 30
Headspace by Injection . . . . . . . . . . . . . . . . . . . . . . . .3 - 33
Production with PullTab. . . . . . . . . . . . . . . . . . . . . . . .3 - 34
Domino Ink Jet Printer A300 . . . . . . . . . . . . . . . . . . . .3 - 39
LS, Patch and Tab Strip . . . . . . . . . . . . . . . . . . . . . . . .3 - 41
Doc. No. OM-81841-0103 3 - 3 (44)

3 Preparation
TechPub_2614345_0104 - TB068413en.fm
3 - 4 (44) Doc. No. OM-81841-0103

3 Preparation Preparing After Weekly Care
Preparing After Weekly Care

Note! If only Daily Care has been performed, start with Preparing
after Daily Care on page 3-23.
1
5 6 1 If the machine has been shut down
turn ON:
• the mains power switch (1)
• the air supply (2)
• the cooling water supplies (3) and
2 (4), depending on which filter is in
3 use
• the steam (7).
Check that the pressure gauge (5) shows

a pressure between 6.0 to 7.0 bar. If
necessary adjust by lifting and rotating
4 the valve (6).
TechPub_2614345_0104 - TB068413en.fm
Cooling water On
Cooling water Off
Doc. No. OM-81841-0103 3 - 5 (44)

Preparing After Weekly Care 3 Preparation
2
On the PullTab panel, turn the PullTab
selector switch to the LH position
(PREPARATION).
3
Press the PROGRAM UP button to step
up to STEP PREPARATION.
TechPub_2614345_0104 - TB068413en.fm
4
1 Open the ASU doors (1).
Insert the packaging material reel into the
machine, see section Reel Handling in
the chapter 6 Supplies of Materials.
5
Threading inside ASU
Compartment
Cut the end of the packaging material as
shown, avoiding crease lines on the tip.
3 - 6 (44) Doc. No. OM-81841-0103

6
Thread the packaging material through
the material holder.
TechPub_2614345_0104 - TB068413en.fm
6a
Thread the packaging material web
through the splicing device (1), then
through the web guide (2).
Doc. No. OM-81841-0103 3 - 7 (44)

2 6b
Thread the packaging material over the
bending roller (1) and under the counter
roller (2).
TechPub_2614345_0104 - TB068413en.fm
6c
Lift and hold the lever (1).
Feed an extra two metres of packaging
material past the counter roller (2) to
form the side shift loop.
3 - 8 (44) Doc. No. OM-81841-0103

1 6d
Thread the packaging material
• between the two shafts (3)
• through the web guide (2)
2
• over the bending rollers (1) and into
3 the ASSU compartment.
Note! Make sure that the side shift
4 loop (4) covers both pair of
photocells (5).
5
TechPub_2614345_0104 - TB068413en.fm
6e
Close the ASU doors and reset the alarms
on the TPOP display.
The packaging material magazine fills
up.
7
Threading inside ASSU
Compartment
Open the ASSU door and open the strip
magazine frame.
Doc. No. OM-81841-0103 3 - 9 (44)

2 8
7 Thread the packaging material:
1 • under the splice detector (1)
3 • through the SA inductor (4)
• through the strip guide wheel (5)
4 • under the roller (6).
Lift and hold the lever (7). Thread the
5 packaging material between the bending
roller (3) and the counter roller (2).
6 Feed approximately two metres of
packaging material past the counter
roller (2).
TechPub_2614345_0104 - TB068413en.fm
8a
Pull down the magazine roller rope (1) to
raise the double magazine roller (3).
Thread the rope around the bolts (2) to
hold the roller (3) in place.
3 - 10 (44) Doc. No. OM-81841-0103

8b
5 3 6 Continue feeding the packaging material:
• between the first roller of the double
magazine rollers (1) and the lifting
device (2)
• up to the roller (6), down under the
second roller of the double magazine
rollers (1)
• through the paper guide (3).
Lift the lever (4) to feed the packaging

material under the counter roller (5).
4 1 2 1
TechPub_2614345_0104 - TB068413en.fm
8c
Pull the packaging material down so it
covers only the first pair of
photocells (1).
Doc. No. OM-81841-0103 3 - 11 (44)

8d
Release the brake (1). Undo the rope (2)
from the bolts (3) to release the double
magazine rollers (5) and stretch the
packaging material (4).
1
4
5
3
TechPub_2614345_0104 - TB068413en.fm
8e
Check that the packaging material is
centred on the rollers.
8f
Prepare the strip applicator. See chapter 6
Supplies of Materials.
Note! There must be enough strip
available in the strip reel for the
packaging material threading to be
done without any strip splice.
3 - 12 (44) Doc. No. OM-81841-0103

8g
Close the ASSU door.
8h
Close all covers and doors on the
machine and reset the alarms on the
TPOP display.
Note! If an alarm is present, take the
appropriate measures or call a
technician.
TechPub_2614345_0104 - TB068413en.fm
9
Ensure that the material lock (1) is
resting against the bending roller (2).
2 1
Doc. No. OM-81841-0103 3 - 13 (44)

10
Production without PullTab
7 3 1 Pull back all the material from under
counter roller (3) and out of the paper
6 2 guide (2).
Continue feeding the packaging material
• over the bypass roller (1)
5 4 • over the bypass roller (4)
• under the bypass sensor (7), and
• under the roller (5).
Feed approximately one metre of

packaging material up through the
platform floor and lock by means of the
material lock (6).
TechPub_2614345_0104 - TB068413en.fm
10 a
On the PullTab panel, turn the selector
switch to the vertical position
(PRODUCTION WITHOUT
PULLTAB).
Close the PullTab doors.
Go directly to item 13 on page 3-17.
3 - 14 (44) Doc. No. OM-81841-0103

11
Production with PullTab
2 1 Continue feeding the packaging material:
• through steering roller (1)
• under counter roller (2)
3 • up over paper brake roller (3)
4 • through the hole punch unit (4)
• through the IS patch unit (5)
5 • through the reseal station (6)
• through the tab station (7).
6
Lock the material under the counter roller
7 of the drive roller (8).
Check that the packaging material covers
only the first pair of photocells (9).
8
TechPub_2614345_0104 - TB068413en.fm
11 a
Close the PullTab door.
When the SINGLE CYCLE button starts
flashing, press it.
The machine feeds sufficient paper to fill
the outfeed magazine.
Doc. No. OM-81841-0103 3 - 15 (44)

11 b
• through the tension device rollers (3)
1
• up behind the roller (2), and
• up through the platform floor,
2 feeding through approximately one
metre of material.
Lock the packaging material by means of

the material lock (1).
Close the PullTab door.
TechPub_2614345_0104 - TB068413en.fm
11 c
Prepare the patch magazine and the tab
magazine. See chapter 6 Supplies of
Materials.
11 d
On the PullTab panel, turn the selector
switch to the RH position
(PRODUCTION WITH PULLTAB).
Close the PullTab doors.
3 - 16 (44) Doc. No. OM-81841-0103

12
3
Threading up to Hydrogen
Peroxide Bath (With Crease
Wheel Unit)
Grip the packaging material from behind
the pneumatic panel (superstructure) and
pull it upwards.
the crease wheel unit (1) as shown.
Make sure that the top creases of the
packaging material match the short edge
of the crease wheel (2).
2 Thread the packaging material under the

splice detector (3).
1
TechPub_2614345_0104 - TB068413en.fm
13
Threading up to Hydrogen
4 Peroxide Bath (Without
Crease Wheel Unit)
Grip the packaging material from behind
3 the pneumatic panel (superstructure) and
pull it upwards.
2 Note! The PullTab will not operate
until the tab sealing temperature is
reached.
1
• through the shaft (1)
• through the web guide (2)
• through the tab folding unit (3)
• under the splice detector (4).
Doc. No. OM-81841-0103 3 - 17 (44)

14
Threading through Hydrogen
Peroxide Bath
WARNING
Hydrogen Peroxide.
Follow the Safety Precautions.
Open the top cover and the top aseptic

chamber door.
14 a
Loosen the knobs (1) at the same time
and remove the hatch (2) of the carrier
2 1 compartment.
TechPub_2614345_0104 - TB068413en.fm
14 b
through the rubber slot (1).
Fold the packaging material up along a
crease line (2).
Note! Crank the handle (4) fully anti-
clockwise until the carrier (3) is above
4 the crease line (2).
3 Press the pins of the carrier (3) through

the material.
2
3 - 18 (44) Doc. No. OM-81841-0103

14 c
4 Crank the handle (1) clockwise to pull
the packaging material through the
3 peroxide bath and up through the
calender rollers (2).
Remove the packaging material from the
2 carrier (3). Make sure that the carrier (3)
is in the end position.
Pull up approximately one and half
metres of packaging material and reshape
the end piece (4).
1
Note! The carrier (3) must be in its
end position without touching the
packaging material.
TechPub_2614345_0104 - TB068413en.fm
4 14 d
1 Continue feeding the packaging material:
• over the roller (1)
• down under the pendulum roller (2)
• up over the roller (3), and
3 • through the tunnel (4) and into the
aseptic chamber.
2 Feed approximately one metre of

packaging material into the aseptic
chamber.
Doc. No. OM-81841-0103 3 - 19 (44)

2 1 2 14 e
Fit the hatch (1) on the carrier
compartment and tighten the knobs (2).
2 14 f
Swing up the lock (1) to make sure the
packaging material does not touch the
dampers (2) while running.
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14 g
Close the top aseptic chamber door and
the top cover.
3 - 20 (44) Doc. No. OM-81841-0103

15
If production is scheduled, continue
according to section Preparing after
Daily Care.
If production is not scheduled:
• press the PROGRAM DOWN button
to step down to STEP ZERO
• turn OFF the air supply (1)
1 • turn OFF the cooling water
2 supplies (2) and (3), depending on
which filter is in use.
The preparation after weekly care is now

finished.
3
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Cooling water On
Cooling water Off
Doc. No. OM-81841-0103 3 - 21 (44)

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3 - 22 (44) Doc. No. OM-81841-0103

3 Preparation Preparing after Daily Care
Preparing after Daily Care

Note! If Weekly Care has been performed, start with Preparing After
Weekly Care on page 3-5.
1
5 6 1 Turn ON:
• the mains power switch (1)
• the air supplies (2)
• the cooling water supply (3) and (4),
depending on which filter is in use.
2
Check that the pressure gauge (5) shows
3 a pressure between 6.0 to 7.0 bar. If
necessary adjust by lifting and rotating
the valve (6).
Make sure that the steam (7) is open.
4
TechPub_2614345_0104 - TB068413en.fm
Cooling water On
Cooling water Off
Doc. No. OM-81841-0103 3 - 23 (44)

Preparing after Daily Care 3 Preparation
2
Honeywell Recorders
Make sure that there is enough chart
paper in the process recorder (for at least
one day of production) and in the
cleaning recorder. If necessary, load the
recorder with new paper, see item 3.
Check that both recorders print properly.
If necessary, change the ink wheel, see
item 4.
For the process recorder, every time the
machine is started for PRODUCTION, it
is suggested to input the following data
on the dotted lines provided:
• machine serial number
• machine type
• data and time
• product and volume
TechPub_2614345_0104 - TB068413en.fm
• operator’s name
• production code.
See the Honeywell manual for details.
3
Chart Paper Load
Pull down the button and open the front
cover.
3 - 24 (44) Doc. No. OM-81841-0103

3a
Pull the pin and pull out the chart
cassette.
TechPub_2614345_0104 - TB068413en.fm
1 3b
Place the fanfold chart in the upper
compartment (1) with the folds in the
vertical plane.
The slots of the fanfold must be on the
RH side, and the graph side at the top.
2 Pull four folds into the compartment (2)
and close the covers of the chart cassette.
3c
Close the covers of the chart cassette.
Doc. No. OM-81841-0103 3 - 25 (44)

3d
Insert the chart cassette and close the
cover.
3e
To reset the paper length counter:
• press and hold for 1-2 seconds the
left arrow button (1) to access the
Quick Action menu
• keep pressing the LEFT ARROW
button (1) until PAPLG=1800 is
SET UP ENTER displayed
TechPub_2614345_0104 - TB068413en.fm
• press ENTER (2) to reset the counter
1 2 • press the LEFT ARROW button (1)
until normal display mode.
4
Ink Wheel Change
Open the display.
3 - 26 (44) Doc. No. OM-81841-0103

4a
Pull off the old ink wheel.
4b
Fit the new ink wheel. Rotate it anti-
clockwise until the ratchet engages.
Note! See chapter 10 Technical Data
for the correct ink wheel type.
TechPub_2614345_0104 - TB068413en.fm
4c
Close the display, insert the chart cassette
and close the front cover.
Doc. No. OM-81841-0103 3 - 27 (44)

5
JUMO Recorders
Make sure that there is enough chart
paper in the combined process and CIP
recorder (for at least one day of
production followed by cleaning). If
necessary, load the recorder with new
paper, see item 6.
Note! On the last one metre of chart
paper there are small stars.
Check that the recorder prints properly. If

necessary, change the print head, see item
7.
Every time the machine is started for
Production, it is suggested to input the
following data on the dotted lines
provided:
• machine serial number
15 cm 10 cm 5 cm
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• machine type
• product and volume
• operator’s name
• production code.
See the JUMO manual for details.
6
/E S
Chart Paper Load
F
ENTER
Push down the button (or turn the knob)
and open the door.
3 - 28 (44) Doc. No. OM-81841-0103

6a
Push down the button and remove the
chart cassette.
/E S F
ENTER
6b
Open the paper guides (1) and (2).
Remove the old chart paper.
If necessary, clean the cassette with a
damp cotton cloth.
for the correct type of chart paper.
TechPub_2614345_0104 - TB068413en.fm
1 2
6c
Place the fanfold chart in the back
compartment (1) with the folds in the
horizontal plane.
The slots of the fanfolding paper must be
on the RH side, and the graph side of the
paper at the top. Pull two folds of paper
into the compartment (2).
2 1
6d
Make sure the sprocket teeth on both
sides of the chart cassette are properly
engaged in the holes of the fanfold chart.
Close the covers of the chart cassette.
Doc. No. OM-81841-0103 3 - 29 (44)

6e
Insert the chart cassette. Push the chart
/E S F
ENTER cassette inwards, on both sides, with a
slight motion upwards.
2
7
Print Head Change
1 Push down the button (or turn the knob)
and open the door (1).
Open the display (2).
TechPub_2614345_0104 - TB068413en.fm
7a
Change the print head.
for the correct print head type.
2
7b
Close the display (1) and the door (2).
1
3 - 30 (44) Doc. No. OM-81841-0103

8
TPOP display.
If an alarm is present, take the
appropriate measures or call a technician.
9
up to step PREPARATION.
TechPub_2614345_0104 - TB068413en.fm
1 10
Check the peroxide heating unit water
pressure (1) is 120 to 150 kPa (1.2 to
1.5 bar).
If incorrect, call a technician.
Note! This pressure should be 70
kPA (0.7 bar) when the machine is
cold.
Doc. No. OM-81841-0103 3 - 31 (44)

1 2 3 4 5 11
Check that the flow in the cooling
circuits is correct.
See chapter 10 Technical Data.
Call a technician for adjustments.
1 Cold water flow, TS right
2 Cold water flow, TS left
3 Cold water flow, final folder
4 Cold water flow, hydraulics
5 De-ionizing circuit
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12
Press the LAMP TEST button.
Check that the buttons on the control
panel are lit (see fig. 1).
Check that the alarm beacons (shown by
the arrows in fig. 2) are lit.
Call a technician to replace any faulty
fig.1 lamp before production starts.
fig. 2
3 - 32 (44) Doc. No. OM-81841-0103

1 2 3 13
Headspace by Injection
Make sure that the HI nozzle (4) is
installed.
Note! The choice of the appropriate
HI nozzle depends on the type of
product and on the desired amount of
headspace.
If the fitted HI nozzle (4), see section

Daily Care item 51 in the chapter 8 Care
and Cleaning, needs replacing then:
• check that the new HI Nozzle is
clean and free from blockages
• spray the outside of the HI nozzle (4)
with disinfectant code G3 before
fitting.

button (5).
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Touch the FILLING SYSTEM

4 5 6 7 button (6).
Touch the HI PIPE button (1). The colour
of the icon becomes blue and the
SETTING WINDOW (2) will be
displayed.
Touch the HI NOZZLE button (3) for the
HI nozzle (4) installed.
Touch the EXIT button (7) to return to
the main window.
Doc. No. OM-81841-0103 3 - 33 (44)

14
Make sure that the strip applicator is
prepared for production. See chapter 6
Supplies of Materials.
Note! There must be enough strip
available in the strip reel for the
packaging material threading to be
done without any strip splice.
15
Production with PullTab.
Make sure that the patch magazine and
the tab magazine are prepared for
production. See chapter 6 Supplies of
Materials.
TechPub_2614345_0104 - TB068413en.fm
16
WARNING
Hydrogen peroxide.
Check the peroxide concentration.

If the machine has a peroxide
concentration meter, see Peroxide
Concentration Meter on page 2-43,
otherwise see chapter 9 Sterilisation
Liquid.
3 - 34 (44) Doc. No. OM-81841-0103

17
Note! If Preparing After Weekly Care
has been carried out, continue with
item 21.
WARNING
Hydrogen peroxide.
Open the top aseptic chamber door.
18
Shape the packaging material end as
shown (dotted line).
Feed the material through the tunnel (1)
and into the aseptic chamber. Feed
through approximately one metre of
1 material.
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19
Note! Only valid for filling machines
with the Crease Wheel.
Make sure that the top creases of the

packaging material match the short edge
of the crease wheel.
Doc. No. OM-81841-0103 3 - 35 (44)

20
Close the top aseptic chamber door.
21
WARNING
Hydrogen peroxide.
Open the upper aseptic chamber door and

the lower aseptic chamber door.
TechPub_2614345_0104 - TB068413en.fm
22
CAUTION
Risk of serious production fault.
Take care to remove all visible
product residue from the pipe.
Sterilisation is effective on clean
surfaces but may not be effective on
product residue.
Wipe off any product residue on the

lower part of the filling pipe with a
sponge.
Use water and cleaning compound code
D. See chapter 10 Technical Data. Rinse
with drinking water.
1 Spray a small quantity of disinfectant

code G3, on the filling pipe covering
entirely the flange area (1), shown
shaded in the picture. See chapter 10
Technical Data.
3 - 36 (44) Doc. No. OM-81841-0103

23
Take out the lower filling pipe (1) from
the container (2).
CAUTION
Risk of damage to the equipment.
1 Do not rinse with water. Allow the
lower filling pipe to drip dry.
24
Make sure the O-ring (1) is fitted and
undamaged, change it if necessary.
Fit the lower filling pipe (2) by means of
the locking pin (3).
3
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1 2
Doc. No. OM-81841-0103 3 - 37 (44)

25
Pull the packaging material down
through:
• the edge rollers (1)
1
• the upper tube support (2)
• the forming ring (3)
• the lower forming ring (4), and
2
• the seal (5).
Pull the packaging material down to the

jaw system.
Check that the jaws grip the packaging
3 material. If necessary pull down more
packaging material.
TechPub_2614345_0104 - TB068413en.fm
5
26
Check that the packaging material is
A correctly positioned, as shown, on each
side of the LS inductor roller.
27
Close the upper aseptic chamber door
and the lower aseptic chamber door.
3 - 38 (44) Doc. No. OM-81841-0103

28
On the control panel, turn the
SELECTOR switch to the LH position
(slow inching).
Press the INCH button to thread the
packaging material through the machine.
29
Check the position of the packaging
material at the areas shown (arrows).
Correct the position if necessary.
TechPub_2614345_0104 - TB068413en.fm
29 a
Check the position of the packaging
material at the areas shown (arrows).
Correct the position if necessary.
30
Domino Ink Jet Printer A300
Switch on the Domino Ink Jet Printer
A300 5 minutes before starting
2 production by pressing the power
switch (1).
1
The printer display (2) turns on.
Carefully follow the instructions shown
on the display (2).
Doc. No. OM-81841-0103 3 - 39 (44)

31
TPOP display.
TechPub_2614345_0104 - TB068413en.fm
32
When the TIGHT TUBE symbol starts to
flash, choose to run the TIGHT TUBE
wasting the packages up to the inlet of
the peroxide bath or to waste the
packages up to the strip applicator.
The first choice is automatically selected.
To select the second choice press the
TIGHT TUBE TO STRIP
APPLICATOR icon (1) in the
PACKAGE COUNTERS window on the
TPOP and then press 1 (2).
1 2
3 - 40 (44) Doc. No. OM-81841-0103

33
When the TIGHT TUBE symbol and the
PROGRAM UP button flash, press the
PROGRAM UP button until the motor
starts.
CAUTION
1 Risk of fire.
If the LS IH power setting (1) during
TIGHT TUBE is set too high, there is
a risk that the packaging material
tube could catch fire.
A warning signal sounds and the machine

inches forward without stopping until the
material tube is sealed with the LS strip.
TechPub_2614345_0104 - TB068413en.fm
34
LS, Patch and Tab Strip
Pick out the last package inched out from
the machine. Check according to section
Package Checks in the chapter 5 Checks,
that:
• the LS strip is correctly positioned
and properly sealed
• the patch strip is correctly positioned
and properly sealed
• the tab (strip) is correctly positioned
and properly sealed.
Doc. No. OM-81841-0103 3 - 41 (44)

35
WARNING
Risk of intoxication.
Keep the doors closed and follow the
Safety Precautions.
When the preheating temperature has

been reached, the SPRAYING symbol is
lit and the SPRAYING starts.
CAUTION
The aseptic chamber doors must not
be opened until the end of the
VENTING sequence. The jaw
system, final folder and doors must
not be opened until the SPRAYING
and DRYING sequence are
completed.
TechPub_2614345_0104 - TB068413en.fm
36
After the spraying sequence the
DRYING symbol remains lit and the
drying sequence begins automatically.
Note! If a small arrow appears on the
screen the sterilisation has failed.
The machine program will then
automatically step down to STEP
ZERO when the drying time is
finished.
The drying sequence takes 15 minutes. A

clock symbol will show the remaining
time.
Note! After the step DRYING and up
to the step PRODUCTION ENDED,
the program steps VENTING,
ASEPTIC CHAMBER DOORS,
ASEPTIC CHAMBER are performed
automatically when the machine
program is stepped down.
3 - 42 (44) Doc. No. OM-81841-0103

37
When the drying sequence is over, the
SIGNAL TO STERILISER symbol and
the PROGRAM UP button begin to flash.
Press the PROGRAM UP BUTTON. The
symbol SIGNAL TO STERILISER
remains lit. (Where there is a connection
between the filling machine and the
steriliser, a request for the product is sent
to the factory).
TechPub_2614345_0104 - TB068413en.fm
38
Production can start when the MOTOR
START symbol and PROGRAM UP
button begin to flash.
Note! If during stops or production
the aseptic chamber doors are open,
or the tube opens or bursts the
machine must be cleaned and
sterilised before production restarts.
Doc. No. OM-81841-0103 3 - 43 (44)

39
Proceed according to the chapter 4 Start.
Note! If the package counter is being
used, set it to zero:
a) In the main TPOP window, touch the

b) Touch the PACKAGE COUNTER
button.
c) Touch the RESET button to reset the
counter.
TechPub_2614345_0104 - TB068413en.fm
3 - 44 (44) Doc. No. OM-81841-0103

4 Start
TechPub_2614345_0104 - TB078413en.fm
Doc. No. OM-81841-0103 4 - 1 (6)

4 Start
This chapter describes how to start the machine for

PRODUCTION after Preparing after Daily Care.
To start the machine after a stop, see chapter 7 Stop.
CAUTION
Hazardous noise.
operation.
TechPub_2614345_0104 - TB078413en.fm
4 - 2 (6) Doc. No. OM-81841-0103

4 Start Table of Contents
Starting Production . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Stop and go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
TechPub_2614345_0104 - TB078413en.fm
Doc. No. OM-81841-0103 4 - 3 (6)

4 Start
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4 - 4 (6) Doc. No. OM-81841-0103

4 Start Starting Production
Starting Production
1
TPOP display.
2
The machine is ready to start when the
MOTOR START symbol is flashing.
Press the PROGRAM UP button; keep it
pressed until the MOTOR START
symbol remains lit and the warning
signal stops.
TechPub_2614345_0104 - TB078413en.fm
3
Stop and go
During the MOTOR START, the
machine starts to waste the needed
number of empty packages and then
stops automatically in design.
The prefilling begins with the start flow
set on TPOP. During the prefilling the
hooter beeps every second until the right
product level is reached.
As soon as the product level is acceptable
(40%), the hooter change the frequency
of the beeps and the PROGRAM UP
button start flashing.
Press the PROGRAM UP button; keep it
pressed until the start sequence begins
and the beep becomes continuous.
Doc. No. OM-81841-0103 4 - 5 (6)

Starting Production 4 Start
4
When the machine restarts, the
PRODUCTION symbol lights up and the
machine automatically lets the packages
through the final folder.
5
Follow the first packages through the
final folder and remove the first two
packages discharged from the machine.
2
1
TechPub_2614345_0104 - TB078413en.fm
6
Carry out the destructive checks. See
section Package Checks in the chapter 5
Checks.
Note! Remember to register the
number of packages taken for
destructive checks. See chapter 2
TPOP.
4 - 6 (6) Doc. No. OM-81841-0103

5 Checks
TechPub_2614345_0104 - TB088413en.fm
Doc. No. OM-81841-0103 5 - 1 (40)

5 Checks
This chapter describes the checks to perform when the

machine is in step PRODUCTION.
WARNING
Hazardous noise.
operation.
TechPub_2614345_0104 - TB088413en.fm
5 - 2 (40) Doc. No. OM-81841-0103

5 Checks Table of Contents
Machine Checks . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Honeywell Recorders . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
JUMO Recorders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 10
Package Checks . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11
Package Identification . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11
Package Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 12
General Instructions and Recommendations . . . . . .5 - 13
Check Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 14
Flowchart - Operator’s QA Checks . . . . . . . . . . . . . . .5 - 15
Operator’s Quality Checks. . . . . . . . . . . . . . . . . . . . . .5 - 16

TechPub_2614345_0104 - TB088413en.fm
Date Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 17
TS (Rough Check). . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 18
TS (Accurate Check). . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 18
Shape and Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 23
Tab Position Check. . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 24
LS Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 25
Tab Longitudinal Position . . . . . . . . . . . . . . . . . . . . . .5 - 26
Folded Tab Length . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 27
Sealed Tab Length . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 27
Tab Transversal Position . . . . . . . . . . . . . . . . . . . . . . .5 - 28
Flap Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 28
Crease Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 29
Doc. No. OM-81841-0103 5 - 3 (40)

Table of Contents 5 Checks
LS Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30
Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
LS Strip Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32
Hole Position (PullTab) . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
Patch (PullTab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37
Tab (PullTab). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 38
Only for ReCap Machine . . . . . . . . . . . . . . . . . . . . . . . 5 - 38
Check Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39
TechPub_2614345_0104 - TB088413en.fm
5 - 4 (40) Doc. No. OM-81841-0103

5 Checks Machine Checks
Machine Checks
This section describes the checks to perform on the filling machine during
PRODUCTION.
Note! Do not leave the machine unattended during PRODUCTION.
1
Monitor the warning lights.When they
are flashing, check the TPOP display and
take the required actions.
TechPub_2614345_0104 - TB088413en.fm
2
Check that the tube flushing flow is
normal.
Note! High flushing flow may cause
reading errors by the photocells. Low
+ -
flow may cause forming problems.
Adjust with the knob (see arrow).
Doc. No. OM-81841-0103 5 - 5 (40)

Machine Checks 5 Checks
1 3
Check that the pressure gauge (1) on
peroxide heating unit water, reads
between 120 to 150 kPa (1.2 to 1.5 bar).
If incorrect, call a technician.
Note! This pressure should be 70
kPA (0.7 bar) when the machine is in
step PREPARATION.
TechPub_2614345_0104 - TB088413en.fm
4
On the service unit, check that all
pressure gauges and flow meters on the
service unit indicate the correct settings.
See chapter 10 Technical Data for correct
2 2 2 2 2
settings.
1 1 1 1 1
0 0 0 0 0
5 - 6 (40) Doc. No. OM-81841-0103

5
Check that the packaging material moves
through the machine properly.
Check that all the strips supply function
correctly.
Check that the packages move through
the jaw system, final folder area and
outfeed correctly.
Refer to the threading diagram and make
checks at the positions shown by the
arrows:
• in the ASU
• in the LH side of the jaw system and
final folder area
• in the aseptic chamber
• in the ASSU
• in the RH side of the jaw system and
final folder area
TechPub_2614345_0104 - TB088413en.fm
• in the outfeed.
Doc. No. OM-81841-0103 5 - 7 (40)

6
Check the forming and shape of the
packages. See section Package Checks.
TechPub_2614345_0104 - TB088413en.fm
7
WARNING
Hydrogen peroxide.
Check the peroxide concentration.

If the machine has a peroxide
concentration meter, see Peroxide
Concentration Meter on page 2-43,
otherwise see chapter 9 Sterilisation
Liquid.
5 - 8 (40) Doc. No. OM-81841-0103

8
Check that all doors are closed. The
doors of the electrical cabinet must be
closed to ensure sufficient cooling.
Check that all safety covers and guards
are fitted.
Make sure the platform, the stairs, and
the area around the machine are clean
and free from loose objects.
TechPub_2614345_0104 - TB088413en.fm
9
Honeywell Recorders
Check that the process recorder prints
properly on all of the channels. If not,
call a technician.
Process recorder channels are as follows:
Ch Colour Function
DI 1 Purple Sterile parameters
DI 2 Red Operational
parameters
DI 3 Green Drive motor On
DI 4 Black In production
AN 1 Blue Temperature in
peroxide bath
AN 2 Brown Temperature in top
aseptic chamber
AN 3 Black Sterile air
temperature
Doc. No. OM-81841-0103 5 - 9 (40)

10
JUMO Recorders
Check that the printing on the recorder is
correct on all channels. If not, call a
technician.
Note! The channels AN4, AN5 and
AN6 are only used during CIP.
Recorder channels are as follows when

the machine is in production:
Ch Colour Function
DI 1 Purple Sterile parameters
DI2 DI4 AN1
DI 2 Red Operational
DI1 DI3 AN2 AN3 parameters
DI 3 Green Drive motor On
AN6
DI 4 Black In production
AN 1 Blue Temperature in
6 peroxide bath
AN5
AN 2 Brown Temperature in top
aseptic chamber
TechPub_2614345_0104 - TB088413en.fm
5 AN 3 Black Sterile air
AN4 temperature
5 - 10 (40) Doc. No. OM-81841-0103

5 Checks Package Checks
Package Checks
This section describes the checks to perform on the packages during
PRODUCTION.
Note! Package Checks and corrective actions will affect the Quality of
the PRODUCTION. Use these checking methods as the minimum
requirement. If there is any doubt about the integrity of the packages,
pick out more packages for further checking. Whenever a fault cannot
be eliminated call a technician.
Package Identification
When selecting packages for quality
checks, always select packages in
sequence.
LH a) When the jaw system is running,

visually identify a package made in
the RH jaw.
RH b) Visually follow this package as it
moves through the infeed unit, the
final folder, the discharger unit, and
TechPub_2614345_0104 - TB088413en.fm
out of the machine.

c) Remove the package made in the RH
jaw and one package either before or
after it.
d) To prevent confusion, mark 1 on the
package made in the RH jaw. Mark 2
on the following package.
2 e) Take a third package for LS checks.
1
Note! The 3rd package does not
need to be marked.
Note! Register the number of

packages taken for checks. See
section Record Package Waste for a
Quality Check in the chapter 2 TPOP.
Doc. No. OM-81841-0103 5 - 11 (40)

Package Checks 5 Checks
Package Terms
9 10 25 27 28 29 30
8 11 31
12 32
26
7 13
25 33
6
14 34
5
4 15 24 35
23 36 37 38
3 16
2 17 22
1 21
18 40 39
TechPub_2614345_0104 - TB088413en.fm
19 20 41
45 44 43 42
1 Bottom left fin corner 16 Bottom fin crease 31 Top transversal seal
2 Bottom front left corner 17 Bottom right fin corner 32 Top inner cross
3 Bottom crease 18 Bottom flap crease 33 Perforation
4 Front side of package/panel 3 19 Double creases 34 Top rear left corner
5 Left side of package/panel 2 20 Register code 35 Rear side of package/panel 1
6 Top front left corner 21 Bottom rear right corner 36 Longitudinal seal (LS)
7 Top flap creases 22 Rear side of package/panel 5 37 Air gap
8 Top left fin corner 23 Right side of package/panel 4 38 LS strip
9 Spout crease 24 Top rear right corner 39 LS overlap
10 Top right fin corner 25 Tab (PT, OE) 40 Bottom rear left corner
11 Top fin crease 26 IS patch (PT, OE) 41 Bottom transversal seal
12 Longitudinal crease 27 Hole (PT, OE) 42 Bottom cutting line
13 Top front right corner 28 Top cross 43 Bottom outer cross
14 Top crease 29 Top outer cross 44 Bottom inner cross
15 Bottom front right corner 30 Top cutting line 45 Bottom cross
5 - 12 (40) Doc. No. OM-81841-0103

General Instructions and

Recommendations
To waste the minimum quantity of
packages and optimise time do as
follows:
extract from Check Plan on page 5-14
Take 3 packages from the conveyor and
follow the instructions on Package
Production
1 Identification on page 5-11.
3 Start Perform the checks according to Check
Plan and Flowchart - Operator’s QA
Checks.
The Check Plan reports:
Date print page • the events considered (e.g.
1 5-16 Production Start) (1)
• the number of packages on which to
perform the test (2)
2 3 4 5
• the evaluation to be performed (3)
• the evaluation instructions page (4)
TechPub_2614345_0104 - TB088413en.fm
• the check box to mark when the

extract from Flowchart on page 5-15
check has been passed (5).
8 The Flowchart - Operator’s QA Checks
reports:
Flap • check sequence (6)
1 sealing • corrective actions (7)
• type of check (8).
6 no
TPOP Note! Use the same 2 packages to
Ok?
setting perform all the checks that require 2
yes
7 packages.
6 Note! The Check Plan can be
TS
8 photocopied and used as template
1 (rough)
during production.
6
no Stop
Ok? call a
Production technician
yes
7 7
Doc. No. OM-81841-0103 5 - 13 (40)

Check Plan
Check also the packages at intervals according to internal quality procedures. During Production
the Start check should be repeated at intervals of maximum 30 minutes and at every start.
After (*) IS strip
Start After LS
packaging 1 Tab
3 3 strip splice 1
material splice Splice
Date print page Date print page

1 5-16 1 5-16
Weight page Weight page

2 5-17 2 5-17
TS page TS page
2 (Rough) 5-18 2 (Rough) 5-18
TS page TS page
2 (Accurate) 5-18 2 (Accurate) 5-18
Shape and page Shape and page
TechPub_2614345_0104 - TB088413en.fm
1 design 5-23 1 design 5-23
Tab page Tab page Tab page

1 position 5-24 1 position 5-24 1 position 5-24
Flap page Flap page

1 sealing 5-28 1 sealing 5-28
Crease page Crease page

1 lines 5-29 1 5-29
lines
Overlap page Overlap page

1 5-30 1
5-30
Surfaces page Surfaces page

1 1 5-31
5-31
LS/SA page LS/SA page LS/SA page

1 5-32 1 5-32 1 5-32
Hole Hole page

Hole page page 1
1 1 position position 5-36
position 5-36 5-36
PullTab page PullTab page PullTab page

1 5-37 1 5-37 1 integrity
integrity integrity 5-37
5 - 14 (40) Doc. No. OM-81841-0103

Flowchart - Operator’s QA Checks
Crease
Date print 1 lines
1
no no TPOP
Stop call a
Ok? Ok?
Production technician setting
yes yes
Weight Overlap
1
2
no no Stop call a
Ok? Adjust Ok? Production technician
weight
yes yes
TS Surfaces
1
2 (Rough)
no no Stop call a
Stop call a Ok?
Ok? Production technician
Production technician
yes
TechPub_2614345_0104 - TB088413en.fm
yes
TS LS/SA
1
2 (Accurate)
no no Stop TPOP
Stop TPOP Ok?
Ok? Production Production setting
setting
yes yes
Hole
Shape and 1 position
1 design
no Stop call a
no TPOP Ok?
setting
yes
yes
PullTab
Tab 1
1 position
Integrity
no Stop call a
no TPOP call a Ok?
setting technician
yes
yes
Flap
1
continue
sealing
Production
no TPOP = Legal requirement related check

Ok? setting = Package integrity related check
yes = Package appearance and line efficiency check
Doc. No. OM-81841-0103 5 - 15 (40)

Operator’s Quality Checks

Tools needed:
• scissors
• stretch pliers, TP No. 78073-0100
• a clean working bench
• template Tab Position check, see
page 5-24
• magnifying glass.
Note! Perform the quality checks in a

well illuminated area.
TechPub_2614345_0104 - TB088413en.fm
Date Print
1 Check the date printing and the coding.
If necessary stop the filling machine and
adjust the date printing following the
instructions supplied with the printer.
5 - 16 (40) Doc. No. OM-81841-0103

Weight
2
1
Weigh the packages.
Record the weights and weight
deviations.
To adjust the package weight during
production, turn the knob on the process
panel:
• plus, increases the package weight
• minus, decreases the package
weight.
This must be done during the step

PRODUCTION.
After setting, pick out new packages and
check them.
+ -
TechPub_2614345_0104 - TB088413en.fm
1 2 3 4 Headspace by Injection
2
If the package weights are the same but
wrong, set the weight by means of the
TPOP.
button (6).
Touch the FILLING SYSTEM
button (5).
Touch the HEADSPACE HI button (1).
The colour of the button becomes blue
and the SETTING WINDOW (2) will be
displayed.
Touch buttons (3) or (4) to increase or
decrease the quantity of headspace in a
package.
Touch the EXIT button (7) to return to
the main window.
5 6 7 After setting, pick up new packages and

check the package weight.
Doc. No. OM-81841-0103 5 - 17 (40)

TS (Rough Check)
2
Unfold the flaps.
Check the integrity of the top and bottom
transversal seal by gently squeezing the
packages by hand.
Critical points are:
• the corners
• the intersections between the LS
creases and the TS
• the crosses where the TS and the LS
meet.
If any product leakage is found, call a

technician.
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2
TS (Accurate Check)
1
Take the packages under investigation.
Cut a sample strip (1) of about 25 mm
width from the top and bottom
transversal seals.
Wash the samples and dry them, with
compressed air from the machine.
1
1
5 - 18 (40) Doc. No. OM-81841-0103

2
Cut off no more than 1 mm from each
side of the package at 90° angle respect
to the TS.
TechPub_2614345_0104 - TB088413en.fm
2a
Bend the TS. The sealing is defective if
there are lumps or ridges in the sealing
area.
This may be caused by too much heat or
high pressure on the jaws during sealing.
To adjust the temperature, see TS IH
Power Setting on page 2-48.
If the pressure is too high call a
technician.
Doc. No. OM-81841-0103 5 - 19 (40)

1 2 3
Insert the edges of the sample (1) into the
gripping jaws (2) of the stretch pliers.
Gently squeeze the handles to stretch the
seal.
Note! Stretching slowly makes
evaluation easier.
Observe that the seal area stretches and

breaks.
3 Continue stretching along the sample (1)
until it has completely opened.
All TS must be stretched and evaluated
4 along the entire seal.
Pay special attention to the TS
corners (3) and where the TS and the LS
4 meet (TS/LS cross) (4).
TechPub_2614345_0104 - TB088413en.fm
3
4
1 2 3 4 3 2 1 Stretch all TS along the entire seal with
the stretch pliers and evaluate them.
Note! It is mainly the sealing on the
product side (area A) that is
important.
5 A
1 Paper board
2 Aluminium foil
3 Polyethylene (double layer)
4 Filling product
5 Blocked area
6 Sealed area
6 7
7 Ridge
8 Cutting line
5 8
5 - 20 (40) Doc. No. OM-81841-0103

4a
Check the TS sealing while tearing it:
The sealing is acceptable if:
• the seal remains intact but a
delamination between the two inner
coatings takes place (fig.1)
fig.1
• the seal remains intact when the joint

is pulled apart, but the Al-foil comes
off on one of the sides presenting a
shiny metal surface (fig.2)
fig.2
• the seal remains intact but a rupture

takes place in the layer of paper
TechPub_2614345_0104 - TB088413en.fm
board (fig.3).
The sealing is defective if:

the seal is so weak that the two plastic
fig.3 layers separate without rupturing (fig.4).
This may be caused by too low a sealing
temperature.
The TS is defective if:

the seal is so overheated that the two PE
fig.4 layers (1) disappear from the sealing area
because they have melted away and the
aluminium foil (2) shows micro-cracks
2 1 and cuts (fig.5).
In this case, specific induction heating
setting must be carried out, see TS IH
fig.5
Doc. No. OM-81841-0103 5 - 21 (40)

4b
Check the TS sealing in the cross area.
Note! The evaluation of the TS also
applies to the evaluation of the cross.
The strip (shown by the arrow) can be

regarded as additional layers of coating
on the Al-foil.
fig.1
a rupture occurs in any of the layers
(fig.1).
The sealing is defective if:
there is no rupture (fig.2). This may be
caused by too low a sealing temperature.
fig.2
TechPub_2614345_0104 - TB088413en.fm
5 - 22 (40) Doc. No. OM-81841-0103

Shape and Design

1 Check the shape of the package.
Correct shape Check that the preformed creases in the
packaging material are correctly aligned
along the top crease.
Low crease position High crease position

TechPub_2614345_0104 - TB088413en.fm
If the crease position is not correct, touch

the MANOEUVRE SYSTEM button in
the TPOP main window.
Touch the DESIGN CORRECTION
button.
Touch the DESIGN CORRECTION
PHOTOCELLS button.
Increase the value if necessary.
To move the crease in the opposite
direction, decrease the value.
Doc. No. OM-81841-0103 5 - 23 (40)

c Tab Position Check

1 Place the template (1) above the
a package (2) so that the package
b surfaces (A), (B) and (C) are in contact
with the inside surfaces (a), (b) and (c) of
the template (1).
a
c Package Template
TBA 1000 S (Hole 50) 1490166-0000
b
TBA 1000 B (Hole 50) 1490164-0000
TBA 1000 S (Hole 85) 1487235-0000
TBA 1000 B (Hole 85) 1487236-0000
1 TBA 1000 Sq (Hole 85) 1499183-0000
TBA 1500 S (Hole 85) 1499181-0000
TPA 1000 Sq (Hole 60) 1500095-0000
2 TBA 1500 S (Hole 90) 2651295-0000
TechPub_2614345_0104 - TB088413en.fm
A
B C
5 - 24 (40) Doc. No. OM-81841-0103

1
LS Position
Check that the LS paper edge (2) is
visible between the two marks (3) of the
template (1).
1
If the paper edge is not visible or is
hidden below one of the two signs, the
2 crease line position (tube position) is
required, see Crease Lines on page 5-29.
3
TechPub_2614345_0104 - TB088413en.fm
Doc. No. OM-81841-0103 5 - 25 (40)

1
Tab Longitudinal Position
Check that the tab edge (4) of the tab (1)
is visible between the two marks (3) of
the template (2).
5 3
4 If the tab edge (4) is not visible or is
1 hidden below one of the two marks (3),
adjust the position of the tab (4) by
means of the TPOP.

button.
TechPub_2614345_0104 - TB088413en.fm
Touch the PULLTAB, RIGHT button.
Touch the PULL TAB POSITION

button.
Adjust the value if necessary.
Note! The adjustment range
corresponds to a movement of ± 2
mm on the Pulltab position, this range
is the same for all volumes. The
actual adjustment will be done in
steps of 0.15 mm each index if the
change is greater then 0.3 mm. Run
at least 80 packages before checking
the position again.
5 - 26 (40) Doc. No. OM-81841-0103

Folded Tab Length

Place the template (1) on the opening so
that the mark (2) is in correspondence to
7 the tab edge (3).
1
6 Check that the folded edge (4) of the
tab (5) is between the marks (6) and (7)
of the template (1).
4
The tab (5) length must not exceed the
2 mark (7). If it does call a technician.
3
5
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Sealed Tab Length

Unfold the tab (1). Place the template (2)
2 on the opening so that the mark (3) is in
correspondence to the tab edge (4).
6
Check that the sealed edge (5) of the
tab (1), corresponds to the mark (6) of the
template (2). If not call a technician
3
4
1
Doc. No. OM-81841-0103 5 - 27 (40)

Tab Transversal Position

Check that the folded edge (4) of the
tab (1) is visible between the two
marks (3) of the template (2). If not call a
2 technician.
4
3
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Flap Sealing
1
Unfold the flaps and check that they are
properly sealed.
If necessary, adjust the sealing
temperature of the flaps, see Overview
Temperature on page 2-45.
5 - 28 (40) Doc. No. OM-81841-0103

Bottom view of package Crease Lines

1
Check the position of the preformed
1 1 crease lines (1).
fig.1
The position is acceptable if:
the creases are opposite one another
(fig.1) either parallel (fig.2) or at an angle
(fig.3).
fig.2
fig.3
TechPub_2614345_0104 - TB088413en.fm
The position is not acceptable if:

fig.4
the preformed crease lines are not
opposite one another (fig.4).
To adjust the position of the preformed
crease lines, turn the knob clockwise to
rotate the tube and move the creases in
the direction shown, and vice versa.
After adjustment, pick out new packages
and check them. Check the longitudinal
sealing according to item 4 on page 5-34.
Doc. No. OM-81841-0103 5 - 29 (40)

LS Overlap
1 Check the width of the LS overlap,
distance A. If the distance A is out of
tolerance, call a technician.
Package A (mm)
A TBA 200 S 4.0 ± 0.5
TPA 250 Sq 5.0 ± 1
TBA 250 S 6.0 ± 1
TBA 1000 Sq 6.0 ± 1
TPA 1000 S 6.0 ± 1
TBA 500 S 7.0 ± 1
TPA 1000 Sq 7.0 ± 1
TBA 200 B 8.0 ± 1
TBA 250 B 8.0 ± 1
TBA 330 S 8.0 ± 1
TBA 500 B 8.0 ± 1
TBA 1000 B 8.0 ± 1
TechPub_2614345_0104 - TB088413en.fm
TBA 1000 S 8.0 ± 1
TBA 1500 S 8.0 ± 1
5 - 30 (40) Doc. No. OM-81841-0103

fig.1 Surfaces
1 Cut two opposite corners (fig.1) and
empty the content of the package.
Cut transversally the front panel of the
fig.2 package, from the lower cut corner to the
opposite one (fig.2 and 3).
Split the TS apart and open the package
(fig.4).
Rinse and dry the package with
compressed air from the filling machine.
Check the outside and inside surfaces of
fig.3 the package for scratches or other
possible defects that can be detected with
the fingernail.
Inside deep scratches might cause
package integrity problems.
If there are any defects, call a technician.
TechPub_2614345_0104 - TB088413en.fm
fig.4
Doc. No. OM-81841-0103 5 - 31 (40)

LS Strip Applicator
1 1
Note! The Longitudinal Sealing side
(LS) is the side of the strip (2) where
1 2 6 3 the packaging material (1) is single.
The Strip Applicator (SA) side is the
side of the strip where the packaging
material (3) is double.
Note! For the MPM strip type, the

strip must be positioned 2/3 on the
A B SA side and 1/3 on the LS side.
Check that the LS strip is symmetrically

1 2 3 positioned on one package. The strip
sealed on the SA (excluding the air gap)
must be less than half the width of the
strip.
Check for any blister or bubble (4) along
the heated zone of the LS strip (2).
A B
TechPub_2614345_0104 - TB088413en.fm
Presence of blisters (4) in the LS side (A)
1/3 2/3 of the strip (2) indicates too much sealing
temperature for the LS induction heater.
Presence of blisters in the SA side (B) of
4 the strip indicates too much sealing
5 temperature for the Strip Applicator
induction heater.
4
On the LS strip (2) there are visible some
small heating lines (5) mainly at the Strip
6 Applicator side.
Note! Stop the machine in SHORT
2 STOP before adjusting the strip
position.
AB
If required, adjust the position of the LS
strip by means of the knob (7) on the strip
roller.
Call a technician in case the setting of the
LS or SA inductors must be changed.
Note! The air channel (6) must be
7 visible.
5 - 32 (40) Doc. No. OM-81841-0103

2
Check that there are no blisters in the Al-
foil.
Cut through the middle of the LS strip,
along the inner edge of the packaging
material.
Pull off the overlapping packaging
material layer along the outside of the
package.
3
Check the strip sealing by slowly pulling
approximately 20 mm of the strip
outwards at an angle of 90°. Pull
extremely slowly over the creases. Take
hold again and pull another 20 mm.
Continue along the whole edge. Pull on
90 both sides (SA and LS).
TechPub_2614345_0104 - TB088413en.fm
Note! If any of the layers come off,

cut the strip and start pulling again.
Doc. No. OM-81841-0103 5 - 33 (40)

1 4
Check the strip sealing.
fig.1
• both inner coatings come off with the
strip (1), leaving the Al-foil bare
(fig.1)
1 • one of the two inner coatings comes

off with the strip (1), leaving a
fig.2 ruptured edge (2) along the seal (fig.
2)
1
• all the inner layers including the Al-
foil come off with the strip (1),
fig.3
although possibly leaving paper
board fibres (3) (fig.3)
TechPub_2614345_0104 - TB088413en.fm
3
1
• the strip separates (delaminates)
when it is pulled off (fig.4).
fig.4
• all the inner layers including the Al-

foil come off with the strip (1), even
possibly leaving part of the inner PE
1 layer (4) on both sides.
4 The sealing is defective if:
fig.5
• the strip (1) comes off leaving the
inner coatings of the package
unaffected (fig.6). This may be
caused by too low a sealing
temperature. To adjust the
1 temperature see LS IH Power Setting
on page 2-49. Check the seal by
fig.6 tearing the strip after each
adjustment. Repeat if necessary.
5 - 34 (40) Doc. No. OM-81841-0103

Hole Position (PullTab)

1
1
Inside view of package Holes 21, 25, 45, 50, On the inside of the package, check the
55, 60, 85, 90 distance B from the centre of the top fin
crease (1) to the edge of the PullTab hole.
Package B ± 0.5 (mm)

B
TBA 250 B Hole 21 4.0
TBA 500 S Hole 25 6.5
TBA 1000 B Hole 45 10.0
1 TBA 1000 S Hole 45 8.9
TBA 1500 S Hole 45 11.0
TBA 1000 B Hole 50 11.4
TBA 1000 S Hole 50 10.3
TBA 500 S Hole 55 8.25
TPA 1000 S Hole 60 8.4
TPA 1000 Sq Hole 60 11.0
TBA 1000 B Hole 85 11.0
TechPub_2614345_0104 - TB088413en.fm
TBA 1000 S Hole 85 9.9

TBA 1000 Sq Hole 85 13.0
TBA 1500 S Hole 85 12.0
TBA 1000 S Hole 90 9.7
TBA 1500 S Hole 90 9.7
Doc. No. OM-81841-0103 5 - 35 (40)

2
1
If necessary, adjust the hole position.
In the main TPOP window, touch the
Touch the PULLTAB, RIGHT button.
Touch the HOLE POSITION
PHOTOCELLS button.
Adjust the value if necessary.
TechPub_2614345_0104 - TB088413en.fm
5 - 36 (40) Doc. No. OM-81841-0103

Patch (PullTab)
1
1
Inside view of package On the inside of the package, check that
the patch is fully sealed onto the inside of
the packaging material, and that it covers
the hole completely.
Also check that there is a minimum of
0.5 mm of patch all around the hole.
If there is not, the package integrity is
defective. Call a technician to set the
patch applicator.
TechPub_2614345_0104 - TB088413en.fm
2
Apply red ink by means of a plastic
pipette to the inside surface of the
packages in the area shown. See chapter
10 Technical Data for the TP No.
Wait for five minutes to let the ink dry.
If too much ink has been applied, wipe
off with a clean dry cloth.
Check that there is no ink penetration
through the edges of the patch.
If there is, the package integrity is
defective. The patch sealing temperature
and/or pressure must be adjusted.
To adjust the temperature see Overview
To adjust the pressure see section PullTab
Unit, LH Side on page 1-8.
Check also that there are no scratches or
wrinkles in the patch.
Doc. No. OM-81841-0103 5 - 37 (40)

Tab (PullTab)
1
1
Check that the tab is sealed to the
packaging material, and that it covers the
hole completely.
If it does not, package integrity is
defective. Call a technician to set the tab
applicator.
TechPub_2614345_0104 - TB088413en.fm
Only for ReCap Machine
2
1 Note! Perform this check before the
cap is applied.
Check that the tab (1) is properly folded

2 at the edge of the sealing area (2).
Incorrectly folded tabs are not
acceptable. Call a technician to set the
not acceptable tab folding device.
acceptable
5 - 38 (40) Doc. No. OM-81841-0103

Outside view of package

3
Check that the inside PE is delaminated.
Check that there is no ink penetration
into the packaging material layers around
the PullTab hole.
If there is, the package integrity is
defective. The patch sealing temperature
and/or pressure must be adjusted.
To adjust the temperature see Overview
To adjust the pressure see section PullTab
Unit, LH Side on page 1-8.
TechPub_2614345_0104 - TB088413en.fm
Check Air Gap

Inside view of package Holes 21, 25, 45, 50,
55, 60, 85, 90
Check that the amount of PE visible
around the edges of the hole is within
tolerance.
C C
0.5 mm ≤ C ≤ 3 mm
Doc. No. OM-81841-0103 5 - 39 (40)

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5 - 40 (40) Doc. No. OM-81841-0103

TechPub_2614345_0104 - TB098413en.fm
Doc. No. OM-81841-0103 6 - 1 (22)

This chapter describes how to load and prepare a new reel

of packaging material and how to thread and splice the
strips.
WARNING
Hazardous noise.
operation.
TechPub_2614345_0104 - TB098413en.fm
6 - 2 (22) Doc. No. OM-81841-0103

6 Supplies of Materials Table of Contents
Strip Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Threading of LS Strip . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5
Preparation of a New Strip Reel . . . . . . . . . . . . . . . . . .6 - 7
New Upper Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 8
New Lower Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 9
Manual Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Patch Strip Threading . . . . . . . . . . . . . . . . . . . . . . . . .6 - 12
Tab Strip Treading . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 13
Patch and Tab Strips Splicing . . . . . . . . . . . . . . . . . . .6 - 14
Packaging Material Supplies . . . . . . . . . . . . . . 6 - 17

TechPub_2614345_0104 - TB098413en.fm
Reel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 17
Splicing Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 19
Checking Packages . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 22
Manual Web Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 22
Manual Web Splice (for Faulty Barcode) . . . . . . . . . .6 - 22
Interrupted Web Splice. . . . . . . . . . . . . . . . . . . . . . . . .6 - 22
Doc. No. OM-81841-0103 6 - 3 (22)

TechPub_2614345_0104 - TB098413en.fm
6 - 4 (22) Doc. No. OM-81841-0103

6 Supplies of Materials Strip Supplies
Strip Supplies
Note! Before touching the strip(s), disinfect hands/gloves.
Note! To avoid unnecessary production stops, always make sure that

the strip reels are prepared and the strips are threaded.
Threading of LS Strip
1
Open the ASSU door.
2
Remove the protective wrapping from
TechPub_2614345_0104 - TB098413en.fm
the strip roller. Make a note of the type of

strip and lot number indicated in the tag
placed on the strip reel.
Note! The individual number
allocated to each reel provides
traceability for the production batch. If
a problem with the packaging
material is found, the lot number must
be quoted in any communication with
Tetra Pak.
Note! For cleaning compound code

PPP-STRIPS information see the chapter Technical
7,5/0,075 Data.
449732:16:3
lot number
Doc. No. OM-81841-0103 6 - 5 (22)

Strip Supplies 6 Supplies of Materials
10
3
Note! The strip shown in grey will be
2 used for production. The strip shown
in black is prepared for splicing.
8
a) Fit a jumbo strip reel (2) to each of
6 the two reel holders.
3
b) Make sure the roller (1) is positioned
with the arrow UP.
c) Thread as shown in the picture. Take
1 UP 7 9 4 care not to twist the strip during the
threading.
1 5 d) Move the slide backwards by means
of the slide knob (4), fit the strip
UP
under the metal finger (5), up to the
groove (6), above the pad (7), down
into position through the two
channels (8) and (9), close the slide.
2 e) Pull the strip that will be used for
production over the roller (10).
TechPub_2614345_0104 - TB098413en.fm
f) Pull out the knob (3) and open the
strip magazine frame.
4
a) Thread the strip over the roller (1).
b) Attach a piece of adhesive tape (4) to
the end of the strip (not wider than
the strip).
c) Pull the pressure roller (3) away from
1 the packaging material and lock into
4 place.
d) Attach the tape (4) to the edge of the
packaging material.
Note! The fastening tape for the strip
can cling to a roller and be pulled off
and away from the packaging
material.
e) Release the pressure roller (3).

f) Thread the strip over the steering
roller (2).
6 - 6 (22) Doc. No. OM-81841-0103

5
a) Close the strip magazine frame and
make sure it locks correctly.
b) Ensure that the strip guard (1) is
positioned on top of the strip
c) Rewind the strip reel slightly to
1 tighten the strip.
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6
Close the ASSU door and reset the
alarms on the TPOP display.
Preparation of a New Strip

Reel
1
Remove the protective wrapping from
the strip roller.
Doc. No. OM-81841-0103 6 - 7 (22)

2
Open the ASSU door.
Remove the empty strip reel and put in a
new one.
3
New Upper Reel
4
Thread as shown in the picture, and
ensure that the strip is placed on the outer
diameter of the roller (1). Take care not to
TechPub_2614345_0104 - TB098413en.fm
twist the strip during the threading.
5 7 2
Move the slide backwards by means of
3 the slide knob (2), fit the strip under the
metal finger (3), up to the groove (4),
1 above the pad (5), down into position
through the two channels (6) and (7),
close the slide.
6 - 8 (22) Doc. No. OM-81841-0103

4
New Lower Reel
3
Thread as shown in the picture. Take care
not to twist the strip during the threading.
Move the slide backwards by means of
4 6 11 the slide knob (1), fit the strip under the
metal finger (2), up to the groove (3),
2 above the pad (4), down into position
through the two channels (5) and (6),
close the slide.
TechPub_2614345_0104 - TB098413en.fm
5
Rewind the strip reel slightly to tighten
the strip.
Close the ASSU door.
The machine is now prepared for an
automatic LS strip splice.
Doc. No. OM-81841-0103 6 - 9 (22)

6
Some packages are discarded after the
splice. Pick out the first three packages
and perform the destructive checks. See
Checks.
2
1 Note! Remember to register the
checks. See chapter 2 TPOP.
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6 - 10 (22) Doc. No. OM-81841-0103

Manual Splicing
1
In some cases it may be necessary to
perform a strip splice manually.
Before doing the splice, make sure that:
• both reels of LS strip are threaded
• the ASSU door of the LS strip
magazine is closed (arrow).
2
Press the MANUAL STRIP SPLICE
button.
The packages with the strip splice will be
discarded automatically.
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3
Some packages are discarded after the
splice. Pick out the first three packages
and perform the destructive checks. See
Checks.
1
checks. See chapter 2 TPOP.
Doc. No. OM-81841-0103 6 - 11 (22)

Patch Strip Threading

1
Fit the patch strip roller to the magazine
roller, note the unwinding direction.
Thread the patch strip through the
magazine as illustrated.
Note! Do not wrinkle the patch strip.
2
a) Thread the strip through the turning
device rollers and under the guide
rollers (1) and (2).
b) Press down the lever (4) to lift the
counter roller (7).
c) Insert the strip between the feeder
TechPub_2614345_0104 - TB098413en.fm
roller (3) and the counter roller (7).
1 2 3 4 7 d) Feed some strip manually by turning
the knob on the applicator.
Note! Manually force the cylinder

piston (6) towards the patch strip and
then back to cut off any excess
strip (5).
6 5
6 - 12 (22) Doc. No. OM-81841-0103

Tab Strip Treading

1
Fit a tab strip roller to the magazine
roller, note the unwinding direction.
Thread the tab strip through the magazine
as illustrated.
Note! Do not wrinkle the tab strips.
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2
a) Thread the strip through the turning
3 2 1 device rollers and under the guide
4 rollers (1) and (2).
b) Press down the lever (4) to lift the
7 counter roller (7).
c) Insert the strip between the feeder
5 roller (3) and the counter roller (7).
d) Feed some strip manually by turning
the knob on the applicator.
Note! Manually force the cylinder

6 piston (6) towards the patch strip and
then back to cut off any excess
strip (5).
Doc. No. OM-81841-0103 6 - 13 (22)

Patch and Tab Strips Splicing

1
The splicing sequence is the same for
both the patch and the tab strip.
A B
Prepare a new patch A or tab B strip
roller. Put a piece of black tape on the
inner side of the strip.
for the correct black tape type.
Note! For the patch strip there are

40-50 seconds available to do the
manual splice. For the tab strip, there
are 50-55 seconds available to do the
splice.
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2
Open the PullTab door and pull out the
magazine.
3
a) Push down the lock grip (1).
1 b) Stretch the strip and cut it with the
knife.
6 - 14 (22) Doc. No. OM-81841-0103

4
Release the lock grip and place the strip
end between the two lock grips and push
down the lock grip.
5
A B Change the strip reel.
TechPub_2614345_0104 - TB098413en.fm
6
1 2 Thread the strip over the roller (2), pass
the first lock grip (1) and place the new
strip under the old one with 2 mm
overlap.
Push down the lock grip and seal the strip
with the black tape piece.
7
Release the two lock grips and push in
the strip magazine.
Close the Pulltab door.
Doc. No. OM-81841-0103 6 - 15 (22)

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6 - 16 (22) Doc. No. OM-81841-0103

6 Supplies of Materials Packaging Material Supplies
Packaging Material Supplies

Note! The packaging material must never touch the floor. Before
touching the packaging material, disinfect hands/gloves.
Reel Handling
1
Pull out the reel holder catch slightly and
hold while pushing in the spring-loaded
lugs.
When the lugs lock, release the reel
holder catch.
2
Insert the reel holder into the core.
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3
Pull out the reel holder catch to release
the spring-loaded lugs.
Note! Check that the lugs have
expanded to lock the reel holder to
the reel.
Doc. No. OM-81841-0103 6 - 17 (22)

Packaging Material Supplies 6 Supplies of Materials
1 2 3 4
Place the packaging material reel on to
the trolley.
Note! Make sure that the reel is
placed in the correct direction of
rotation.
Lift the reel by pressing down the

lever (1) and pumping the handle (2).
Pull up the lever (1) to lower the reel.
The lever (3) operates the brake.
TechPub_2614345_0104 - TB098413en.fm
5
Remove the plastic wrapping from the
reel. Remove and keep the P-order tag.
Note! The unique P-order and reel
numbers allocated to each packaging
material reel and printed on the P-
order tag provide traceability for the
production batch. If a problem with
the packaging material is detected
these numbers must be quoted in any
communication with Tetra Pak.
Cut approximately two full turns of

packaging material from the reel.
Note! The arrow marks on the side of
the reels indicate where there are
factory splices. The packages
carrying a factory splice will be
discarded automatically.
Always check the packages after a

factory splice, see section Package
Checks in the chapter 5 Checks.
6 - 18 (22) Doc. No. OM-81841-0103

Splicing Preparation
1
WARNING
Risk of entanglement.
During production there are moving
parts in the compartment.
Open the ASU door behind the empty

packaging material reel.
2 Lift the lever (1) and pull the paper reel
1 handler lever (2) fully until the lever (1)
locks into place.
Remove the empty reel holder.
Transfer the new reel from the trolley on
to the paper reel handler.
Lift the lever (1) and push paper reel
handler lever (2) fully until the lever (1)
locks into place.
TechPub_2614345_0104 - TB098413en.fm
2
Pull down the material holder.
Pull out the pin and open the cutting
table.
Doc. No. OM-81841-0103 6 - 19 (22)

3
Press the MATERIAL LOCKING button
to release the material catches.
Remove the old web of packaging materi-
al from the material holder.
4
Clean the cutting table with a wet
sponge.
Disinfect the cutting table. Use cleaning
compound code G, see chapter 10
Technical Data.
TechPub_2614345_0104 - TB098413en.fm
5
the cutting table.
First fold the packaging material upwards
along the top crease (arrow), then
downwards, in order to obtain a sharp
crease.
6 - 20 (22) Doc. No. OM-81841-0103

6
Line up the top crease with the edge of
the cutting table and push the packaging
material against the guide pin (arrow).
7
Keep the packaging material in this
position and press the MATERIAL
LOCKING button.
TechPub_2614345_0104 - TB098413en.fm
8
Cut the packaging material by means of
the knife.
Note! Leave the knife in its RH
position after the cut.
Pull out the pin and close the cutting

table.
Fold up the material holder to production
position.
Close the ASU door.
Doc. No. OM-81841-0103 6 - 21 (22)

Checking Packages
Pick out and check the first two packages
after the splice, see section Package
Checks in the chapter 5 Checks.

1 number of packages taken for
TPOP.
Manual Web Splice

Press the MANUAL WEB SPLICE
button.
When the machine has performed the
splice, open the ASU door behind the
packaging material reel not in use.
Follow the instructions from item 2, on
TechPub_2614345_0104 - TB098413en.fm
page 6-19.
Manual Web Splice (for Faulty

Barcode)
If the barcode of the packaging material
is out of specification, then perform a
manual splice as follows.
Press for 0.5 seconds the MANUAL
WEB SPLICE button and the SHORT
STOP button simultaneously.
Follow the instructions from item 2, on
page 6-19.
Interrupted Web Splice

If the machine stops when a packaging
material splice is being performed, the
SPLICE INTERRUPTED alarm appears
on the TPOP.
To restart the machine, acknowledge the
alarm, remove the cause of the stoppage
and follow the procedure in Manual Web
Splice on page 6-22.
6 - 22 (22) Doc. No. OM-81841-0103

7 Stop
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Doc. No. OM-81841-0103 7 - 1 (14)

7 Stop
This chapter describes the different types of stop conditions

and how to stop the machine under normal operating
conditions.
WARNING
Hazardous noise.
operation.
Note! When possible, the machine should normally be stopped in a

SHORT STOP or a NORMAL STOP during PRODUCTION.
TechPub_2614345_0104 - TB108413en.fm
7 - 2 (14) Doc. No. OM-81841-0103

7 Stop Table of Contents
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Security Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Short Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Short Stop Time Exceeded . . . . . . . . . . . . . . . . . . . . . .7 - 8
Missing Patch/Tab Stop . . . . . . . . . . . . . . . . . . . 7 - 9

Normal Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
Production Finished Stop . . . . . . . . . . . . . . . . . 7 - 12

Interrupting the Automatic Sequence. . . . . . . . . . . . .7 - 13
TechPub_2614345_0104 - TB108413en.fm
Doc. No. OM-81841-0103 7 - 3 (14)

7 Stop
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7 - 4 (14) Doc. No. OM-81841-0103

7 Stop Emergency Stop
Emergency Stop
When there is a risk of serious danger to people or to the machine, push
any of the EMERGENCY STOP buttons (arrows) as quickly as possible.
1
When there is a risk of serious danger to
people or to the machine, press any of
the emergency stop buttons (arrows)
immediately:
a) All machine movements and
functions stop instantly.
b) The pneumatic system de-pressurizes
with some exceptions. See chapter
Safety Precautions.
c) The machine program steps down to
STEP ZERO.
Take the following actions:
a) Eliminate the cause of the stop.
b) Reset the EMERGENCY STOP
TechPub_2614345_0104 - TB108413en.fm
button.
(behind cover) c) Empty from the tube any remaining
product residue by cutting it open.
d) Register the cause and number of lost
packages in the collect system. See
chapter 2 TPOP.
e) Clean the machine according to
section Daily Care in the chapter 8
Care and Cleaning.
f) Restart production. See section
Preparing after Daily Care in the
chapter 3 Preparation.
Doc. No. OM-81841-0103 7 - 5 (14)

Security Stop 7 Stop
Security Stop
All hazardous areas of the machine are fitted with safety switches. If any
door or guard fitted with a safety switch is opened the machine will perform
a SECURITY STOP.
1
During PRODUCTION the machine will
stop immediately if:
• the doors of the aseptic chamber (1),
1 (2) and (3) are open
• the side doors are open.
2 See also chapter Safety Precautions.

If any of the aseptic chamber doors (1),
(2) or (3) have been opened, the machine
3 resets to STEP ZERO. Follow the
instructions from item 2 on page 8-5 in
section Daily Care in the chapter 8 Care
and Cleaning.
If the side doors of the jaw system and
TechPub_2614345_0104 - TB108413en.fm
final folder have been opened, close the
door, reset the alarm on the TPOP, then
press the FINAL FOLDER INCHING
button on the TPOP.
If any other doors have been opened,
close them and reset the alarm on the
TPOP.
(behind cover)
7 - 6 (14) Doc. No. OM-81841-0103

7 Stop Short Stop
Short Stop
Use the SHORT STOP button to stop the machine for 15 minutes or less.
1
Use the SHORT STOP button to stop the
machine for 15 minutes or less.
a) Select whether to stop the LH or the
RH pair of jaws in an open position
by turning the selector switch.
b) Press the SHORT STOP button and
the machine stops in design with the
selected jaw pair in an open position.
(A time bar is displayed on the TPOP
showing the time left since the Short
stop button was pressed).
c) Register the stop reason in the collect
system. See chapter 2 TPOP.
Note! If the crank is inserted while

the machine is in SHORT STOP, the
machine automatically resets to
TechPub_2614345_0104 - TB108413en.fm
EMERGENCY STOP.
Note! If the package material splice

is in the peroxide bath while the
machine is in SHORT STOP, the
machine automatically steps down to
DRYING.
Doc. No. OM-81841-0103 7 - 7 (14)

Short Stop 7 Stop
2
a) Press the PROGRAM UP button to
restart the machine.
b) Pick up some packages to check the
LS seal. Discard any packages with a
defective LS seal. See section
Package Checks in the chapter 5
Checks.
c) Pick out packages and carry out the
destructive checks. See section
Package Checks in the chapter 5
Checks.
d) Register the number of packages
taken to check the LS seal and for
TPOP.
TechPub_2614345_0104 - TB108413en.fm
3
Short Stop Time Exceeded
If the machine has been stopped for more
than 15 minutes, the machine program
steps down to step DRYING.
If the machine restarts between 15 to 20
minutes, it wastes the aseptic chamber
packages.
If the machine restarts in more than 20
and the hydrogen peroxide bath
packages.
Note! Make sure to inch the machine
to empty the product from the tube.
Restart the machine as usual. See chapter

4 Start.
7 - 8 (14) Doc. No. OM-81841-0103

7 Stop Missing Patch/Tab Stop
Missing Patch/Tab Stop

If any patch or tab is missing the machine will perform a MISSING PATCH/
TAB STOP.
1
When the machine stops in SHORT
STOP due to a missing patch or tab, open
the PullTab door.
2
a) Remove any jammed strip from the
patch feeder.
b) Remove any jammed strip from the
TechPub_2614345_0104 - TB108413en.fm
tab feeder.
c) Carefully remove any plastic residue
from the sealing plates and knives
Doc. No. OM-81841-0103 7 - 9 (14)

Missing Patch/Tab Stop 7 Stop
3
WARNING
Risk of burns.
The parts may be hot.
On the non-printed side of the packaging

material, use black tape to cover all the
open holes.
for the correct type of black tape.
TechPub_2614345_0104 - TB108413en.fm
4
a) If required, thread the patch strip and
the tab strip. See chapter 6 Supplies
of Materials.
b) Close the PullTab door.
c) Restart the machine by pressing the
PROGRAM UP button.
7 - 10 (14) Doc. No. OM-81841-0103

7 Stop Normal Stop
Normal Stop
Use NORMAL STOP to stop the machine during PRODUCTION.
1
To stop the machine during production,
press the PROGRAM DOWN button.
The machine program steps down to
DRYING. The SIGNAL TO
STERILISER symbol and the DRYING
symbol are lit.
The machine continues until the product
is emptied from the tube and then stops.
Register the stop reason in the collect
system. See chapter 2 TPOP.
If the machine restarts in less than 15
minutes, it wastes the minimum number
of packages to go in design.
If the machine restarts between 15 to 20
TechPub_2614345_0104 - TB108413en.fm
packages.
If the machine restarts in more than 20
and the hydrogen peroxide bath
packages.
Restart the machine as usual. See chapter
4 Start.
Note! If the machine has been
stopped for more than 20 minutes,
inch the machine to renew the
material tube in the aseptic chamber.
Doc. No. OM-81841-0103 7 - 11 (14)

Production Finished Stop 7 Stop
Production Finished Stop

Use PRODUCTION FINISHED if this is the planned time to end
PRODUCTION.
1
To stop the production run, press the
PROGRAM UP button.
The machine program steps up to
PRODUCTION ENDED.
As soon as the tube is empty, there is a
pause for two minutes.
Note! To interrupt the automatic
sequence see Interrupting the
Automatic Sequence on page 7-13.
TechPub_2614345_0104 - TB108413en.fm
2
After the pause the machine program
steps to VENTING ASEPTIC
CHAMBER for 10 minutes. A time bar
on the TPOP display shows the
remaining time.
After the step VENTING ASEPTIC
CHAMBER, the machine automatically
proceeds to step DOORS ASEPTIC
CHAMBER.
The peroxide fumes are exhausted, the
compressor stops, and the aseptic
chamber doors can be opened.
Perform maintenance. See section Daily
Care in the chapter 8 Care and Cleaning.
7 - 12 (14) Doc. No. OM-81841-0103

7 Stop Production Finished Stop
Interrupting the Automatic

Sequence
3
During the two minute pause before the
program steps to VENTING ASEPTIC
CHAMBER, it is possible to proceed
straight to step VENTING, or return to
Go immediately to PRODUCTION.
VENTING ASEPTIC CHAMBER Return to PRODUCTION
• To step to VENTING ASEPTIC
CHAMBER, press the PROGRAM
UP button for three seconds.
• To return to PRODUCTION press
the PROGRAM DOWN button.
– The program steps to DRYING.
– The SIGNAL TO STERILISER
symbol and the PROGRAM UP
button start to flash.
– Press the PROGRAM UP button
and restart the machine as usual.
See the Start section.
TechPub_2614345_0104 - TB108413en.fm
Doc. No. OM-81841-0103 7 - 13 (14)

Production Finished Stop 7 Stop
TechPub_2614345_0104 - TB108413en.fm
7 - 14 (14) Doc. No. OM-81841-0103

8 Care and Cleaning
TechPub_2614345_0104 - TB118413en.fm
Doc. No. OM-81841-0103 8 - 1 (60)

8 Care and Cleaning
This chapter describes how to clean and maintain the

machine. Perform Daily Care after every PRODUCTION
run. Perform Weekly care once a week or after every 120
hours of operation.
Note! Use only Tetra Pak recommended cleaning compounds when
cleaning parts which may come into contact with hydrogen peroxide.
Cleaning with non-recommended compounds may cause an
explosion!
TechPub_2614345_0104 - TB118413en.fm
8 - 2 (60) Doc. No. OM-81841-0103

8 Care and Cleaning Table of Contents
Daily Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
After Production with HI. . . . . . . . . . . . . . . . . . . . . . . . .8 - 7
After Production with HI Bypassed. . . . . . . . . . . . . . . .8 - 8
Intermediate Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .8 - 17
Final Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 18
Honeywell Recorders . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 24
JUMO Recorders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 25
Honeywell Process and Cleaning

Recorders (OE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 29
JUMO Process and Cleaning Recorders (OE) . . . . . .8 - 29

TechPub_2614345_0104 - TB118413en.fm
After Cleaning with HI . . . . . . . . . . . . . . . . . . . . . . . . .8 - 34
HI Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 34
Weekly Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37
Gasket replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 49
Change Cutting Rail and Dollies . . . . . . . . . . . . . . . . .8 - 53
Change Knife. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 54
Change Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 55
Clean Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 59
Doc. No. OM-81841-0103 8 - 3 (60)

8 Care and Cleaning
TechPub_2614345_0104 - TB118413en.fm
8 - 4 (60) Doc. No. OM-81841-0103

8 Care and Cleaning Daily Care
Daily Care
This section describes what to do after each PRODUCTION run or at least
every 24 operating hours.
1
WARNING
Hydrogen peroxide.
Open the upper aseptic chamber door.

TechPub_2614345_0104 - TB118413en.fm
2
Cut the packaging material at the point
A.
A
Doc. No. OM-81841-0103 8 - 5 (60)

Daily Care 8 Care and Cleaning
3
WARNING
Hydrogen peroxide.
Close the upper aseptic chamber door.
4
Press the INCHING button until the
packaging material tube has been fed out.
TechPub_2614345_0104 - TB118413en.fm
5
Open the final folder door.
8 - 6 (60) Doc. No. OM-81841-0103

6
WARNING
Risk of burns.
The nozzles and other parts of the
final folder may be hot. Wear
personal protective equipment.
Clean the four heating nozzles of the flap

heater (arrow) in the final folder with a
brass wire brush. Check that the air holes
on the nozzles are not clogged after the
cleaning.
Blow clean with compressed air.
TechPub_2614345_0104 - TB118413en.fm
2 7
After Production with HI
a) Loosen the clamps (1) and remove
1 the pipe (2).
3 b) Remove the O-ring (3), the
4 nozzle (4) and the gasket (5). They
5 6
will be cleaned separately later.
c) Fit the gasket (6), and reconnect the
pipe (2).
d) Fit the pipe (2) in place by means of
the clamps (1).
e) Disconnect the pipe (7). Swing it
over to CIP position (LH position as
8 shown in the picture) and connect it.
Make sure that the O-ring (3) is in
place.
f) Make sure that the locking device (8)
is tightened.
Doc. No. OM-81841-0103 8 - 7 (60)

8
After Production with HI
Bypassed
No special cleaning procedures are used
after production with HI bypass.
Note! Make sure that the locking
device (1) is tightened.
TechPub_2614345_0104 - TB118413en.fm
9
Pull the bow clamp outwards.
8 - 8 (60) Doc. No. OM-81841-0103

10
Remove the locking pin (1) to remove the
lower part of the filling pipe.
Note! These parts are cleaned later
after CIP and external cleaning have
been started.
2
Remove, check and clean the O-ring (2).
1
TechPub_2614345_0104 - TB118413en.fm
Doc. No. OM-81841-0103 8 - 9 (60)

11
Carefully note how the pressure roller (1)
is assembled, then disassemble it.
CAUTION
Remove all product residue from the
1 parts. Sterilisation is effective on
clean surfaces but may not be
effective on product residue.
2 WARNING
Chemical products.
Using cleaning compound code D, clean

all parts of the LS strip pressure roller (1)
and the spring (2).
Note! Before handling clean parts,
disinfect hand/gloves with cleaning
TechPub_2614345_0104 - TB118413en.fm
compound code H, see chapter 10
Technical Data.
After cleaning, rinse with drinking

water and place the components in a dry,
clean place.
8 - 10 (60) Doc. No. OM-81841-0103

12
CAUTION
product residue.
Wipe off any product residue on the

1 lower part of the filling pipe with a
sponge.
Use water and cleaning compound code
D. See chapter 10 Technical Data. Rinse
with drinking water.
Technical Data.
Spray a small quantity of disinfectant

TechPub_2614345_0104 - TB118413en.fm

Technical Data.
Doc. No. OM-81841-0103 8 - 11 (60)

13
Place the cleaning sleeve flange (1) on
the flange of the filling pipe. Secure the
cleaning sleeve flange (1) with the
pin (2).
1
TechPub_2614345_0104 - TB118413en.fm
1 14
Lift the sprinklers (1) to the cleaning
position.
Clean and if necessary remove lime
deposits from the sprinklers nozzle holes.
8 - 12 (60) Doc. No. OM-81841-0103

15
Check and change if necessary the
gasket (1) on the cleaning sleeve (2).
3 Fit the cleaning sleeve (2) to the filling

pipe and secure it with the two
1 catches (3).
Note! Make sure that the sensor
plate (4) is aligned with the
sensor (5).
2
4
TechPub_2614345_0104 - TB118413en.fm
5 4
Cleaning sleeve with combined

valve and sensor plate
The cleaning sleeve (2) may be fitted
with a combined valve and sensor
plate (6).
CLOSED OPEN
Doc. No. OM-81841-0103 8 - 13 (60)

16
Place the draining hose (1) safely away
from jaws or from the final folder
movements.
Close the valve (2) on the cleaning
sleeve (3).
Check and change if necessary the
8 gaskets (5) on the return pipe (6).
3 Fit the return pipe (6) and its gaskets (5)
to the cleaning sleeve (3) and to the
4 machine body frame by means of the
clamps (4).
plate (7) is aligned with the
4
2 sensor (8).
5 6 7 5
TechPub_2614345_0104 - TB118413en.fm
CLOSED OPEN
8 - 14 (60) Doc. No. OM-81841-0103

17
WARNING
Risk of personal injury.
The components may be hot. Wear
4 heat-resistant protective gloves.
Loosen the clamp (1) and remove the

blank-off flange (2) from the cleaning
pipe.
Loosen the clamps (3) and (4).
Remove the clamp (4) and check the
gaskets for wear and/or damage. Change
if necessary.
4
1 2 3
TechPub_2614345_0104 - TB118413en.fm
18
Turn and fit the switch-over pipe (1) to
the cleaning position by means of the
5 clamp (3). Tighten the clamps (2)
and (3).
Fit the blank-off flange (4) to the
4 production pipe and tighten the
clamp (5).
1
plates are aligned with the sensors.
2
3
Doc. No. OM-81841-0103 8 - 15 (60)

19
TPOP display.
TechPub_2614345_0104 - TB118413en.fm
20
Touch the CIP-PROGRAM button to
select CIP cleaning. The
INTERMEDIATE CLEANING symbol
appears on the TPOP display.
Select either INTERMEDIATE
CLEANING or FINAL CLEANING, see
items 20 a and 20 b.
8 - 16 (60) Doc. No. OM-81841-0103

20 a
Intermediate Cleaning
CAUTION
C-Valve
Risk of product contamination.
Intermediate cleaning does not clean
the steam barrier valve (C-valve). Do
not use intermediate cleaning if there
is idle time between cleaning and
1 production and as a replacement for
final cleaning.
If the product remains in the product line,

perform cleaning in the
INTERMEDIATE CLEANING mode.
A-Valve
There will be a steam barrier (1) between
the cleaning liquid (2) and the
product (3). All parts of the machine
filling system, except the steam barrier
valve (C-valve), are cleaned.
INTERMEDIATE CLEANING must be
2 3
TechPub_2614345_0104 - TB118413en.fm
performed immediately after an

B-Valve unplanned stop, such as an Emergency
stop, when production needs to be
restarted immediately after cleaning.
To perform INTERMEDIATE
CLEANING, go to step 20 c.
For further information concerning
FINAL CLEANING and
INTERMEDIATE CLEANING, see
Technical Manual: Cleaning of Tetra
Brik Aseptic Filling Machines.
Doc. No. OM-81841-0103 8 - 17 (60)

C-Valve 20 b
Final Cleaning
CAUTION
1 When product still remains in the
product line, remember never to
clean with the switch in position for
cleaning the steam barrier space.
Empty the product line before
activating FINAL CLEANING.
A-Valve
FINAL CLEANING must be performed
after every production run, while the
product line is also being cleaned.
All parts in contact with the product
inside the valve will be cleaned,
including the steam barrier valve (1) (C-
2 3 valve).
B-Valve
1 Steam barrier To activate FINAL CLEANING, turn the
2 Cleaning liquid CLEANING STEAM BARRIER
TechPub_2614345_0104 - TB118413en.fm
3 Line product non-sterile SPACE key switch to the right.
The FINAL CLEANING symbol on the
TPOP displays the colour in blue.
The Cleaning Steam Barrier Space key is
spring-loaded and returns in its initial
position when released.
C
B
A
Note! Make sure there are no other
machines in the PRODUCTION
phase, connected to the same
product line.
For further information concerning

FINAL CLEANING and
INTERMEDIATE CLEANING, see
Technical Manual: Cleaning of Tetra
Brik Aseptic Filling Machines.
8 - 18 (60) Doc. No. OM-81841-0103

20 c
WARNING
Chemical products.
Follow the Safety Precautions. Do
not open any doors during cleaning.
CAUTION
Opening a door causes the valves to
close immediately which can damage
valves (cleaning fluid flows at 8,000 l/
hour).
Note! To interrupt the cleaning

procedure before starting the CIP,
see page 2-15.
CAUTION
Do not turn On the factory CIP
cleaning system before starting the
TechPub_2614345_0104 - TB118413en.fm
CIP program. It may cause damage

to the CIP inlet valve.
To start CIP, press the PROGRAM UP

button when it flashes. The CIP icon
stops flashing.
Turn On the factory CIP cleaning system.

Check that there are no leaks in the
cleaning sleeve connections.
Doc. No. OM-81841-0103 8 - 19 (60)

21
WARNING
Chemical products.
Check the detergent level in the

container. If necessary, top up with the
cleaning compound code C1. See chapter
10 Technical Data.
TechPub_2614345_0104 - TB118413en.fm
22
Use the cleaning handle (1) to open the
cleaning valve in the service unit.
23
Touch the EXTERNAL CLEANING
button.
8 - 20 (60) Doc. No. OM-81841-0103

24
When the PROGRAM UP button begins
to flash, press it to start the cleaning.
A time bar is displayed on the TPOP
showing the remaining time.
Note! Do not open the doors during
cleaning. Do not turn off the
compressed air and the water supply
until CIP cleaning and external
cleaning have been completed.
Note! For details on how to interrupt

the cleaning procedure before
starting the EXTERNAL CLEANING,
see page 2-15.
TechPub_2614345_0104 - TB118413en.fm
25
Check visually through the glass that the
cleaning nozzles are functioning
properly. Ensure the foam is evenly
distributed over all areas.
Call a service technician if any nozzle
does not rotate.
Doc. No. OM-81841-0103 8 - 21 (60)

26
CAUTION
3 Sterilisation is effective on clean
product residue.
Clean the pin (1), the lower filling

1 pipe (2) and the floater (3) separately by
hand. Use water and the cleaning
2 compound code D. See chapter 10
Technical Data. Rinse with water.
Technical Data.
TechPub_2614345_0104 - TB118413en.fm
27
Store the cleaned lower filling pipe into
an appropriate tank/container. Use the
cleaning compound code F. See chapter
10 Technical Data.
8 - 22 (60) Doc. No. OM-81841-0103

28
Headspace by Injection
WARNING
1 Risk of eye injury.
Wear eye protection.
The headspace the HI nozzle (3), the O-

3 ring (1) and the gasket (2) must be
cleaned.
Remove the O-ring (1) and the gasket (2)
from the HI nozzle (3) and clean them
with cleaning compound E. See chapter
10 Technical Data.
2
Clean the inside and the outside of the HI
nozzle (3) and blow clean with
compressed air. Store the HI nozzle (3) in
a dry and clean place.
Make sure that the O-ring (1) and
TechPub_2614345_0104 - TB118413en.fm
gasket (2) are clean and without defects.

Change if necessary.
29
On the strip applicator, blow clean the
counter roller (1) and pressure roller (2).
Clean the counter roller (1) and pressure
roller (2) with a sponge. Use cleaning
compound code G1 or G2. See chapter
10 Technical Data.
1
Note! Check the rollers surface for
wear and/or damage.
Doc. No. OM-81841-0103 8 - 23 (60)

30
Clean the PullTab photocell lenses and
the reflectors with a clean dry cloth.
Note! A dirty lens causes reading
errors which can affect production.
TechPub_2614345_0104 - TB118413en.fm
31
Honeywell Recorders
Check that the printing on the cleaning
recorder is correct on all the channels. If
not, call a technician.
the machine is in cleaning:
Ch Colour Function
AN 4 Blue Concentration
AN 5 Brown Flow
AN 6 Black Temperature
8 - 24 (60) Doc. No. OM-81841-0103

32
JUMO Recorders
Check that the printing on the recorder is
correct on all channels. If not, call a
technician.
Note! The seven other channels are
only used during production.

AN4 AN5 AN6 the machine is in cleaning:
Ch Colour Function
6 AN 4 Blue Concentration
5 AN 5 Brown Flow
AN1
4 AN 6 Black Temperature
AN2 3
AN3
TechPub_2614345_0104 - TB118413en.fm
33
Carefully remove the LS inductor (1) and
1 place it on the provided holder (2) in the
aseptic chamber.
Check the LS-inductor guide roller (3).
3 Check that all rollers in the forming ring
rotate freely. If necessary, call a
technician.
Taking care not to damage the surface,
carefully remove all residue inside the LS
inductor (1).
Fit the LS inductor (1).
Doc. No. OM-81841-0103 8 - 25 (60)

34
1 disinfect hand/gloves with cleaning
3 compound code H, see chapter 10
2
Technical Data.
Make sure that the part number on the

pressure roller is facing the correct way.
Place the pressure roller on the pin (1).
Check that the spring (2) is on the right-
hand side of the pressure roller.
Check that the slot in the pressure roller
hood (3) is towards the filling pipe.
Fit the pressure roller onto the filling
4 5 pipe, locking it into place with the
hood (3).
Make sure the LS counter pressure
roller (5) is correctly in contact with the
counter roller (4). If not, make sure the
spring (2) is facing the correct way.
TechPub_2614345_0104 - TB118413en.fm
35
8 - 26 (60) Doc. No. OM-81841-0103

36
Blow clean the photocell lenses in the
splicing unit with compressed air.
TechPub_2614345_0104 - TB118413en.fm
37
Note! Photocells are mounted on a
moveable bracket. When cleaning,
take care not to change the setting of
the photocell.
Clean the eight photocell lenses and the

reflectors in the ASU packaging material
compartment with a clean dry cloth.
Doc. No. OM-81841-0103 8 - 27 (60)

38
Clean the photocell lenses on the design
correction unit with a clean dry cloth.
TechPub_2614345_0104 - TB118413en.fm
39
Wipe down all the rubber seals on the
doors of the jaw system and final folder
area with a sponge to remove water
residue.
8 - 28 (60) Doc. No. OM-81841-0103

40
Honeywell Process and
Cleaning Recorders (OE)
When the CIP and the external cleaning
are finished, press the Feed key on both
recorders to feed some chart paper.
Open the recorders and tear off the
process report and the cleaning report.
Check the print quality on each report. If
necessary, change the ink wheel. See
item Ink Wheel Change on page 3-26.
Give the reports to the person responsible
for evaluation.
TechPub_2614345_0104 - TB118413en.fm
41
JUMO Process and Cleaning
Recorders (OE)
When the CIP and the external cleaning
are finished:
a) Open the door (1).
1 b) Tear off the process and cleaning
report.
/E S F
ENTER
c) Close the door (1).
Check the print quality on each report. If

necessary, change the print head. See
item Print Head Change on page 3-30.
/E S F
Give the reports to the person responsible
ENTER for evaluation.
Doc. No. OM-81841-0103 8 - 29 (60)

42
WARNING
Chemical products.
Empty the CIP line by opening the

valve (1) on the lower cleaning sleeve.

TechPub_2614345_0104 - TB118413en.fm
OPEN
42 a
Disconnect the return pipe and remove it
from the machine.
8 - 30 (60) Doc. No. OM-81841-0103

43
a) Release the two catches (1) and
4 remove the cleaning sleeve (2).
b) Remove the pin (3) from the cleaning
3 sleeve flange (4).
1
c) Remove the flange (4) and insert the
pin (3) into the cleaning sleeve
flange (4).
2
TechPub_2614345_0104 - TB118413en.fm
44
WARNING
The components may be hot. Wear
heat-resistant protective gloves.
1 Loosen the clamp (1) and remove the
2 blank-off flange (2) from the production
pipe.
Loosen the clamps (3) and (4).
Remove the clamp (4). Check the gaskets
for wear and/or damage. Change if
necessary.
3
4
Doc. No. OM-81841-0103 8 - 31 (60)

45
Turn and fit the switch-over pipe (1) to
1 2 2 the production position. Tighten the
clamps (2) and (3).
Fit the blank-off flange (4) to the
cleaning pipe and tighten the clamp (5).
plates are aligned with the sensors.
5 4 3
TechPub_2614345_0104 - TB118413en.fm
46
TPOP display.
47
up to step CIP DRYING.
The machine will step automatically to
STEP ZERO after 9 minutes when the
CIP DRYING step is completed.
Note! The CIP DRYING must be
repeated in case of interruption of the
drying sequence.
8 - 32 (60) Doc. No. OM-81841-0103

48
Open the final folder unit door.
TechPub_2614345_0104 - TB118413en.fm
1 49
Lower the sprinkler (1) to the production
position.
50
Push the bow clamp inwards.
Doc. No. OM-81841-0103 8 - 33 (60)

51
2 After Cleaning with HI
a) Loosen the clamps (1) and remove
the pipe (2).
b) Remove the gasket (3).
1
c) Check that the HI nozzle (5) is free
6 from blockages.
3
5 d) Spray the outside of the HI nozzle (5)
4
with disinfectant code G3.
e) Fit the gasket (4), the HI nozzle (5)
7 and the O-ring (6), and refit the
pipe (2).
f) Fit the pipe (2) in place by means of
the clamps (1).
8 g) Make sure that the O-ring (7) is clean
and without defects. Change if
necessary.
h) Make sure that the locking device (8)
is tightened.
TechPub_2614345_0104 - TB118413en.fm
52
1 HI Bypass
a) Make sure that the plug (2) is fixed in
2 place by means of the clamp (1).
b) Make sure that the pipe (3) is in the
RH position (production).
c) Make sure that the locking device (4)
is tightened.
4 3
8 - 34 (60) Doc. No. OM-81841-0103

53
Daily Care has now been completed.
When resuming PRODUCTION, start
1 from Preparing after Daily Care in the
2 chapter 3 Preparation.
To perform Weekly Care go to the
section Weekly Care on page 8-37.
If Weekly Care or PRODUCTION is not
scheduled, ensure that the air supply (1)
is OFF and the cooling water supplies (2)
3 or (3) are OFF, depending on which filter
is in use.
Cooling water On
TechPub_2614345_0104 - TB118413en.fm
Cooling water Off
Doc. No. OM-81841-0103 8 - 35 (60)

TechPub_2614345_0104 - TB118413en.fm
8 - 36 (60) Doc. No. OM-81841-0103

8 Care and Cleaning Weekly Care
Weekly Care
This section describes what to do once a week or at least every 120 operating
hours.
1
If Daily Care has just been carried out,
continue with item 2.
1 Otherwise turn On:

2 • the air supply (1)
• the cooling water supplies (2)
and (3), depending on which
filter (4) is in use.
3
TechPub_2614345_0104 - TB118413en.fm
4
Cooling water On
Cooling water Off
Doc. No. OM-81841-0103 8 - 37 (60)

Weekly Care 8 Care and Cleaning
2
Cut the LS strip away from the
packaging material. Rewind both LS
strips back onto the reels and remove
them from the machine.
3
Cut off the packaging material under the
material holder and remove the
packaging material reel/reels from the
ASU.
Secure the end of the reel with tape.
Close all the doors and reset the alarms
TechPub_2614345_0104 - TB118413en.fm
Step up to step PREPARATION.
Press the MATERIAL LOCKING button
to release the packing material in the
ASU.
Step down to STEP ZERO.
4
To release the strips on the patch feeder
and the tab feeder in the PullTab, press
down the lever (1) to lift the counter
roller (2) and pull the strip back (3).
8 - 38 (60) Doc. No. OM-81841-0103

5
Rewind the patch strip and the tab strip
back on to the reels. Remove the reels
from the machine.
TechPub_2614345_0104 - TB118413en.fm
6
WARNING
Hydrogen peroxide.
There is risk of hydrogen peroxide
residue on the packaging material
when removing it from the hydrogen
peroxide bath. Follow the Safety
Precautions.
Cut the packaging material at the places

shown by the arrows. By hand remove all
the packaging material from the filling
machine.
Doc. No. OM-81841-0103 8 - 39 (60)

7
WARNING
Risk of eye injury.
Vacuum clean the inside of the ASU

(floor and walls).
TechPub_2614345_0104 - TB118413en.fm
8
WARNING
Risk of eye injury.
Blow clean the ASSU sealing unit with

compressed air.
WARNING
Chemical products.
Clean all the rollers on the strip

applicator with a sponge. Use cleaning
10 Technical Data.
Wipe dry with a clean cloth.
Clean the heating device with a sponge.
Use cleaning compound code G1 or G2.
See chapter 10 Technical Data.
8 - 40 (60) Doc. No. OM-81841-0103

9
WARNING
Risk of falling.
The material carriers in the ASU must
be safely locked in either inner or
outer position.
Clean all rollers and the material holders

in the ASU with a sponge. Use cleaning
compound code G1or G2. See chapter 10
Technical Data.
Clean the packaging material
compartment with a sponge. Use
cleaning compound code G1 or G2. See
chapter 10 Technical Data.
TechPub_2614345_0104 - TB118413en.fm
10
In the PullTab, check that the one-way
roller (3) moves freely on the IS patch
station and on the tab station.
2 Clean the surface of the rollers (1)

and (2) using cleaning compound code
G1 or G2. See chapter 10 Technical Data.
1
Doc. No. OM-81841-0103 8 - 41 (60)

10 a
1 Clean the following components in the
PullTab thoroughly with a sponge:
• the hole punch unit (1)
2
• the packaging material guide (2)
3 • the IS patch station (3)
• the reseal station (4)
• the tab station (5).
4
TechPub_2614345_0104 - TB118413en.fm
10 b
Clean all rollers in the PullTab with a
sponge. Use cleaning compound code G1
or G2. See chapter 10 Technical Data.
8 - 42 (60) Doc. No. OM-81841-0103

11
Clean the patch and the tab strip
magazines and their rollers. Use cleaning
10 Technical Data.
Wipe with a clean cloth and clean water.
Wipe dry with a clean cloth to prevent
the packaging material from sticking to
the rollers.
TechPub_2614345_0104 - TB118413en.fm
1 12
Blow clean the tab folder device (1) with
compressed air.
Check that the holes in the nozzle (2) are
not clogged.
Doc. No. OM-81841-0103 8 - 43 (60)

13
WARNING
Hydrogen peroxide.
2 Follow the Safety Precautions.
Clean and check inside the aseptic

chamber:
a) Open the top aseptic chamber door
1 and remove the hatch (1) from the
carrier compartment.
b) Check that the surface on both the
rollers (2) are smooth and intact.
c) Use a sponge and distilled water
only to clean these following parts:
• the calender rollers (2)
• the inside of the chamber and the
rollers
• the window of the top aseptic
chamber door
TechPub_2614345_0104 - TB118413en.fm
• the roller in the carrier compartment.
d) Close the top aseptic chamber door

and fit the hatch (1) onto the carrier
compartment.
14
Clean all rollers shown in grey in the
picture, the bending roller, the web guide
and the splice guard with a sponge. Use
cleaning compound code G1 or G2. See
8 - 44 (60) Doc. No. OM-81841-0103

15
Remove the cover shown by the arrow.
16
WARNING
Hydrogen peroxide.
a) Loosen the screws (5).

b) Remove the screws (4) and lift to
remove the bottom lid (3).
TechPub_2614345_0104 - TB118413en.fm
c) Spin the peroxide bath roller (1) by

hand to make sure it rotates easily.
d) Check for pieces of LS strip and
paper dust.
e) Clean and rinse the peroxide bath
roller (1) with a sponge and distilled
water only.
f) Check the condition of the gasket (2).
g) Fit the lid (3) and tighten the
screws (4) and (5).
1 2 3
4 5
Doc. No. OM-81841-0103 8 - 45 (60)

17
Fit the cover.
Open the aseptic chamber door to reach
the upper filling pipe.
18
Note which way the part number on the
LS strip pressure roller is facing.
Press on the spring (2) and lift up the
hood (3). Turn the spring sideways and
remove the LS strip pressure roller from
the pin (1) on the upper filling pipe.
TechPub_2614345_0104 - TB118413en.fm
3
2
8 - 46 (60) Doc. No. OM-81841-0103

18 a
Carefully note how the pressure roller is
assembled, then disassemble it.
CAUTION
1 Remove all product residue from the
parts. Sterilisation is effective on
2 WARNING
Chemical products.
Using cleaning compound code D clean

all parts of the LS strip pressure roller.
Technical Data.
TechPub_2614345_0104 - TB118413en.fm
After cleaning, rinse with drinking

water.
Make sure the roller (1) and its shaft (2)
are not worn or damaged. Change if
necessary.
Reassemble the pressure roller and place
the components in a dry, clean place
Doc. No. OM-81841-0103 8 - 47 (60)

19
Remove the locking device (1).
Loosen the nut (2).
3 2 1 Hold the filling pipe (3) while loosening

the screw (4).
Remove the upper filling pipe (3).
TechPub_2614345_0104 - TB118413en.fm
20
CAUTION
2 Risk of serious production fault.
product residues.
Immerse the filling pipe (1) in the bath

with cleaning compound code F. Take
care that the top connection area (2) does
not come into contact with the water.
Remove all product residue from the
pipe (1).
Note! Make sure the top connection
area (2) does not come into contact
with water.
1
Allow the filling pipe (1) to drip dry.
8 - 48 (60) Doc. No. OM-81841-0103

21
Gasket replacement
Change the gasket (1) each time the
1 regulating valve is removed from the
filling pipe.
22
CAUTION
1 Remove all product residue from the
parts. Sterilisation is effective on
2
TechPub_2614345_0104 - TB118413en.fm
WARNING
Chemical products.
Use cleaning compound G1 or G2 to

clean the rollers (1) and the forming
rings (2), (3), (4) and (5). See chapter 10
3
Technical Data. Check the rollers for
surface damage and make sure that they
rotate freely in both directions. If
necessary call a technician.
4
CAUTION
5 Allow the roller to dry. Do not dry with
compressed air.
Doc. No. OM-81841-0103 8 - 49 (60)

23
WARNING
Hydrogen peroxide.
Clean the inside of the aseptic chamber

and the door windows with a sponge. Use
the cleaning compound code D. See
Rinse with drinking water.
TechPub_2614345_0104 - TB118413en.fm
24
Technical Data.
3 2 1 Fit the upper filling pipe (3).
Tighten the screw (4).
Tighten the nut (2).
Tighten the locking device (1).
8 - 50 (60) Doc. No. OM-81841-0103

25
1 disinfect hand/gloves with cleaning
3 compound code H, see chapter 10
2
Technical Data.
Make sure that the part number on the

pressure roller is facing the correct way.
Place the pressure roller on the pin (1).
Check that the spring (2) is on the right-
hand side of the pressure roller.
Check that the slot in the pressure roller
hood (3) is towards the filling pipe.
4 5 Fit the pressure roller on the filling pipe,
locking it into place with the hood (3).
Make sure the LS counter pressure
roller (5) is correctly in contact with the
counter roller (4). If not, make sure the
spring (2) is facing the correct way.
TechPub_2614345_0104 - TB118413en.fm
26
Carefully remove the LS inductor (1) and
1 place it on the provided holder (2) in the
aseptic chamber.
Check the LS-inductor guide roller (3).
3 Check that all rollers in the forming ring
rotate freely. If necessary, call a
technician.
Taking care not to damage the surface
carefully remove all residue inside the LS
inductor (1).
Doc. No. OM-81841-0103 8 - 51 (60)

27
CAUTION
Make sure that all visible product
residue has been removed from the
pipe.

1 Technical Data.
Spray a small quantity of disinfectant

Technical Data.
TechPub_2614345_0104 - TB118413en.fm
28
Make sure that the locking device (1) is
tightened.
8 - 52 (60) Doc. No. OM-81841-0103

29
Change Cutting Rail and
Dollies
WARNING
Risk of cutting injury.
3 The knife is sharp and may be hot.
Use gloves to avoid injuries.
9
2 1 Note! Perform the following work on
both the jaw pairs:
6
a) Crank a jaw pair to the open position.
b) Remove the springs (1), the
catch (2), and the hoses (3) from the
volume flap.
8 7 c) Remove screws (4) and (5) and the
washer (6).
4 Note! During re-assembling the
5 screws (4) must be tightened with a
TechPub_2614345_0104 - TB118413en.fm
torque of 42 Nm.
d) Remove the screws (7).

e) Pull and remove the two cutting
rails (8) and the dollies (9).
f) Clean the parts and inspect the two
CASE 1
cutting rails (8) and the dollies (9).
g) Change them if damaged or worn
out.
h) Assemble in the reverse order.
8
Note! Take care to position the
profiles correctly when fitting the
CORRECT WRONG WRONG WRONG
cutting rails (8) and the dollies (9),
see figure. The two sharp edges of
the rubber part of the dolly (9) must
Smooth edge
Sharp edge
CASE 2 be facing outwards from the rail (8).

Smooth edge
Sharp edge
CORRECT
Doc. No. OM-81841-0103 8 - 53 (60)

30
Change Knife
WARNING
Risk of cutting injury.
The knife is sharp and may be hot.
11 12 Use gloves to avoid injuries.
Visually check the knife for wear and/or

damage.
Perform the following work on both the
cutting jaws:
10 a) Crank a jaw pair to the open position.

9 3
b) Remove the springs (1) the catch (2)
2 1 and the hoses (3) from the volume
flap.
c) Remove the screws (4) and (5) and
6 the washer (6).
5
Note! During re-assembling the
TechPub_2614345_0104 - TB118413en.fm
screws (4) must be tightened with a
8 7 torque of 42 Nm.
d) Remove the screws (7).

4
e) Pull off the two cutting rails (8) and
the dollies (9).
f) Pull off the knife group (10) and
remove the knife (11) from the
link (12).
g) Change the knife (11) if necessary.
h) Lubricate the knife (11) holder with
silicon grease code L, before
assembling.
i) Assemble in the reverse order.
Note! Take care to position the

profiles correctly when fitting the
cutting rails (8) and the dollies (9).
8 - 54 (60) Doc. No. OM-81841-0103

31
Change Oil
WARNING
3 Risk of personal injury.
Wear protective gloves!
4
Perform the following work on both the
cutting jaws.
1
a) Crank a jaw pair to the lower
horizontal position.
5
b) Drain the oil from the bearing
housing (1) by removing the drain
plugs (2) and the plugs (4).
c) Fit and tighten the drain plugs (2).
6 d) Fill up the bearing housing (1) with
oil. Use lubricant code H. See
2 e) Fit the filling plugs (4).
TechPub_2614345_0104 - TB118413en.fm
7
f) Crank the jaw pair slightly to access
and loosen the screw to remove the
oil pipe connection (3).
g) Step up to step PREPARATION.
8 h) Touch the MANOEUVRE button (5)
i) Touch the MAINTENANCE
SERVICE UNIT LEFT button (6).
j) Touch the MANUAL
LUBRICATION button (7).
k) Touch the START button (8).
l) Check that oil comes out from the oil
pipe connection (3).
m) Fit the oil pipe connection (3).
Doc. No. OM-81841-0103 8 - 55 (60)

32
CAUTION
Risk of damage to the equipment!
Do not clean the inductors with a
metallic brush.
a) Clean the inductor (1) with a nylon

or hard bristle flat brush (2). Check
for damage and/or wear that could
affect sealing quality.
b) If necessary, call a technician to
change the inductor (1).
c) Check that the catches (3) and the
1 catch return springs (4) are
4 functioning: lift each catch (3) and
release. The catch (3) should return
3 directly to the stop position.
d) Clean the catches (3) and the catch
springs (4).
2 e) Call a technician to change the
TechPub_2614345_0104 - TB118413en.fm
catches (3) and the catch springs (4)
if necessary.
33
WARNING
Chemical products.
Check the oil level in the central

lubrication tank. Top up if necessary. Use
lubrication code H. See chapter 10
Technical Data.
Note! Pump slowly as the level rises
faster in the tank than in the level
indicator.
8 - 56 (60) Doc. No. OM-81841-0103

34
Change the hydrogen peroxide, see
chapter 9 Sterilisation Liquid.
CAUTION
The peroxide must be changed
weekly to prevent paper dust and
impurities accumulating in the tank. If
this is not done, it can lead to
peroxide stability problems.
35
WARNING
Chemical products.
a) Touch the Manoeuvre button (1) on

the TPOP.
b) Touch the Maintenance service unit
TechPub_2614345_0104 - TB118413en.fm
left button (2).

c) Touch the Hydraulic oil level
button (3) Check the hydraulic oil
1 2 3 4 level.Top up if necessary. Use
lubrication code C. See chapter 10
Technical Data.
Note! Do not overfill!
5 d) Fill up with oil through the nipple (5)

until the maximum level in the
hydraulic oil level display (4) is
reached.
Doc. No. OM-81841-0103 8 - 57 (60)

36
Open the cover shown by the arrow.
36 a
WARNING
1 Hydrogen peroxide.
2 WARNING
Risk of eye injury.
TechPub_2614345_0104 - TB118413en.fm
a) Remove the screws (1).

3 b) Lift out the filter (2).
c) Clean the filter (2) thoroughly in
distilled water and, if necessary,
blow dry with compressed air. Rinse
the filter (2) in distilled water.
d) Check the gasket (3) and change it if
necessary.
e) Fit the gasket (3) and the filter (2).
f) Fit and tighten the screws (1).
36 b
Close the cover shown by the arrow.
8 - 58 (60) Doc. No. OM-81841-0103

37
1
Clean Filters
Note! During PRODUCTION only
one filtering line must be open.
a) Close the four water valves (1).

2 b) Unscrew the filter housing (4) and
remove the filter insert (2).
c) Clean the filter insert (2) with
3 compressed air or change if
necessary.
d) Check the seal ring (3) for damage.
4 e) Fit the filter insert (2), fit the seal
ring (3) and tighten the filter
housing (4).
f) Open two water valves (1) in one
filtering line and make sure that there
is no leakage.
g) Repeat items a) to f) for the other
TechPub_2614345_0104 - TB118413en.fm
filter.
38
Clean the platform floor with a brush. Do
not use any water.
Clean the outer machine surfaces with a
Polish the stainless steel plating with
paraffin oil.
Clean the windows on the machine with a
Doc. No. OM-81841-0103 8 - 59 (60)

39
Weekly care is now complete. When
resuming production after weekly care,
start from the Preparing After Weekly
1 Care in chapter 3 Preparation.
2 If PRODUCTION is not scheduled:
• turn OFF the air supply (1)
• turn OFF the cooling water (2) or (3).
TechPub_2614345_0104 - TB118413en.fm
8 - 60 (60) Doc. No. OM-81841-0103

TechPub_2614345_0104 - TB128413en.fm
Doc. No. OM-81841-0103 9 - 1 (12)

This chapter describes how to handle hydrogen peroxide.
WARNING
Hydrogen Peroxide.
TechPub_2614345_0104 - TB128413en.fm
9 - 2 (12) Doc. No. OM-81841-0103

9 Sterilisation Liquid Table of Contents
Concentration Check . . . . . . . . . . . . . . . . . . . . . 9 - 5
Hydrogen Peroxide Concentration (by weight) . . . . . .9 - 7
Peroxide Concentration at Machine Start-up . . . . . . . .9 - 8
Peroxide Concentration during Production . . . . . . . . .9 - 8
Change Hydrogen Peroxide . . . . . . . . . . . . . . . . 9 - 9

Change Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 12
TechPub_2614345_0104 - TB128413en.fm
Doc. No. OM-81841-0103 9 - 3 (12)

TechPub_2614345_0104 - TB128413en.fm
9 - 4 (12) Doc. No. OM-81841-0103

9 Sterilisation Liquid Concentration Check
Concentration Check
This section describes how to manually check the concentration of the
hydrogen peroxide.
1
The following equipment is required:
• aerometer (1) with thermometer
• graduated plastic test tube (2) with an
inside diameter of 35 - 50 mm.
Note! The equipment must be

thoroughly cleaned.
Open the valve (arrow) and draw

approximately 250 ml of hydrogen
peroxide from the tank into a clean
vessel.
Pour a small amount of hydrogen
peroxide into the graduated test tube (2).
Lower the aerometer (1) into the test
TechPub_2614345_0104 - TB128413en.fm
tube (2) making sure that it contains

enough liquid to float the aerometer (1).
If there are air bubbles on the
aerometer (1) stir gently until the bubbles
disappear.
1 Read the density at the liquid level on the
aerometer (1) and at the same time read
the temperature.
Doc. No. OM-81841-0103 9 - 5 (12)

Concentration Check 9 Sterilisation Liquid
2
Evaluate the hydrogen peroxide
concentration (in terms of percent by
weight) from the nomogram.
With a ruler, join the density value of the
kg/l ˚C sample with the temperature value to get
1.200 80 the hydrogen peroxide concentration.
1.190
1.180
Note! Photocopying and/or resizing
the nomogram may distort its
1.170
H2O2 w/w accuracy. This could lead to an
1.160
50 %
incorrect evaluation of the hydrogen
1.150
45 %
peroxide concentration.
1.140
1.130
40 % To check the accuracy of the nomogram,
1.120 refer to the following table reporting the
35 %
1.110 concentration and density values
1.100 30 % calculated at 20 °C:
1.090
25 %
1.080
1.070
°C kg/l % w/w
20 %
20 1.056 15
TechPub_2614345_0104 - TB128413en.fm
1.060
15 %
1.050 20 20 1.075 20
1.040 10 % 20 1.094 25
1.030
5%
20 1.113 30
1.020 20 1.132 35
1.010 0%
20 1.153 40
1.000 0
20 1.174 45
Sample nomogram
20 1.195 50
If the concentration is below 30% or

above 50%, change the hydrogen
peroxide. See section Change Hydrogen
Peroxide on page 9-9.
Note! If the hydrogen peroxide
concentration is between 30% and
35%, repeat the check every 30 min.
If the concentration decreases, stop the

machine and call a technician.
9 - 6 (12) Doc. No. OM-81841-0103

9 Sterilisation Liquid Concentration Check
Hydrogen Peroxide Concentration (by weight)
kg/l ˚C
1.200 80
1.190
1.180
70
1.170
H2O2 w/w
1.160
50 %
1.150 60
45 %
1.140
1.130
40 %
50
TechPub_2614345_0104 - TB128413en.fm
1.120
35 %
1.110
1.100 30 % 40
1.090
25 %
1.080
30
1.070 20 %
1.060
15 %
1.050 20
1.040 10 %
1.030
5% 10
1.020
1.010 0%
1.000 0
970630
Doc. No. OM-81841-0103 9 - 7 (12)

Concentration Check 9 Sterilisation Liquid
Peroxide Concentration at
Machine Start-up
Note! Values to be applied during
“Preparation after daily care”.

If the hydrogen peroxide concentration is
between 32% and 35%:
• repeat the check every 30 min
• if the concentration decreases, stop
the machine and call a technician.
TechPub_2614345_0104 - TB128413en.fm
Peroxide Concentration
during Production
If the hydrogen peroxide concentration is
between 32% and 35%:
• repeat the check every 30 min
• if the concentration decreases, stop
the machine and call a technician.
9 - 8 (12) Doc. No. OM-81841-0103

9 Sterilisation Liquid Change Hydrogen Peroxide
Change Hydrogen Peroxide

This section describes how to change the hydrogen peroxide in the dilution
tank and how to change the hydrogen peroxide container.
1
WARNING
Hydrogen peroxide.
Open the door of the hydrogen peroxide

container compartment.
Lift the cap (arrow) to disengage the
hydrogen peroxide container.
Place the cap on the bracket at the side of
the compartment.
TechPub_2614345_0104 - TB128413en.fm
Doc. No. OM-81841-0103 9 - 9 (12)

Change Hydrogen Peroxide 9 Sterilisation Liquid
2
Open the valve (arrow) to empty the
dilution tank. It takes approximately 5
minutes.
Note! When the machine has been in
production for more than 24 hours,
the hydrogen peroxide concentration
in the dilution tank is less than 1%.
When the tank is empty, close the valve.
TechPub_2614345_0104 - TB128413en.fm
3
Open the valve (arrow) to drain the
hydrogen peroxide from the tank into the
dilution tank. It takes approximately
5 minutes.
When the tank is empty, close the valve.
9 - 10 (12) Doc. No. OM-81841-0103

9 Sterilisation Liquid Change Hydrogen Peroxide
4
Fit back the cap to engage the hydrogen
peroxide container.
TechPub_2614345_0104 - TB128413en.fm
5
Follow the instructions on the TPOP
when the alarm PEROXIDE
CONTAINER LEVEL lights up.
Change the hydrogen peroxide container.
See item Change Container on page 9-12.
It takes approximately three full
containers to fill up the hydrogen
peroxide tank.
Doc. No. OM-81841-0103 9 - 11 (12)

Change Hydrogen Peroxide 9 Sterilisation Liquid
Change Container
1
WARNING
Hydrogen peroxide.
Always transport and keep the
1 hydrogen peroxide containers stored
with the lid (2) installed.
2 Open the door of the hydrogen peroxide

container compartment.
Lift the cap (1) to disengage the
hydrogen peroxide container.
Place the cap on the bracket at the side of
the compartment.
Put the lid (2) onto the connection and
tighten it.
Remove the container from the machine.
TechPub_2614345_0104 - TB128413en.fm
2
1 Place a full container with 35% w/w
hydrogen peroxide in the machine.
Remove the lid (2) and place it to one
side.
Fit the cap (1) to engage the hydrogen
2 peroxide container.
9 - 12 (12) Doc. No. OM-81841-0103

10 Technical Data
TechPub_2614345_0104 - TB138413en.fm
Doc. No. OM-81841-0103 10 - 1 (18)

10 Technical Data
This chapter provides the standard values for setting this

machine and information on the recommended chemicals
and lubricants to be used with this machine.
TechPub_2614345_0104 - TB138413en.fm
10 - 2 (18) Doc. No. OM-81841-0103

10 Technical Data Table of Contents
Setting Values . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
Pressure Setting Values . . . . . . . . . . . . . . . . . . . 10 - 5
Temperature Setting Values . . . . . . . . . . . . . . . . 10 - 9
Coolant Flow Values . . . . . . . . . . . . . . . . . . . . . 10 - 11
Consumption Data . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13
Cleaning Compounds . . . . . . . . . . . . . . . . . . . 10 - 14
Lubricant Recommendations . . . . . . . . . . . . . 10 - 15
TechPub_2614345_0104 - TB138413en.fm
Doc. No. OM-81841-0103 10 - 3 (18)

10 Technical Data
TechPub_2614345_0104 - TB138413en.fm
10 - 4 (18) Doc. No. OM-81841-0103

10 Technical Data Setting Values
Setting Values
This section provides the correct setting values for this machine.
Pressure Setting Values

Pressure Symbol Value (kPa (bar))
Air spray 200 (2.0)
Central lubrication oil 3000 (30)
Cold water 300 - 450 (3.0 - 4.5)
Cooling water system 200 (2.0)

TechPub_2614345_0104 - TB138413en.fm
Flap blowing 200 - 300 (2.0 - 3.0)
Flap sealing top left and right 150 (1.0 - 1.5)
Flap sealing bottom left and right 150 (1.0 - 1.5)
(Cont'd)
Doc. No. OM-81841-0103 10 - 5 (18)

Setting Values 10 Technical Data
(Cont'd)
Foaming 500 (5.0)
Hold down device (bellows) 270 (2.7)
Peroxide tank filling 20 (0.2)
Product pressure (dependant on product 50 - 250 (0.5 - 2.5)

and local conditions)
Calender roller 200 - 300 (2.0 - 3.0)
TechPub_2614345_0104 - TB138413en.fm
Photocells, design correction, air blast:
- for machine equipped with old peroxide 20 (0.2)
pump TP No. 996388-0400
- for machine equipped with old peroxide 60 (0.6)
pump TP No. 996388-0500
Warm water (red) 300 - 450 (3.0 - 4.5)
(Cont'd)
10 - 6 (18) Doc. No. OM-81841-0103

(Cont'd)
Air 600 -700 (6 - 7)
Overpressure final folder 10 - 20 (0.1 - 0.2)
Tab folder 300 - 350 (3.0 - 3.5)
Steam 170 ±30 (1.7 ± 0.3)

TechPub_2614345_0104 - TB138413en.fm
Pendulum roller 50 - 300 (0.5 - 3.0)
Cap blowing, PT 250 (2.5)
Waste blowing, PT 300 (3.0)
(Cont'd)
Doc. No. OM-81841-0103 10 - 7 (18)

(Cont'd)
Tension unit- pressure roller, PT 200 (2.0)
Drive motor - pressure roller, PT 450 (4.5)
Patch counter jaw, PT 250 (2.5)
Tab counter jaw, PT 250 (2.5)
TechPub_2614345_0104 - TB138413en.fm
Main air inlet, PT21 600 (6.0)
10 - 8 (18) Doc. No. OM-81841-0103

Temperature Setting Values

Temperature Symbol Value (° C)
Air superheater 360
Cooling water (compressor) 10 - 12
Cooling water 2-5
Flap heating, top (left and right) 420 ± 20

TechPub_2614345_0104 - TB138413en.fm
Flap heating, bottom (left and right) 530 ± 20
Heat sterilisation 280
Top aseptic chamber 95
Bottom aseptic chamber (Not in use)
(Cont'd)
Doc. No. OM-81841-0103 10 - 9 (18)

(Cont'd)
Temperature Symbol Value (° C)
Warm water (red) 55 - 60
Peroxide bath 73
Peroxide tank 73
Heat exchanger Max. 93
TechPub_2614345_0104 - TB138413en.fm
Water bath 63
Steam 125
HI spraying 65
Tab sealing 180
10 - 10 (18) Doc. No. OM-81841-0103

Coolant Flow Values

Flow Symbol Value (l/m)
Cold water flow, TS right 0.8
Cold water flow, TS left 0.8
Cold water flow, final folder 2.0
Cold water flow, hydraulic cooler 2.5

TechPub_2614345_0104 - TB138413en.fm
De-ionizing circuit 1.5
Doc. No. OM-81841-0103 10 - 11 (18)

Consumption Data
Consumption Unit Value
Hydrogen peroxide % w/w 35
l/h 1.5 - 2.0
Alkali cleaning detergent l/h 1.2
Consumables
Standard Consumable Materials
Leak detection fluid (red ink) TP No. 90298-26
Black tape
- Patch and tab strip splice TP No. 90144-52
- To cover holes TP No. 90144-070 for hole 60
TechPub_2614345_0104 - TB138413en.fm
TP No. 90144-071 for holes 21, 25, 45, 50,
55, 85 and 90
Honeywell Process recorder

- Ink wheel TP No. 90332-324
- Fan fold chart TP No. 90332-325
JUMO Process recorder

- Print head TP No. 90459-87
- Fan fold chart TP No. 90459-0084
LS strip
- LHL TP No. 8893-952-01
- PPP TP No. 8842-951-01
(Cont'd)
10 - 12 (18) Doc. No. OM-81841-0103

(Cont'd)
-
Standard Consumable Materials
Patch strip
- holes 21, 25, 45, 50 and 85 TPI No. 8865-967-01
- holes 55 and 90 TPI No. 8865-963-01
- hole 60 TPI No. 8865-964-01
Tab strip
- hole 21 TPI No. 8738-727-01
- hole 25 TPI No. 8738-729-01
- holes 45, 50 and 85 TPI No. 8738-728-01
- hole 55 TPI No. 8738-724-01
- hole 60 TPI No. 8757-733-01
- hole 90 TPI No. 8738-725-01

TechPub_2614345_0104 - TB138413en.fm
Miscellaneous
Noise declaration See the IM of the Noise declaration

equipment.
Doc. No. OM-81841-0103 10 - 13 (18)

Cleaning Compounds 10 Technical Data
Cleaning Compounds
Note! Use only Tetra Pak recommended cleaning compounds when
cleaning parts which may come into contact with hydrogen peroxide.
Cleaning with non recommended compounds may cause an
explosion!
Comparable qualities from other suppliers may be selected in compliance

with the technical requirements listed in the table.
All cleaning compounds must comply with local legal requirements. The
supplier recommendations for concentration and temperature should be
followed. When dosing the products automatically, their concentrations
should be checked. Hard water > 5 fH° (French degree of hardness).
Cleaning Code Example (2004-05)

Type of Pure Formulated Products
Product Chemicals
Henkel JohnsonDiversey
Cleaning A Alkali NaOH 1.5% P3-mip RC VC13 (Soft water)
CIP P3-N 421 VC7 (Hard water)
B 1 Acid HNO3 1% P3-Horolith L31 VA5
TechPub_2614345_0104 - TB138413en.fm
2 Acid H3PO4 1% P3-Horolith FPC VA3
P3-Horolith MSW
3 Acid HNO3 + H3PO4 VA4
External C 1 Alkali foam TBA/21, P3-Topax 12 VF9
cleaning TBA/22, A3/Flex and
(Automatic) A3/Speed
2 Alkali Solution TBA/8, P3-mip FPC VK12
TBA/19 P3-FPC
Manual D 1 Alkali solution P3-mip FPC VK12
cleaning P3-FPC
(Wiping) E 1 Acid solution HNO3 0.5% VA5 (1%)
2 Acid solution H3PO4 0.5% VA3 (1%)
3 Acid solution Acetic Acid 0.5% VF12
Manual F 1 Low alkali foam P3-Topax 99 VS1
disinfection 2 Low alkali solution P3-Steril BG VT1
(Immersion) KL-HC 34 UKES
3 Acid Solution Hydrogen peroxide Oxonia Aktiv 30 VT6
Peracetic acid
Manual G 1 Alcoholic solution Isopropanol 70% Al-des VT10
disinfection Alcodes
(Spray) 2 Alcoholic solution Ethanol 70%
3 Acid Solution Hydrogen peroxide Oxonia Aktiv 30 VT6
Peracetic acid
Hand H Spitacid H4
disinfection H5
10 - 14 (18) Doc. No. OM-81841-0103

10 Technical Data Lubricant Recommendations
Lubricant Recommendations
WARNING
Certain lubricants can cause injury if they come into contact with the
eyes, skin, mucous membranes, or clothing. Always follow the
manufacturer’s instructions for handling chemical products.
The table below lists only a selection of lubricants with their respective
designations.
Comparable lubricants from other suppliers may be selected with the aid of
the lubricant specifications (document No in the table).
Lubricant specifications may be ordered from:
Tetra Pak Global Technical Support AB, Ruben Rausings gata, SE-221 86
LUND, Sweden.
Lubricant Code Part No. Example

(used when ordering Supplier Product Designation
from Tetra Pak) (2004-06)
A
Motor oil 90 296-28 Statoil PowerWay D2 10W-30
TechPub_2614345_0104 - TB138413en.fm
B
High-pressure oil 90 296-73 BP Energol GR-XP 220
90 296-78 Esso Spartan EP 220
Statoil LoadWay EP 220
Mobil Mobilgear 630
Shell Omala oil 220
90 296-72 BP Energol GR-XP 150

Esso Spartan EP 150
For use in production Statoil LoadWay EP 150
plant with start Mobil Mobilgear 629
temperature below 5° C. Shell Omala oil 150
C
Hydraulic oil 90 296-53 BP Bartran HV 32
Esso Univis N 32
Statoil HydraWay HVX 32
Mobil DTE Oil 13
Shell Tellus Oil T 32
D
Mist lubrication oil 90 296-80 BP Autran DX
Esso ATF Dextron II
Statoil TransWay DX II
Mobil ATF 220
Shell ATF Dextron II
E
Compounded cylinder 90 296-77 BP Energol AC-C460
oil 90 296-2 Esso Cylesso TK 460
Statoil CylWay FZ 460
Mobil 600W Super Cylinder Oil
Shell Valvata Oil J460
Doc. No. OM-81841-0103 10 - 15 (18)

Lubricant Recommendations 10 Technical Data

F
Lithium 90 296-68 BP Energrease LS EP 2 / XRB2 EP
grease, Esso Esso MP Grease/Beacon EP 2
EP type Statoil UniWay LI 62
Mobil Mobillux EP 2
Shell Grease 1344 LiEP 2
Shell Calithia EP Grease T2
H
High-pressure oil 90 296-75 BP Energol GR-XP 320
90 296-76 Esso Spartan EP 320 / Mobilgear 632
(mineral) 320
Mobil Mobilgear 632
Shell Omala oil 320
90 296-73 BP Energol GR-XP 220

90 296-78 Esso Spartan EP 220
For use in production Mobil Mobilgear 630
plant with start Shell Omala oil 220
temperature below 5° C.
TechPub_2614345_0104 - TB138413en.fm
K
Circulation oil 90 296-15 BP Energol CS 100
Esso Teresso 100
Statoil TurbWay 100
Mobil DTE Oil Heavy
Shell Tellus Oil 100
L
Silicon grease 90 296-9 Grease 55322-30 ACC to M 1255.322
TUBE 100 GR
M
Lithium grease, EP 90 296-70 BP Energrease LS EP 1
type Esso Beacon EP 1
Statoil UniWay LI 61
Mobil Mobillux EP 1
N
PTFE 90 296-91 Sikema
grease
O
Lithium complex 90 296-61 BP Energrease LS 3
grease Esso Unirex N3
Statoil UniWay HT-63
P BP Energol RC 68
Synthetic compressor 90 296-54 Esso Compressor Oil 68
oil Statoil CompWay 68
Mobil Rarus 427
Shell Corena Oil H68
Q
Low friction assembly 90 296-12 Dow Molykote G-N Plus
paste Kluber Unimoly Plus
10 - 16 (18) Doc. No. OM-81841-0103

10 Technical Data Lubricant Recommendations

R
Synthetic grease 90 459-246 Kluber Klubersynth UH1 14-1600
S
Synthetic hydrocarbon 90 296-10 Mecman 435-1
grease
T
Synthetic lubricating 90 459-0340 Shell Cassida HDS2
grease
U
Hydraulic fluid 90 459-1310 Shell Cassida Fluid HF32
V
Oil 90 296-104 Molykote Molykote Foodslip EP Gear Oil 220
W
Hydraulic fluid 90 458-1427 Shell Hydraulic Oil 46
Shell Tellus T 46
X
Oil 90 296-105 Kluber Lubrication Kluberoil 4 UH1-220
Y
Lubrication oil 90 458-2735 Mobil Mobil SHC 634
TechPub_2614345_0104 - TB138413en.fm
Lubricant 90459-3876 Kluber Syntheso D 460 EP

(Worm gear)
Grease 90459-1052 Shell Albida HLS2
(Worm gear) 90459-1063 Mobil Mobilith SHC 460
Oil AGIP Blasia S 320
(Gear box) BP Energol SG 220 (ISO 220)
Shell Tivela WC
Mobil Glygoyle 30 (ISO 220)
Kluber Syntheso D EP 320
Doc. No. OM-81841-0103 10 - 17 (18)

Lubricant Recommendations 10 Technical Data
TechPub_2614345_0104 - TB138413en.fm
10 - 18 (18) Doc. No. OM-81841-0103


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OM

Doc. No. OM-81841-0103

Series No./ Machine No. Sign.

8 Care and Cleaning

A list of all optional equipment, optional

Doc. No. OM-81841-0103

Tetra Pak Carton Ambient S.p.A.

Date Installed Kit Added Pages Removed Pages Signature

Doc. No. OM-81841-0103 i - 1 (14)

This chapter contains basic information about this manual

i - 2 (14) Doc. No. OM-81841-0103

Abbreviations and Terminology . . . . . . . . . . . . . i - 12

How to Use This Operation Manual . . . . . . . . . . i - 13

C: Supplies and Checks. . . . . . . . . . . . . . . . . . . . . . . . i - 14

Doc. No. OM-81841-0103 i - 3 (14)

i - 4 (14) Doc. No. OM-81841-0103

• Operation Manual (OM)

Doc. No. OM-81841-0103 i - 5 (14)

3.4 Motor 3 Drive

Doc. No. MM-123457-0108 3 - 15 (102)

i - 6 (14) Doc. No. OM-81841-0103

• A pointer arrow (1) indicates the position of an object.

Doc. No. OM-81841-0103 i - 7 (14)

i - 8 (14) Doc. No. OM-81841-0103

Doc. No. OM-81841-0103 i - 9 (14)

i - 10 (14) Doc. No. OM-81841-0103

Doc. No. OM-81841-0103 i - 11 (14)

Abbreviations and Terminology

i - 12 (14) Doc. No. OM-81841-0103

How to Use This Operation Manual

Doc. No. OM-81841-0103 i - 13 (14)

Safety General A: General Information

C: Supplies and Checks

i - 14 (14) Doc. No. OM-81841-0103

Doc. No. OM-81841-0103 ii - 1 (36)

Read the Safety Precautions

ii - 2 (36) Doc. No. OM-81841-0103

Safety Messages Description. . . . . . . . . . . . . . . ii - 5

Doc. No. OM-81841-0103 ii - 3 (36)

Handling and Storage of Cooling

Equipment for Lifting and Moving Loads . . . . ii - 35

ii - 4 (36) Doc. No. OM-81841-0103

Safety Messages Description

Doc. No. OM-81841-0103 ii - 5 (36)

ii - 6 (36) Doc. No. OM-81841-0103

There are two types of safety sign

Pos. ISO sign ANSI sign

Rotating blade can crush and cut.

Hazardous voltage could be present with power supply

Doc. No. OM-81841-0103 ii - 7 (36)

Pos. ISO sign ANSI sign

Chemical burn hazard.

ii - 8 (36) Doc. No. OM-81841-0103

Locations of Safety Signs

Doc. No. OM-81841-0103 ii - 9 (36)

ii - 10 (36) Doc. No. OM-81841-0103

Doc. No. OM-81841-0103 ii - 11 (36)

ii - 12 (36) Doc. No. OM-81841-0103

Change inoperative components of the safety system immediately.

Doc. No. OM-81841-0103 ii - 13 (36)

EMERGENCY STOP Push-Buttons

ii - 14 (36) Doc. No. OM-81841-0103

After installation and maintenance, and before this equipment is inched or