Tem 3759999 0101

TeM
Technical Manual
For Aseptic Package Checks
3760000-0100
Tetra Pak® E3/Speed FP
k
Tetra Pa
meter
Am
Digital
4
3
2
1
Y
READ
WARNING
Read and follow all safety precaution instructions throughout this
document and on safety signs attached to the equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.
Doc. No. TeM-3759999-0101

Public
Copyright © 2023 Tetra Pak International S.A.
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 Packaging Solutions.
, Tetra Pak, and all other trademarks displayed in this document are the property of the
Tetra Pak International S.A. Tetra Pak Packaging Solutions together with Tetra Pak
International S.A. form part of ‘the Tetra Pak Group’. The content of this document is in
accordance with the design and construction of the machine or equipment at the time of
publishing. The Tetra Pak Group reserves the right to introduce design modifications without
prior notice.
The English language version of this document contains the original instructions. All other
language versions are translations of the original instructions.
This document was produced by:
Tetra Pak Packaging Solutions
Via Delfini 1
41123 Modena
Italy
Doc. No. TeM-3759999-0101

Issue 2023-03
Public
This document is valid for: Introduction
1 Checks
2 Quick Checks - Package
Equipment Serial No.
Year of Manufacture 3 Quick Checks - Seals
4 Quick Checks - Openings and
Closures
TeM
Technical Manual
5
6
7
Daily Checks - Package
Daily Checks - Transversal
Seal
Daily Checks - Openings and
Closures
8 Tools and Templates
For Aseptic Package

Checks
3760000-0100
Equipment configurations that this

document is valid for are described on the
next page.
Doc. No. TeM-3759999-0101

Issue 2023-03
Tetra Pak Packaging Solutions
Public
Additional Specification Information
In addition to the name and bill of material number on the front page, this table specifies the kits and options that
the user manual is valid for at the time of release.
For changes made to this user manual after the time of release, see the Update Log table after this table.
If the equipment has a kit or option installed that is not listed in the aforementioned tables, it is recommended to
confirm the validity of this user manual. Contact technical.publications@tetrapak.com for confirmation.
Name Bill of Material Additional Information

Tetra Pak® E3/Speed FP 648423-0100
Public
Introduction
®
Doc. No. TeM-3759999-0101 5 (142)
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Introduction
Description
This chapter contains basic information about this document and the related
Tetra Pak® equipment.
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Introduction Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Abbreviations and Terminology ............................... 9

Safety Precautions ............................................. 10
Safety Messages Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Definition of Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Document Information ..........................................11

Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Differentiation of Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Table of Contents Introduction
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Introduction Abbreviations and Terminology
Abbreviations and Terminology*

The table contains all abbreviations and terminology used throughout this user
manual. Among these abbreviations may be the official abbreviated forms of product
names and trademarks belonging to the Tetra Pak Group.
Abbreviation/Terminology Meaning Translation
B Base (package shape) Base (package shape)
CIP Cleaning In Place Cleaning In Place
DC DreamCap DreamCap
DIMC Direct Injection Direct Injection
Moulded Concept Moulded Concept
DQSS Digital Quality Sampling Digital Quality Sampling
System System
E Edge (package shape) Edge (package shape)
FC FlexiCap FlexiCap
HC HeliCap HeliCap
ISO International International
Organization for Organization for
Standardization Standardization
LH Left hand Left hand
LS Longitudinal Seal(ing) Longitudinal Seal(ing)
LW LightWing LightWing
MaPS Magnetic Position Magnetic Position
System System
MiM Micro Injection Micro Injection
Moulding Moulding
MSE Strip type (used in case Strip type (used in case
of Oxygen sensitive of Oxygen sensitive
high quality products) high quality products)
OM Operation Manual Operation Manual
PE Polyethylene Polyethylene
PLH Pre Laminated Hole Pre Laminated Hole
PT PullTab PullTab
QDMS Quality Data Quality Data
Management System Management System
RH Right hand Right hand
S Slim (package shape) Slim (package shape)
TBA Tetra Brik® Aseptic Tetra Brik® Aseptic
TeM Technical Manual Technical Manual
TGA Tetra Gemina Aseptic Tetra Gemina Aseptic
(package shape) (package shape)
TP Tetra Pak Tetra Pak
TPA Tetra Prisma® Aseptic Tetra Prisma® Aseptic
TSA Tetra Stelo Aseptic Tetra Stelo Aseptic
(package shape) (package shape)
TS Transversal Sealing Transversal Sealing
WgC WingCap WingCap
UP Update Pages Update Pages
®
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Safety Precautions Introduction
Safety Precautions
Before starting any work on the equipment, it is compulsory to read the Safety
Precautions chapter in any of the existing documents of the equipment.
Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a signal
word.
The safety alert symbol 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 document to
inform the user of hazards.
Danger indicates an imminently

DANGERI
DANGER hazardous situation which, if not
avoided, will result in death or serious
injury.
Warning indicates a potentially

WARNING hazardous situation which, if not
avoided, could result in death or
serious injury.
Caution indicates a potentially

CAUTION 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.
Definition of Lockout Procedure

A lockout procedure is a procedure to put each necessary energy isolating device in
its safe position to prevent the energisation of the equipment, such as when a
maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an energy
isolating device cannot be operated.
An energy isolating device is a mechanical device that physically prevents

transmission or release of energy, such as an electrical supply disconnecting
device.
When a utility should be LOCKED in the OFF position according to the Equipment
Status row of a Procedure Start Table, the lockout procedure for that utility is
applicable.
A detailed instruction for the specific lockout procedure(s) for this equipment is
found in the General chapter of the Maintenance Manual, or the General section of
the Maintenance Instructions chapter of the Technical Manual.
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Introduction Document Information
Document Information
Before interacting with the test equipment, carefully read the instructions in the
applicable documentation pertinent to the activity.
Note that the document may apply to several variants and describes all designs.
There may therefore be descriptions of systems and details that are not found on
your equipment.
Equipment that is shown in the illustrations may, depending on the design, differ from
your equipment.
Any item that is named specifically in this document is to be considered a designated

item for the equipment. Designated items are verified by the Tetra Pak Group for use
with the equipment.
The Tetra Pak Group will not be held responsible for any damage, loss, injury, or
death that is caused by not following the instructions in the documents that are
provided with this equipment. Also, the Tetra Pak Group will not be held responsible
for the above due to failure to use designated items that are specified in the
documents that are provided with this equipment.
The ”Public” classification given for this document means that the document is public
information. As public information, the document is created to be provided to
receivers outside the Tetra Pak Group.
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Doc. No. TeM-3759999-0101 11 (142)
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Document Information Introduction
Page Layout
Every main page in a manual contains a header and a footer. The page header
contains the chapter name (1) and the section name (2). The page footer contains
the page number (3), and the document number (4). See also the Page Numbering
section.
1 2
9 General 9.2 Technical Data
Doc. No. MM-2730517-0103 41 (60)
4 3
1 Chapter name
2 Section name
3 Page number
4 Document number
.
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Introduction Document Information
Page Numbering
A page number has two parts:
• consecutive page number (1)
• total number of pages (2) in user manual
31 (356)
1 2
1 Consecutive page
number
2 Total number of pages
Note! The letters UP (3) may appear before the consecutive page number (4) if the
user manual includes update pages. The consecutive page number (4) and the total
number of pages (5) of update pages do not follow the existing sequential page
numbering of the user manual.
UP-11 (18)
3 4 5
3 UP
4 Consecutive page
number
5 Total number of pages
.
Typographical Conventions
Physical buttons on the operator panel, emergency stop devices, program steps, and
program tasks are given in CAPITAL LETTERS.
Names of buttons, entry fields, menu items, or other objects that allow the user to
control the user interface are given in Courier.
Information that is displayed on the user interface, is to be repeated in the document,
but is not used to control the user interface, is given in COURIER CAPITAL LETTERS.
Cross-references are underlined.

In position lists, the numbers in square brackets following the items in the lists refer
to the position numbers in the Spare Part List.
Differentiation of Information
In this document there can arise a need to differentiate between various information.
Information in these cases is identified/differentiated using the introductory
texts Valid for: or Not Valid for:, followed by differentiation text.
Examples of differentiation texts are texts due to variants, rebuilding kits, or other
parameters, such as serial number, package type/shape/volume, region, and so on.
(Cont’d)
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Document Information Introduction
(Cont’d)
If multiple differentiation texts are given on the same level in the information
hierarchy (that is, there exists several Valid for: statements in the same place), each
statement is applicable independent of the other Valid for: statements. That is, if one
of the Valid for: statements applies to your situation, then the differentiated text
applies.
Symbols
Symbols used in illustrations.
A pointer arrow indicates the position of

an object.
A zoom arrow indicates that an object

view is enlarged. The arrow points
towards the enlarged view of the object.
A rotation movement arrow indicates

rotational movement of an object. The
arrow points in the direction of rotation.
A straight movement arrow indicates
movement of an object.
The arrow points in the direction of
movement.
.
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1 Checks
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Document Information 1 Checks
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1 Checks 1.1 Introduction to Package Checks
1.1 Introduction to Package Checks

This section describes the checks to perform on packages during PRODUCTION.
CAUTION
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 checks.
Whenever a fault cannot be eliminated, call a technician.
1.1.1 General Information

Perform the package checks according to
vv
the test methods described in this manual.
Use the test flow charts to determine what

actions (if any) are needed after each
package check.
Carefully read the package schematic
representations to become fully acquainted
with the terminology used to describe the
different components and characteristics of
the package.
Use the 1.3.1 Package Sample Size Table

for Quick Checks and the 1.3.2 Package
Sample Size Table for Daily Checks to
collect the number of packages needed.
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1.2 Terminology 1 Checks
1.2 Terminology
1.2.1 Package
1.2.1.1 TBA package (No Opening)
1 Bottom left fin corner 12 Longitudinal crease 22 Top inner cross 31 LS strip
2 Bottom front left corner 13 Top front right corner 23 Top outer cross 32 Bottom rear left corner
3 Bottom crease 14 Top crease 24 Top cutting line 33 LS overlap
4 Front side of 15 Bottom front right 25 Top transversal seal 34 Bottom transversal
package/panel 3 corner 26 Top cross seal
5 Left side of 16 Bottom fin crease 35 Bottom cutting line
27 Perforation
package/panel 2 17 Bottom right fin corner 36 Bottom outer cross
6 Top front left corner 28 Top rear left corner
18 Bottom rear right 37 Bottom inner cross
7 Top flap creases corner 29 Rear side of
package/panel 1 38 Bottom cross
8 Top left fin corner 19 Rear side of
package/panel 5 30 Air gap 39 Double creases
9 Spout crease 40 Bottom flap crease
20 Right side of
10 Top fin crease package/panel 4
11 Top right fin corner 21 Top rear right corner
.
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1 Checks 1.2 Terminology
1.2.2 Direct Injection Moulded Concept - Overview

1.2.2.1 LightCap, WingCap, LightWing
3 4
2
5
1 6
LightCap
LightCap
1 Packaging Material grip seal
2 Threads
3 Membrane
4 Pull-ring
5 Pouring lip
6 Crown
.
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1.3 Package Selection and
Identification 1 Checks
1.3 Package Selection and Identification

The selection of packages varies depending on package configuration, packaging
machine system, and whether a sampling unit is used.
There are two kinds of tests: QUICK checks and DAILY checks. The quick checks
are for fast quality control and performed close to the packaging machine. The daily
checks need more time and a controlled lab analysis environment.
Tables 1.3.1 Package Sample Size Table for Quick Checks and 1.3.2 Package
Sample Size Table for Daily Checks give an overview of the package sampling size
needed for the frequent checks and daily checks package opening and packaging
machine system.
Refer to the respective packaging machine Operation Manual for the correct
collection, identification and marking of the sample packages.
.
1.3.1 Package Sample Size Table for Quick Checks

Number of packages to collect for the checks.
DURING PRODUCTION AND PRODUCTION START

PACKAGE SPECIFICS PACKAGE CHECKS + LS STRIP CAP CAP TOTAL
TIGHTNESS (RED INK CHECKS OPENING
INJECTION) CHECKS
DIMC opening 12 (including cap/cap opening checks)

12
- PRODUCTION START
E3/Speed FP DIMC opening 6 (including all cap/cap opening checks)
- at 15.000 packages batch 1: 6 from jaws 1 - 6 6
batch 2: 6 from jaws 6 - 1
.
AT CHANGED FILLING MACHINE SETTINGS:

EXTRA PACKAGES FOR CHECKING LS STRIP TIGHTNESS
(RED INK INJECTION)
E3/Speed FP 10
.
AT LS STRIP SPLICES
E3/Speed FP 2
.
1.3.2 Package Sample Size Table for Daily Checks

Number of packages to collect for the daily checks.
CAP MEMBRANE
PACKAGE SPECIFICS PACKAGE TESTS TOTAL
TESTS
6
E3/Speed FP DIMC No opening 10 (one from each 16
forming station)
Note! The quantity of packages described equals the amount of packages

necessary to perform each of the checks and should not be considered as an
.
absolute value, rather the minimum quantity needed.
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1 Checks Identification
1.3.3 Tools and Consumables

The following tools are needed to perform
vv
package checks:
• Package Integrity Tool Kit, TP 3725939-
0000
• scissors
• syringe
• needle
• steel ruler
• package templates
• a clean workbench in a well-illuminated
area
• scales for weighing
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Identification 1 Checks
1.3.4 Red Ink Mixing Instructions
WARNING vv
Contact with chemicals can cause
serious injury, or illness.
Always read and follow the instructions in the
safety data sheet supplied by the
manufacturer or local supplier, when
handling chemicals.
Red ink is an isopropanol-based leak
detection solution. The solution has the
ability to penetrate small cracks and pinholes
that may be present in the barrier layers in
the package.
This simulates the migration of micro-
organisms through the packaging material
layers.
The red colour comes from the dye,

Erythrosine B. The dye allows visual
detection of any ink leakage into the board
material and in individual cases, micro
channels, and product residues in the seals.
Red ink should be used at room temperature
where it does not interact with the polymer
layers in the package.
Other solvents, like turpentine, may damage
the polymer layers and, as a consequence,
lead to incorrect results.
See the safety data sheets for information
about handling the chemicals prior to mixing.
It is recommended to use rubber gloves and
safety goggles.
To mix red ink, the following tools and
equipment are needed:
• Milligram scale
• Two bottles with screw cork, 1 litre
• Funnel (avoid funnels with very smooth
inside surfaces since this adds to the
filtering time)
• Whatman grade one filter paper, pore size
11 μm, or better.
• Gloves
• Safety goggles
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1 Checks Identification
The ingredients are the following.
vv
Erythrosine B:
• CAS No. 16423-68-0
• Molecular weight 879.84 g/mol
Note! Several different substances are

labelled Erythrosine B. There are also a
number of synonyms to the correct one.
Make sure that the CAS number is 16423-
68-0.
Do not attempt to use any other dye than

Erythrosine B.
• The dye purity should be at least 90%
• Available as Tetra Pak material number
351752-0025
• Isopropanol (isopropyl alcohol, 2-
propanol)
• CAS no. 67-63-0 (or similar)-> 99.5 %
purity
Mixing procedure:
• Weigh about 1.5 g of Erythrosine B.
• Mix the Erythrosine B with 1 litre of
isopropanol in a bottle.
• Shake well and leave it overnight. A
shorter time leads to a less saturated
solution (paler ink)
• Pour the solution through a funnel with a
paper filter into a second bottle.
The red ink is ready to use.
• Store the solution in a closed container to

minimise evaporation.
• Expiry date is about two years from the
day of mixing.
Density of the mixed solution should be 786

±3 g/l.
Note! If filtering is slow due to clogging, it is
possible to perform a prefiltering using a less
dense paper filter.
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1.4 Package Sample Utilization - Quick
Checks 1 Checks

Checks
1.4.1 Package Sample
Sample Utilization at Production Start
Package Jaw System Package Sample

Samples Link
12 No. 1-5 or 7-11 No. 6 or 12 No. 13 No. 14
14 No. 1-6 or 8-13 No. 7 or 14 No. 15 No. 16
Printing
�
Weight
�
Forming
�
Flap Sealing
�
Crease Lines
�
Internal Surfaces
�
LS Overlap
�
LS Strip Application
�
LS Strip Tightness
�
TS Rough
�
TS Accurate
� �
.
(Cont’d)
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1 Checks Checks
(Cont’d)
Sample Utilization at 30.000 Packages
Package Check Jaw System Link Package Sample

12 No. 1-5 or 7-11 No. 6 or 12
14 No. 1-6 or 8-13 No. 7 or 14
Printing
�
Weight
� �
Forming
�
Flap Sealing
�
Crease Lines
�
Internal Surfaces
�
LS Overlap
�
�
TS Rough
�
TS Accurate
� �
.
Sample Utilization at Packaging Material and Strip Splices
Package Sample
Package Check No. LS 1 No. LS 2
Forming (Shape and Design)
� �
�
LS Strip Tightness
�
.
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Checks 1 Checks

Valid for: E3/Speed FP with DIMC
Sample Utilization at Production Start
Package Samples
Package Check No. 1-6 No. 7-10 No. 11 No. 12
Printing
� �
Weight
� �
Forming
�
Flap Sealing
�
Crease Lines
�
Internal Surfaces
�
LS Overlap
�
�
LS Strip Tightness
�
TS Rough
� �
TS Accurate
� �
Cap Openability
� � �
Cap Position
�
Cap Forming (outer

side) �
Cap Forming (inner

side) �
Cap Integrity
�
Cap Seal
� � �
.
(Cont’d)
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1 Checks Checks
(Cont’d)
Sample Utilization at 15.000 Packages (Jaw Pairs 1 to 6)
Package Samples
Package Check No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Printing
� � � � �
Weight
� � � � �
Forming
�
Flap Sealing
� � � � � �
Crease Lines
�
Internal Surfaces
�
LS Overlap
�
LS Strip
Application �
TS Rough
� � � � �
TS Accurate
� � � � �
Cap Position
� � � � � �
Cap Forming
(outer side) � � � � � �
Cap Forming
(inner side) � � � � � �
Cap Seal
� � � � � �
.
(Cont’d)
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Checks 1 Checks
(Cont’d)
Sample Utilization at 15.000 Packages (Jaw Pairs 6 to 1)
Package Samples
Package Check No. 6 No. 7 No. 8 No. 9 No. 10 No. 1
Printing
� � � � �
Weight
� � � � �
Forming
�
Flap Sealing
� � � � � �
Crease Lines
�
Internal Surfaces
�
LS Overlap
�
LS Strip
Application �
TS Rough
� � � � �
TS Accurate
� � � � �
Cap Position
� � � � � �
Cap Forming
(outer side) � � � � � �
Cap Forming
(inner side) � � � � � �
Cap Seal
� � � � � �
.
Sample Utilization at Packaging Material and Strip Splices
Package Sample
Package Check No. LS 1 No. LS 2
Forming (Shape and Design)
� �
�
LS Strip Tightness
�
.
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1.5 Package Sample Utilization - Daily
1 Checks Checks
1.5 Package Sample Utilization - Daily

Checks
Note! These checks should also be made at production start.

Valid for: E3/Speed FP No Opening
Package Samples
Package Check
No. 1-12 (12 links)
No. 1-14 (14 links)
Package Integrity by Conductivity
�
Leakage by Red Ink

�
TS Integrity by Dissolving
�
TS Integrity by Red Ink

�
.

Package Check Package Samples
No. 1-10 No. 11-15

Package Integrity by Conductivity
�
Leakage by Red Ink

�
TS Integrity by Dissolving
�
TS Integrity by Red Ink

�
Injection Gate (LightCap only)

�
Cap Membrane
�
.
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1.6 Quick Checks Flowcharts 1 Checks
1.6 Quick Checks Flowcharts

1.6.1 Packages Flow
Flowchart Description
The Flowchart of Package Checks displays:
• the checks to be performed in the sequence described in the checking scheme
table.
• the type of checks.
• the necessary actions (if any) to be taken depending on the result of the
completed check.
.
Check Type Action if not approved

Printing ● Stop production - call technician
↓
Weight ● Adjust weight - check again
↓
Forming (Shape Adjust TPOP settings - check again
*
& Design)
↓
Flap Sealing * Stop production - call technician
↓
Crease Lines * Adjust settings in TPOP - check again
Δ
↓
Internal Surfaces * Stop production - call technician
Δ
↓
LS Overlap * Adjust settings in TPOP - check again
Δ
↓
LS Strip Stop production - call technician
Δ
Application
↓
Δ
Tightness
↓
TS Rough Δ Stop production - call technician
↓
TS Accurate Δ Stop production - call technician
↓
ALL CHECKS DONE
- Continue Production
- Provide additional packages to Laboratory QA checks
* = Package appearance and line efficiency related check

Δ = Package integrity check
● = Legal requirement related check

.
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1 Checks 1.6 Quick Checks Flowcharts
1.6.2 Packages Flow

Flowchart Description
The Flowchart of Package Checks displays:

• the checks to be performed in the sequence described in the checking scheme
table.
• the type of checks.
• the necessary actions (if any) to be taken depending on the result of the
completed check.
.
* = Package appearance and line efficiency related check

Δ = Package integrity check
● = Legal requirement related check

.
(Cont’d)
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1.6 Quick Checks Flowcharts 1 Checks
(Cont’d)
Check Type Action if not approved

Printing ● Stop production - call technician
↓
Weight ● Adjust weight - check again
↓
Forming (Shape Adjust TPOP settings - check again
*
& Design)
↓
Flap Sealing * Adjust TPOP settings - check again
↓
Crease Lines * Adjust settings in TPOP - check again
Δ
↓
Internal Surfaces * Stop production - call technician
Δ
↓
LS Overlap * Stop production - call technician
Δ
↓
Δ
Application
↓
Δ
Tightness
↓
TS Rough Δ Stop production - call technician
↓
TS Accurate Δ Stop production - call technician
↓
Cap Openability Stop production - Adjust settings in TPOP -

*
start and check again
↓
Cap Forming Stop production - call technician
Δ
(outer side)
↓
Cap Forming Stop production - call technician
Δ
(inner side)
↓
Cap Position Δ Stop production - call technician
↓
Cap Integrity Δ Stop production - call technician
↓
Cap Sealing Δ Stop production - call technician
↓
ALL CHECKS DONE
- Provide additional packages to Laboratory QA checks
.
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1 Checks 1.7 Daily Checks Flowchart
1.7 Daily Checks Flowchart

Check Action if not approved
Conductivity check
↓ ↓
Negative result Positive result
↓
↓ Check leakages Call technician
by red ink (Technician decides further checks)
↓
Dissolve packages
urgent = Method 1 acid
not urgent = Method 2 alkaline Call technician
TS check with red ink
Seal pattern check
↓ ↓
ALL CHECKS DONE
.
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Doc. No. TeM-3759999-0101 33 (142)
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1.7 Daily Checks Flowchart 1 Checks
34 (142) Doc. No. TeM-3759999-0101

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Public
2 Quick Checks - Package
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Doc. No. TeM-3759999-0101 35 (142)
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1.7 Daily Checks Flowchart 2 Quick Checks - Package
36 (142) Doc. No. TeM-3759999-0101

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2 Quick Checks - Package 2.1 Preparation
2.1 Preparation
Before starting the package checks, make
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sure that the:
• correct number of package samples have
been taken.
• package samples have been correctly
identified and marked.
• all the necessary tools and consumables
are available.
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Doc. No. TeM-3759999-0101 37 (142)
2.2 Printing 2 Quick Checks - Package
2.2 Printing
Check the date and code printing.
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If necessary stop the packaging machine
and adjust the date printing according to the
instructions supplied with the printer.
38 (142) Doc. No. TeM-3759999-0101

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2 Quick Checks - Package 2.3 Weight
2.3 Weight
Weigh the packages and record their
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weights and weight deviations.
After setting, pick out new packages and
check them.
For any adjustments of the package weight,

please refer to the Operation Manual.
Note! Check the tare of the package in case
of packaging material PO (Production Order)
change.
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Doc. No. TeM-3759999-0101 39 (142)
2.4 Appearance 2 Quick Checks - Package
2.4 Appearance
Check the packages for wrinkles, cracks, or
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any other defects.
40 (142) Doc. No. TeM-3759999-0101

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2 Quick Checks - Package 2.5 Shape and Design
2.5 Shape and Design

2.5.1 TBA, TPA Package, Check without Template
1
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Check Shape and Creases
Check the shape of the package.
Check that the preformed creases in the

packaging material are correctly aligned
along the edges of the package.
To adjust the package creases see Design
Correction Offset in Package Forming Unit
Correct shape TBA Window in the OM.
package
Low crease position High crease position
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Doc. No. TeM-3759999-0101 41 (142)
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2.6 Longitudinal Crease Lines 2 Quick Checks - Package
2.6 Longitudinal Crease Lines

1 2 1 1
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Check Crease Lines
Unfold the flaps (1) and then lift the package
fin (2).
Note! To correctly check the crease line
alignment, it is important to unfold the flaps.
Checking the crease line alignment with the
flaps in the folded position may provide an
incorrect indication of the crease line
alignment due to the package folding.
Bottom view of package Check the position of the preformed crease
lines (3).
2 2 The position is good if:
• if the crease lines are opposite one
1 1 another (Fig. 1).
Fig.1 The position is acceptable if:

• if the crease lines are slightly shifted, but
2 2 are still touching one another (Fig(s): 2
and 4). Cap application (if any) may be
1 1 compromised.
The position is not acceptable if:

Fig.2
• if the crease lines are shifted and are not
touching one another (Fig(s): 3 and 5).
2 2
Note! Figures 2 and 3 show a misalignment
1 1 caused by a twisted tube.
In figures 4 and 5 the misalignment is related
Fig.3 to the LS overlap.
Note! For machine equipped with MaPS, to
2 2 adjust the position of the preformed crease
lines follow the procedure Static Mark
1 1 Position in Tube Forming Unit Window, see
the OM.
Fig.4 For other machines, please refer to
Operation Manual for details.
2 2
1 1
Fig.5
42 (142) Doc. No. TeM-3759999-0101

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2 Quick Checks - Package 2.7 LS Overlap
2.7 LS Overlap
1
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Check the width of the overlap (distance A)
Package Distance A
TBA 1000 E 8.0 ±1.0 mm
A Measure LS overlap use a steel ruler (or a

calliper, if available).See in the picture, the
overlap is between 7,5 and 8,0 mm.
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Doc. No. TeM-3759999-0101 43 (142)
2.8 Flap Sealing 2 Quick Checks - Package
2.8 Flap Sealing

1
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Check Flap Sealing
Unfold the flaps and check that they are
correctly sealed.
Note! If marks due to the excess of heating
are present, reduce the flap sealing
temperature. In particular, check the
perforation at the top flap and the bottom
TS.
To adjust the flap sealing follow the
instructions in Final Folder Unit Window in
the OM.
Note! Depending on the packaging
material, different flaps sealing settings
might be required.
44 (142) Doc. No. TeM-3759999-0101

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2 Quick Checks - Package 2.9 Internal Surfaces
2.9 Internal Surfaces

1
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Check Internal Surfaces
Cut two opposite corners (Fig.1) and empty
the content of the package.
Cut transversely the front panel of the
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 the package and dry gently with
compressed air from the packaging machine
or dry with a paper towel.
Fig.1 Fig.2 Note! Improper use of compressed air
could create defects in the packages.
Preparing the samples in this shape allows a
fast preparation and avoids the risk of cutting
the package internal surfaces.
Check the outside and inside surfaces of 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.
Fig.3 Fig.4
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Doc. No. TeM-3759999-0101 45 (142)
2.9 Internal Surfaces 2 Quick Checks - Package
46 (142) Doc. No. TeM-3759999-0101

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3 Quick Checks - Seals
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Doc. No. TeM-3759999-0101 47 (142)
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2.9 Internal Surfaces 3 Quick Checks - Seals
48 (142) Doc. No. TeM-3759999-0101

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3 Quick Checks - Seals 3.1 Longitudinal Seal
3.1 Longitudinal Seal

1
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LS Strip Application Evaluation
Checks
The LS strip application evaluation consists
of five steps:
• Visual check of the LS strip position.
• Visual check of the heat pattern width and
position.
• Visual check of the strip seals for
deviations in the heat and/or pressure
distributions.
• Quality Check - Tear Down Method.
• Quality Check - Strip seal tightness.
2
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Zonoscope
Use the Zonoscope (Tetra Pak tool 90243-
0203) to enhance the contrast from the heat
pattern.
The heat pattern can also be inspected by
using reflected light in some angles.
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Doc. No. TeM-3759999-0101 49 (142)
3.1 Longitudinal Seal 3 Quick Checks - Seals
3
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MPM Strip Position Viewer
Use the Strip Position Viewer (Tetra Pak
tool 90610-4419) for a visual inspection of
the heat pattern around the MPM strip and
the strip position.
4
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MSE Strip Position Viewer
Use the Strip Position Viewer (Tetra Pak
tool 90610-4420) for a visual inspection of
the heat pattern around the MSE strip and
the strip position.
50 (142) Doc. No. TeM-3759999-0101

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3.1.1 LS Strip Position

1
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LS Strip Position Check
The Longitudinal Sealing side (LS) of the
seal is where the packaging material is
single. The Strip Applicator side (SA) of the
seal is where the packaging material is
double.
Packages with MPM LS strip type

Check that the strip (1) is centred in the seal.
An air gap (2) should be present in the

centre of the seal.
Use the Strip Position Viewer (Tetra Pak tool
90610-4419) for a visual inspection of the
MPM strip position.
Packages with MSE LS strip type

50 % SA
In any package with MSE LS strip type, the
MPM LS strip type strip is off-centred with respect to the seal; ~
60% of the strip covers the SA side.
Use the Strip Position Viewer (Tetra Pak tool

90610-4420) for a visual inspection of the
MSE strip position.
Note! When a risk of strip folding on MPM is
apparent, apply the setting of MSE.
To adjust the strip position, please refer to
the Operation Manual for instructions.
40% 60%
MSE LS strip type
Strip folding
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Doc. No. TeM-3759999-0101 51 (142)
3.1.2 Heat Pattern

1
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In the heat pattern check, the LS strip seal
on SA and LS sides are inspected visually
for defects caused by incorrect heat and/or
pressure distribution.
Carefully, visually, verify the heated area of
both SA and LS application to ensure that
the heat and pressure applied are correct.
If a too high heat or pressure are applied, the

heat line is often also under the strip.
The sealing systems are either based on hot
air or inductive heating.
Note! Induction heating and hot air give
different results in terms of visual
appearance, therefore it is important to know
which kind of sealing system is used during
the package check phase.
The heat pattern should be visible at least 1
mm outside both sides of the strip.
Use the Strip Position Viewer tool for quick
checks.
2
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Example 1 - Longitudinal Wrinkles
Minor wrinkles in the machine direction are
often visible on the LS side. They have no
impact on the strip seal tightness. The seal is
good.
LS SA
Example 1
52 (142) Doc. No. TeM-3759999-0101

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3
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Example 2 - Wrinkles Under the
Strip
Minor wrinkles, or heating lines, under the
strip are often present. They are visible
mainly on the SA side. They have no impact
on the strip seal tightness. The seal is good
LS SA
Example 2
4
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Example 3 - Overheated Strip
and/or Uneven Pressure Settings
Excessive heat settings or uneven pressure
(often caused by a loose LS roller) may lead
to wrinkles that can have impact on the
packaging material. The seal quality is
acceptable but at the next possible occasion,
call a technician to perform corrective
actions.
LS SA
Example 3
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Doc. No. TeM-3759999-0101 53 (142)
5
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Example 4 - Blistering
Check for blisters or bubbles along the
heated zone of the strip. Occasionally they
can be seen also under the strip. Blisters on
the LS or SA side of the strip indicate that
the sealing temperature is too high. This may
have impact on the seal integrity and should
therefore be adjusted immediately. Check
the strip seal tightness using red ink.
LS SA
Example 4
6
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Example 5 - PE Residuals
Polymer residues can become trapped
under the strip. The strip seal tightness may
be affected. Corrective actions should be
performed immediately. Check the strip seal
tightness at the wrinkles with red ink.
LS SA
Example 5
54 (142) Doc. No. TeM-3759999-0101

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3.1.3 Visual Check

1
5 vv
Check for blisters or bubbles (5) along the
heated zone of the LS strip (2). The
6 presence of blisters (5) in the LS side of the
strip (2) indicates too much sealing
temperature for the LS heater.
5 Presence of blisters in the SA side of the
7 strip indicates too much sealing temperature
for the strip applicator heater.
On the LS strip (2) there are some small

heating lines (6) visible mainly on the SA
2 side.
Note! The air channel (7) must be visible.
LS SA
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Doc. No. TeM-3759999-0101 55 (142)
3.1.4 Seal Quality - Tear Down Method

1
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Cut Package
Cut through the air channel in the middle of
the LS strip, along the inner edge of the
packaging material.
Pull off the outer layer of packaging material
(1) where it is double, to check the overlap. A
good overlap gives stability to the package. If
there is any defect, corrective actions should
be taken.
2
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Pull LS Strip
Check the strip 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
90
edge. Pull on both sides (SA and LS).
Note! If any of the layers come off, cut the
strip and start pulling again.
1 3
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Check the strip sealing.
The sealing is acceptable if:
• all inside polymer layers come off with the
strip (1), leaving the Al-foil bare.
56 (142) Doc. No. TeM-3759999-0101

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1 4
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Acceptable Sealing
• the inside polymer layers separates
(delaminates) and comes off with the strip
2 (1), leaving a ruptured edge (2) along the
seal.
1 5
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Acceptable Sealing
3 • all the inner layers including the Al-foil
come off with the strip (1), although
possibly leaving paper board fibres (3).
6
1 Acceptable Sealing
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• the strip (1) separates (delaminates)
when it is pulled off.
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Doc. No. TeM-3759999-0101 57 (142)
1 7
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Acceptable Sealing
4 The sealing is acceptable if:
• all the inner layers including the Al-foil
come off with the strip (1), even possibly
leaving part of the lamination layer (4) on
both sides.
1 8
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Defective Sealing
The sealing is defective if:
• the strip (1) comes off leaving the inner
coatings of the packaging unaffected. In
this case, stop PRODUCTION and call a
technician for specific settings.
58 (142) Doc. No. TeM-3759999-0101

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3.1.5 Seal Quality - LS Strip Tightness

1
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Cut and Dry Package Samples
To perform this check take:
• two packages when machine setting are
stable
• ten packages when machine settings
have been recently changed.
Note! Be careful not to over stress samples

during their preparation.
Cut open the packages as illustrated. Cut the
corner (1) at one end of the LS seal.
1
Rinse and dry with a paper towel the
packages without folding along the top and
bottom creases in reverse direction.
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Doc. No. TeM-3759999-0101 59 (142)
2
3 2 Inject Red Ink into Package
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Prepare some red ink fluid (2) in a syringe.
Place the needle (3) of the syringe into the

air channel (4) of the LS.
Cover the injection point with a piece of
paper towel (5) to absorb any ink spilled and
inject the red ink along the entire LS length.
Due to red ink soaking from the paperboard

on SA side (7), use a new paper towel to
4
wipe down the SA side of the LS strip. The
LS is defective if there is red ink on the paper
towel.
Call a technician in case of defects.
5
Critical points are where LS meets the top
and bottom creases.
Note! When a channel is detected verify the
heat and pressure distribution, see 3.1
Longitudinal Seal.
60 (142) Doc. No. TeM-3759999-0101

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3
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Check Distance D
Measure the shortest distance between the
strip edges and the red ink. Pay extra
D attention to possible deviations at the crease
lines.
• If the distance D is large than 0,5 mm, the
sample is correct and production is safe.
• If the distance D is between 0,2 and 0,5
mm, is still acceptable, but corrective
actions should be performed to put the
process back in safe conditions.
• If the distance D is smaller than 0,2 is not
acceptable. Production should be
SA side stopped.
LS side
Dimension Distance D (mm)
Approved > 0.5
Warning* 0.2 ≤ D ≤ 0.5
Not approved < 0.2
* Production is safe but with reduced

robustness/margins.
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Doc. No. TeM-3759999-0101 61 (142)
3.2 Transversal Seal 3 Quick Checks - Seals
3.2 Transversal Seal

3.2.1 Rough Check
1
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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.
For DIMC Equipment:

Squeeze the package and check the
tightness of the cap seal around the hole and
the cap moulding.
Critical points are:
• the membrane
• the packaging material hole edge.
If any product leakage is found stop the

machine and call a technician.
Note! If there is leakage from between the
pre-laminated hole and the package, call a
technician.
Valid for: LightCap
62 (142) Doc. No. TeM-3759999-0101

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3 Quick Checks - Seals 3.2 Transversal Seal
3.2.2 Accurate Check - Tear Down Method

1
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Prepare Package Sample
Cut a sample strip (1) of about 25 mm in
width from the top and bottom transversal
seals.
Wash the samples and dry gently with
compressed air from the packaging machine
or dry with a paper towel.
Note! Improper use of compressed air
1 could create defects in the packages.
1
2
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Cut Sample
Cut off no more than 1 mm from each side of
the package at a 90° angle to the TS.
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Doc. No. TeM-3759999-0101 63 (142)
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3
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Check Sealing Area
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.
If the pressure is too high call a technician.
To adjust the power and correct the TS

sealing, follow the instructions in Package
Forming Unit Window, in the OM.
64 (142) Doc. No. TeM-3759999-0101

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1 2 5 4
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Stretch Sample
Insert the edges of the sample (1) into the
gripping jaws (2) of the stretch pliers.
Gently squeeze the handles to stretch the

seal.
Stretching slowly makes evaluation easier.
6
Observe that the inner layers stretches and
breaks.
5 Stretch gently, a little bit at a time, from both
ends towards the LS/TS cross:
3 • Start streching at the end positions (3)
illustrated in the picture.
• Continue stretching towards the LS/TS
4 cross.
• Finish by stretching at the LS/TS cross,
position (4).
3 The TS must be stretched and evaluated

along the entire seal.
CORRECT
Pay special attention to the TS corners (5)
and where the TS and the LS meet TS/LS
cross (6).
WRONG
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Doc. No. TeM-3759999-0101 65 (142)
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1 2 3 4 3 2 1 5
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Stretch Sample
Stretch the TS along the entire length of the
seal with the stretch pliers and evaluate the
seal.
It is mainly the sealing on the product side of

area A that is important.
5 A
6 7
5 8
1 Paper board 5 Blocked area

2 Aluminium foil 6 Sealed area
3 Polyethylene (double 7 Ridge
layer) 8 Cutting line
4 Filling product
6
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Acceptable TS Sealing
Check the TS sealing.
• The seal remains intact but a
delamination between the two inner
coatings takes place.
7
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• 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.
66 (142) Doc. No. TeM-3759999-0101

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8
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• The seal remains intact but a rupture
takes place in the layer of paper board.
9
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Defective TS Sealing
• The seal is so weak that the two PE
layers separate without rupturing.
Adjust the power to correct the TS sealing,

follow the instructions in Package Forming
Unit Window, in the OM.
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Doc. No. TeM-3759999-0101 67 (142)
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2 1 10
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Defective TS Sealing
The TS is defective if:
• The seal is so overheated that the two PE
layers (1) disappear from the sealing area
because they have melted away and the
aluminium foil (2) shows micro-cracks and
cuts.

11
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Cross Area Check
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 coating the Al-
foil.
• a rupture occurs in any of the layers
fig.1 (fig.1).

• there is no rupture (fig.2). This may be
caused by too low a sealing power.

fig.2
68 (142) Doc. No. TeM-3759999-0101

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4 Quick Checks - Openings
and Closures
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Doc. No. TeM-3759999-0101 69 (142)
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3.2 Transversal Seal 4 Quick Checks - Openings and Closures
70 (142) Doc. No. TeM-3759999-0101

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4 Quick Checks - Openings and Closures 4.1 LightCap
4.1 LightCap
4.1.1 Position
2 1
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1 Note! The hole (2) is used to check the
neck of the cap.
Put the template (1) over the package and
check that the neck of the cap enters
smoothly into the hole (2).
If the template (1) does not fit correctly, call a

technician.
Note! For the correct template for the
package, see 8 Tools and Templates.
C 2
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Positioning of cap
Valid for: Lightcap 30
Check that the Pre-Laminated Hole, PLH, is
positioned on the packaging material
according to the specification.
Check the distance A and B between the

hole and the cap to make sure that the cap is
A centred in the longitudinal direction.
Check the distances C and D between the
hole and the cap to make sure that the cap is
centred in the transversal direction.
If the cap is not centred in the transversal or

B longitudinal directions, call a technician.
D
A = B ±0.5 mm
C = D ±1.0 mm
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Doc. No. TeM-3759999-0101 71 (142)
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4.1 LightCap 4 Quick Checks - Openings and Closures
4.1.2 Openability
1
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Note! The cap openability check must be
performed 20 minutes after the package
samples have been taken from the
conveyor.
Note! Pull the ring in the opposite direction
of the two main legs as shown in the image,
see the arrows.
Open the LightCap and check that the
LightCap opens easily and breaks the
membrane.
Check that the tear-off seal has been
completely removed and that no residue
remains.
72 (142) Doc. No. TeM-3759999-0101

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4.1.3 Cap Forming

1
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LightCap (outer side)
Check that the following LightCap parts are
completely formed:
• the crown (1)
• the pull-ring (2)
Make sure that the packaging material (3) is

visible in the crown (1) all around the
LightCap neck.
Check that there are no plastic flashes
along:
• the top of the neck (4)
• the neck thread (external tools junctions)
(5)
• around the crown (6).
Call a technician for any of the above

forming problems.
4 2 1 6 3 5
Check the forming of the crown:
• If PLH is not visible all around the neck in
one package, call a technician
• If more than 25% of the crown is missing
in one package, call a technician
• If one or more missing legs of the crown
always on the same station/position
reported in 3 consecutive following OM
checking intervals for cap forming: call a
technician.
• If there is a sporadic tendency of
incomplete crown perimeter this is an
aesthetical deviation. Production can
continue by following standard package
checks
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Doc. No. TeM-3759999-0101 73 (142)
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2
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LightCap (inner side)
Check that the inside sealing area of the
LightCap is formed.
The LightCap forming is not acceptable if

there are plastic flashes (1) or underfilled
areas (2) around the sealing area inside the
packages.
Call a technician for any forming problems.
1 2
74 (142) Doc. No. TeM-3759999-0101

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4.1.4 Cap Integrity

1
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Use a pair of scissors to cut the package in
half.
Apply red ink to the inside of the package in
the area indicated in the illustration.
Leave the red ink inside the package for

approximately 5 minutes. Wipe off with a
clean dry paper towel and wait for the ink to
completely dry.
2
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Score the top of the package with a knife as
indicated in the illustration. Remove the top
layer of the packaging material to reveal the
internal fibre.
Make sure there is no evidence of red ink in
the fibre layer.
If red ink is visible, call a technician.

Note! Problems with cap sealing may result
in unsterile packages. Always call for a
technician.
3
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Check that the red ink has not passed
through the membrane in the perimeter area
indicated in the illustration.
If red ink has passed through the membrane,

call a technician.
Problems with LightCap sealing may result
in unsterile packages. Always call for a
technician.
Cross section view.
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Doc. No. TeM-3759999-0101 75 (142)
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4.1.5 Cap Seal

1 1
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Check the cap sealing by pulling off the cap
parts from the inside of the packages.
2
The seal is acceptable if the inner coating
(2) comes off with the cap (1), leaving a
ruptured sealing surface (3) on the
packaging material around the hole.
The seal is defective if the cap comes off
leaving the inner coating of the packaging
3 material unaffected.
Note! Problems with cap sealing may result
in unsterile packages.
Always call for a technician for problems with
cap sealing.
76 (142) Doc. No. TeM-3759999-0101

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5 Daily Checks - Package
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Doc. No. TeM-3759999-0101 77 (142)
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4.1 LightCap 5 Daily Checks - Package
78 (142) Doc. No. TeM-3759999-0101

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5 Daily Checks - Package 5.1 Introduction
5.1 Introduction
The Daily Checks describe the checks to be performed at production start and then
at least once per day.
CAUTION
Daily Checks and corrective actions can affect the Quality of the Production.
Whenever a fault cannot be eliminated, call a technician.
5.1.1 General Recommendations

The following Daily Checks are provided as
vv
a guideline of how to perform a laboratory
assessment of Tetra Pak packages.
The quantity of packages described equals
the amount of packages necessary to
perform each of the checks and should not
be considered as an absolute value, rather
the minimum quantity needed.
The preparation of chemicals is under the
laboratory responsibility.
If conductivity and dissolving tests are to be

performed in parallel extra packages are
needed.
Follow the sequence of checks as described
in the 1.6 Quick Checks Flowcharts.
Record the checks performed using a
Record or Sample Collecting sheet. Archive
the test samples together with the record
sheet, and keep them as part of the
company Quality Assurance program.
Note! Examples of Recording and Sample
collecting sheets are available on request.
If necessary, photocopy the 1.6 Quick
Checks Flowcharts and mark the check box
when each check has been completed.
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Doc. No. TeM-3759999-0101 79 (142)
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5.1 Introduction 5 Daily Checks - Package
5.1.2 Chemical Terminology

1
vv
The following lists the formula and the
corresponding compounds used in the Daily
Package Checks:
Formula Extended
CuCl2 Copper Cloride
NaOH Sodium Hydroxide
HCl Hydrocloric Acid
Na2CO3 Sodium Carbonate
80 (142) Doc. No. TeM-3759999-0101

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5 Daily Checks - Package 5.2 Conductivity Check
5.2 Conductivity Check

1
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Equipment Needed
The following equipment is needed:
• scissors
• plastic container
• Ammeter (TP No. 90243-0110 or 90610-
3637)
• beakers and bowls
• table salt
• Red ink, see 1.3.4 Red Ink Mixing
Instructions.
3 2
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Method Description
Note! If occasional defective packages are
suspected, larger-scale investigation can be
5 6 carried out by measuring the electrical
1 conductivity.
If deviations are detected during
measurements, the whole package section
must be checked using red ink.
The following equipment is required:
• plastic container approximately 30 cm
diameter, 10 cm depth
• ammeter with battery and electrodes
• 1% table salt solution (e.g. 10g table salt
in 1 Litre water).
2 4 7 4 The water is rendered electrically conducting
by the addition of table salt.
1 Table salt solution in 5 Black electrode
container If the internal polyethylene coating is
6 Red electrode
2 Plastic container damaged, electric current will flow and the
7 Table salt solution in
3 Ammeter ammeter will display a reading.
package
4 Half package
®
Doc. No. TeM-3759999-0101 81 (142)
5.2 Conductivity Check 5 Daily Checks - Package
5.2.1 Preparing the Package

1
vv
Note! Handling of the samples is of vital
importance in the whole evaluation. Care
and attention must be used at all stages of
the evaluation.
Cut the package in half on the front side
panel (the one without the LS), using the
scissors.
Empty out the packages content.
Wash carefully the two halves of the
package with water.
Dry thoroughly the cut edges of the package
with paper towel.
82 (142) Doc. No. TeM-3759999-0101

®
5.2.2 Using the Analogue Ammeter

1
vv
Prepare Test with Ammeter
Pour the salt solution (1) into the container
(2).
Insert the electrodes of the ammeter (3) into

1 2 the salt solution (1) and check if the ammeter
displays a reading.
Fill the two halves of the package (4) with the
3 salt solution to about 1/2 level and dry the
cut edges again with a paper towel.
Place the halves of the package (4) into the

salt solution (1).
®
Doc. No. TeM-3759999-0101 83 (142)
2
vv
Perform Test with Ammeter
Immerse black electrode (5) of the ammeter
3 (3) in the salt solution (1) and the red
electrode (6) in the salt solution inside the
6 package (7).
Note! Be sure that sample edges are
completely dry since presence of water may
5 cause bridging of current and false reading.
Check the ammeter (3) display.
• If the ammeter does not display a reading,
the inner layer of PE is intact.
1 • If the ammeter displays a reading, the
inner layer of PE is damaged: red ink test
is needed.
Test both packages halves in the same way.

7 Note! The salt solution can be used several
times. Change the solution when it is not
clear or once a week.
• If there is no deflection of the ammeter,
continue testing the package from item
6.1 Sample Preparation for Dissolving
• If there is a deflection of the ammeter, test
the package with red ink, from next item.
84 (142) Doc. No. TeM-3759999-0101

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5.2.3 Using the Digital Ammeter

2 1 1
vv
Prepare Test with Ammeter
Pour the salt solution into the container.
Switch on the Ammeter. LED 4 will flash
every third second when the Ammeter is on.
4 Insert the black electrode (1) and the red

electrode (2) of the Ammeter into the salt
solution. LED 3 or 4 should light up. If not,
check the salt concentration.
3 Fill the two halves of the package with the
salt solution to about 1/2 level and dry the
cut edges again with a paper towel.
Place the package halves into the salt

solution in the container.
1 Black electrode 3 LED

2 Red electrode 4 LED
®
Doc. No. TeM-3759999-0101 85 (142)
2 1 2
vv
Perform Test with Ammeter
Immerse the black electrode (1) of the
ammeter in the salt solution and the red
electrode (2) in the salt solution inside the
package.
Note! Be sure that sample edges are
completely dry since presence of water may
cause bridging of current and false reading.
Check the ammeter display.
• If none of LED 1 to 4 lights up, the inner
layer of PE is intact.
• If any of LEDs 1 to 4 lights up, the inside
layers are damaged and a red ink test
should be performed.
• If the ammeter reading is unstable, wipe
1 Black electrode the edges once more and take a new
2 Red electrode reading. If necessary, leave the sample to
dry for five minutes, then take a new
reading. If still unstable, proceed with the
red ink test
Test both package halves in the same way.

Note! The salt solution can be used several
times. Change the solution when it is not
clear or once a week.
• If there is no deflection of the ammeter,
continue testing the package from item
• If there is a deflection of the ammeter, test
the package with red ink, from next item.
Note! The READY diode on the Digital

Ammeter will light up when the test circuit is
properly closed. If READY diode remains
dark, check the wires and the probe
connections. If a package half is tested
several times in a sequence, the READY
diode will light up only the first time the
circuit is closed.
86 (142) Doc. No. TeM-3759999-0101

®
5 Daily Checks - Package 5.3 Check for Leakages with Red Ink
5.3 Check for Leakages with Red Ink

1
vv
Prepare Package Sample
Dry carefully the inside of the halves of
packages with a paper towel.
Cut the package to separate the two halves.
2
vv
Add Red Ink to Package Sample
Use a pipette to apply some red ink inside
the half package that displayed a deflection.
Swirl the red ink around.
Leave the red ink inside the package for 5
minutes.
Remove any excess of red ink from the

inside of the package with a plastic pipette.
®
Doc. No. TeM-3759999-0101 87 (142)
5.3 Check for Leakages with Red Ink 5 Daily Checks - Package
1
3
vv
Remove Outer Layer of PE
Remove the red ink with a pipette and dry
the insides of the package half with a paper
towel.
Note! Do not use compressed air to dry the
package from ink.
Let it dry before carefully removing the outer
layer of PE, splitting the packaging material.
The outer PE and some paper board (1) will
come off.
Note! If ink is still in the package when this
operation is performed, artefact defects may
1 be created.
2 4
vv
Check for Red Mark
Check for any red marks (2) over the paper
board layer over the package sample.
The presence of red marks indicates that the
package leaks or that the inner PE pouch is
damaged. In this case, call a technician.
88 (142) Doc. No. TeM-3759999-0101

®
6 Daily Checks - Transversal
Seal
®
Doc. No. TeM-3759999-0101 89 (142)
Public
5.3 Check for Leakages with Red Ink 6 Daily Checks - Transversal Seal
90 (142) Doc. No. TeM-3759999-0101

®
Public
6 Daily Checks - Transversal Seal 6.1 Sample Preparation for Dissolving

1 1
vv
Unfold Package Flaps
Take the cut package and unfold the top
flaps (1) and bottom flaps (2).
®
Doc. No. TeM-3759999-0101 91 (142)
6.1 Sample Preparation for Dissolving 6 Daily Checks - Transversal Seal
2
vv
Cut the Package
Flatten the package.
Note! Cut with a distinctive cut type (3) part
of the sample to easily identify the top TS
side (4) of the sample.
Cut out the pieces A and B to leave an I
A shaped sample, as shown in the drawing.
At the side not including the LS (5) cut away

the pieces C and D to leave the final shape
3 (6).
B Carefully wash and dry the samples, inside

4 and outside.
Mark each sample, on the inner PE, with

progressive numbers (7), to identify from
which jaw pairs the package comes.
C D
5
6
7
2
92 (142) Doc. No. TeM-3759999-0101

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6 Daily Checks - Transversal Seal 6.1 Sample Preparation for Dissolving
3
vv
Remove Outer Layer
Carefully remove the outer layer of
polyethylene, splitting the packaging
material.
The outer polyethylene layer and some

paper board (8) will come off to obtain the
sample to utilize for the test.
8
2
®
Doc. No. TeM-3759999-0101 93 (142)
6.2 Dissolving the Samples 6 Daily Checks - Transversal Seal
6.2 Dissolving the Samples

WARNING vv
Alkali and Acid.
Always follow the Safety precautions when
working with acid and alkalis. Preparing and
working with hydrochloric acid solutions and
sodium hydroxide solutions must be carried
out under well ventilated conditions as fumes
may be given off. Wear protective goggles
and gloves. For the preparation always use
heat resistant glass beakers. Used liquids
should be disposed of in accordance with the
prevailing regulations.
The microbiological quality of the TS is
checked by chemically exposing the inner
coating (dissolving method) and checking its
tightness by means of the leak detection fluid
(red ink).
Note! The LS strip is extremely sensitive to
chemical treatments. Pay attention to
carefully follow the dissolving instructions to
preserve the sample and avoid wrong
samples assessment (MSE strip is
particularly sensitive to high temperature
and long chemical exposure).
94 (142) Doc. No. TeM-3759999-0101

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6 Daily Checks - Transversal Seal 6.2 Dissolving the Samples
Determine which type of dissolving method
vv
to use according to the time available for
checking the samples. Two methods are
available:
• using CuCl2 in hydrochloric acid (37%) as
the aluminium foil dissolving agent.
This method is preferred when the
urgency on the results is high and before
production start. In this case follow the
instructions in 6.2.1 Method 1 - Dissolving
with an Acid Agent.
Note! The neutralizing step of this
method is mandatory. If not performed the
sample will be inconclusive and the LS
strip negatively affected.
• using NaOH in water as the aluminium foil
dissolving agent: the speed of reaction is
lower (approximately 12 to 24 hours).
This method is preferred when the
amount of samples is large. In this case
follow the instructions in 6.2.2 Method 2 -
Dissolving with an Alkaline Agent.
®
Doc. No. TeM-3759999-0101 95 (142)
6.2.1 Method 1 - Dissolving with an Acid Agent

1
vv
Equipment Needed
This consists of three solutions, bath (1),
bath (2), bath (3).
The equipment and chemical preparations
needed are:
• Concentrated HCl
• CuCl2
• Na2CO3
• Distilled water
1 2 3 • Tongs
• Indelible felt-tipped pen
• Water bath
• Fume extractor
• Laboratory gloves (single use).
2
vv
Preparation of Bath 1
(hydrochloric acid)
WARNING
Do not use a direct flame!
4 The solution is prepared at room
temperature but must be heated using a
water bath (4) at 55 to 60°C when in use.
Dilute the HCl 1:1 with distilled water.
1
Add 1wgt% CuCl2 (e.g. 1 lt HCl, 1 lt distilled
water, 20 gr. CuCl2).
Store the prepared bath (1) in a glass

container with a glass lid.
Note! The bath might be filtered when it
becomes dirty (filter at room temperature)
and used for several TS examinations.
96 (142) Doc. No. TeM-3759999-0101

®
3
vv
Preparation of Bath 2
(hydrochloric acid at room
temperature)
Dilute the HCl 1:3 with distilled water. Add
0.5 wgt% CuCl2 (e.g. 250 cc HCl, 750 cc
distilled water, 5 gr. CuCl2).
Store the chemical in a glass container with
a glass lid.
2
Note! The bath might be filtered when it
becomes dirty (filter at room temperature)
and used for several TS examinations.
4
vv
Preparation of Bath 3 (sodium
carbonate at room temperature)
Note! The bath (3) spoils very quickly. The
preparation of a new solution becomes
necessary if its bubbling does not start when
the samples are immersed in the solution.
Prepare 10 wgt% solution of Na2CO3 in
distilled water (e.g. 100 gr Na2CO3, 1 lt
3 distilled water).
Store the chemical in a glass container with
a glass lid.
Note! The bath might be filtered when
become dirty (filter at room temperature).
The consumption of this bath is high
compared to the others.
Note! This step is mandatory. If not
performed the sample will be inconclusive
and the LS strip negatively affected.
®
Doc. No. TeM-3759999-0101 97 (142)
5
vv
Immerse Sample in Bath 1
6 Note! Use one sample (5) at a time.
Immerse the samples (5) into the Bath 1
with the aid of the tongs (6) and leave it there
for approximately four minutes at 60 °C
(warm water bath (4)).
5 Note! The bath temperature setting may

need further adjustment. When samples are
immersed, if the reaction is too fast
(depending on how much board has been
4 removed), the bath temperature could be
lowered, even down to 50°C.
1 Remove the samples with the tongs and
immerse them in Bath 3 to neutralize them.
Note! The sodium carbonate bath (3)
should bubble. If not, prepare a new
3 solution.
6
vv
Rinse Samples in Water
8
CAUTION
Chemical burn hazard.
Wear personal protective equipment.
Put the sample under tap water. The
lamination layer (7) will separate from the
aluminium foil (8) and can be easily
removed.
7
If not, put it back in Bath 1 for some extra
time and rinse again the samples.
The inner pouch of PE and the aluminium foil

(8) are left.
98 (142) Doc. No. TeM-3759999-0101

®
7
vv
Immerse Sample in Bath 2
Note! This step is the most delicate. If it is
not performed correctly, the sample can burn
6
and be spoiled due to building of high
temperature.
Immerse the samples completely and no
more than two at a time in bath 2 with the aid
2 of the tongs (6). Take them away from the
bath in fast sequence.
The aluminium layer will become detached.

5 After separation, the sample (5) is reduced
to a single inner coating.
The sample (5) now needs to be neutralized
in bath 3 and then rinsed carefully with tap
water.
Dry the samples with paper towel and leave

3 them on filter paper.
Continue with 6.4.1 Inductors.
5
®
Doc. No. TeM-3759999-0101 99 (142)
6.2.2 Method 2 - Dissolving with an Alkaline Agent

1
vv
Prepare Solution
This consists of a 15% NaOH solution in
water.
800 Prepare 15 wgt% NaOH distilled water
1 solution by adding, while stirring, water to the
NaOH pellets in a beaker (1).
600 2 The solution (2) becomes warms while water
is added to the NaOH pellets.
400 The solution should be used at room
temperature but pay attention not to wait too
long as it might loose in efficiency if not
200
carefully closed.
Note! CIP solution (normally 30%) can be
used after dilution 1:1.
Note! At least 150 ml solution per sample is
needed.
2
1 Immerse Samples
vv
Carefully immerse the samples (3)

3 completely in the dissolving solutions (2)
800 without covering the glass beaker (1) as
hydrogen fumes give off.
2 Note! It is important that the samples are
600 completely below the liquid surface.
Note! The solution immediately starts to
400 bubble and becomes warm. If not, make
sure the solution has been freshly prepared.
Leave the samples in the dissolving solution
200 for 12 to 24 hours.
Note! The temperature of the solution
should not exceed 40 °C.
If necessary, place the beaker in a tray with
cooling water.
100 (142) Doc. No. TeM-3759999-0101

®
4 5 3
vv
Rinse Sample
WARNING
Chemical burn hazard.
Wear personal protective equipment.
Before rinsing the samples make sure that
the aluminium foil has disappeared. If not
leave the samples in the solution a little
longer or prepare a fresh solution.
Carefully rinse and split the samples under
tap water (4). The inner coating pouch (5) of
the sample becomes very easy to peel off
and separate from the rest of the packaging
materials (6).
6 Continue with 6.4.1 Inductors.
®
Doc. No. TeM-3759999-0101 101 (142)
1 4
vv
Dissolving With An Ultrasonic
Bath
Optionally, an ultrasonic bath (1) can be
used to speed up the dissolving process with
the alkaline agent. The time in solution can
then be reduced to about 2 hours.
Note! The ultrasonic frequency in the bath
should be between 33 and 37 kHz. Using a
higher frequency, the risk for destroying the
samples is high.
• Fill the ultrasonic bath (1) with the alkaline
solution.
• Fill the ultrasonic bath (1) with water (3).
• Place a support rack (7) in the bottom of a
plastic container (4). Fill the plastic
container (4) with the alkaline solution (5).
• Place the plastic container (4) in the US
bath (2), however make sure the plastic
container (4) is not touching the bottom
on the US bath (2), see schematic picture
for illustration. This can be achieved by
external handles or another support rack
(7).
• Immerse the TS samples (6) into the
NaOH solution (5). Make sure they are
below the liquid level all the time.
4 5 • The heater on the ultrasonic bath (1)
should be set at 40° C.
2 • Set the timer at 2 hours. Do not leave the
samples (6) in the US bath (2) for too long
3 6 time.
• After about 2 hours, check if the
aluminium foil has dissolved completely.
• If it has not, leave the TS samples (6) in
7
the NaOH solution (5) a short while
1 Ultrasonic bath 5 NaOH Solution longer, or prepare a fresh solution.
2 US Bath 6 TS Sample
3 Water 7 Support Rack
4 Plastic Container
102 (142) Doc. No. TeM-3759999-0101

®
6.2.3 Drying the Samples

1
vv
WRONG Note! Do not dry the sample by reversing
the bags. Sample can be spoiled easily. Dry
the inside of the bags by carefully using
paper towel.
Take one sample at a time.
Dry it carefully by inserting paper towel (1) in

the bag and moving it carefully along the TS
and in the bag corners.
Be sure that the sample is completely dry.
Water prevents a good check.
Take note of the appearance of the sealing.

Critical spots like bending off at the corners
and irregularity of the sealing are very easy
to spot.
Continue with 6.4.1 Inductors
CORRECT
®
Doc. No. TeM-3759999-0101 103 (142)
6.3 Tightness Test using Red Ink 6 Daily Checks - Transversal Seal
6.3 Tightness Test using Red Ink

1
vv
Pour some red ink fluid (2) into the pouch of
the inner coating (3) using a plastic pipette
2 (1). Spread the red ink in the pouch with your
finger, being careful not to apply too much
pressure.
1 Leave it to stand for some time and then
check the sample.
3 • any channel of red ink is present through
the sealing
In case channels are present, the fluid will

pass through and stain the outside of the
inner coating pouch.
Check again when the ink inside the sample

is completely dry and, if necessary, call a
technician.
104 (142) Doc. No. TeM-3759999-0101

®
6 Daily Checks - Transversal Seal 6.4 Seal Pattern Check
6.4 Seal Pattern Check

1
vv
The dissolving solution evaluation of the TS
is both an inspection of the seal pattern and
test of the seal tightness.
The steps for performing this evaluation are:

a) Use red ink to check for any channels in
the ridge area,
b) Visually check the seal pattern for
unsealed areas and irregularities,
c) Check the sealing process dimensions.
For the evaluation of the seal pattern it is

recommended to use the Seal Viewer, see
the left picture.
The Seal Viewer should be used with a

loupe with magnification 10x. It comes with a
smartphone table that allows pictures to be
captured through the loupe.
The Seal Viewer can be ordered at TetraPak,
see the TP No. in 8 Tools and Templates.
®
Doc. No. TeM-3759999-0101 105 (142)
6.4 Seal Pattern Check 6 Daily Checks - Transversal Seal
6.4.1 Inductors
1
vv
Heat Pattern Check
Note! The checks for the heat pattern or
seal pattern differ for twin loop inductor and
single loop inductors.
Identify the TS inductor installed on the
packaging machine and then see:
• 6.4.2 Seal Pattern with Single Loop
Inductor
Single loop inductor
• 6.4.3 Seal Pattern with Twin Loop
Standard Inductor
• 6.4.4 Seal Pattern with Twin Loop Inclined
Ridge Inductor.
Twin Loop standard inductor
Twin loop inductor with inclined ridge
106 (142) Doc. No. TeM-3759999-0101

®
6.4.2 Seal Pattern with Single Loop Inductor

1 9 2 3 2 4 1
vv
Seal Pattern Check
Note! The Seal Pattern check is a
qualitative assessment of the sealing. A
good light and a 10X lens is sufficient for
monitoring the production quality. Holding
the sample with both the hands, check all
the critical spots like bending off (1) at the
corners.
5 6 7 8 Note! It recommended to use Tetra Pak
Seal Viewer (Tetra Pak item 3543653-0000)
1 Bending off 6 Ridge imprint
together with a 10x a LED scale lupe (Tetra
2 Strip 7 Seal pattern cutting Pak item 90609-9972). Optionally, the Peak
3 LS air gap side
8 Cutting side scale loupe (Tetra Pak item 90609-9913)
4 Product side can be used with the Seal Viewer.
9 Ridge imprint shadow,
5 Seal pattern product product side Take note of the appearance of the seal
side
pattern product side (5) and seal pattern
cutting side (7) and check:
• for channels passing though the TS
• for plastic lumps or any other irregularities
of the sealing
• reduced heat pattern due to blocked
seals.
®
Doc. No. TeM-3759999-0101 107 (142)
D 9 C 2
vv
Measure Seal Pattern
The dimensions B, C, and D of the seal
pattern are measured from the centre of
B ridge imprint shadow, product side (9), to the
end of the seal pattern on the product side.
Dimension Acceptable NOT
(mm) Acceptable
(mm)
B ≥ 0.2 < 0.2
B (TBA 125 ≥0 <0
B S and
packages
with HC23)
C ≥1 <1
D C D ≥1 <1
Ruptures in the sample, other than in the TS

area (such as corners), are due to sample
handling. Although the ridge imprint in the
sample could be broken due to the handling
of the dissolving process, it does not affect
the TS integrity.
Note! Do not challenge the sample in any
other way (for example stretch pliers) as the
mechanical properties have been changed
by the dissolving. At this stage samples
have to be evaluated by means of a visual
inspection and red ink only.
108 (142) Doc. No. TeM-3759999-0101

®
6.4.3 Seal Pattern with Twin Loop Standard Inductor

1
1 8 1 vv
Seal Pattern Check
7 7 qualitative assessment of the sealing. A
2 good light and a 10X lens is sufficient for
monitoring the production quality.
4
Note! It recommended to use Tetra Pak
9
Seal Viewer (Tetra Pak item 3543653-0000)
3 together with a 10x a LED scale lupe (Tetra
Pak item 90609-9972). Optionally, the Peak
10 scale loupe (Tetra Pak item 90609-9913)
can be used with the Seal Viewer.
Holding the sample with both the hands,
check all the critical spots along the TS. Take
note of the appearance of the seal pattern
product side (4) seal pattern cutting side (6)
and check:
• for channels passing through the
complete TS
• for plastic lumps or any other irregularities
10
of the sealing
• reduced seal pattern due to blocked seals
in the cross.
Note! Bubbles (10) in the seal pattern are

typical for Twin Loop inductor seals. They
are located between the ridge imprint (6)
and the product side (3).
1 Bend off 6 Ridge imprint shadow

2 Product side line product side
7 Strip
3 Cutting side
8 LS air gap
4 Seal pattern product
side 9 Seal pattern cutting
5 Ridge imprint side
10 Bubble
®
Doc. No. TeM-3759999-0101 109 (142)
6 4 2
vv
The dimensions C and D of the seal pattern
4 are measured from the centre of ridge
imprint shadow line product side (6), to the
end of the seal pattern on the product side
(4).
D C Dimension Acceptable NOT
(mm) Acceptable
(mm)
C ≥1 <1
D ≥1 <1
Ruptures in the sample, other than in the TS

area (such as corners), are due to sample
handling. Although the ridge imprint in the
sample could be broken due to the handling
of the dissolving process, it does not affect
the TS integrity.
by the dissolving. At this stage samples
have to be evaluated by means of a visual
inspection and red ink only.
110 (142) Doc. No. TeM-3759999-0101

®
6.4.4 Seal Pattern with Twin Loop Inclined Ridge

Inductor
1 6 5 4 5 7 8 1 1
vv
Seal Pattern Check
2
qualitative assessment of the sealing. Use
illuminated background when evaluating the
3 samples with a 10X lens.
Note! It recommended to use Tetra Pak
1 Bend off 5 LS strip Seal Viewer (Tetra Pak item 3543653-0000)
2 Product side 6 Seal pattern together with a 10x a LED scale lupe (Tetra
3 Cutting side 7 Seal line, product side Pak item 90609-9972). Optionally, the Peak
4 LS air gap 8 Seal line, cutting side scale lupe (Tetra Pak item 90609-9913) can
be used with the Seal Viewer.
Holding the sample with both the hands,
check all the critical spots along the TS. Take
note of the appearance of the seal line,
product side (7) and seal line, cutting side (8)
and check:
• for channels with red ink passing through
the complete TS
• for plastic lumps any irregularity of the
seal
• for reduced seal pattern due to blocked
areas
• for critical areas such as bend off (1) in
corner and in LS strip (5) overlap
®
Doc. No. TeM-3759999-0101 111 (142)
7 8 2
vv
Measure the minimum seal pattern
dimensions on both sides of the sample. The
measurement shall be taken from the seal
Bi Di Ci
line, product side (7) identified with red ink,
to the seal line, cutting side (8).
Dimension BI CI (mm) DI (mm)
(mm)
Approved Bi ≥ 0,7 Ci ≥ 1,5 Di ≥ 1,5
Warning* - 0,7 ≤ Ci < 0,7 ≤ Di <
1,5** 1,5**
Stop Bi < 0,7 Ci < 0,7 Di < 0,7
Production
Bi
*Production is safe but with reduced
robustness/margins
**Clean seal pattern width without mouse
teeth and product entrapment
Bi, Ci and Di dimension be measured from
the red ink infiltrated seal line, product side,
to the seal line cutting side (see Example 1).
If product has infiltrated the seal line from the
product side, the Bi, Ci and Di dimensions
Ci are measured as the shortest distance
between the red ink infiltration to the seal
line on the cutting side (8), see Example 1.
Di
Di
Example 1
112 (142) Doc. No. TeM-3759999-0101

®
6.4.5 Mouse Teeth Check in Single Loop and Twin

Loop Standard Inductor Seals
Valid for: Single Loop and Twin Loop standard inductors
1
vv
Mouse Teeth Description
Mouse teeth (1) are an irregularity visible
after package dissolving and indicates the
presence of product in the area between the
transversal cutting and the transversal
sealing.
In the Mouse teeth evaluation to allow

logging the data, four zones are defined.
1
They are labelled E1 to E4.
Use the flowchart 6.4.7 Mouse Teeth
Evaluation Flow Chart to determine the
corrective actions to be taken if mouse teeth
are defected.
2
7 vv
Zone Description
6 E4
5 Zone Definition Mouse teeth
detection
4 E3 E1 From seal line, Minor mouse
cutting side (2) teeth (1)
3 E2 to center line, detected
2 E1 cutting side
(3).
E2 From center Moderate
1 Mouse teeth 5 Center Line, Ridge line, cutting mouse teeth
2 Seal Line, Cutting Side Imprint
side (3) to (1) detected
6 Ridge Imprint Shadow ridge imprint
3 Center Line, Cutting Line, Product Side
Side shadow line,
7 Seal Line, Product cutting side
4 Ridge Imprint Shadow
Side (4).
Line, Cutting side
E3 From ridge Mouse teeth
imprint (1) detected in
shadow line, the ridge
cutting side (4) imprint but not
to center line, exceeding the
ridge imprint center line,
(5). ridge imprint
(5).
E4 From center Mouse teeth
line, ridge (1) length
imprint (5). to goes beyond
seal line, the center line,
product side ridge imprint
(7). (5).
®
Doc. No. TeM-3759999-0101 113 (142)
3
vv
Acceptable Mouse Teeth
If there are no mouse teeth (1) detected in
the samples, sealing quality is approved and
PRODUCTION can continue
1
If the mouse teeth (1) detected in the
samples are visibly reaching ZONE E1 or
E1 ZONE E2, sealing quality is approved and
PRODUCTION can continue
samples are visibly reaching ZONE E3,
Package sample of TS with mouse teeth (1) in ZONE E1 sealing quality is approved and
PRODUCTION can continue but at the next
PRODUCTION STOP, call a technician to
perform the following corrective actions:
• Change the dollies, see Change Dollies in
the MM
1
• Check the inductors for damage and the
inductor ridge heights, see Pressure Jaw -
Check Inductor in the MM
• Check the hydraulic pressure of the
E2
catches, see Hydraulic Unit - Set
Pressure in the MM
• Check Block/Plunger status, see Yoke -
Check Plunger and Locating Piecesin the
Package sample of TS with mouse teeth (1) in ZONE E2 MM
Make sure to log all data regarding the

mouse teeth (1) quality, see Mouse Teeth
1 Quality Evaluation- Trend Over Time.
E3
Package sample of TS with mouse teeth (1) in ZONE E3
114 (142) Doc. No. TeM-3759999-0101

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4
vv
Not Acceptable Mouse Teeth
E4 samples are visibly reaching ZONE E4 the
sealing quality is not approved,
PRODUCTION must be stopped.
Call a technician to perform the corrective
actions.
the MM
1 catches, see Hydraulic Unit - Set
Package sample of TS with mouse teeth (1) in ZONE E4, see the Pressure in the MM
table at the begging of the chapter for ZONE definition • Check Block/Plunger status, see Yoke -
Check Plunger and Locating Piecesin the
1 Mouse teeth
MM
If after performing the corrective actions,

mouse teeth (1) are still detected, replace
the cutting jaw knives. Then repeat the
dissolving and TS analysis on two
consecutive packages when PRODUCTION
is restarted.
If there are no improvements, call a
technician.
®
Doc. No. TeM-3759999-0101 115 (142)
6.4.6 Mouse Teeth Check (for Twin Loop Inclined

Ridge Inductor)
1
vv
Prepare and Dissolve Package
Samples
Prepare and dissolve two consecutive
package samples according to the
procedure described in 6.1 Sample
Preparation for Dissolving and 6.2 Dissolving
the Samples.
Mouse teeth are an irregularity visible after

package dissolving and indicates the
presence of product in the area between the
transversal cutting and the transversal
sealing.
Use the flowchart 6.4.7 Mouse Teeth
Evaluation Flow Chart to determine the
corrective actions to be taken if mouse teeth
are detected.
116 (142) Doc. No. TeM-3759999-0101

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2
vv
Mouse Teeth Description
Distinguish the mouse teeth as irregularities
with sharp contrast, (see Figure 1).
Do not mistake the mouse teeth as

variations the sealed area, (see Figure 2).
Note! Ruptures in the sample somewhere
other than in the TS area (like corners) are
due to sample handling.
by the dissolving. At this stage, samples
shall only be evaluated by means of a visual
inspection and red ink.
Figure 1: Mouse teeth Figure 2: Contrast variations in

deviation sealed area
®
Doc. No. TeM-3759999-0101 117 (142)
3
vv
Measure Mouse Teeth
Measure the distance Di between the mouse
teeth and the seal line, product side
identified with red ink as shown in the
illustration.
If the distance Di is < 0,7mm this is not
Package sample of TS without mouse teeth
acceptable.
1 2 If the distance Di is 0,7 ≤ Di < 1,5 mm this is
acceptable with warning and PRODUCTION
can continue.
2 3
3
Di
3
Package sample of TS with acceptable mouse teeth
1 Mouse teeth
2 Product side
3 Cutting side
118 (142) Doc. No. TeM-3759999-0101

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6.4.7 Mouse Teeth Evaluation Flow Chart

Check Action if not approved
Dissolve packages
Check the mouse teeth size according to the quality zones
↓ ↓ ↓
Quality Zone up Quality Zone E3 Quality Zone E4
to E2
↓
Change dollies
↓
Check hydraulic Set hydraulic pressure according
pressure to MM and re-check
↓ ↓
Check condition Change the inductors and re-
of the inductors check
↓
Check inductor Change the inductors and re-
ridge heights check
↓
Check Apply all

Block/Plunger corrective
status actions for quality
zone E3
↓
Check & confirm
mouse teeth size Change the knives and re-check
at quality zone
up to E2
↓ ↓
Continue production
.
®
Doc. No. TeM-3759999-0101 119 (142)
6.4.8 TS Fingers Check

1 1
3 vv
TS fingers (1) are vertical finger shaped
cavities in the TS, formed in clusters or along
the whole sealing. TS fingers (1) are a
continuation of mouse teeth crossing the
E4
ridge imprint shadow line, cutting side (2)
towards the seal line, product side (3).
If TS fingers (1) are detected in the samples,
this is not acceptable and PRODUCTION
2 must be stopped.
Call a technician to perform the following

corrective actions:
the MM
catches, see Hydraulic Unit - Set
Package sample of with TS fingers (1) in ZONE E4, see the table Pressure in the MM
on 6.4.5 Mouse Teeth Check in Single Loop and Twin Loop
Standard Inductor Seals for ZONE definition • Check Block/Plunger status, see Yoke -
Check Plunger and Locating Pieces in the
1 TS Finger MM
2 Ridge Imprint Shadow
Line, Cutting Side If after performing the corrective actions, TS
3 Seal line, Product Side fingers (1) are still detected, Replace the
cutting jaw knives and repeat the dissolving
and TS analysis on two consecutive
packages when PRODUCTION is restarted.
If there are no improvements, call a

technician.
120 (142) Doc. No. TeM-3759999-0101

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6.5 Control Charts – Seal Pattern
6 Daily Checks - Transversal Seal Dimensions
6.5 Control Charts – Seal Pattern Dimensions

Log all measurements to follow the trend over time of the seal pattern dimension. By
so, the corrective actions can be done before the quality is compromising the
production.
Note! Change in power setting, packaging material specification, components and

type of product will affect the seal pattern width. The trend charts need to be
complemented with any type of events that might affect the seal pattern dimensions
1
vv
Example 1 – Stable trend
Seal pattern dimension is monitored over
time. Trend is stable over time with few
samples deviating into warning zone.
Production is safe.
Stable trend
2
vv
Example 2 – Stable Trend with Low
Values
Seal pattern dimension is monitored over
time. The dimension values are small but at
no occasion below the specification limit.
Production is stable but under less robust
conditions.
Stable trend with low values
®
Doc. No. TeM-3759999-0101 121 (142)
Dimensions 6 Daily Checks - Transversal Seal
3
vv
Example 3 – Negative Trend
Seal pattern dimensions over time is
monitored. Trend is negative over time with
increasing samples in deviating from how
normal production has been. Production is
safe but corrective actions shall be taken to
get back into normal seal pattern
dimensions.
Note! Make sure to log any changes made
Negative trend in packaging machine settings, component
change, change in power setting for possible
correlation with the reduction of
measurements.
If seal pattern dimensions reach warning
zone after confirmed negative trend*,
perform the following corrective actions in
order.
*6 points in a row decreasing from normal

production.
During production:
• Check power setting – any recent
changes made? Adjust if needed.
Check hydraulic pressure. Adjust if needed.

Production stop:
• Change dollies
Visual inspection of inductor for damages.

• Change if needed.
122 (142) Doc. No. TeM-3759999-0101

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6 Daily Checks - Transversal Seal Dimensions
4
vv
Example 4 – Values Below
Specification Limit
If seal pattern dimensions reach the not
accepted zone, production is not safe.
Perform the following corrective actions:

• Corrective actions stated in the warning
zone,
• Call a Technician, perform root cause
Values below specification limit analysis.
Quarantine all product from the last

acceptable test.
Inspect and quarantine production and
decide on its fate.
®
Doc. No. TeM-3759999-0101 123 (142)
6.6 Control Charts – Mouse Teeth
Dimensions 6 Daily Checks - Transversal Seal

Dimensions
1
vv
Log all measurements to follow the trend
over time of the mouse teeth extension. By
Mouse Teeth Quality Zone
so, the corrective actions can be done before

4 the quality is compromising the production.
3 Note! Change in power setting, packaging
material specification, components and type
2 of product will affect the mouse teeth
1 extension. The trend charts need to be
complemented with any type of events that
0 might affect the mouse teeth extension.
0 1 2 3 4 5 6 Create a chart with the sample number (2)
Sample Number
on the X axis and the mouse teeth quality
zone (1) on the Y axis
Make sure to log the mouse teeth quality
zone (1) as shown in the table below
Mouse teeth quality zone Log as
Not visible 0
E1 1
E2 2
E3 3
E4 4
124 (142) Doc. No. TeM-3759999-0101

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7 Daily Checks - Openings
and Closures
®
Doc. No. TeM-3759999-0101 125 (142)
Public
Dimensions 7 Daily Checks - Openings and Closures
126 (142) Doc. No. TeM-3759999-0101

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7 Daily Checks - Openings and Closures 7.1 Equipment
7.1 Equipment
1
vv
The following equipment is needed:
• syringe
• deionised water
• colorimetric strip
• razor blade knife
• microscope
• plasticine material
®
Doc. No. TeM-3759999-0101 127 (142)
7.2 LightCap 7 Daily Checks - Openings and Closures
7.2 LightCap
7.2.1 Residue Check
1
vv
Immediately after the package comes out of
the equipment machine, before it passes
under the Capper for Lid application carefully
inspect the cap membrane; no particles,
dust, solid residue, or drops should be visible
(see fig.1). In case of drops of any size (see
fig.2), verify that the residual peroxide is
within the specified limits.
Analyse the packages as follows.
Fig 1
Using a clean syringe, fill the neck with 2.5
ml of deionised water. Open the
colourimetric strip package and take one
strip. Immerse the colourimetric strip in the
previously injected water and analyse the
peroxide concentration in the deionised
water following the strip manufacturer
instructions. If the measured value is higher
than 30 ppm, call a technician to verify that
the cap-flushing equipment is working
correctly.
Fig 2
Note! The colourimetric strip must be stored
according to the manufacturers instructions.
128 (142) Doc. No. TeM-3759999-0101

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7 Daily Checks - Openings and Closures 7.2 LightCap
7.2.2 Injection Gate Check

1
vv
Check the forming station indicator number
(1) marked outside the cap. The number
indicates in which forming station the cap
was made, see the table below.
Moulding Number of
1 Station Marks
1 1
2 2
3 0
2
vv
Check the shape of the injection gate.
If necessary, use a lens to magnify the view.
3
vv
Check the injection gate.
The injection gate is acceptable if:
• The sides are higher than the centre.
• The injection gate is symmetrically
shaped.
Example of an acceptable injection gate with

a new internal tool.
4
vv
The injection gate is acceptable if:
• The sides are higher than the centre.
• The injection gate is symmetrically
shaped.
• The top edges are rough but symmetrical.
Example of an acceptable injection gate with

an old internal tool.
®
Doc. No. TeM-3759999-0101 129 (142)
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5
vv
The injection gate is defective if:
• The injection gate has not enough
plastics.
• The injection gate is not symmetrically
shaped.
Note! Problems with injection gate may

result in unsterile packages. Always call for
a technician.
6
vv
• The injection gate has not enough
plastics.
shaped.

a technician.
7
vv
• The injection gate has more plastics than
necessary.
shaped.

a technician.
130 (142) Doc. No. TeM-3759999-0101

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7.2.3 Membrane Thickness Check

1
vv
Check the forming station indicator number
(1) marked outside the cap. The number
indicates in which forming station the
LightCap was made.
1 2
vv
Manual Cutting
WARNING
Risk of cutting.
2 Wear the protective gloves.
Cut the cap along the cutting line (1). For a
sharp cut, use a razor blade knife.
Cut the package along the cutting line (2).
Cut the cap one more time along the cutting

line (3), about 4 mm large, using the edge of
3 the razor blade knife to obtain a sharp cut.
®
Doc. No. TeM-3759999-0101 131 (142)
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3
vv
2 Put the cut sample (1) on the plasticine
material (2) to secure it in the correct
1 position. The sample has to be horizontal
and perpendicular to the measuring
direction.
Using the microscope, measure the

membrane thickness A in the sample. If
necessary, call a technician.
Note! For the Dino-Lite microscope, make
sure to select the LightCap-150X calibration
in the DinoCapture software. Set the focus
wheel of the Dino-Lite microscope to a
magnification of approximately 150 and
check that the magnification is reported in
the magnification tab.
Opening A (mm)
A
LightCap 24 0.18 ±0.02
LightCap 30 0.17 +0.02/-0.00
132 (142) Doc. No. TeM-3759999-0101

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4
vv
Cutting with Tool
Note! The aim of the neck membrane tool is
to allow the check of the LightCap
membrane in a simpler, faster and
repeatable way.
Note! Use the cutting tool TP No. 3310812-
0300 to perform the cutting.
Put the cut sample (1) on the plasticine
material (2) to secure it in the correct
position. The sample has to be horizontal
and perpendicular to the measuring
direction.
Using the microscope, measure the
membrane thickness A on both sides of the
sample. If necessary, call a technician.
Note! For the Dino-Lite microscope, make
sure to select the LightCap-150X calibration
in the DinoCapture software. Set the focus
wheel of the Dino-Lite microscope to a
magnification of approximately 150 and
1 check that the magnification is reported in
2 the magnification tab.
Opening A (mm)
LightCap 24 0.18 ±0.02
LightCap 30 0.17 +0.02/-0.00
®
Doc. No. TeM-3759999-0101 133 (142)
Public
Special Cases vv
5
Clean Cut
The ideal case. Measure to get the minimum
thickness of the membrane.
6
vv
Cut with Minimum Deformation
Measure to get the minimum thickness of the
membrane without plastic deformations.
7
vv
Plastic Flash (burrs and not minor
deformations)
membrane without burrs.
Note! If possible use a little brush to remove
the burrs.
Note! If burrs are systematic, then change
the knife that is used to cut the sample.
134 (142) Doc. No. TeM-3759999-0101

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8
vv
Different Thickness
membrane without plastic deformations.
Repeat the measure to verify the value.
9
vv
Excessive Plastic Deformations
(slow cut)
Remove the sample. Repeat the procedures
to cut and verify the sample. If the new
samples show any deformations, then verify
the blade condition (clean or change) and
the correct alignment of the blade and the
groove on the cutter base.
®
Doc. No. TeM-3759999-0101 135 (142)
Public
10
vv
Reversed Blade (section not
measurable for high deformation)
Verify the position of the blade. If necessary,
turn around the blade. Repeat the
procedures to cut and check the cap.
Verify if the sample is taken from YES part.
Verify if the blade is in good status and is
cleaned and sharpened.
136 (142) Doc. No. TeM-3759999-0101

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Public
8 Tools and Templates
®
Doc. No. TeM-3759999-0101 137 (142)
Public
7.2 LightCap 8 Tools and Templates
138 (142) Doc. No. TeM-3759999-0101

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Public
8 Tools and Templates 8.1 Special Equipment
8.1 Special Equipment

Tools
Package Integrity Tool Kit that includes: TP No. 3725939-0000
• Digital Ammeter TP No. 90610-3637
• Zonoscope TP No. 90243-0203
• Strip Position Viewers TP No. 90610-4419

90610-4420
• Stretch Pliers TP No. 78073-0101
• Seal Viewer TP No. 3543653-0000
• Loupe 10x TP No. 90609-9972
(Cont’d)
®
Doc. No. TeM-3759999-0101 139 (142)
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8.1 Special Equipment 8 Tools and Templates
(Cont’d)
Tools
LightCap position template TP No. 3043723-0000
Valid for: TBA 1000 E
Valid for: Tetra Pak E3/Speed FP
Neck Membran Tool TP No. 3310812-0300
140 (142) Doc. No. TeM-3759999-0101

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Doc. No. TeM-3759999-0101

Doc. No. TeM-3759999-0101

For Aseptic Package

Equipment configurations that this

Doc. No. TeM-3759999-0101

Tetra Pak Packaging Solutions

Name Bill of Material Additional Information

6 (142) Doc. No. TeM-3759999-0101

Abbreviations and Terminology ............................... 9

Document Information ..........................................11

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8 (142) Doc. No. TeM-3759999-0101

Abbreviations and Terminology*

Safety Messages Description

Danger indicates an imminently

Warning indicates a potentially

Caution indicates a potentially

Definition of Lockout Procedure

An energy isolating device is a mechanical device that physically prevents

10 (142) Doc. No. TeM-3759999-0101

Any item that is named specifically in this document is to be considered a designated

9 General 9.2 Technical Data

Doc. No. MM-2730517-0103 41 (60)

12 (142) Doc. No. TeM-3759999-0101

Cross-references are underlined.

A pointer arrow indicates the position of

A zoom arrow indicates that an object

A rotation movement arrow indicates

14 (142) Doc. No. TeM-3759999-0101

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16 (142) Doc. No. TeM-3759999-0101

1.1 Introduction to Package Checks

1.1.1 General Information

Use the test flow charts to determine what

Use the 1.3.1 Package Sample Size Table

18 (142) Doc. No. TeM-3759999-0101

1.2.2 Direct Injection Moulded Concept - Overview

1.3 Package Selection and Identification

1.3.1 Package Sample Size Table for Quick Checks

DURING PRODUCTION AND PRODUCTION START

DIMC opening 12 (including cap/cap opening checks)

Number of packages to collect for the checks.

AT CHANGED FILLING MACHINE SETTINGS:

Number of packages to collect for the checks.

1.3.2 Package Sample Size Table for Daily Checks

Note! The quantity of packages described equals the amount of packages

20 (142) Doc. No. TeM-3759999-0101

1.3.3 Tools and Consumables

1.3.4 Red Ink Mixing Instructions

The red colour comes from the dye,

22 (142) Doc. No. TeM-3759999-0101

Note! Several different substances are

Do not attempt to use any other dye than

The red ink is ready to use.

• Store the solution in a closed container to

Density of the mixed solution should be 786

1.4 Package Sample Utilization - Quick

Sample Utilization at Production Start

Package Jaw System Package Sample

24 (142) Doc. No. TeM-3759999-0101

Sample Utilization at 30.000 Packages

Package Check Jaw System Link Package Sample