WB Tba8110v

Course introduction 1
TBA/8 introduktion 2
TBA/8 110V Package and packaging material 3
Training Document Package integrity 4
This Training Document is intended for
Training purpose only, and must not be
used for any other purpose.
The Training Document is not replacing
Forming of material web 5
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such. Sealing 6
Note!
For safe and proper procedures, refer to
the equipment specific documentation.
Design correction system 7
Filling system 8
Name:
................................................................................................................
Drive and jaw system 9
................................................................................................................
Final folder 10
Automatic splicing unit 11
Hydraulic and lubrication systems 12
Water and pneumatic systems 13
Cleaning 14
Sterile air system 15
Peroxide system 16
Electrical equipment 17
18
Technical Training Centre 19

Lund, Sweden
WB-94-01
Issue 1/0010
1
Course
Introduction
Technical Training Centre

Information regarding
Safety Regulations at the
Technical Training Centre in Lund
This list summarizes a number of items which may concern you, as a
participant in this training course. Read the list, and if anything re-
mains less than clear, or if you have any questions, feel free to contact
your instructor.
1. Study and follow the sections on Safety in the course literature, for
instance the OM, MM and EM.
2. You are entitled to ask persons who have no business to be near the
machine, to stay at distance, for safety reasons.
3. Never touch any other machines than those used in your own training
course.
4. There may be cables which are still electrically live, although they
have been disconnected from their terminals.
5. In some machines, safety switches may be bridged or disconnected,
for training reasons.
6. Find out exactly where the emergency stop switches for the machine
as well as the conveyor are located.
7. When starting a machine, the person doing the starting must make
absolutely sure that this does not expose anyone else to danger.
8. Certain chemicals, used in your training course, may be hazardous to
your health and constitute a danger of fire or explosion. Make sure
you know how such chemicals are marked and how to handle them.
9. It is strictly prohibited to wear rings, watch, or necktie when working
with the machine. This prohibition also applies to loose-fitting
clothes or anything else that might get caught in the machinery.
10. A first aid kit and stretcher are kept in the machine hall.
11. Study the information on what to do in case of fire and which escape
routes to follow. A diagram of escape and evacuation routes is posted
in every classroom.
12. If you observe or discover anything that might jeopardize safety,
immediately tell your instructor.
Technical Training Centre 1/9701 TM-00001

Information to Course Participants at
the Technical Training Centre in Lund
Welcome to Technical Training Centre!
Here is some information which might be helpful to you as a course
participant. If you need additional information or help, feel free to ask
your instructor.
Start of course Normally, the first day of your course begins at 08.30. Your instructor will
meet and welcome you in the coffee room.
Daily time schedule
Classes 08.00 - 09.30
Breakfast 09.30 - 10.00
Classes 10.00 - 12.00
Lunch 12.00 - 13.00
Classes 13.00 - 16.00
Your instructor will tell you if there are any changes in the schedule.
Breakfast Breakfast is free of charge and served in the restaurant, where a special area
has been reserved for Technical Training Centre course participants. Breakfast
consists of coffee or tea and bread rolls. If you want anything in additional, for
instance from the serving counters of the restaurant or cafeteria, you have to
pay for it yourself. Your instructor will help you with the procedure.
Lunch Lunch is served in the restaurant. You can choose among several dishes; men-
us are posted at the restaurant entrance and in the coffee room.
If you are a customer course participant, your instructor will give you a cash
card. For participants other than customers, cash cards are for sale in the caf-
eteria. Your instructor will help you with the procedure.
Coffee room You are invited to use the coffee room and the vending machine during all
breaks in classes.
Smoking The entire Tetra Pak plant, outdoors as well as indoors, is a no smoking area.
Smoking is allowed though in the smoking-room adjoining the machine hall.
Telephones If you need to call long-distance within Sweden or abroad, please use the
phone in the telephone room. There are also telephones in the coffee room and
in the spare parts store, adjoining the machine hall. These phones are for local
or internal calls only. When using the phones, please be brief, as there may be
others who wish to make calls. Furthermore, there is a pay-phone outside the
assembly-hall.
Computers There are three computers for the use of course participants. Two computers
in the machine hall, on which ORBIS (the Tetra Pak Intranet) is available, and
one in the coffee room, on which Internet and the World Wide Web is availa-
ble.
Technical Training Centre 2/9903 TM-00010 1

ID card On your first day you will recieve an ID card. This card must be returned at
the Tetra Pak Main reception at the end of the course. Anyone not handing the
card back will be charged SEK 400.
Safety regulations At the start of the course, your instructor will go through the Safety Regula-
tions (TM-00001). These regulations must be strictly observed. In case you are
uncertain about anything in the regulations, you must clarify it with your in-
structor.
Course evaluation You are requested to write down your comments on the course on the Course
Evaluation form. At the end of the course your instructor will collect all the
forms.
Working clothes It is necessary to wear safety shoes in the Technical Training Centre, while
working at the machines. If you didn’t bring your own, safety shoes are for
sale in the Tetra Shop. Your instructor will take you there. For your use during
the course, you may borrow a set of coveralls.
Each participant is given a locker in the changing-room. The instructor will
hand you the locker key. You may then select a set of coveralls from the cov-
eralls cabinet in the changing-room. Your instructor will help you if needed.
You may exchange your coveralls for clean ones every Monday morning. Ask
your instructor if you need to change at any other time. Used and soiled cov-
eralls are to be placed in the laundry basket in the changing-room.
At the end of the course you have to empty and lock your locker and return the
key to the instructor. If you wish to retain your locker for a subsequent training
course, tell your instructor.
Valuables You are responsible for your own valuables.
Money exchange To change currency or cash traveller’s cheques, please go to the cashier’s of-
fice, which is open 09.00 - 16.00.
Hotels In the coffee room, there is a list of the various hotels, with addresses, phone
numbers, etc. If you want to change hotel during the course period, please con-
tact the course co-ordinator at Technical Training Centre.
Transport Certain hotels provide free of charge transport to and from Tetra Pak. Ask the
hotel receptionist about this. If you wish to use this service, you must tell the
receptionist the day before.
Travel arrangements Go to the Resespecialisterna travel agency for reservations, reservation chang-
es, or confirmation of reservations. The travel agency is located at the plant
and open 07.30 - 17.30 (fridays - 17.00).
Visa Course participants from certain countries require visas in case they wish to
visit another scandinavian country, for example Denmark. The Resespecial-
isterna travel agency deals with all visa applications and related matters. A
Letter of Guarantee, which is required to apply for a visa, can be obtained from
the course co-ordinator at Technical Training Centre.
Medical care For medical care, unless it is an emergency situation, go to Citykliniken, lo-
cated in the centre of Lund. Information concerning this clinic is posted on the
notice board in the coffee room.
Leisure time In the coffee room you will find information about the city of Lund and the
surrounding region as well as on available facilities and activities.

Sport Centre Bookings for the Tetra Pak Sport Centre are free of charge and can be made at
the Main Guard, located next to the Main Reception. If you visit the Sport
Centre, you must enter and leave via the Main Guard.
Gifts and souvenirs Gifts, souvenirs, articles of clothing, etc. are on sale in the Tetra Shop, which
is open 09.00 - 15.00.
Tetra Pak 1 Main Reception

Part of the plant at 2 Main Guard
Ruben Rausings gata
Lund
3 Technical Training Centre
4 Restaurant
5 Cashier´s office
6 Resespecialisterna Travel agency
7 Sport Centre
8 Tetra Shop
1 2
315
305
4 306
313 310
3 101
8 5 309 311
6
N
106 7
107
111

2
TBA/8
Introduction

TBA/8
A reliable and safe aseptic system
TBA/8
Technology for
Customer Satisfaction
Long history, stable performance. The TBA/8 filling

machine is well-known for its reliability, safety and
not the least its aseptic performance. Besides the
possibility to produce volumes from 355 ml to
1500 ml, package ranges such as Tetra Prisma
and package shapes such as Square, Slim and
Base, a variety of openings can be run on TBA/8.
All this makes the TBA/8 filling machine and addi-
tional equipment the choice for long, stable runs
with a low cost factor. During the history of the
machine continuous improvement has been
applied, new technology has added functionality
and also the life time of key components has been
improved. TBA/8 is the low-cost, high-performing
solution for both new and established customers.
Offering Different Package Range,
Volume, Shape and
Filling Alternatives
Tetra Prisma Baseline Slimline Squareline
The Tetra Brik Aseptic system is based on the

principle of sealing each package under the pro-
duct level. The result is a completely full package.
Certain products, however, need to be shaken
before use. In these cases a completely full packa-
ge is not desired, therefore optional extra equip-
ment for the TBA/8 allows the filling of packages
either with or without headspace. Headspace is
achieved by sealing the package through the pro-
duct flow, as illustrated in the diagram. Headspace
also allows filling by weight and a greater choice
of volumes. The proportion of headspace can be
up to approximately 20% of the package volume
depending on the type of the product.
Product
Sterile air
or inert gas
Family Packs
355-1500 ml
Enlarging a Wide Range
of Openings
Tetra Brik Aseptic packages offer a wide range of

openings making it possible to choose the best
opening alternative to suit a particular product.
For a low-cost system the Scissor or Perforation
opening are ideal. As alternatives a PullTab can be
applied to all package volumes, or a drinking
Straw (Straw Hole) to packages up to 500 ml.
Reclosable options are offered with the UniCap for
package volumes up to 500 ml, ReCap2 from
500 ml upwards, ReCap3 for TBA 1000 B and
TBA 1000 S and SpinCap for TBA 1000 Sq.
Monitoring the Production
Saving Manpower
Proper working environment

TBA/8 offers a good working environment for the
operator. All moving parts are enclosed, resulting
in a safe workplace with a low noise level.
The machines are reliable and designed so that
essential components can be exchanged in a rota-
tional service system. Worn machine units can
thus be rapidly replaced with exchange units on
site which means more efficient production.
Functional reliability
The machines are controlled by a PLC
(Programmable Logic Control) system. This is a
fast, precise system which provides a high degree
of reliability. The operator is informed of any speci-
fic action needed by clear signals displayed on the
control panel. The control panel has been designed
to lighten the workload of the operator; its displays
are quick to grasp and it can be installed either on
the right-hand or left-hand side of the machine.
This means that it is easy for a single operator to
manage more than one machine.
TBA/8
Reliable Technology
10
1. Control panel.
2. Container for hydrogen peroxide, closed
system.
3. Reel of packaging material.
4. Special trolley with hydraulic lift to handle
packaging material.
5. Automatic splicing equipment for packa-
ging material.
6. Date-stamping unit.
7. Loops of packaging material, to ensure
smooth, jerk-free feed and also to allow 9
continuous production when new pack-
8
aging material is spliced in.
8. Most of the machine's electrical system
is located here.
9. The packaging material is sterilised in a
deep bath of heated hydrogen peroxide. 7
10. Strip applicator which applies a plastic 6
strip to one edge of the packaging mate-
rial. Later, at the longitudinal sealing sta- 5
ge, this is welded to the opposite edge.
The result is a tight and durable seal.
11. Rollers (squeegee rollers) which remove
the hydrogen peroxide from the pack- 4
aging material.
12. Nozzles for hot, sterile air, to dry the
packaging material.
13. The packaging material starts to be sha-
ped into a tube here.
14. Filling pipe.
3 2
TBA/8 Machine Functions
11 12
15. Element for the longitudinal sealing which

13 welds the two edges of the packaging
material together.
16. "Short-stop element” which completes
the longitudinal sealing when the machi-
ne restarts after any brief halt in produc-
tion.
14 17. The TBA/8 is designed so that two or
more machines can be connected to
form compact production units, sharing a
common platform.
15
18. Photocells, which control the machine's
automatic design correction system.
16
19. Casing which can be raised and lowered,
17 covering the automatic external cleaning
system and the final folder, where the top
and bottom flaps are folded over and
sealed onto the package.
18 20. The packages are sealed beneath the
19 surface of the liquid using induction heat.
The heat comes from jaws which also
20 shape and cut off the packages.
21. In the final folder the top and bottom fla-
ps of the package are sealed in two lines.
21 22. Discharge of finished packages.

23. Bath which automatically fills with water
22
and detergent for external cleaning of the
machine.
1 23
Hygienic and Efficient
Material Handling
The packaging material is supplied in standard or

jumbo reels. An ideal layout of premises is for the
packaging material store to be adjacent to the pro-
duct packaging hall. This is an efficient solution for
large plants, which also improves the level of
hygiene and the quality of the working environment
in the packaging hall. The finished packages in
turn can be sent by conveyor to another room for
distribution packaging. The TBA/8 is just as suita-
ble for small production plants as large. Using a
special trolley (a jumbo reel for the one-litre volu-
me weighing 300 kg), the operator can easily
wheel a new reel of packaging material up to the
filling machine and prepare for the next splice.
The filling machine has equipment which automati-
cally splices a new reel of packaging material to
the one in use when it is empty, without the inter-
vention of the operator.
The package made from the spliced material is
rejected automatically by the filling machine.
A single jumbo reel for the one-litre volume has
enough material for over 8,000 packages, corre-
sponding to 1 and a 1/2 hours production. For the
375 ml volume, one reel contains enough for
12,300 packages which lasts for over two hours
production.
The Maximum Hygiene of a
Dependable and Safe Aseptic System
The exterior of the filling machine is made entirely

from stainless steel. This makes cleaning of the
platform, the aseptic compartment and the spli-
cing table extremely efficient.
In addition to external cleaning, which includes the
parts of the machine that shape and seal the
packages, an SCU (Separate Cleaning Unit) is
available as optional equipment. This system takes
about 30 minutes to clean the product valve and
upper filling pipe.
An SCU can be connected to one or two filling
machines. This system, developed by Tetra Pak,
contributes to the machine's high level of hygiene.
Cleaning is controlled by a Programmable Logic
Control (PLC) program. The operator performs only
a few simple operations before pressing the start
button for the relevant cleaning program.
Efficient Retail Handling
Products in Tetra Brik Aseptic packages make

retail handling and display easier and more econo-
mical. They do not need to be refrigerated, so they
can be placed anywhere in the store.
There are many distribution packaging options,
and the printed design of the package can be
developed to help selling the product whether it is
displayed on shelves or in whole pallet loads.
Tetra Pak Marketing Services AB. Code 8222 en. Date 07.99 AD: Ikos Printed in Italy
We reserve the right to introduce design modifications without

Business Unit Tetra Brik prior notice. Tetra Pak and Tetra Brik Aseptic are trademarks
belonging to the Tetra Pak Group.
TBA/8
Tetra Brik Aseptic packaging machine
TBA/8 1100 (110V)
The machine packages liquid food in Tetra Brik Aseptic packages.
Capacity External cleaning system
Packages per hour 6000 +4%,-0%* Supply pressure, kPa (bar) [psi] 300-450 (3-4.5) [43.5-65]
Package volumes, cm3 (ml) see table Hot water consumption,
Headspace equipment can give intermediate volumes. litres (US gal) per cleaning cycle 500 (133)
* For TBA 1000 Sq 5500+4%, -0% Hot water temperature, °C (°F) 50-75 (122-167)
Special detergent consumption,
litres (US gal) per cleaning cycle 2 (0.5)
Electric power
Cleaning time, minutes (approx.) 60
Phase, frequency Hz, voltage V 3N+PE, 50/60, 400/230
Recommended main fuse to obtain Noise level
selectivity, A 100
Other voltages require an adaption Sound power level, Lw
trasformer and a different sized main fuse. According to ISO 3746, dB (A) 92±4
Effect during preheating, kW 39* 41** Sound power level, Lp
Effect during sterilization, kW 23* 25** At optimal room conditions, dB (A) 73
Effect during production, kW 25* 27**
Effect during cleaning, kW 5 Packing for shipment
* Without PullTab ** With PullTab
The machine is shipped in three wooden crates with the
following dimension in mm (ft in) and weights in kg (lbs)
Compressed air
Crate 1 Crate 2 Crate 3
Supply pressure, kPa (bar) [psi] 600-700 (6-7) [87-102] Length 5220 (17’2”) 3300 (10’10”) 2100 (6’11”)
Consumption, l/min. (cu ft/min.) 450 (16) Width 2370 (7’10”) 1800 (5’11”) 1400 (4’8”)
Height 2860 (9’5”) 1480 (4’10”) 1650 (5’5”)
Net weight 5600 (12350) 1200 (2645) 750 (1650)
Cooling water
Gross weight 6900 (15200) 1600 (3525) 1000 (2205)
Supply pressure, kPa (bar) [psi] 300-450 (3-4.5) [43.5-65]
Max. inlet temperature, °C (°F) Installation of TBA/8 1100 according to drawing No 1-449880-6
Cooling water 20 (68)
Mains water 20 (68) Optional equipment
Consumption, l/min. (US gal/min)
Cooling water 5 (1.3) • Headspace by Low level filling allows max. 20% headspace, HL.
Mains water 8 (2.1) • Automatic Strip Splicing Unit, ASSU.
The cooling water can be recirculated, provided the machine • Recirculation of cooling water, see above.
is connected to a closed cooling system. • PullTab unit, PT8.
• Separate Cleaning Unit, SCU, for cleaning of product valve
and filling pipe.
Product
• ASU in separate room.
Supply pressure, kPa (bar) [psi] 50-250 (0.5-2.5) [7.5-36] • High viscosity kit, HVA.
Maximum pressure fluctuation, • For further information about optional equipment, please
kPa (bar) [psi] ±10 (±0.1) [±1.5] contact Sales Administration, Business Unit Tetra Brik,
Modena
Steam
Opening alternatives
Supply pressure overpressure,
kPa (bar) [psi] 170±30 • Opening for cutting.
(1.7±0.3) [24±4.4] • Perforated wave opening for tearing.
Temperature, °C (°F) 130 (266) • Perforated opening for tearing with high fin*.
Consumption, kg/h (Ibs/h) 2.4 (5.3) • Opening for pouring with PullTab*.
• ReCap opening for certain volumes*.
• UniCap opening for certain volumes*.
Hydrogen peroxide, H202
• Hole for straw for certain volumes.
Consumption, l/h (US gal/h) 1.5-2.0 (0.4-0.5) • Requires modifications of standard machine version.
TBA/8
Tetra Brik Aseptic packaging machine TBA/8 1100 (110V)
Dimension of package and packaging material
Package Packaging material
Type of Volume Dimensions, mm Quantity of packages Weight of reel Tetra Pak Marketing Services AB. Code 7294 en. Date 06.99 AD: Ikos Printed in Italy
package cm3 (ml) A B C per reel (max.) in Kg (max.)
Standard Jumbo Standard Jumbo
TBA 355 B 104 47 76 14000 185

TBA 375 S 134 47 62 3500 12300 74 188
TBA 500 B 88 63 94 4000 73
TBA 500 S 147 47 76 3300 11500 60 209
TBA 750 B 131 63 94 2700 10000 70 300
TBA 750 S 176 54 83 8700 260
TBA 1000 B 166 63 94 2500 8700 70 300
TBA 1000 S 196 59 90 2300 8200 88 315
TBA 1000 Sq 198 71 72 1900 7400 70 300
TPA 1000 S 200 53/64 84/95 7500 300
B = Baseline S = Slimline Sq = Squareline
We reserve the right to introduce design modifications without

Business Unit Tetra Brik
prior notice. Tetra Pak and Tetra Brik Aseptic are trademarks
belonging to the Tetra Pak Group.
Tetra Brik TBA/8 100V
Left hand side
Workbook Tetra Brik TBA/8 100V

Issue 950123
159
Left hand side
1. Peroxide tank
2. Cooler for electrical cabinet
3. LS element (Longitudinal sealing)
4. Spray unit
5. Air knives
6. Jaw system
7. Cleaning tray
8. Squee-gee rollers inside the Aseptic chamber
9. Final folder
10. Sterile air pipe/CIP return pipe
11. IH cabinet
12. Product pipe
13. Aseptic chamber
14. Control panel
15. Peroxide container
16. ASU- switch and pushbuttons
17. Control panel electrical cabinet
18. ASU splicing unit
19. Drive unit
20. Electrical cabinet
21. SA-strip applicator
22. Diluting tank
23. Sterilization bath (peroxide bath and water bath)
24. Dating unit
25. Peroxide bath bottom cover
26. Packaging material reel
27. Machine plate with machine identification data

Issue 950123
159
Right hand side

Issue 950123
159
Right hand side
1. Door to valve panel

2. SA element (Strip applicator)
3. Driven bending roller
4. Fuse cabinet
5. Pushbuttons for emergency stop, Short stop, and package ejector
6. Hydraulic unit
7. Air pressure guages, LS (longitudinal sealing)
8. Knob for adjusting the movable tube support
9. Level glass for water bath
10. Air pressure guages, SA (strip applicator)
11. Refilling of the water bath
12. Crank for cranking the material web throgh the Peroxide bath
13. Compressor, sterile air system
14. Steam barrier valve (C-valve)
15. Strainer for air inlet to compressor
16. Product valve (A-valve)
17. Water separator, sterile air system
18. Sterile air valve (B-valve)

Issue 950123
159
Left hand side

Issue 950123
159
Right hand side

Issue 950123
159
Control panel
?1 0 1
?2 2
?3 3
?4 4
?5 5
Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1100 1/9904 OH 807:1
Control panel
Supervision panel
26 27 127 128
28 36 37
68
73
75
74
29 35
38 76 125 126
34 39
40
30 33
41
123 124
31
44 42
43
46 72 121 122
47
45
71
78 25
48
50 119 120
49
32
24 69 52
51 53
63
23 77 117 118
55 54
56 70
115 116
65
21 57
22 64
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113 114
66
59 108
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107
82 83 84 85 86 87 88 89 90 91 92 60
111 112
61 106
1 2 3 4 5 6 7 8 9 80 81
105
62
10 11 12 13 14 15 16 17 18 19 20 104
109 110

Lund, Sweden TBA/8 1100 1/9904 OH 807:2
TBA/8 1(8)
No: 5:5/99
Date: March/99
TECHNICAL BULLETIN
Internal Information
TBA/8 648022-110V. New development step.
Issuer: Pollastri Marco

Page 2
Index
SUPERSTRUCTURE ......................................................................................................................... 4
Adjustable forming bow clamp 1000S-SQ.................................................................................... 4
Filling pipe with new locking pin (1000SQ, 1000S and 1000B).................................................... 4
Steam pipe, protection plate........................................................................................................ 4
DRIVE UNIT....................................................................................................................................... 4
Hold down device. Ball bearing replace bushings ....................................................................... 4
JAW SYSTEM .................................................................................................................................... 4
Volume flap springs in stainless steel 1000B ............................................................................... 4
Knife holder spring (All volumes)................................................................................................ 4
Single piece knife (All volumes).................................................................................................. 4
Waved formed Volume flaps 500S ............................................................................................... 4
FINAL FOLDER................................................................................................................................. 4
Reversed fin 1000SQ (new version) ............................................................................................. 4
AUTOMATIC SPLICING UNIT ....................................................................................................... 5
New door locks............................................................................................................................ 5
New knives holder ....................................................................................................................... 5
Paper holder improvement .......................................................................................................... 5
Missed splice detector................................................................................................................. 5
Splice brake in Date unit............................................................................................................. 5
STRIP APPLICATOR ........................................................................................................................ 5
New Paper guide......................................................................................................................... 5
Adjustable strip guide ................................................................................................................. 5
ELECTRICAL EQUIPMENT............................................................................................................ 6
OPTIONAL EQUIPMENT ................................................................................................................ 7

PLMS (Packaging Line Monitoring System) ................................................................................ 7
PLMS Basic kit................................................................................................................................ 7
PLMS Serial Communication ....................................................................................................... 7
PLMS Line Supervision................................................................................................................. 7
PLMS Off-Line Analysis.................................................................................................................. 7
CONTACT PERSONS........................................................................................................................ 8
Ordering .......................................................................................................................................... 8
Availability and Delivery times ........................................................................................................ 8
Technical training ............................................................................................................................ 8
Technical information ...................................................................................................................... 8
TB No: 5:5/99
Page 3
This new development step of TBA/8 named 1100 ( eleven

zero zero) has mainly been done to modernize the TBA/8
machine with GE Fanuc, which is our future PLC system.
It is already introduced in our other Tetra Brik machines.
It is very important to be aware of that training is needed

for technicians who are not familiar with GE Fanuc. (Please
contact your normal training supplier). Otherwise the machine
can be handled by people who knows TBA/8 100V.
A number of other improvements (below listed) are also

introduced. They are in shape of RK:s introduced as
standard, and small improvements which improves the
efficiency.
The available Volumes and Optional Kits are the same as for
100V.
The first delivery date for this development step will be

mentioned in an other place in this bulletin or in a separate
document.
We are convinced that this development step will make the

TBA/8 even better and wish good luck with your new
machines.
Ulf Johansson
Project leader
TB No: 5:5/99
Page 4
SUPERSTRUCTURE
Adjustable forming bow clamp 1000S-SQ
New bows clamp a bit wider than the old one and with only five rollers
instead of seven in order to support and form the packaging material in a
smoother way. See TB 5:22/98.
Filling pipe with new locking pin (1000SQ, 1000S and 1000B)
Reinforced locking pins (lower and upper filling pipe) introduced to avoid
breaking and falling into the product. See TB 5:1/99.
Steam pipe, protection plate

No risks of ac/cidental burning to operators due to exhaust steam pipes on
Final Folder. See TB 2:3/98.
DRIVE UNIT
Hold down device. Ball bearing replace bushings
To increase the service lifetime, bushings are replaced with ball bearings.
See TB 5:21/98.
JAW SYSTEM
Volume flap springs in stainless steel 1000B
New springs and stoppers replace rubber dampers in order to improve
package forming and to prevent any damages on cutting and pressure jaws.
See TB 5:8/97.
Knife holder spring (All volumes)

New square sectioned spring introduced to increase lifetime. See TB 5:48/98.
Single piece knife (All volumes)

These knives reduce unwanted movements/play and ensure increased working
lifetime. See TB 5:35/98.
Waved formed Volume flaps 500S

Reduced problems with paper tube pinching. See TB 5:12/98.
FINAL FOLDER
Reversed fin 1000SQ (new version)
Make it possible to fold the top fin in the opposite direction in order to create
a larger area on the top of the package to position the ReCap or the Flexicap.
See TB 5:51/98.
TB No: 5:5/99
Page 5
AUTOMATIC SPLICING UNIT

New door locks
Prevent the ASU doors from being opened by the vibrations generated when a
splice is performed causing unnecessary machine stoppages. See TB 5:44/98.
New knives holder

To improve splice quality.
Paper holder improvement

Improve paper splice positioning accuracy. See TB 5:11/98.
Missed splice detector

A photocell is mounted to read the pack material; if a splice fails, the
photocell detects the end of pack material and stops the filling machine
immediately. See TB 5:34/98.
Splice brake in Date unit

A reinforced spring for piston return, so to avoid machine stops during paper
splice.
STRIP APPLICATOR
New Paper guide
Introduced to:
• remove unwanted pack material movements
• improve strip application
• reduce risks of packaging material ripping and paper tube opening
See TB 5:9/98
Adjustable strip guide

To facilitate the regulation of the strip guide roller, no tools needed to adjust
strip position. See TB 5:52/98.
TB No: 5:5/99
Page 6
ELECTRICAL EQUIPMENT
• GE FANUC replace TPMC

• IH switch replaces one of the IH generators
• Multiplex cards replace panel interface
• Alarm beacon in three colours
• Filter 90024-31 replaced by 90024-60
• New Final Folder Frequency converter (Siemens Micromaster Vector)
• New symbols on alarm panel
• Sound alarm when starting machine
• New program software
1. Final Folder control by Analogue speed
2. Indication on Control Panel when a web splice is passing the Aseptic
chamber
3. Indications on Control panel and machine jumps in Short stop position
when paper recorder alarm occur (paper ended, cassette out or battery
low).
4. Missed web splice possible splice out of design
5. New C-valve control
6. New steam alarm parameters
7. Circulation of peroxide after low level in tank
8. No inching without strip broken alarm in step 1 Preheating
9. No stop when machine goes out of design (search for a new position)
10. Temperature alarm shown from start (20 min)
TB No: 5:5/99
Page 7
OPTIONAL EQUIPMENT
PLMS (Packaging Line Monitoring System)
PLMS kit is fitted in the machine with the purpose of data collection.
It is structured as optional kit/optional equipment, which means that could be
fitted on the machine from the delivery or applied as rebuilding kit.
PLMS Basic kit

The system is equipped with the basic TPOP and a small operator interface
(8.4 touch screen display).
The system collects data from the FM, operator input and the line (collecting
from the last point in the TP line).
PLMS Serial Communication

This is generally an option of the PLMS basic kit used for automatic data
transfer from the FM to a dairy PC.
It is mainly composed of serial converters, cables, PLMS Send and PLMS
Receive software.
PLMS Line Supervision

It is an option of the PLMS basic kit used for connecting the different TP DE
composing the packaging line.
This option together with the specific DE option will make it possible to
collect the performance of the single equipment composing the line into the
PLMS. It is mainly composed of cables and connectors (5 pieces).
PLMS Off-Line Analysis

This is the tool for analysing the PLMS collected data.
It is a part of the PLMS basic kit.
It uses the machine log files in a remote computer and generates graphs and
reports. The analysed data presented graphically or in a report form are used
for management purpose analysing the performance of the machine,
distribution equipment, line or comparing the performance of two or more
machines and lines.
Graphs and reports are also valid tools for trouble shooting.
TB No: 5:5/99
Page 8
CONTACT PERSONS
Ordering
Sales Administration TP International SA, Lausanne, Switzerland
Sara Cachaldora, tel +41 21 7292663
Availability and Delivery times

Sales Administration BUTB, Modena, Italy
Paola Botti, tel +39 059 898119
Technical training
Training coordinator System 8 BUTB Lund, Sweden
Nils Erik Olsson, tel +46 46 362328
Technical information
Liaison System 8 BUTB Modena, Italy.
Marco Pollastri tel +39 059 898598
TB No: 5:5/99
3
Package and
packaging material

Packaging Material
Introduction
The packaging material protects the product from being affected by the
environment. Furthermore, it gives the steadiness needed to shape and
maintain the shape of the package. The packaging material also gives
information about the content of the package, and makes it easy to handle
and transport.
Construction
The packaging material is a laminate, i.e. built by several layers. The
construction differs somewhat as to whether it is a TB- or a TBA material.
TB = Tetra Brik A typical TBA material is built from outside an inward as shown in the
TBA = Tetra Brik Aseptic picture and description below.
1
2
5
6
7
8
Construction of the packaging material.
1. Outer coating protects the package against external humidity.

2. Printing
3. Paper board, bleached, offers a good printing surface.
4. Paper board, unbleached, strengthens the package.
5. Lamination, a plastic layer which enables the paper board to stick to
the aluminium layer.
6. Aluminium protects against oxygen and light.
7. Internal coating 1 offers adhesion against the aluminium layer.
8. Internal coating 2 offers tightning against the product and enables
package sealing.
Note!
The structure of the packaging material varies depending on the product being
packed. Further information is given in section Different material for different
products, page 15-4.
Technical Training Centre 2/0007 TM-00080 Training Document. For training purpose only. 15-1
The picture below describes what type of effects the different layers in the
material protects against.
Moisture Micro-or-
of water Light ganisms Oxygen Odours
Outer coating
Printing
Paper board, bleached
Paperboard, unbleached
Lamination
Aluminium
Internal coating 1
Internal coating 2
Product Flavour
The converting process

The converting process is the part where the paper board is transformed into
finished packaging material, ready to use. It can be divided into three groups:
• Printing and creasing. The design is printed on the paperboard and
continues through the creasing tools. The creasing tools create creases,
i.e. the folding instructions of the package, opening perforations and holes
for straws.
Crease pattern and opening

perforation of a package
15-2 TM-00080 Training Document. For training purpose only. Technical Training Centre 2/0007
• Laminating - The roll will be transported to the laminator or a warehouse.
Roll = Roll of packaging material
several packages wide. In the laminator different layers will be laminated to the printed paper-
board. First the paperboard goes through a unit for flame treating in order
to burn off dust and to make it easier for the plastic layer to get stuck. When
the layers have been laminated to the paperboard, the thickness of the
different plastic layers and the surface of the packaging material will be
checked according to specifications.
• Slitting - After laminating, the roll is transferred to the slitter where the
big roll is slit into reels. The slitting process is almost fully automatic and if
any defects on the packaging material are detected, the reel will be sent to
rewinding; the defective part is cut out and the reel is spliced. Then each
reel will be wrapped in shrinking film and stacked on a pallet.
Plastic The plastic used by Tetra Pak in the packaging material is PolyEthylene.
PolyEthylene is a thermoplastic, which means that it can be melted and shaped
more than once. There are different kinds of PolyEthylene. The most common
ones are HDPE, High Density PolyEthylene, and LDPE, Low Density
PolyEthylene. Tetra Pak mostly use LDPE.
PolyEthylene consists of positive as well as negative features. The positive
features are:
• it is water proof
• it enables sealing of the package
• it is possible to coat in thin layers
• it is transparent and does not affect the design printing
• it is neutral, meaning that it does not affect the product
• it is chemically resistant, i.e. it does not react together with other
substances
The negative features are:
• it does not stand to much heat or cold
• it is grease soluble
• it can not protect the product against oxygen
Adhesion plastic In all j-materials, e.g. TBA/j, the packaging material contains an adhesive
plastic in the internal coating 1, see page 15-1. This offers a strong and durable
adhesion with the aluminium, which prevents the product from piercing the
plastic. Thus, the plastic will not unstuck from the aluminium layer.
Paperboard Paperboard is used as main support to allow the package to stand up, maintain
its shape even with product inside, and sustain sufficiently physical stress.
The type of paper board used by Tetra Pak varies due to type and size of the
package and the printing technique involved. The most common paperboards
are duplex, unbleached and bleached.
• Duplex consists of two layers of paperboard; one thin bleached (white)
layer for the printed design and one unbleached layer, which strengthens
the material. Duplex is the most common material and standard for TBA
packages. The picture on page 15-1 shows a duplex material.
• Unbleached material completely consists of unbleached (brown)
paperboard with the printed design on the brown surface.
• Bleached material completely contains bleached, white paperboard.
All types of paperboard used by Tetra Pak can be clay-coated, i.e. the board is
coated with a layer of white clay to get an even surface to print on, e.g. duplex
clay-coated. Coating with white clay enables the use of unbleached paper-
board and still getting a white surface to print on, i.e. unbleached clay-coated.
The paperboard is supplied in big rolls. The packaging material is printed,
creased, and laminated on these rolls in the converting factories.
Aluminium offers good barrier qualities and protects the product against light, Aluminium
oxygen, odour, and damp. It can be laminated into very thin layers and only a
small amount is used for each package. The thickness of the aluminium layer
is less than 7 µm.
Furthermore, aluminium has a good conductivity, which is useful when the
package is sealed by so called induction heating. Materials without the
aluminium layer cannot be sealed by this method.
Packaging material that contains K-film as the most inner layer, is used when K-film
packaging aggressive products and products that are sensitive against residual
flavours. Examples of aggressive products are: tomato products, alcohol, oil,
and feta cheese. Water and other small-tasting products are sensitive against
residual flavours.
K-film is manufactured through film blowing techniques. This method means
that the plastic is stretched and oriented in the length- as well as the transversal
directions. K-film is applied on the material as complete film. Other coatings
are extruded onto the material, i.e. a thin layer of melted plastic will be
extruded onto the material.
K-film decreases the residual flavour of the product. It is also tighter than
extruded film, and this makes it more difficult for aggressive products to
pierce the plastic and cause microscopic cracks. Since the product gets no
chance to pierce the plastic, there is no risk of corrosion in the aluminium
layer.
Different materials for different products

The type of packaging material is chosen according to the product to be
packaged. The most common types of packaging materials provided by
Tetra Pak are:
• TBA/m - Used for UHT milk products, sweet and condensed milk,
flavoured milk products, and soya bean products.
• TBA/j - Used for juice and drinks, flavoured milk products, soya bean
drinks, coconut drinks, tea, coffee, and vinegar products with maximum
1% acetic acid.
Outside LDPE layer, 12 g/m2
Paperboard and printing

Lamination layer LDPE, 25 g/m2
Aluminium foil, 17 g/m2
Adhesive polymes, 6 g/m2
Inside LDPE layer, 29 g/m2
Example of TBA/j material
• TBA/w - Used for wine and alcoholic drinks with less than 20% alcohol.
• TBA/m MF - Used for the same products as TBA/m but with a metallised
film added on the outside.
• TBA/j MF - Used for the same products as TBA/j but with a metallised
• TBA/w MF - Used for the same products as TBA/w but with a metallised
k = A layer of k-film has been • TBA/jk - Used for products that will be heated in their package.
added
• TBA/wk - Used for alcoholic drinks with more than 20% alcohol.
• TBA/ok - Used for oil products.
• TBA/tk - Used for tomato products, dressings, soups, and sauces.
• TBA/ak - Used for water.
• TWA/j - Used for juice products in Tetra Wedge Aseptic machines.
• TFA/j - Used for juice products in Tetra Fino Aseptic machines.
Strips
Two types of strips are used in the Tetra Brik packages: Longitudinal Seal
Strip, generally called LS-strip, and PullTab Strip.
LS strip The longitudinal seal strip is applied on the inside of the longitudinal sealing.
It prevents the product from soaking into the packaging material, so-called
edge suction. The strip also strengthens the protection against oxygen and
assists to seal the tube.
Packaging material
Longitudinal seal strip
LDPE LDPE LDPE

Primer Primer
HDPE PET EVOH
Primer Primer
LDPE LDPE
LDPE
LHL PPP/PPPW LSE

LSE−STRIPS
LHL−STRIPS PPP−STRIPS
7,5/0,1 7,5/0,075 7,5/0,075
62125 Longitudinal seal and different
409813 types of LS strips. 115382
code number code number code number
Tetra Pak uses three different strip core polymers, depending on the oxygen
permeability wanted:
• HDPE - High Density PolyEthylene
• PET - PolyEthylene Terephtalate
• EVOH - Ethylene Vinyl Acetate with Alcohol groups
From these polymers three basic types of LS strips have been developed:
• LHL has a core of HDPE, coated on both sides by LDPE, Low Density
PolyEthylene. This strip is convenient for products that do not require high
oxygen barriers, e.g. pasteurised milk.
• PPP/PPPW has a core of PET, coated with primed layers of LDPE and is
convenient for products that require a good oxygen barrier. It has been
developed to give resistance to alcoholic products. This is the standard strip
for TBA material.
• LSE has a core of EVOH, coated with primed layers of LDPE and is
convenient for products that require very high oxygen barriers.
When producing packages with PullTab openings, a hole is punched into the PullTab strip
packaging material before filling and sealing. An inside patch is sealed above
the hole to the inner surface of the packaging material. Then the PullTab is
sealed on the outer surface of the packaging material and on the part of the
inside patch left uncovered by the hole.
PullTab openings
To be able to do this, the inside patch and the PullTab must consist of different
materials. The inside patch is cut out from a multilayer blown film, composed
with a core of EVOH, coated with primed layers of LDPE. This gives a good
barrier against oxygen and a sufficiently small thickness to be correctly open.
The PullTab is cut from a laminated foil, composed with printed aluminium
which provides mechanical strength and aesthetics, and LDPE which
provides sealing against the inside patch and the packaging material.
LDPE Al
Primer
EVOH LDPE
Primer
LDPE
Materials for TBA PullTab
Different printing methods

Printing is the process of applying ink to create colours, words and designs.
Tetra Pak uses different printing methods such as Flexo, Offset and
Rotogravure. They are described below.
Flexo has become the most common printing method and it is used today for Flexo
all types of printed designs.
Flexo is a relief-printing method. A roller collects the colour, transfers it to the
Relief printing = Printing method
where the cliche’ sections, which colour roller (anilox roller), which applies the colour onto the cliché. Then the
transfer the colour, are raised. cliché prints the design directly on the paper.
The plates used for Flexo printing are flexible and are made of mouldable
natural or synthetic rubber compounds or of photo polymer materials.
Function principle for Flexo
Rubber cliche’ Counter

pressure
Colour transfer
Anilox roller = A laser engraved (anilox)
roller that has a specific pattern
of holes or “cups”.
Roller, collecting
the colour
Paper
There are two types of Flexo:

• Flexo line - used for simpler printed designs without any photos.
CT = Continuous Tone. Like in • Flexo process - used for printed designs with photos (CT).
photograph or illustration.
The main difference between Flexo line and Flexo process is that process is a
four color printing. By using the four process colours, yellow, magenta, cyan
Screen pattern = small dots and black, you can reproduce any tint, including photographic pictures. In a
line printing, the color tint is mixed in a bucket before it is poured into the
printing machine.
The pictures below show examples of one typical line-design and one
process-design.
Line-design Process-design
Offset is used for printed designs with photographic pictures. In comparison Offset
with the flexo process, offset yields a somewhat better quality of the picture.
Colour roller
Dampening roller
Printing plate
Paper
Rubber roller
Counter pressure
Function principle for Offset
Offset is a flat printing method. A colour roller applies the colour on the Flat printing = Printing method,
printing plate. The colour is then transferred to a rubber roller, which applies where the sections which transfer
the colour are in level with the
the printed design on the paper. plate.
The principle of offset printing is that certain parts of the printing plate are
water-repelling while other parts are able to absorb and keep the water. Damp
is continuously transferred to the printing plate from the dampening roller. As
the printing colour contains a certain amount of grease, it will not stick to the
wet surfaces. The colour will only stick to the water-repelling surfaces. The
water-repelling surfaces are the picture itself.
The offset printing plate is made from a sheet of aluminium.
Offset is like flexo process a four-colour printing. In a four-colour printing the
design is built by screen patterns. By using the four process colours, yellow,
magenta, cyan, and black, you can reproduce any tint, including photographic
pictures.
Rotogravure is a printing method, which is rather rare today. It yields an Rotogravure

extremely high printing quality and may be used for expensive printed designs
or very large series.
Rotorgravure is a deep gravure printing method. The printed design is Gravure printing = Printing method
engraved in a cliché and then the cliché will be coloured. The excess colour where the immersed sections col-
lect the colour and transfer it to the
will be scratched away, leaving only colour in the engraving. When the cliché
paper.
is pressed against the paper, the engraving colour is soaked from the cliché.
Since the engraving can have various depths, the deep printing method offers
a variation beteween 0 - 100% of the colour saturation in the printing. This is
the answer to the extremely high printing quality.
Counter pressure
Paper
Cliche’ Scraper
Colour
Function principle for Rotogravure
Production Order Label and Pallet Label

The Production order and Pallet labels are labels on the packaging material
reel and on the pallet containing reels. The labels inform about the content and
are used for claims, for instance.
1
3
9
10
8
Production order label
The Production order label contains the following information:

1. Place of production
2. Production order number
3. Web position number (reel number)
4. Identification number
5. Type of packaging material
6. Volume of package
7. Quantity of packages on the reel
8. Date of production
9. Customer address
10. Bar-code containing parts of above information
2
4
5
Pallet label
The Pallet label contains the following information:

1. Production order number
2. Pallet number
3. Reel number
4. Quantity of packages on the reel
5. Quantity of packages on the pallet
Packaging Material Claims

Packaging material claims, usually represent substantial amounts of money.
Therefore every effort must be made to use the packaging material produced
and delivered. As a rule, packaging material produced and delivered within
specification, will not be accepted as a claim by Tetra Pak.
A prerequisite for a claim of packaging material, is that the filling machine is
upgraded to recommended standard and adequately maintained. Packaging
material claims will not be accepted if the material has not been stored in
accordance with local recommendations or the recommended storage
conditions in the Installation Manual.
Below is a description of how to handle a packaging material claim:
1. The customer makes his complaint to the Area Technical Service
Manager, on a packaging material report form, or in accordance with the
local producer if applicable.
2. The Area Technical Service Manager then confirms the complaint by
returning a copy of the packaging material report form to the customer.
3. As a first step, the Technical Service Department sends a service engineer
to the customer to investigate the nature of the complaint.
4. The packaging material on hold is moved to a separate location and clearly
marked. When the complaints are involving suspicious packaging mate-
rial, the producer is contacted and the responsible market is informed.
5. A detailed description of the fault in accordance with the Fault Code List
Packaging Material, the disturbances occurred on the packaging machine
and the name of the person who inspected the goods, are given on the
claim report form. The original of the completed claim report form is sent
to the receiver at the producing plant together with representative samples
of the packaging material, two meters from each reel.
Fault Code List Packaging The Fault Code List consists of seven head groups. Within these groups there
Material L009 are ten sub groups, each sub group consists of ten detailed fault denomina-
tions. The head group, 900 Filling machine, is intended to be used by
Technical Service as an indication to the producer of how the packaging
material behaves in the filling machine. The codes 100-800 are used to give
a more precise direction of where the fault occurs on the packaging material.
This to enable faster handling of the claim.
Further more detailed information are available from Market Companies in
these documents:
General Rules For Packaging Material Claims, G007
Packaging Material Claims and Complaints, I011
Fault Code List Packaging Material, L009
Recommendations
Tetra Brik packaging material is supplied in protected and palletised reels, Storage
which are sufficiently resistant to damage it might be exposed to in the course
of normal handling and storage.
Some advice to ensure maximum utilisation from the packaging material is
provided below
1. Keep the storage premises clean and use them exclusively for the
packaging material.
2. The optimal temperature range for storing the packaging material is
between 10 and 30 °C. Do not allow the temperature to fall below 0 °C.
3. Maintain a relative humidity between 30 and 70%. Do not store the
packaging material in excessively damp or moist areas. No pipes etc.
which may produce condensation should run through the storage
premises.
4. It is important that the packaging material attains a temperature close to
that of the packaging room. Therefore it is advisable to withdraw it from
the storage premises one day before use and keep it in a suitable place
inside the packaging room.
5. Under normal circumstances, reels of packaging material are double-
wrapped. Each reel is tightly shrink-wrapped and each pallet is enclosed in
shrink material. Do not remove this until shortly before the reel is placed
in the machine.
6. Always store the reels on pallets and not directly on the floor. Position the
pallets at a sufficient distance from the walls to ensure efficient handling
of the pallets.
7. Pallets can be stacked three high provided a rigid divider board is placed
on top of the lower pallets. The transportation pallet is only a one-way unit
and its strength has limitations, therefore avoid excessive scuffing and
chafing.
Always take the greatest care when handling the packaging material. Below is Handling
some advice:
1. Before touching the packaging material, disinfect your hands.
2. The packaging material must never touch the floor.
3. Do not remove the shrink wrapping from the reel until you have placed it
in the trolley.
4. Unwind one revolution of the packaging material from the reel and check
for damages. If damages are found on the packaging material, be sure to
remove enough packaging material to avoid this to enter the filling
machine.
5. Keep the Production order label.
4
Package integrity

This booklet does not exist as an electronic document.
Order the booklet from the Technical Training Centre.
Ordering No: Booklet Transversal Sealing Evaluation,
English.
For more information regarding training material ordering:

http://151.183.8.19/ttc/material.htm
5
Forming of
material web

6
Sealing

Inner coating
Paper board
Cooling water
Product
Principle of ridge inductor sealing

2
1
Tetra Pak Processing & Packaging Systems AB Machine type Issue
Technical Training Centre, Lund, Sweden 3/0008 OH 225
Used for Transversal Sealing TBA
To perform a transversal seal on a TBA machine is required:
• Pressure
• Heat
• Cooling
The heating application used is induction heating (IH). This is a clean form of
heating. One of its advantages is that the heating takes place in the work space,
the aluminium foil. This reduces the losses, normally associated with heating,
to a minimum. The heat causes the plastic to melt and thus the packages can
be sealed. The seal will be cooled before the pressure is released.
Cooling water High frequency current
Inductor coil Metal object Magnetic field

(copper tube) (aluminium foil)
A
A-A
7KHSULQFLSOHRI,QGXFWLRQ+HDWLQJ
Packaging material Inductor coil

(aluminium foil) (copper tube)
Ferromagnetic
Counter rubber
material
Cutting jaw Pressure jaw
7UDQVYHUVDOVHDOLQJ7%$
Technical Training Centre 1/0007 TM-00191 Training Document. For training purpose only. 1
Textbook
TPIH-2000
MT-83014-2

Lund, Sweden
This textbook has been compiled by the Technical
Training Centre in Lund.
Some of the pictures in the book are also available as
OH pictures.
For further information on training material, please contact
the Technical Training Centre.
Issue 2/9608
© 1998, Technical Training Centre

No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocop-
ying, recording or otherwise, without permission in writing from Technical Training Centre.
TPIH-2000
Training Document
used for other purpose.
equipment, and must not be used as such.
Note!

Contents
General information on IH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TPIH-2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Comparison between TPIH- 2000 and older IH generators . . . . . . . . . . . . . 13
TPIH test instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General information on IH
TPIH-2000 is a generator, which generates a high–frequency current. This
Induce = to bring current is utilized to induce heat in the packaging material, for instance in
about, to produce
transversal sealing. TPIH stands for Tetra Pak Induction Heating.
IH = induction heating The TBA machines are equipped with IH generators, and the high–frequency
current induces heat in the aluminium foil layer of the packaging material. The
heat causes the plastic (PE layers) to melt, and thus the packages can be sealed.
The induced heat causes the

Heat induced in the plastic (PE) to melt, so that the
aluminium layers packages can be sealed.
PE Al PE Paper PE
PE Paper PE Al PE
PE=Polyethylene Al=Aluminium
Induction heating is also employed to heat the PE layer at the opening arrange-
ment of the package. The heat changes the structure of the PE layer, making
the plastic more brittle. For this reason, the package becomes easier to open.
The method of heating a material without a direct source of heat, i e to produce
heat in the material, is based on a current of high frequency. One could say that
the high–frequency current transfers energy to the material,
There are two ways of producing heat by means of high–frequency current:
• Induction heating (for instance transversal sealing in TBA machines)
• Dielectric heating (for instance in a microwave oven)
Technical Training Centre2/9608 Training Document. For training purpose only. 5

Induction heating is used to heat materials which are electrically conductive Induction heating
(metals). This is the method employed in the TBA machines for transversal se-
aling, zone heating at the opening arrangement of the package, longitudinal se-
aling (TBA/21), strip application (TBA/21), and splicing of the packaging
material (TBA/21).
The diagram below shows the principle of this method.
High–frequency current
Coil
Magnetic field
Electric conductor
Induced current
The high–frequency current creates a magnetic field around the coil. This
magnetcic field oscillates in time (at the same frequency) with the current, in-
ducing a current in an electric conductor placed in the magnetic field. In its
turn, the induced current oscillates in time with the magnetic field and produ-
ces the energy that heats the material.
In the TBA machines, induction heating works as shown in the diagram below.
IH generator
Current path in the

aluminium foil
Inductor
The IH generator (TPIH-2000) generates a current of high frequency. The in-

ductor functions as a coil and creates a magnetic field. Heat is induced in the
packaging material as a result of a current being induced in the aluminium foil.
This leads to the melting of the PE layers, so that they can be sealed.
6 Training Document. For training purpose only. Technical Training Centre 2/9608
Dielectric heating Dielectric heating is used to heat non–conductive materials, such as wood.
This method is also employed in microwave ovens.
The diagram below shows the principle of this method.
High–frequency current
Electric field
Plates
Material, e g wood
The high–frequency current produces an electric field between the plates. The
field oscillates in time with the current, and the molecules of the material will
in their turn also oscillate in time with the field. The oscillations produce en-
ergy, which heats the material.
Note
In order for this method to work, the material must contain ions or polar mo-
lecules, i e molecules which are influenced by electric fields. Water molecules
are polar, and as wood always contains a certain amount of moisture, it is
perfectly possible to heat wood according to this method.

TPIH-2000
An IH system incorporating a TPIH generator is designed as the diagram be- IH system
low shows.
Potentiometer
IH generator, TPIH-2000
Current rail
Inductor
Transformer
Coaxial cable
The generator converts the mains voltage to a high–frequency voltage. The

magnitude of the high–frequency voltage is set by means of the potentiometer
as a percentage of the maximum voltage; for instance, 850 translates as 85%
of the maximum voltage. In its turn, the high–frequency voltage determines
the power in the inductor. This relationship of the voltage is proportional to the
square of the power; for instance, if the potentiometer is set at 850, the power
in the inductor becomes 0.85 x 0.85 = 0.72, i e 72% of the maximum power.
On page 10, more can be found on the relationship between voltage and power.
The coaxial cable conducts the high–frequency current to a transformer near
the inductor. The transformer has a transformation ratio of 5:1, i e it reduces
the voltage and increases the current by a factor of 5. Consequently, the power
remains unchanged, but low voltage in the inductor cuts down the danger of
spark–over and improves safety.
The last part of the passage of the current to the inductor goes through a current
rail. In the current rail, power losses occur, and for this reason, the rail is made
as short as possible.
The inductor functions as a coil and creates a magnetic field which induces
current in the packaging material.
Usually, a TBA machine is equipped with several IH generators, for instance
three, one for each pair of jaws and one for the zone heater.
Generator TPIH-2000 On the front of the generator, there is an alarm panel, connections for control
signals and power inputs, and an output for high–frequency current. The light–
emitting diodes on the alarm panel indicate faults and errors etc, and can be
used to facilitate fault–finding.
Alarm panel
Connections for
control signals
Connections for po-

wer inputs
Output for HF current

HF=high frequency

Explanation of the light–emitting diodes on the alarm panel:
Output Voltage Low (red). If this is the only red light–emitting diode that is
on, one of the following faults has occurred: 1) The generator is defective and
must be replaced. 2) 10 V DC is not being supplied to the potentiometer. 3)
The potentiometer has been set at too low a value. 4) The potentiometer is de-
fective.
Mains Voltage Low (red). Power feed to the generator is insufficient. At least
one of the phases supplies less than 85% of the nominal power, and the gene-
rator cannot in its turn provide the correct power. Check the input power fuses.
Temperature High (red). The temperature inside the generator is too high.
Most likely, the fan is defective. If this is the case, the complete generator as-
sembly must be replaced.
Load Error (red). There is an error in the load, i e the coaxial cable, current
rail, transformer, or inductor.
Output On (green). Lights up when a pulse is being converted into the correct
load, i e when the system functions correctly.
Control Voltage On (green). The power feed to the control section functions
correctly.
The diagram below shows the connections for the control signals and input po-
wer. The No at each connection, shows how the cable concerned is marked.
30 Power alarm. Common alarm to PLC for: Output

30 28 Voltage Low, Mains Voltage Low, and Load Error.
28
26 26
24 Temperature alarm to PLC.
22 24
20
16 22 Power setting from POT.
14 20 10 V DC to POT
12 16 0V
8
14 24 V DC
12 0V
8 Sealing pulse from PLC
30 30 Neutral
26 26, 230 V AC 50/60 Hz
22 Three–phase 230/400 V AC 50/60 Hz
18 22 Phase R
18 Phase S
10 Phase T
10 6 Neutral
6
4 4 Ground
Function The TPIH-2000 generator works in accordance with the block diagram below.
It comprises an power section and a control section.
TPIH-2000
Control section
Temperature alarm PLC

Power alarm PLC
Sealing pulse PLC
Power setting POT
24 V DC
230 V AC
Power section
Triple pulse Voltage re- Output

Power step Filter
rectifier gulator transformer
The control section is powered by 230 V AC and 24 V DC. It controls, for in-
stance, voltage and frequency, and monitors the unit. It also controls the alarm
panel.
The power section is powered by 3x400 V AC and incorporates the following
functions:
Triple pulse rectifier, which converts the alternating voltage (AC) into a di-
rect current (DC) of appr 325 V.
Voltage regulator, which stabilises the direct voltage at appr 350 V.
Power step, which converts the direct voltage into a high–frequency square
pulse of 350 V, 0.5 MHz.
Filter, which generates a sinus–shaped high–frequency alternating voltage of
300 V, 0.5 MHz.
Transformer, with a ratio of 1:1, which is used to isolate the load from the
generator. The load comprises the coaxial cable, transformer, current rail, and
inductor.

As previously mentioned, the power in the inductor is determined by the out- Power regulation
put voltage from the generator. In order to understand how the output voltage
is regulated, we have to take a closer look at what happens in the filter section
of the generator.
Uin Filter Uout
In order to regulate the output voltage, the fact is exploited that the ratio bet- At the resonance frequency,
ween the output and input voltages (Uout /Uin) in the filter is not constant. This the ratio between output and
input voltage reaches maxi-
ratio depends on the frequency, as shown in the diagram below. mum.
Uout /Uin Resonance frequency

Maximum power
Minimum power
Regulation range
Frequency
0.485 0.550 (MHz)
The 0.485-0.550 MHz frequency range is utilized to regulate the output volta-
ge and thus the output power. Within this frequency range, the ratio between
output and input voltage is virtually linear. Thus it is the frequency which is
altered in order to regulate the power. The setting of 999 on the potentiometer
is equal to a frequency of 0.485 MHz, which gives maximum power (2kW).
The setting of 850 corresponds to a frequency which gives the power of 0.852 x
maximum power (0.852 x 2=1.4 kW), etc.
Note
This way of calculating disregards the fact that the phase angle, cosine ϕ, varies
with the power. At low power, cosine ϕ is reduced; for instance, at a potentio-
meter setting of 440, the power may be 0.9 x 0.442 x maximum power.
Comparison between TPIH-
2000 and older IH generators
TPIH-2000 has been installed in the following machines from the develop-
ment step specified.
• TBA/8 060V
• TBA/9 140V
• TBA/10 120V
• TBA/21
The significant difference between TPIH-2000 and the older model generator
is that TPIH-2000 is a transistor generator, while the older model is an electro-
nic valve generator. A comparison between the two generator types shows the
following differences:
• The output power of TPIH-2000 is adjustable while the machine is run-
ning. This is not possible with the older IH generator.
• In TPIH-2000, the output power is not dependent on the mains voltage
(within a range of -15 to +10 per cent of the nominal value). In the old
model, there is a direct relationship between mains voltage and output
power.
Much of the loss occurs in the • TPIH-2000 consumes 1.5 kW while the old model uses up appr 4 kW.
current rail. In the TPIH-2000 Nevertheless, the inductor power is equally high, appr 1 kW, which is due
system, a major part of the to the losses in the TPIH-2000 system being lower.
current rail has been replaced by
a coaxial cable. But the coaxial
TPIH-2000
cable cannot cope with as high an
amperage as a rail, so therefore
the current is transformed in a
transformer near the inductor
Generator
instead of in the generator itself.
Inductor
Coaxial cable
Current rail
Transformer
Old model IH generator
Generator
Inductor
Current rail
• The voltage across the inductor in the TPIH-2000 system is 40-50 V; in the
old IH generator it is appr 90 V. Low voltage is preferable as it reduces the
danger of spark–over and improves safety.
• The frequency in TPIH-2000 is 0.5 MHz, compared with 1.8 MHz in the
old generator.
• TPIH-2000 is based on transistor technology, and the old model IH genera-
tor on electronic valves. Transistors are very reliable with a long working
life, while valves have a limited life.
• Inside TPIH-2000, there is no high-tension. Maximum voltage is 400 V,
while the high-tension section of the old model generator carries 5000 V.

TPIH test instrument
For TPIH-2000, there is a special test instrument (TP 68462-101). It can be
used for the measuring of:
• HF voltage
• HF current
• Load phase angle (cosine ϕ)
• Pulse time (duration)
The test instrument is intended to be connected in series with the coaxial cable
from the generator, as shown in the diagram below.
Printer socket
Display
Selector
To be connected to generator
To be connected to
coaxial cable Note that a user’s manual for the
instrument is being supplied.
The measuring results can be used to calculate the power and impedance of the
load.
P=U x I x cosϕ (Power = Voltage x Amperage x Cosine ϕ)
Z=U/I (Impedance = Voltage/Amperage)
Impedance is to be roughly 50 Ω. Normal value is 40-65 Ω.
Note
The pulse time is determined by the machine PLC and does not require adjust-
ment.
If the special test instrument for TPIH-2000 is not available, the pulse time can Pulse time meter
be measured by means of a pulse time meter (TP 102 90243-90) and the HF HF voltmeter
voltage by means of an HF voltmeter (TP 103 90243-114). In this case, mea-
suring is done at the copper rail by the inductor (secondary transformer side).
Instruction manual Note: The following is copy of the instruction manual enclosed to the TPIH
test instrument 68462.
TPIH test instrument 68462

Instructions (rev Sep 91)
The TPIH test instrument is used for checking the high frequency part of a
TPIH system.
1 Connecting
The instrument is connected in series with the coaxial cable between the
generator and the IH-transformer, usually closest to the generator.
NOTE: Connection and disconnection of the test instrument must be done,
when the generator is not pulsing e g with the machine in the short stop po-
sition.
2 On and off
The instrument is started with a rotary switch. Approximately five minutes
after the latest activation of the switch, the instrument is automatically
turned off.
3 Measuring
Voltage (V), Current (A), Phase angle between voltage and current (de-
grees) and Pulsetime can all be measured. Disregard any numbers that are
displayed prior to the measurements. When the measurement is finished
note the values directly.
a Pulses
The toggle switch to the right is put in position ”pulse”. The instrument
measures and stores pulse time after every pulse. The voltage, current and
phase angle are measured and stored after half the pulse time. In order for
the instruments to make correct measurements, i e in the middle of the puls-
es, at least 2 pulses are needed. The LED ”pulse” lights up during the
pulse and ”sample” lights up when a measurement is taking place. Put the
toggle switch in position ”hold” when no more new measurements are
needed.
b Continuous signals
The toggle switch to the right is put in position ”Continuous”. The instru-
ment shows the measurements for voltage, current and phase angle appr. 3
times/second. If, at a certain point, the measurements are to be stored, the
toggle switch is put in position ”hold”.
c Single pulse
The rotary switch is turned to position ”pulse time” and the toggle switch
to the right to position ”Continuous”. The toggle switch to the left is used
to preset an expected pulse time (N.B.! Pos. values). Change the toggle
switch to the right to position ”pulse”. It is now possible to measure a sin-
gle pulse.

4 Power, energy etc
By using the measured values several others can be calculated.
Power = Voltage x Current x Cos (phase angle) (W).
Pulse energy = Power x Pulse time (mWs).
The Impedance’s absolute value = Voltage/Current (ohm).
Cos 0° = 1 Cos ±5 = 0.996 Cos ±10 = 0.985
Cos X 1 - x2 : 6700 -40° < x < 40°
5 Trouble shooting for load error

If there is a load problem only short pulses are delivered by the generator.
The results from the measurements will be approximate but they could
make trouble shooting easier. During a pulse with load problem the LED
”sample” is lit up during the entire pulse, while LED ”pulse” is off.
Load examples Phaseangle Voltage/Current
(Test instrument connected (Degrees) (Ohm)
closest to the generator)
Optimal load (no load problem) 0 50
Normal load (no load problem) ±15 40 - 65
Short circuit in coax. cable, pos (3) 1 - 10 (1)
contacts, primary of IH-transf.
Open circuit in same as above. neg (3) 200 - 2000 (2)
Short circuit in inductor, pos 10 - 20
current rail, secondary of IH-
transformer.
Open circuit in same as above neg 2-5
No packaging material on the neg 5 - 15
inductor.
(1) = The greater value, the greater distance between problem and
instrument.
(2) = The greater value, the shorter distance between problem and
instrument.
(3) = The greater phase difference, the greater distance between
problem and instrument.
6 Connection of chart recorder

To record voltage, current and phase as a function of time a chart recorder
e g Brush can be connected.
1 Connect the included cable to the recorder.
marking ”V” : Voltage 100 mv = 100 V
marking ”C” : Current 50 mv = 1 A
marking ”P” : Phase 10 mv = 1 ˚
marking ”O” : O
2 Isolate cables that are not used.
3 Connect to the instrument. The toggle switch to the right is put in
position ”pulse”.
7 Battery
The instrument is powered with a standard 9 V battery e g 6LR61. An al-
caline battery gives approximately 40 hours operation. When approximate-
ly 5 hours operation are left, ”batt” is displayed. The instrument gives
correct values until 000 is displayed and it switches off automatically. The
battery eliminator is used when you want to measure during long time, e g
with a recorder. With the battery eliminator connected and the rotary
switch in position ”batt” the display should show 8,5 V - 14 V.
8 Accuracy
Accuracy for new instruments used according to 3a and 3b.
Voltage ± (2 % + 1 V) 100 - 350 V
Current ± (2 % + 0,03 A) 2-7A
Phase ± (5 % + 2 ˚) -30° - +30°
Pulse time ± (2 % + 2 ms) 10 - 1000 ms
To compare two instruments, connect them in series. Then interchange
them since the values depend on the distance from the load, especially if
the load differs from 50 ohm.
9 General
The instrument can operate in temperatures from 0 to 45 ˚C.
It should not be used immediately after major temerature change.
Store the instrument in a dry place.
Temporary storage temperature: -20 to +60 ˚C
Do not use the instrument if water has penetrated into it.
Do not dismantle the instrument when the coaxial cables are connect-
ed.
The panel can be opened if the lower screw in the middle is loosened.

7
Design correction
system

Design control summary DCS8
• PID regualtion for fast and safe regualtion.
• 26 bit register code reading.
• Mean design error of the two latest packages are used to get a smooth run-
ning system.
• Maximum design error is 1.5 mm. If the error is greater the package is
ejected.
• If more than three consecutive packages have a design error greater than 20
mm, the sytem enters precorrection.
• If more then four consecutive register codes are not read, the system enters
precorrection.
• The design is kept in short stop.
Design correction
Folding Flaps
A=45 A=12
A=9 A=6
A=3 A=0

Lund, Sweden TBA/8 1/9905 OH 825
Design Correction
TMCC
55823
Fault
Power
S 1 (Register mark)
S 2 (Design ok)
S 3 (Precorrection)
S 4 (Piston position 12 mm)
789A
BCD
3456
EF 2
1
28 26 27 25
M.Y
C1
78
A
M.Y
C3
13 B
M.Y
C2
14
M.Y C
C4
12
D
Regulated
Air Pressure
3 Bar
Main Air Pressure
TBA/8 100V 1
Design Correction
Issue 950102
116
Design correction
Cylinder
Lund, Sweden
A=3 A=0
A=6
A = 45 A = 12 A=9
R R
R
Machine type
R R R
A A
A
A A A
B B
B
B B B
Issue
1/9904
C C
C
C C C
D D
D
D D D
OH 823
R R
R
R R R
DC - Motor Drive Control
12
Fuse 3.15 AF
13
42 N
1
14 43 P
Power
44
15 45
F
46 2
16 A
47
Flashing Trip
11 overload
IxR
Ext Speed
3
10
Acc Ramp
7 Internal Speed 4
1
2
6
8
3 5
9
1. POWER indicator.
2. TRIP, indicates an overload on the output. Flashing at current limit.
Fixed light, when switched off due to overload.
3. EXT SPEED, indicates that external speed is selected.
4. INTERNAL SPEED 1, indicates that internal speed 1 is selected.
5. INTERNAL SPEED 2, indicates that internal speed 2 is selected.
6. INTERNA SPEED LED 1 + 2, indicates that internal speed 3 is selected.
7. Potentiometer for setting internal speed 1.
10. ACC. RAMP, potentiometer for setting acceleration ramp.
11. I x R compensation. Adjustment for different motor powers. Too high
settings will result in unstable motion.
12. PROTECTIVE EARTH
13. NEUTRAL
14. PHASE
15. FIELD
16. ARMATURE
Technical Training Centre 1/9910 TM-00131 Training Document. For training purpose only.
Design correction
Lund, Sweden
Diagram
LEDs on valves
Folding
Y 78 Y 13 Y 14 Y 12
Machine type
flaps
position (A) (B) (C) (D)
0
TBA/8
80 120
3
80 120
6
80 100 rpm 120
9
Issue
80 120
1/9904
12
80 120
45
OH 824
Precorr.
Optimal Paperfeed
Reading a register code
The register code is a printed mark on the packaging material. When it passes
the photocells, the cells read the 26 digital information bits in a particular
order. These bits are decoded into a pulse, the design signal, in the TMCC.
Note!
The photocells continuously read the pattern of the printed design on the pack-
aging material, but the reading of the 26 register code bits in the right order is
required to enable the decoding of a design signal.
What happens? When one of the photocells reads a flank on the register code, both photocells
register what they ’see’: blank, white, positive flank, or negative flank. This is
translated into a binary code (ones and zeroes) as follows:
Black 1
White 0
Positive flank 1 (white to black)
Negative flank 0 (black to white)
The binary code is stored in a shift register as it is read when the register code
passes the photocells. The contents of the shift register are compared
continuously with the contents of another register with fixed contents. When
the lines of ones and zeroes are identical in both registers, the register code has
been decoded, and a pulse, the design signal, is generated.
Shift register where the binary

11010001111011010001111000 code from the photocells is
stored
11010001111011010001111000
Register with fixed contents
The design signal is generated when the

contents of the two registers are identical.
Below, an example is shown of how the photocells read the register code.
Here photocell B reads a negative

flank and A reads black 10 (A, B)
is transmitted to the shift register.
Here photocell B reads a positi-

ve flank and A reads white 01
(A, B) is transmitted to the shift
A B

7HWUD3DN )XQFWLRQDO'HVFULSWLRQ 1(15)
Modena, Italy T Rosenlöf
DCS8, Design Control System, TB/A/8 1994-07-01
47 832 - 010V ECN 21 046
7DEOHRI&RQWHQW
1. TABLE OF CONTENT ...................................1 10. DESIGN ADJUSTMENT POTENTIOMETER ....8
2. ABBREVIATIONS .........................................1 11. ENCODER FUNCTION AND GRAY CODES ...9
3. INTRODUCTION ..........................................1 12. OUTPUT SIGNALS ....................................9
4. DESIGN CONTROL SYSTEM OVERVIEW .......2 13. TERMINAL (PC) COMMUNICATION .............9
5. TMCC CONNECTIONS ................................3 14. VOLUME PARAMETER TRANSFER ...........11
6. BASIC PROGRAM FUNCTIONS .....................5 15. BENDING ROLLER REVS SETTING ...........12
7. OTHER PROGRAM FUNCTIONS ....................6 16. DIAGNOSTIC OUTPUT.............................13
8. TMCC FRONT PANEL SWITCH ...................7 17. PROGRAM DOWNLOAD...........................13
9. TMCC FRONT PANEL LEDS ......................8 18. APPENDICES .........................................14
$EEUHYLDWLRQV
DCS8 Design Control System for TB/A/8 filling machines
DCS21 Design Control System for TBA/21 filling machines
DCU Design Correction Unit (68 457-010V)
EEPROM Electrically Erasable/Programmable Read-Only Memory
LED Light Emitting Diode
MultiStep MultiStep Design Correction Unit (67 382-010V)
MUPP Multi-purpose Potentiometer (558 389-010V)
PC Personal Computer
PID Proportional, Integral and Derivative control algorithm
PLC Programmable Logic Controller, (like TPMC or GE-Fanuc)
TMCC Tetra Pak Multi-Purpose Compact Controller (558 230-010V)
,QWURGXFWLRQ
The DCS8 program is intended for the TB/A/8 filling machines, and the program runs on the TMCC, Tetra
Pak Multi-purpose Compact Controller, hardware. The program reads the register mark photocells at the
paper tube and the machine angle encoder. From these parameters the output is calculated via a PID-
algorithm. The output value sets the new bending roller motor speed and the folding flap position.
The history of this program originates from the fact that the previous systems, the MultiStep and the DCU,
no longer are possible to produce, due to that the processor chip in these designs no longer is available.
The DCS8 program together with the TMCC hardware will now replace these systems in new designs, as
well as for rebuilding old machines in case of malfunction. (A similar program, DCS21, together with TMCC,
is in use in the TBA/21 filling machine. This machine relies on a servo motor controlled folding flap system
instead of the TB/A/8 bending roller and air cylinder design.)
This Functional Description is intended for users of the DCS8 "function", i.e. electrical designers, test
engineers, service engineers and alike. Its purpose is to give a full understanding of the behaviour of the
DCS8 program together with the TMCC as a system. (The internal structures of the DCS8 program will not
be discussed. For electronic system development purposes a special report covering these areas is
available.)

47 832 - 010V ECN 21 046
'HVLJQ&RQWURO6\VWHP2YHUYLHZ
The design control system can be illustrated as below, where TMCC is the central part in the system, and
all other parts in the system are connected to the TMCC. Inside the TMCC symbol is a simple
representation of the functional blocks of the software:
Photocells TMCC
Read
Photocells
α Angle Encoder Read

Angle Encoder
Potentiometer
Calculation
(PID) Bending Roller Motor
Output to
Bending Roller
and Folding Flaps Folding Flap Air Cylinder
PLC Terminal, (PC)

Communication
with PLC
and Terminal
Parameter Bending Roller Sensor

Settings
The connections and the functions are explained in the following pages. The DCS8 program flow is further
explained in the "Basic Program Functions" chapter.

47 832 - 010V ECN 21 046
70&&FRQQHFWLRQV
The TMCC is a general purpose hardware and its inputs and outputs are fully controlled by the software, in
this case the DCS8 program. The connections below have been chosen for the DCS8 function (a pin
connection diagram is available in the appendices):
1
70&&
+24V
2 Power Supply 25
Ground C1 Air Valve
26
C2
9 HighOut0-3 27
Angle Encoder, bit0 C3
10 28
C4 Air Valve
11
12 6
AnalogOut1 Bending Roller Out Signal
13 LowIn0-7
14 31
Register Mark Photocell Pulse
15 HighOut6-7 32
Design OK
16
Angle Encoder, bit7
5
17
AnalogOut0 Diagnostic Analogue Output
Register Mark Photocell, (4bar)
18 HighIn0-1
Register Mark Photocell, (3bar)
3
Design Adjustment Pot (MUPP) AnalogIn0
20
DCS8 Enabled HighIn3
7
Bending Roller Sensor FastIn0
22 30
Volume Enable HighOut5 Volume Acknowledge
23
Volume Clock HighIn5-7
24
Volume Data
19
HighIn/LowOut2 Not Used
4 21
Not Used AnalogIn1 HighIn/LowOut4 Not Used
8 29
Not Used FastIn1 HighOut4 Not Used
7KHIXQFWLRQVRIWKHVHVLJQDOVDUHDVIROORZV VRPHIXQFWLRQVDUHIXUWKHUH[SODLQHGLQWKHIROORZLQJ
FKDSWHUV
9 +24 Volt power supply. From the Electrical Cabinet +24V supply.
*URXQG Ground power supply. From the Electrical Cabinet ground connection.
$QJOH(QFRGHUELWELW
24V inputs from the machine angle encoder that has 8 bits and counts from 0 to 255
(decimal). bit7 is the Most Significant Bit (MSB) and bit0 is the LSB.
5HJLVWHU0DUN3KRWRFHOO EDUV
24V input from the register mark photocell positioned beside the paper tube above the jaw
system. The (4bars) indicates that this photocell reads the 4 bars part of the register mark
(also called FORFN).

47 832 - 010V ECN 21 046
5HJLVWHU0DUN3KRWRFHOO EDUV
24V input from the register mark photocell positioned beside the paper tube above the jaw
system. The (3bars) indicates that this photocell reads the 3 bars part of the register mark
(also called GDWD).
'HVLJQ$GMXVWPHQW3RW 0833
Analog (0-10V) input from the Design Adjustment Potentiometer (in this case, the Multi-
purpose Potentiometer, MUPP). A voltage close to 0V means that the paper tube position
(compared with the jaws) will be higher than with a voltage close to 10V (in other words: an
increasing voltage on this input will move the paper tube downwards in the jaw system).
The total tube adjustment range is ± 5 mm.
'&6(QDEOHG
24V input from the PLC. When this signal is:
• LOW (0V) - the DCS8 sets the precorrection mode.
• HIGH (24V) - the DCS8 runs in the regulating mode.
(Refer to next chapters for explanation of the precorrection and regulating modes).
%HQGLQJ5ROOHU6HQVRU
24V input from an inductive sensor mounted on the bending roller motor. This sensor is
used for setting the maximum and minimum speed of the motor.
9ROXPH(QDEOH
9ROXPH&ORFN
9ROXPH'DWD
These 24V input signals are controlled from the PLC. They are used for transmitting the
Repeat Length and Production Sector values to the DCS8 program. Refer to the chapter
below describing this transmission protocol.
&&&&$LU9DOYH
These four 24V outputs from the TMCC controls the pressurised air valves that are
connected to the air cylinder controlling the folding flaps. The combinations below are valid:
& & & & $LUF\OLQGHUSRVLWLRQ

0V 0V 0V 0V Precorrection
0V 0V 24V 0V 12 mm
0V 0V 24V 24V 9 mm
0V 24V 0V 24V 6 mm
24V 0V 24V 0V 3 mm
24V 0V 24V 24V 0 mm
24V 24V 24V 24V Only used 200 ms before shifting from 6 mm to 3 mm positions
and vice versa. This means that the air cylinder may temporarily
jump to the 0 mm position.
%HQGLQJ5ROOHU6LJQDO
Analog (0-10V) output signal connected to the motor controller card for the bending roller
motor. The exact working range for this signal is determined during the setting of the
maximum and minimum bending roller speed (refer to that chapter), but is approx. from 5V to
8V.
5HJLVWHU0DUN3KRWRFHOO3XOVH
24V output to the PLC. This is a 40 ms long pulse sent when the DCS8 program has decoded
a register mark. The pulse is delayed with the sum of:
• a constant delay corresponding to 32.7 mm tube movement,
• a variable delay depending of the Design Adjustment Pot (± 5 mm).
(This delay corresponds to the MultiStep function).

47 832 - 010V ECN 21 046
'HVLJQ2.
24V output to the PLC. This signal is HIGH (24V) as long as:
• the design error of a package is less than ±1.5 mm or
• the mean design error of the two latest packages are less than ±1.5 mm.
(These conditions corresponds to the MultiStep function).
'LDJQRVWLF$QDORJ2XWSXW
An analogue (0-10V) output that sets one of the following signals after each package:
6:SRVLWLRQ )XQFWLRQ
8 Design error of current package.
9 Mean design error of the two latest packages.
A Filtered design error ("90% old + 10% new"-algorithm).
B Output signal to bending roller and folding flaps.
C Filtered output signal
D Design Adjustment Pot signal
Refer to the appropriate chapter below for a complete description of this function.
9ROXPH$FNQRZOHGJH
This is a 24V output to the PLC. Refer to the chapter below describing the transmission
protocol for volume parameters.
1RW8VHG
These inputs and outputs are not used in the DCS8 program. They should be left
unconnected.
%DVLF3URJUDP)XQFWLRQV
The DCS8 program for the TMCC is written in the C-language and it is not possible to modify this without
the proper knowledge and development tools (this must be done in a technical development facility). The
parameters that need to be changed (e.g. volume parameters) are controlled from the PLC.
3URJUDPIORZ
At start-up or reset (the TMCC may be reset manually by setting the SW1 switch on the front panel in
position "0" for a few seconds, and then back to its previous position) the DCS8 program initiates all its
internal variables and reads the volume parameters sent from the PLC. After this first step the program
enters an eternal loop, i.e. it repeats the program over and over again. This loop has the following basic
functions:
• Wait for a valid photocell reading of the register mark. This routine decodes the edges of the register
mark (and of the other part of the design as well) and for every edge (black to white, white to black) it
stores the photocell values in a shift register. The shift register is a 26-bit single register (compared to
the first MultiStep routine that used two separate shift registers with 6 and 7 bits respectively, which in
some cases could cause a false decoding). This shift register is compared with a special pattern that
corresponds to a correct register mark. If they are equal a register mark has been detected and the
program can proceed with its calculations.
• When the register mark has been detected the DCS8 program reads the machine angle encoder. To
get an acceptable accuracy of the machine angle an interpolation is done by comparing the remaining
time of the current angle (i.e. until the angle encoder changes to a new value) with the time for a
complete angle. This gives a decimal number (for example, 72.95) telling where the register mark is in
relation to the machine jaw system.
• When the register mark has been detected the DCS8 program also sends the Register Mark Photocell
Pulse signal to the PLC. This signal is, for compatibility reason with the MultiStep, delayed a certain time

47 832 - 010V ECN 21 046
from the actual register mark detection. The delay time depends of the current machine speed and
corresponds to a distance on the paper tube. This distance is independent of volume settings. The delay
is a constant 32.7 mm in addition to a variable delay depending on the Design Adjustment
Potentiometer position (±5 mm).
• The calculated register mark angle is now compared with the preferred design angle, i.e. the production
sector set from the PLC offset by the Design Adjustment Potentiometer setting (for example, 74 - 1.25 =
72.75). The comparison gives the angle error and together with the repeat length it is possible to
calculate the design error in millimetres for the current package (the example: 72.95 - 72.75 = 0.20;
0,20 * 245(repeat length) / 128(no of sectors per package) = 0.38 mm design error). The design error is
positive if the register mark (the design) is too "high" in relation to the jaw system, and vice versa.
• The design error is used as an input to the PID control algorithm. Actually, it is the mean design error of
the two latest packages that are used, this giving a more smooth running system in case of different
mechanical adjustments of the left and right side of the machine. The algorithm uses a quadratic P-part,
which means that it has a faster response for larger design errors. Otherwise, it is a standard PID with
integral and output range limitations. The P, I and D factors have been tested on filling machines to give
a well working design control in both normal production and start/stop sequences.
• When the PID algorithm has calculated a new output value, ranging from 0 (precorrection), 1(minimal
paper pull) to 255 (maximal paper pull), this is converted into an analogue signal for the bending roller
and a digital setting of the air valves for the air cylinder controlling the folding flaps. The conversion is
illustrated in the chapter "Output Signals".
• From the calculated design error the DCS8 program also decides whether it should accept the package
or not. If the package is accepted the DesignOK signal to the PLC is set. The decision is based upon the
following rules:
'HVLJQ(UURU 3DFNDJH$FFHSWHG
Design error of last package is less than ±1.5 mm YES
Mean design error of last two packages is less than ±1.5 mm YES
Otherwise NO
• The DCS8 program then start again to search for a new register mark.
Besides this main program flow the DCS8 program also checks if anything is sent from a terminal through
the RS-232 serial interface. If so, it returns the appropriate answers to the terminal, refer to the "Terminal
communication" chapter.
2WKHU3URJUDP)XQFWLRQV
Besides the basic program functions described above the DCS8 program performs some other functions
and decisions:
3UHFRUUHFWLRQYV5HJXODWLQJPRGH
• The air cylinder and, consequently, the folding flaps can be set in six different positions, one
precorrection and five regulating positions (0, 3, 6, 9 and 12 mm).
• The precorrection mode is used when the paper tube is far out of design, to move it as fast as possible
to the correct position. The precorrection position lets the paper tube "move upwards" in relation to the
jaws, approx. 10 to 25 mm each jaw stroke (depends on volume and filling on/off).
• A normal production start always begins in the precorrection mode. A number of packages are thrown
away before the PLC starts its search for the filling sector, i.e. when the Register Mark Photocell Pulse

47 832 - 010V ECN 21 046
is found in this sector the filling is turned on. The filling sector is chosen so that when the paper tube is
fully filled then the design control system has also found the correct design position.
• The DCS8 program continuously calculates the design error, also during precorrection mode. When, in
this mode, the design error becomes less than ±8 mm the DCS8 program switches into regulating
mode. I.e. it tries to find the correct air cylinder position, one of the 0 mm to 12 mm positions. The fine
adjustment is then done with the bending roller out signal.
• When in regulating mode the DCS8 program tries to keep as low design error as possible. When:
the design error is less than ±1.5 mm, or
the mean design error of the two latest packages is less than ±1.5 mm,
then the Design OK signal (and front panel LED) is turned on. The filling machine is "in production".
• When the DCS8 program runs in the regulating mode it continues in this mode until:
• more that WKUHHFRQVHFXWLYH packages have a design error greater than ±20 mm,
• more than IRXURegister Marks should have passed the photocells, i.e. they are missed,
• the PLC resets the DCS8 Enable signal.
When one, or more, of these condition is true the DCS8 program switches to precorrection mode.
• When the filling machine is in short stop the design control system remains in regulating mode. When
started again the DCS8 program tries to keep the design control as good as possible, just like in normal
production mode.
9ROXPH3DUDPHWHUV
• Normally the volume parameters are sent from the PLC, refer to the "Volume Parameter Transfer"
chapter.
• However, for test purposes and in special cases, it is possible to set a default Repeat Length and
Production Sector with the SW2 switch on the TMCC side (the TMCC must be pulled out of the rack
system). The 3URGXFWLRQ6HFWRUis always set to GHF , this may be changed with the "A" command
from a terminal. The Repeat Length may be set to one of:
6:3RV $
5HSHDW/HQJWKPP 115 130 140 160 173 190 207 226 245 268
• If SW2 is set to anything else than those values above, a message "No volume set" will be displayed on
the terminal at a TMCC start-up or reset.
70&&)URQW3DQHO6ZLWFK
The front panel switch SW1 is used both for setting the bending roller revs and for selecting one of the
available formats for the diagnostic output. This chapter contains the basic principle for setting the switch,
the functions above are fully described in their respective chapters.
6: )XQFWLRQ
3URJUDPPLQJPRGH in this position it is possible to download the DCS8 program. Refer
to the "Program Download" chapter.
WR %HQGLQJ5ROOHU5HYV6HWWLQJ These positions are used to set the Bending Roller Revs.
Refer to the "Bending Roller Revs Setting" chapter.
WR' 'LDJQRVWLFRXWSXWPRGH These positions select one of the available formats for the
diagnostic output. Refer to the "Diagnostic Output" chapter.
( Not used.
) $XWRPDWLF%HQGLQJ5ROOHU5HYV6HWWLQJ In this position the Bending Roller Revs are set
automatically. Refer to the "Bending Roller Revs Setting" chapter.
127(,QQRUPDOSURGXFWLRQPRGHWKH6:VKRXOGEHVHWWRSRVLWLRQ

47 832 - 010V ECN 21 046
70&&)URQW3DQHO/('V
The TMCC front panel LEDs have the following meaning in QRUPDOSURGXFWLRQPRGH:
/(' )XQFWLRQ
)$8/7 Not used in this program
32:(5 Should be turned on (Green). Indicates that the power supply to the TMCC is correct.
6 Flashes when a Register Mark is detected, the flash being approx. 40 ms.
6 Turns ON when the design is within ±1.5 mm i.e. "in production".
6 ON = Precorrection position.
6 ON = 12 mm air cylinder position.
LEDs S3 to S8 are only turned on one at a time.
When the LEDs are IODVKLQJVLPXOWDQHRXVO\ this indicates a malfunction in the program. It is possible to
find out the type of error by noticing which LED is QRW flashing:
/('QRWIODVKLQJ 0HDQLQJ
6 Error in EEPROM writing. This error indicates that there may be a hardware
problem within the TMCC when trying to store the bending roller revs
manually or automatically.
6 No Bending Roller Sensor pulses. This indicates either:
• that the bending roller is not rotating, or
• a faulty or badly adjusted sensor, or
• a bad connection between sensor and TMCC.
Besides these meanings the LEDs are used for VSHFLDOIXQFWLRQV in the Bending Roller Revs Setting, refer
to that chapter.
'HVLJQ$GMXVWPHQW3RWHQWLRPHWHU
The Design Adjustment Potentiometer is used to move (fine-adjust) the design position in relation to the jaw
system. This device is a MUPP (Multi-purpose Potentiometer), which outputs a 0-10V analogue signal
depending of the position of the potentiometer knob. The signal is sent to the TMCC and the DCS8
program converts the voltage level into an angle offset that is then added to the constant production sector
set by the PLC. The adjustment range corresponds to a movement of ±5 mm on the design position, this
range being the same for all volumes.
The potentiometer is turned clockwise to move the design downwards in relation to the jaw system, and
vice versa:

47 832 - 010V ECN 21 046
(QFRGHU)XQFWLRQDQG*UD\&RGHV
The angle encoder is connected to the machine main shaft and outputs 128 degrees (values) for each
package. The encoder is a 256 degrees version which means that one package range from 0 to 127
degrees and the following from 128 to 255 degrees and then back to 0 again.
The value sent to the TMCC is Gray-coded, which means that only one of the eight signals (bits) changes
for each change in degree (this prevents erroneous angle values on the signal lines.) This also means that
the DCS8 program must convert the value into a "normal" representation before it can be used in
calculations. A conversion table is given in the appendices.
2XWSXW6LJQDOV
The PID algorithm calculates a new output value for every package. The calculated output value ranges
from 0 to 255. This value is converted into an analogue signal for the bending roller and four digital signals
to the air valves controlling the folding flap air cylinders. The bending roller signal overlaps the air cylinder
positions (hysteresis) as below:
Cylinder
position
Bending Roller Revs (rpm)
mm
80 120
12
80 120
9
80 120
6
80 120
3
80 120
0
1 48 64 96 112 144 160 192 208 255 Output Value
2XWSXWYDOXH sets the precorrection position of the air cylinder and sets 100 rpm on the bending roller.
The digital +24V signals to the air valves are called C4, C3, C2 and C1. The combinations used to get the
cylinder positions are:
&\OLQGHUSRVLWLRQ & & & &

Precorrection 0V 0V 0V 0V
12 mm 0V 0V +24V 0V
9 mm 0V 0V +24V +24V
6 mm 0V +24V 0V +24V
3 mm +24V 0V +24V 0V
0 mm +24V 0V +24V +24V
3/6 mm change +24V +24V +24V +24V
The "3/6 mm change" position is used for 200 ms when the air cylinder changes from 3 mm to 6 mm or
vice versa. This is due to the mechanical functions of the air cylinder. During this time the cylinder may
jump to the 0 mm position and then back to the correct setting.
7HUPLQDO 3& FRPPXQLFDWLRQ

A terminal, or a PC with a terminal program, is not necessary during normal production, but may be used
for test and service purposes. Through the serial interface it is possible to see the design error, output
values and other DCS8 status values.

47 832 - 010V ECN 21 046
The communication is a standard RS-232 serial interface. Use a cable suitable for the TMCC and the PC
(terminal). Necessary pin connections are:
3&SLQ 70&&SLQ
IHPDOH PDOH
2 3
3 2
5 5
If you are using a PC, any terminal program may be used, like "TIT" or "Windows Terminal". Configure the
program for:
• Baudrate: 9600
• Parity: None
• Bits: 8
• Stopbits: 1
• Flow Control: None
The commands and parameters, if any, to the DCS8 program is entered on the keyboard, and the
command is executed when the RETURN key is entered. (The commands and parameters are not echoed
on the terminal). The functions described below are available:
$QQQ Angle nnn. The Production Angle (=machine angle) may be set with this command. nnn is the
new angle value, ranging from 0 to 255 decimal degrees. Normally the Production Angle is set
from the PLC, but this command overrides the PLC setting. It may be used in test purpose to
find the correct nominal Production Angle, which will later be set from the PLC. Note that the
Design Adjustment Pot setting is added to this value.
For example: $ sets the Production Angle to 72 degrees (110 octal).
'GGG D-constant: Sets the D parameter in the PID controller algorithm, in 1/100 units. The original
value will be restored after a TMCC reset.
( Displays the current Encoder value, first the hexadecimal Gray code, then converted to octal.
)RRR Force ooo. This command forces the outputs, Bending Roller speed and Air Cylinder position,
to a certain value which is (ooo-1). F0 resets the forcing:
) Reset (disable) output force.
) Force to Precorrection output.
) Force to output = 1.
...
) Force to output = 254.
(This means that output=255 is not possible but since it is a small step in the upper region of
the output range this has no practical meaning.)
,LLL I-constant: Sets the I parameter in the PID controller algorithm, in 1/100 units. The original
3SSS P-constant: Sets the P parameter in the PID controller algorithm, in 1/100 units. The original
5Q Reporting ON/OFF. This command enables and disables the automatic reporting of the design
error and output value for every package.
5 Disable reporting.
5 Enable reporting.

47 832 - 010V ECN 21 046
6 Status: This command displays a list of parameters that may be of interest for test and service
purposes:
DesignError, mean: A filtered* value in mm.

Output, mean: A filtered* value (0-255).
Machine Speed: In packages per hours.
Design Angle Const: The Production Angle set from the PLC.
Design Angle +pot: The Production Angle + the Design Adjustment Pot offset.
MaxRevs, MinRevs: The voltages set on the bending roller output for maximum and
minimum speed.
Pot: A value 0-255 depending on the Design Adjustment Pot position.
Pc=, Ic=, Dc=: The constants for the PID controller algorithm.
* = Filter algorithm: 90%(old values) + 10%(new values)
9ROXPH3DUDPHWHU7UDQVIHU
The Repeat Length and the Production Angle may be sent from the PLC to the DCS8 program. This
sending uses four digital +24V signals and the protocol is as follows:
)URP3/&
VolumeEnable
VolumeClock
VolumeData
)URP70&&
VolumeAcknowledge
8. Repeat the message until

1. Set VolumeEnable 5. Output last bit
VolumeAcknowledge is set
2. Output bit 1 6. Toggle VolumeClock
3. Toggle VolumeClock 7. Reset VolumeEnable
4. Shift out all data bits
• The bit time must be at least 5 ms.

• The output bits are shifted with the least significant bit (LSB) first:
/6%!5HSHDW/HQJWK06%!/6%!3URGXFWLRQ$QJOH06%!
• The Repeat Length is in 1/10 of mm, i.e. a repeat length of 245 mm is sent as 2450.
• The Production Angle is in integer degrees, i.e. a sector of 123 is sent as 123. (Octal or decimal
degrees notation is irrelevant since the number is sent in bit format which is the same for both
alternatives.)
2WKHUIHDWXUHV
• The signal VolumeAcknowledge in the protocol is useful when, for example, the PLC starts up earlier
than the TMCC, or if the TMCC is replaced or reset during power on. In these cases the
VolumeAcknowledge is reset to low and the PLC should start to send the message again.
• The DCS8 program must receive at least two complete message that are exactly the same before is
sets the VolumeAcknowledge signal.
• It is also possible to send the maximum and minimum Bending Roller Revs settings from the PLC. (This
feature is not used in the current application). In this case the maximum and minimum values are sent
as 16-bit numbers with the LSB bit first. The format is then:

47 832 - 010V ECN 21 046
/6%!5HSHDW/HQJWK06%!/6%!3URGXFWLRQ$QJOH06%!/6%!0LQ5HYV06%!/6%!0D[5HYV06%!
The MinRevs and MaxRevs values are in the range 0-255 and the correct value must be determined
through a test sequence:
6HQGYDOXHVIURP3/&!5HDGWKH%HQGLQJ5ROOHU5HYV!&RUUHFWWKHYDOXHVDQGVHQGDJDLQ
%HQGLQJ5ROOHU5HYV6HWWLQJ
The Bending Roller Revs may be set manually or automatically.
To start with the automatically this setting needs a sensor at the bending roller motor shaft. This sensor
must transmit one pulse per revolution of the shaft. The length of the pulse is not important, only the raising
edge is used for rev calculation. The automatic setting is initiated when the SW1 switch on the TMCC front
panel is set to position "F".
127(WKDWWKHEHQGLQJUROOHUPRWRUPXVWEHUXQQLQJ HQDEOHG GXULQJWKHDXWRPDWLFVHWWLQJ7KLV

PD\EHDFFRPSOLVKHGE\VHWWLQJWKHDSSURSULDWHELWLQWKH3/&,IWKHPRWRULVQRWUXQQLQJDQHUURU
LVLQGLFDWHGE\IODVKLQJ/('VRQWKHIURQWSDQHO
The DCS8 program then outputs a first voltage setting to the motor controller and after a few seconds it
determines the bending roller speed. If then the speed is too low the DCS8 program tries a higher voltage
setting, and vice versa. This trying continues until the correct MinRevs value has been found, and this takes
approx. 15 sec. Then the MaxRevs value is set in the same way. When both values are found they are
stored in the EEPROM.
The progress of the automatic revs setting is indicated by the LEDs flashing for every "try" voltage set by
the DCS8 program. The final EEPROM storing is indicated with a long flash (approx. 1 sec.) After this flash
the setting procedure is terminated and the SW1 switch may be set to the production position "8".
The manual setting of the bending roller speed may be done in two different ways, either via the PLC
(described in the previous chapter) or by the use of the SW1 front panel switch:
• When set from the PLC some of the SW1 positions described below may be used to set the minimum
and maximum bending roller speed (pos. 1 and 4).
• When setting the bending roller speed with the SW1 the following positions are used:
6:SRV )XQFWLRQ
1 Output minimum bending roller speed.
2 Decrease the minimum speed.
3 Increase the minimum speed.
4 Output the maximum bending roller speed.
5 Decrease the maximum speed.
6 Increase the maximum speed.
7 Store the values in the EEPROM.
8 Normal production position
0DQXDO6HWWLQJ3URFHGXUH
1. Set the enable signal to the bending roller motor to start the motor.
2. Set SW1 to "1" and the motor will start to revolve with its current minimum speed.
3. Read the bending roller speed with a tachometer.
4. If the speed is too high, set the SW1 to "2". The speed will now decrease with approx. 1 rpm / sec.
5. Otherwise, if the speed is too low, set SW1 to "3", and the speed increases.
6. When correct minimum speed has been reached, set SW1 to "4". The motor now runs with its
current maximum speed.

47 832 - 010V ECN 21 046
7. Read the bending roller speed with a tachometer.

8. If the speed is too high, set the SW1 to "5". The speed will now decrease with approx. 1 rpm / sec.
9. Otherwise, if the speed is too low, set SW1 to "6", and the speed increases.
10. When correct maximum speed has been reached, set SW1 to "7", and wait for at least one flashing
of the front panel LEDs. This shows that the set values have been stored in EEPROM.
11. Set the SW1 to production position "8" and reset the forced enable signal to the motor.
'LDJQRVWLF2XWSXW
To facilitate diagnosis of the design control system the analogue output on TMCC pin 5 may be connected
to a paper recorder or an oscilloscope. The following output signals are available on this pin:
6:SRV )XQFWLRQ 2XWSXWIRUPDW

8 "Normal" position, outputs the calculated design 0 to 10 V =>
error of every package. -5 to +5 mm design error
9 Outputs the average (mean) design error of the two 0 to 10 V =>
last packages. -5 to +5 mm design error
A Outputs a filtered* average of the design error. 0 to 10 V =>
-5 to +5 mm design error
B Outputs the calculated output signal to the Bending 0 to 10 V =>
Roller and Air Cylinder. The output range of 0 to 255 0 to 255 range of output signal
is the value calculated accord. to the chapter
"Output Signals"
C Outputs a filtered* average of the output signal. 0 to 10 V =>
0 to 255 range of output signal
D Outputs the Design Adjustment Potentiometer 0 to 10 V =>
setting -5 to +5 mm adjustment range
* = Filter algorithm: 90%(old values) + 10%(new value)
3URJUDP'RZQORDG
The DCS8 program should be downloaded to the TMCC during machine production, but it may be
necessary to do a new download if the TMCC has been replaced or if a new release of the DCS8 program
is available. The download is done from a PC with at least one diskette station and one serial RS-232
interface. Refer to the "Terminal (PC) Communication" chapter for a description of the communication
parameters.
'RZQORDGSURFHGXUH
1. &RQQHFWWKHFDEOH between the PC and the TMCC front panel connector.
2. 6HWWKH6: front panel switch to position "0"
3. Insert the program diskette marked "47 832 - x01" (x = current revision) into the PC diskette station.
4. 6WDUWWKHGRZQORDGSURJUDP TMCC.EXE by entering the command: $70&&HQWHU!
5. When the program menu appears enter the communication port in use, normally "1".
6. Now a directory listing will appear. Select the A: drive by pressing the <HOME> key.
7. A list of the files on diskette A: will appear. 6HOHFWWKHILOH'[ ([ = current revision) by using
the arrow keys. (First use the right arrow to select the file window).
8. When the file is selected SUHVVWKHIXQFWLRQNH\)!, and the automatic download starts.
9. The progress of the download may be monitored in the lower part of the screen.
10. When the new program is downloaded without errors press the function key <F10> to exit the
TMCC.EXE download program.
11. If a label (with the program number and LED functions) is supplied together with the diskette this label
should be affixed to the TMCC front panel, aligned with the LEDs.
12. Set the TMCC front panel switch 6:WRSURGXFWLRQSRVLWLRQ and the download procedure is
finished.

47 832 - 010V ECN 21 046
$SSHQGLFHV
*UD\&RGH7DEOH
*UD\ 2FWDO 'HF *UD\ 2FWDO 'HF *UD\ 2FWDO 'HF *UD\ 2FWDO 'HF
---- ---- 0 0 -••- ---- 100 64 ••-- ---- 200 128 •-•- ---- 300 192
---- ---• 1 1 -••- ---• 101 65 ••-- ---• 201 129 •-•- ---• 301 193
---- --•• 2 2 -••- --•• 102 66 ••-- --•• 202 130 •-•- --•• 302 194
---- --•- 3 3 -••- --•- 103 67 ••-- --•- 203 131 •-•- --•- 303 195
---- -••- 4 4 -••- -••- 104 68 ••-- -••- 204 132 •-•- -••- 304 196
---- -••• 5 5 -••- -••• 105 69 ••-- -••• 205 133 •-•- -••• 305 197
---- -•-• 6 6 -••- -•-• 106 70 ••-- -•-• 206 134 •-•- -•-• 306 198
---- -•-- 7 7 -••- -•-- 107 71 ••-- -•-- 207 135 •-•- -•-- 307 199
---- ••-- 10 8 -••- ••-- 110 72 ••-- ••-- 210 136 •-•- ••-- 310 200
---- ••-• 11 9 -••- ••-• 111 73 ••-- ••-• 211 137 •-•- ••-• 311 201
---- •••• 12 10 -••- •••• 112 74 ••-- •••• 212 138 •-•- •••• 312 202
---- •••- 13 11 -••- •••- 113 75 ••-- •••- 213 139 •-•- •••- 313 203
---- •-•- 14 12 -••- •-•- 114 76 ••-- •-•- 214 140 •-•- •-•- 314 204
---- •-•• 15 13 -••- •-•• 115 77 ••-- •-•• 215 141 •-•- •-•• 315 205
---- •--• 16 14 -••- •--• 116 78 ••-- •--• 216 142 •-•- •--• 316 206
---- •--- 17 15 -••- •--- 117 79 ••-- •--- 217 143 •-•- •--- 317 207
---• •--- 20 16 -••• •--- 120 80 ••-• •--- 220 144 •-•• •--- 320 208
---• •--• 21 17 -••• •--• 121 81 ••-• •--• 221 145 •-•• •--• 321 209
---• •-•• 22 18 -••• •-•• 122 82 ••-• •-•• 222 146 •-•• •-•• 322 210
---• •-•- 23 19 -••• •-•- 123 83 ••-• •-•- 223 147 •-•• •-•- 323 211
---• •••- 24 20 -••• •••- 124 84 ••-• •••- 224 148 •-•• •••- 324 212
---• •••• 25 21 -••• •••• 125 85 ••-• •••• 225 149 •-•• •••• 325 213
---• ••-• 26 22 -••• ••-• 126 86 ••-• ••-• 226 150 •-•• ••-• 326 214
---• ••-- 27 23 -••• ••-- 127 87 ••-• ••-- 227 151 •-•• ••-- 327 215
---• -•-- 30 24 -••• -•-- 130 88 ••-• -•-- 230 152 •-•• -•-- 330 216
---• -•-• 31 25 -••• -•-• 131 89 ••-• -•-• 231 153 •-•• -•-• 331 217
---• -••• 32 26 -••• -••• 132 90 ••-• -••• 232 154 •-•• -••• 332 218
---• -••- 33 27 -••• -••- 133 91 ••-• -••- 233 155 •-•• -••- 333 219
---• --•- 34 28 -••• --•- 134 92 ••-• --•- 234 156 •-•• --•- 334 220
---• --•• 35 29 -••• --•• 135 93 ••-• --•• 235 157 •-•• --•• 335 221
---• ---• 36 30 -••• ---• 136 94 ••-• ---• 236 158 •-•• ---• 336 222
---• ---- 37 31 -••• ---- 137 95 ••-• ---- 237 159 •-•• ---- 337 223
--•• ---- 40 32 -•-• ---- 140 96 •••• ---- 240 160 •--• ---- 340 224
--•• ---• 41 33 -•-• ---• 141 97 •••• ---• 241 161 •--• ---• 341 225
--•• --•• 42 34 -•-• --•• 142 98 •••• --•• 242 162 •--• --•• 342 226
--•• --•- 43 35 -•-• --•- 143 99 •••• --•- 243 163 •--• --•- 343 227
--•• -••- 44 36 -•-• -••- 144 100 •••• -••- 244 164 •--• -••- 344 228
--•• -••• 45 37 -•-• -••• 145 101 •••• -••• 245 165 •--• -••• 345 229
--•• -•-• 46 38 -•-• -•-• 146 102 •••• -•-• 246 166 •--• -•-• 346 230
--•• -•-- 47 39 -•-• -•-- 147 103 •••• -•-- 247 167 •--• -•-- 347 231
--•• ••-- 50 40 -•-• ••-- 150 104 •••• ••-- 250 168 •--• ••-- 350 232
--•• ••-• 51 41 -•-• ••-• 151 105 •••• ••-• 251 169 •--• ••-• 351 233
--•• •••• 52 42 -•-• •••• 152 106 •••• •••• 252 170 •--• •••• 352 234
--•• •••- 53 43 -•-• •••- 153 107 •••• •••- 253 171 •--• •••- 353 235
--•• •-•- 54 44 -•-• •-•- 154 108 •••• •-•- 254 172 •--• •-•- 354 236
--•• •-•• 55 45 -•-• •-•• 155 109 •••• •-•• 255 173 •--• •-•• 355 237
--•• •--• 56 46 -•-• •--• 156 110 •••• •--• 256 174 •--• •--• 356 238
--•• •--- 57 47 -•-• •--- 157 111 •••• •--- 257 175 •--• •--- 357 239
--•- •--- 60 48 -•-- •--- 160 112 •••- •--- 260 176 •--- •--- 360 240
--•- •--• 61 49 -•-- •--• 161 113 •••- •--• 261 177 •--- •--• 361 241
--•- •-•• 62 50 -•-- •-•• 162 114 •••- •-•• 262 178 •--- •-•• 362 242
--•- •-•- 63 51 -•-- •-•- 163 115 •••- •-•- 263 179 •--- •-•- 363 243
--•- •••- 64 52 -•-- •••- 164 116 •••- •••- 264 180 •--- •••- 364 244
--•- •••• 65 53 -•-- •••• 165 117 •••- •••• 265 181 •--- •••• 365 245
--•- ••-• 66 54 -•-- ••-• 166 118 •••- ••-• 266 182 •--- ••-• 366 246
--•- ••-- 67 55 -•-- ••-- 167 119 •••- ••-- 267 183 •--- ••-- 367 247
--•- -•-- 70 56 -•-- -•-- 170 120 •••- -•-- 270 184 •--- -•-- 370 248
--•- -•-• 71 57 -•-- -•-• 171 121 •••- -•-• 271 185 •--- -•-• 371 249
--•- -••• 72 58 -•-- -••• 172 122 •••- -••• 272 186 •--- -••• 372 250
--•- -••- 73 59 -•-- -••- 173 123 •••- -••- 273 187 •--- -••- 373 251
--•- --•- 74 60 -•-- --•- 174 124 •••- --•- 274 188 •--- --•- 374 252
--•- --•• 75 61 -•-- --•• 175 125 •••- --•• 275 189 •--- --•• 375 253
--•- ---• 76 62 -•-- ---• 176 126 •••- ---• 276 190 •--- ---• 376 254

47 832 - 010V ECN 21 046
--•- ---- 77 63 -•-- ---- 177 127 •••- ---- 277 191 •--- ---- 377 255
&RQQHFWLRQ'LDJUDP
+24V
1 +24V 70&& LowIn0 9
10
AngleEncoder0 (LSB)
2 LowIn1 AngleEncoder1
Ground 0V 11
LowIn2 AngleEncoder2
LowIn3 12
AngleEncoder3
LowIn4 13
AngleEncoder4
DesignAdjustmentPot LowIn5 14
3 AnalogIn0 AngleEncoder5
LowIn6 15
4 AnalogIn1 AngleEncoder6
LowIn7 16
AngleEncoder7 (MSB)
5 AnalogOut0
DiagnosticOutput HighIn/LowOut0 17
6 AnalogOut1 RegisterMarkPhotocell, 4bar (clock)
BendingRollerSignal HighIn/LowOut1 18
RegisterMarkPhotocell, 3bar (data)
HighIn/LowOut2 19
7 FastIn0
BendingRollerSensor HighIn/LowOut3 20
8 FastIn1 DCS8Enabled
HighIn/LowOut4 21
HighIn/LowOut5 22
VolumeEnable
HighIn/LowOut6 23
VolumeClock
56&$1 HighIn/LowOut7 24
VolumeData
FP3 Transmit
FP2 Receive HighOut0 25
C1
FP4 StatusOut HighOut1 26
C2
FP6 StatusIn HighOut2 27
C3
FP5 Ground HighOut3 28
C4
FP7 +10V HighOut4 29
FP1 CANhigh HighOut5 30
VolumeAcknowledge
FP9 CANlow HighOut6 31
Photocell pulse
FP8 NoConnect HighOut7 32
DesignOK
+24V
MUPP
Ground
8
Filling system

AP-Valve
440630-020V
(Aseptic Product Valve)
C

Lund, Sweden 1/0003 OH 453:2
9
Drive and jaw system

Securityswitches
Hold down device
10
Final folder

Final Folder
Drive system
Lund, Sweden TBA/8 1100 1/9905 OH 849
Final folder
Station wheel
Parts in motion
Packages

Technical Training Centre, Lund, Sweden TBA/8 090V 1/9412 OH 491:1
Parts in motion
Packages
Final folder
Conveyor
Final folder
Feeder
Stationary parts
Parts in motion
Driving parts
Packages
Final folder
Discharger
Stationary parts
Parts in motion
Driving parts
Packages
Conveyor driving
Final folder
Chain tensioner
Parts in motion
Driving parts
Pressure device left
Non return
Pressure
guard
Indexing unit
Chain
Bearing
Pump Drive shaft
Filter
Oil filter
Pressure device right
Final folder
Lubrication
system
Oil
Air inlet
Oil filling
Oil draining
Oil level checkpoint

Pressure device left
Final folder
Technical Training Centre, Lund, Sweden
Tetra Pak Processing & Packaging Systems AB
Lubrication system
Non return
Pressure
guard
Indexing unit
Chain
Bearing
Pump Drive shaft
Filter
Machine type
Oil filter
TBA/8 090V
Pressure device right

Issue
1/9412
OH 495:2
Oil
Grease
Air inlet
Oil filling
Oil draining
11
Automatic splicing unit

Automatic Splicing Unit
Overview
Lund, Sweden TB/8 TBA/8 1/9610 OH 586
Basic function of ASU
Stop Drive Rotation
cylinder roller monitor
Crease wheel
Impulse transmitter wing
Sprocket wing
Material brake
Dancer
Heating jaw rollers
Knife
Bellows
cylinder
Pressure jaw
Brake
cylinder
Material holder
Release screw
Counter block
Photocell
sensors

Lund, Sweden TB/8 TBA/8 1/9610 OH 587:1
Production

Splicing step 1

Splicing step 2

Splicing step 3

Splicing step 4

12
Hydraulic and
lubrication systems

Central Lubrication
System
General
The central lubrication system provides lubrication to the machine.
Lubrication reduces wear and prolongs the lifetime of components in the
machines.
Basic function of the lubrication system
To lubrication point
A B
Dosing valve
Main line
Lubrication pump
Lubrication
oil
At a pressure stroke, the oil is fed from a lubrication pump through the main
line to the dosing valves. From the dosing valves the oil is dosed to the
bearings, bushings, sliders etc. that should be lubricated. The quantity of
lubrication oil to each lubrication point, is dependent on the size of the dosing
valve, compare A and B in the figure above.
The central lubrication system used in Tetra Brik machines, is a high pressure
system. The lubrication pump is pneumatic and the oil pressure is 5-7 MPa
at the pressure stroke. It is a one way system, which implies that the oil is
consumed at the lubrication points.
The central lubrication system of each machine is documented as a diagram.
In order to simplify and make the diagram easier to read, the various
components are shown as symbols. It is very important that the correct central
lubrication diagram is used when working with a particular machine. There are
many models and versions of machines, and some of them have been rebuilt
or modified and differ from their original design.
Components
A description of the main components in the central lubribrication system
follows below.
The lubrication oil is kept in a tank with a built in pump. Oil tank
Venting pipe
Filling connection
Level sensor
Main line
Level
glass
Built in pump
The lubrication oil tank is equipped with filling connection, venting pipe,
level sensor, level glass and a built in pump.
The pressure guard monitors the oil pressure. If the pressure does not reach the Pressure guard
preset value, an alarm will be activated. The pressure guard can also monitor
that the discharge pressure is continued properly after a pressure stroke.
Main line
Pressure gauge The central lubrication system can be equipped with a pressure gauge which
shows the pressure in the high pressure side of the system.
Central lubrication pump The lubrication pump is a pneumatic single acting piston. The pump feeds the
oil with a required pressure at each pressure stroke. The oil pressure is nine
times higher than the incoming air pressure. The pump is also responsible for
the important decompression, i.e. the discharge pressure, in the main line after
reaching the end of the pressure time.
Main line Suction pipe
Mounted locating head
Return spring
Pump cylinder piston
Air cylinder
Air piston
Incoming air pressure
The central lubrication pump consists of an air cylinder with an air piston
which put pressure on the pump cylinder piston. The pump also contains a
mounted locating head, which includes all the necessary valves, connections
to the suction pipe and the main line.
Level sensor The lubrication oil tank is equipped with a level sensor that will activate an
alarm when the oil level is too low.
Maximum level
Minimum level
When the level is below the minimum level a signal is sent to the control
system of the machine. The minimum level is set at a level which prevents the
suction tube from sucking air into the system. The maximum level can be used
to control automatical filling.
When refilling the central lubrication tank, the oil is fed through a hose Oil filter
provided with a filter mounted in line in the hose. The filter will take away dirt
and particles that may interfere with the function of the pump, dosing valves
etc.
Distribution blocks are used as junctions for the hoses that distribute the oil to Distribution block
different dosing valves in the machine.
The dosing valves ensure that the correct amount of lubrication oil is fed to the Dosing valve
lubrication points. It works like a mechanically operated volumetric piston
pump.
Lubricating
pipe
Non return
valve
Return spring
Dosing chamber
Piston
Piston housing
The dosing valve consists of a piston housing with a piston that at a pressure
stroke, forces the oil upwards, through the non return valve and into the
lubrication pipe. It also contains the return spring which forces the piston
back into its rest position after the pressure stroke.
Function
The oil is fed from the central lubrication pump through the main line and
the distribution blocks to the dosing valves. From the dosing valves the oil
is distributed to the lubrication points with set quantities of 10 mm3, 30 mm3,
or 50 mm3, independent of each other. It is the size of the piston in the dosing
valve that determines the amount of oil to be dosed. The PLC of the machine
controls and supervises the lubrication system.
Basic sketch of a central lubrication system
Dosing valves Dosing valves
Distribution block
Lubrication oil
Compressed air
Pressure guard
Main line
Filling connection
PLC
Central lubrication
pump Button for manual
lubrication
The lubrication cycle can be devided into three phases:
• Rest position - At the rest position the air piston does not move.
The lubrication pump and the dosing chambers are filled with oil.
Dosing
chamber
Air piston
Lubrication oil
Compressed air
• Pressure stroke - At the pressure stroke oil is fed to the lubrication points.
Lubricating
pipe
Main line
Non return
valve
Non return
valve
Piston
Air piston
Lubrication oil
Compressed air
The air piston in the lubrication pump goes up and forces the oil into the
system. The oil passes a non return valve and continues through the main
line to the dosing valves. The dosing valve piston goes up and forces the oil
through a non return valve into the lubrication pipe and out to a lubrication
point.
• Discharge pressure - At the discharge pressure, the lubrication pump and
the dosing chamber in the dosing valve, will be refilled with oil.
Suction pipe
Non return
valves Non return
valve
Return
Pump cylinder spring Dosing
chamber
Piston
Air piston Piston

housing
Lubrication oil
Compressed air
The return spring of the air piston, forces the piston back to its rest position.
Lubrication oil flows from the lubrication oil tank through the suction pipe
into the pump cylinder. At the same time the main line is decompressed
through the non return valves.
The dosing chamber is then refilled with oil through the small gap between
the piston housing and the piston. The non return valve in the dosing valve
is closed which prevents a return flow of the oil.
At the discharge pressure, the system is decompressed to a lower pressure of
approx. 0.2-0.5 MPa. The lower remaining pressure is important for refilling
the dosing valves. If there is no remaining pressure, air might enter the system
through leaks. The time needed for the discharge pressure depends on:
• the viscosity of the oil
• the running temperature
• the size of the system
The next pressure stroke must not occur until the dosing valves have been
refilled i.e. the system has been decompressed.
There are two different lubrication cycles. The diagram below shows an Lubrication cycles
example.
Single lubrication pulse
15 min
Lubrication 10 s 10 s
Checking 8s 8s
- oil level 2s 2s
- pressure
Long lubrication cycle
Lubrication 10 s 30 s 10 s 30 s 10 s 30 s 10 s 30 s 10 s
Checking 8s 8s
- oil level 2s 2s
- pressure
• Single lubrication pulse - During production the machine will be

automatically lubricated with one lubrication pulse every 15 min. The
interval may vary from one machine to another.
• Long lubrication cycle - A long lubrication cycle consists of a number of
lubrication pulses within a set time interval. It is automatically initiated
from PLC at different occasions e.g. when:
- the machine is initially started
- the machine has been cleaned by external cleaning
A long lubration cycle can also be initiated by pushing the button for manual
lubrication e.g. when:
• the main lines need to be filled up after an interference or a service
Information on the proper type of oil to be used in the central lubrication Refilling
system, can be found in the Maintenance Manual and the Operation Manual.
The central lubrication tank can be filled manually or automatically.
• Manual refilling - The central lubrication tank is refilled by using a
transportable pump and tank. The hose is connected to the oil tank in the
machine by way of a quick release coupling. The oil is then pumped from
the transportable oil tank into the lubrication tank.
A transportable oil tank connected to the oil tank in the machine
• Automatic refilling - In an automatic filling set up, the lubrication tanks of
each machine are connected to a central storage. The oil is pumped out to
the machines.
PLC PLC
Set up for automatic refilling
A solenoid valve is mounted at each oil tank, and when the oil level is low,
the solenoid valve opens and refilling take place. When the proper level has
been reached, the filling valve closes and the filling ends.
Bleeding The central lubrication system does not work if air enters the system. If air has
entered the system, it must be bled to restore its proper function.
Function check A function check of the lubrication system is made according to the service
interval and at every interference in the system. Then for example oil pressure
and the function of the dosing valves are checked.
TETRA
Lubrication system TB/8 and TBA/8

PAK
N
W
L
I J I I J I
D 23 33 23 F L U U L F 23 33 23 D
Lund, Sweden
MAIN ARM L L L MAIN ARM
F F
YOKE I 38 38 I
I 37
I H I I H I
37 I YOKE
26 27 26 E E 26 27 26
H 34 34 H
I 39 39 I
I H I H H I I I I H H I H I
43 44 43 42 F 40 41 41 F F 41 41 40 F 42 43 44 43
H I H H LINK SYSTEM LINK SYSTEM H H I H

F 55 52 53 54 54 53 52 55 F
57 51 51 50 F F 50 51 51 57
H J J H H J J H
I 48 ARM W.AXLE CUT ARM W.AXLE CUT 48 I

H 28 28 H
Machine type
H 47 I I I H H I I I 47 H
H 29 F 48 57 48 50 50 48 57 48 F 29 H
68 1 CHAIN, OIL PUMP
F L U M F
67 1 BEARING, OIL PUMP
66 1 BEARING, DRIVE SHAFT
TB/8 090V TBA/8 090V
65 1 GEAR, DRIVE UNIT

M L 64 1 GEAR, IMPULSE EMITTER
ARM W.AXLE PRESSURE ARM W.AXLE PRESSURE 63 1 OIL TRAY, IMPULSE EMITTER
J 21 62
I 65 AC AC 64 I 61 4 BEARING,CAM−FOLDING FLAP, REGISTER RETENTION
H 20
D AC 63 H D 60 4 BEAING HOUSING, CAM FOLDING FLAP, REGISTER RETENTION
E
E E 59
58 4 CAM, VOLUME CURVE PIECE
HOLD DOWN DEVICE 57 4 VOLUME FLAP AXLE
56
I I I I LINK, FOLDING FLAP MECHANISM
E E 55 2
E 58 58 58 58 E 54 2 COUNTER ROLLER, FOLDING FLAP MECHANISM
J 60 60 J
53 2 BRACKET, FOLDING FLAP MECHANISM
H 61 61 H
VOLUME CURVE PIECE L VOLUME CURVE PIECE 52 2 CAM ROLLER, FOLDING FLAP MECHANISM
51 4 CARRIER, CUTTING JAW
50 4 CURVE ROLLER VOLUME FLAP, CUTTING JAW
B L U T 49
E M E 48 6 BEARING HOUSING, PRESSURE JAW
J 60 L 60 J 47 2 JOINT ROD, PRESSURE JAW
H 61 61 H 46
45
44 2 TOOTHED SEGMENT, YOKE
MACHINE BODY 43 4 BEARING, ARM WITH AXLE CUT, YOKE
REGISTER U REGISTER
INFEEDER DELIVERY UNIT 42 2 GUIDE, YOKE
RETENTION RETENTION 41 4 BEARING, ARM WITH AXLE, PRESSURE, YOKE
Issue
H H H H H H L L L H H H
40 2 SPRING HOUSING, YOKE
5 4 4 3 3 5 G F 8 7 7 GUIDE BEARING − LOWER, YOKE
39 2
FOLDING
1/9208
AH AF AH AH AF AF 38 2 GUIDE BEARING − UPPER, YOKE

AF AH AH H H UNIT H H AIR CONN. 6 37 2 LINK − LOWER, YOKE
AK AL AK AK AL R S P 36
1 2 E L U L E 2 1
TANK PUMP 35
AL AK AK AL
AK AH AH AK L AK AH AH AK 34 2 YOKE LINK − UPPER, MAIN ARM
33 2 CAM ROLLER, MAIN ARM
WHEEL L. WHEEL R. 32
31
AD 30 1 INDEXING UNIT
AC 90266−19 − " O 2.5/1.5 29 2 OPERATION ROD−CATCH MOVEMENT, LINK SYSTEM
AB 90274−2 1 PRESSURE GUARD 28 2 BEARING ROD IN FRONT, LINK SYSTEM
AA 90137−0005 4 BANJO CONNECTION 27 2 BERAING ROD REAR, LINK SYSTEM
SEPARATE LUBRICATION SYSTEM FINAL FOLDER I H I H I H H I H H H I Z 26 4 CAM ROLLER, LINK SYSTEM
G 13 12 13 14 13 11 L G 10 12 12 12 12 13 Y 90032−34 2 JUNCTION BLOCK PRESSURE DEVICE 25
X 90048−0420 1 FILTER 24
LUBRI− AB
OH 443
AH AH AH AH AF AF W 90134−54 1 CONNECTION 23 4 JOINT − LINK, MAIN ARM

CATION AF AH AC AF AF AH V 90048−0033 1 PUMP 22
SYSTEM X AK AK AK AK AL AL U 90032−44 6 JUNCTION BLOCK 21 1 ROLLER AND BEARINGS, HOLD DOWN DEVICE
AL AK AL AL AK T 434202 1 PIPE O 6x1 20 1 BEARING REAR, HOLD DOWN DEVICE
CONVEYER S 434203 1 SUCTION PIPE O 8x1 19
AG AE AF R 292297−102 1 TANK 18
Q 17
P 90048−18 1 PUMP 16 8 BEARINGS AND AXLES,PRESSURE DEVICE, R. AND L.
67 RS O AXLE, PRESSURE DEVICE, R. AND L.
15 4
C AE PUMP N 90274−27 1 PRESSURE GUARD 14 1 AXLE, GEAR WHEEL, CONVEYOR
K 16 V AF 66 RS 16 K M 90166−109 − HOSE O 4/2 13 4 AXLE, CONVEYOR
K 16 RS AF 30 68 16 K L 90166−108 − " O 6/3 12 5 OIL BRUSH, CONVEYOR
K 16 AA AF 15 RR AA AF 15 RR 16 K K 90151−4 − PIPE 3/32" 11 1 GEAR WHEEL, CONVEYOR
K 16 AF 15 RR K AF 15 RR 16 K RT 90230−31 1 NON RETURN VALVE 3.5 BAR J 90092−54 11 METERING VALVE 50mm 3 10 1 CHAIN TENSIONER, CONVEYOR
AA AA
Y AF RS RS AF Y RS 90092−81 5 METERING VALVE CJB5 I 90092−53 43 " " 30mm 3 9
RR 90092−38 4 " " CJB1 H 90092−52 52 " " 10mm 3 8 1 AXLE, DELIVERY UNIT
RT AE AM AE C
AM 90415−33 1 OIL FILTER G 90032−40 3 JUNCTION BLOCK 6−WAYS 7 2 OIL BRUSH, DELIVERY UNIT
AL 90092−48 9 OIL BRUSH F 90032−39 17 " " 4−WAYS 6
AK 90134−58 15 BANJO CONNECTION E 90032−38 13 " " 2−WAYS 5 2 AXLE, INFEEDER
PRESSURE DEVICE L. PRESSURE DEVICE R. AH 90166−0143 − HOSE O 2.5/1.6 D 90032−43 4 " " 3−WAYS 4 2 CHAIN TENSIONER, INFEEDER
AG 443150 1 SUCTION PIPE C 90032−35 2 " " 8−WAYS 3 2 GUIDE, INFEEDER
AF 90166−51 − HOSE O 4/2.5 B 90032−46 1 " " 6−WAYS 2 2 CAM R. AND L. , WHEEL
AE 90166−11 − " O 6/4 A 1 2 CAM R. AND L. , WHEEL
LETT TP−NO QUA DESCRIPTION LETT TP−NO QUA DESCRIPTION NO QUA LUBRICATION POINT
Hydraulic System
General
Hydraulics are a way to create movement by means of hydraulic oil under
pressure. In Tetra Brik filling machines, hydraulics is used in order to create
the high pressures, the distinctive positions and fast movements, which are
needed for sealing and cutting as well as for movements in the final folder.
Functional principle for hydraulics

Hydraulic oil Hydraulic oil
Piston Return spring
Hydraulic oil with pressure
Hydraulic oil not under pressure

Hydraulic cylinder Hydraulic cylinder
When the hydraulic oil is fed at a high pressure to the hydraulic cylinder, the
piston moves outwards. When the pressure releases, the return spring will
press the oil out of the cylinder and the piston will move inwards.
The hydraulic system of the machine is documented as a diagram. In order
to simplify and facilitate the understanding of the diagram, the various
components are shown as symbols. The shape of the hydraulic system varies
according to the machine type, development step, and possible rebuilding of
the machine. Therefore, it is essential that the appropriate hydraulic diagram
is used when working on the machine.
Components
Below is a description of the main components of the hydraulic system.
Hydraulic oil tank The hydraulic oil tank functions as a reservoir for the hydraulic oil in the
system. Some components of the hydraulic system, are placed on the oil tank.
Pressure reducing Pressure regulator

valve
Level- and temperature transmitter
Filling
connection
Pressure gauges
Hydraulic oil tank
The hydraulic oil is filled into the tank by an external pump. At the time of
filling, the hydraulic oil is filtered through a filter attached to the filler hose.
The hydraulic oil in the tank may be drained through a drain valve. The tank
is open to the surroundings and thus not pressurised.
The level transmitter can indicate two or three levels; high, low and if a third Level transmitter and
exist, soon low level. temperature transmitter
The built in temperature transmitter, senses the temperature. It is normally set
at 70 °C. If the temperature exceeds the set level, an alarm will indicate that
the temperature is too high.
The oil cooler cools the hydraulic oil. Oil cooler
Hydraulic oil Hydraulic oil
ooling Cooling
ater water
Oil cooler, length section Oil cooler, cross section
The oil cooler is a type of heat exchanger in which water is used as a cooling
media. The cooling water can be re-circulated. The heat is created by the
friction, formed when the oil is transported in the hydraulic system.
A hydraulic oil pump is used in order to pressurise the hydraulic oil. The pump Hydraulic oil pump
is a gear pump, driven by an electric motor.
Outlet
Inlet Hydraulic oil not under pressure
Filter A filter strains solid particles and other impurities, which may block valves
and cylinders. Particles and impurities could also in other ways, have a
negative influence on the function of the hydraulic system. The filter has an
indicator, which shows whether the filter is blocked and needs to be replaced.
Indicator
Overpressure
valve
Inlet Outlet
Filter
An internal overpressure valve protects the filter against too high pressures.
This may happen if the filter is blocked and the oil cannot pass. In order to
prevent damage to the filter, the overpressure valve will open at a set pressure
and let the oil pass through.
Non-return valve Non-return valves are used in order to control the flow directions of the
hydraulic system.
Accumulator The accumulator is used in order to keep an even pressure in the system when
the various valves open and close.
Pressurised nitrogen
Hydraulic oil
An accumulator is a pressurised vessel, divided into two chambers. The upper

chamber is filled with pressurised nitrogen and the lower one is filled with
hydraulic oil. The upper chamber functions as a counter pressure, i.e. it will
press oil out to the system when the consumption is higher than the pump
supply, and it will let the oil in, when the consumption is lower than the pump
supply.
A pressure regulator sets the system pressure. The system pressure is used for Pressure regulator
the catch cylinders, for example. A pressure gauge shows the system pressure.
The pressure-reducing valve is used in order to reduce the system pressure, for Pressure reducing valve
example to the cutting cylinders. A pressure gauge shows the pressure.
Hydraulic oil with full pressure
Hydraulic oil with reduced pressur
The throttlings are used to reduce the flow in the pipe, for exampel to the Throttling
cylinders. A lower flow during the pressurisation, reduces the speed of the
pistons in the cylinders. This reduces the risk of mechanical damage when the
cylinder reaches its final position. However, the throttling will not influence
the final pressure in the cylinder.
Valve Valves direct the hydraulic oil to and from the cylinders. When the valve is
open, oil is fed into the cylinder at high pressure. When the valve is closed, the
pressure is released and the oil flows back into the tank. The valves are either
electrically controlled by a signal from the machine control system, or
mechanically controlled by a cam.
Open valve Closed valve
Flow inlet Flow outlet
Cylinder Cylinder
Impulse transmitter When mechanically controlled, the valve functions as part of a, so-called,
impulse transmitter. This transmitter is connected to the jaw system by a
timing belt in order to remain synchronised with the jaw system. The impulse
transmitter consists of cams and valves. The cams affect the valves by one
high part of the cam and one low part of the cam.
Cam
The low part of the cam opens the valve and the cylinder is pressurised.
The high part of the cam closes the valve and ensures that the cylinder is
unaffected. During high cam, the oil from the cylinder is directed back to
the tank.
Note!
The situation can also be reversed, i.e. the low part of the cam closes the valve
while the high part opens the valve and pressurises the cylinder. It depends on
how the system is designed.
Function
The working principle of a hydraulic system is shown below.
14 14
12 13 13
10 10
7
11 9
6
8
1
5 M
4
3
2
The motor-driven pump (1) suctions hydraulic oil from the hydraulic oil tank
(2) through the cooler (3). The level transmitter (4) and the
temperature transmitter (5) are mounted in the tank. The pump forces the
hydraulic oil through the filter (6) and pressurises the accumulator (7). On
the filter there is an indicator (8), which shows when the filter is blocked and
needs to be replaced. The pressure regulator (9) sets the system pressure. In
front of the cylinders there are throttlings (10) in order to reduce the speed of
the pistons in the cylinders, and by that, prevent damage to these components.
To some parts of the system, the pressure is reduced by a pressure reducing
valve (11). A cam (12), or an electric signal from the control system, operates
the valves (13) to the cylinders (14).
The hydraulic cylinders perform mechanical movements in the machines.

• The catch cylinders are connected to the catches. When the cylinder is
activated, the inductor and the pressure jaw are pulled together, causing
pressure on the packaging material tube. This pressure is used for sealing
the transversal seal, and as a hold-down for the cutting. The return
movement takes place when the oil pressure is released and the spring
forces the catches back.
• The cutting cylinder is connected to the knife, which cuts the packaging
material tube into single packages. When the cylinder is pressurised, the
knife will move forwards, cutting the tube. The return movement takes
place when the oil pressure is released and the spring forces the knife back.
• The pull-down device and the pressure device, shape the package in the
final folder. This is valid for machine types TBA/9 and TBA/19 only.
The cylinders in the pull-down device and the pressure device, are operated
by hydraulic oil and have spring returns.
Force – The hydraulic pressure determines the force, by which the hydraulic
cylinder will affect the load. When the pressure decreases, also the force
decreases. Consequently, when the pressure increases, so does the force. The
pressure is set by a pressure regulator.
Speed – By throttling the flow to the cylinder, the speed of the piston
movement can be regulated. This is done by the use of throttlings on the con-
nections between valves and cylinders.
Hydraulic oil In order to maintain an efficient flow of energy in a hydraulic system, the
correct type of hydraulic oil must be used. Information about which oil type to
be used for the different machines, is found in the Maintenance Manual as well
as in the Operation Manual.
The following is required for an oil to function properly in a hydraulic system.
• The hydraulic oil must have a viscosity to seal small gaps and clearances, in
order to avoid leakage. The hydraulic components often lack elastic seals.
• The hydraulic oil must lubricate the components in order to reduce the
wear. Since the clearances and gaps in the hydraulic components are small,
there is a risk of direct contact between the parts in a components. When
there is direct contact, the material is worn off and the gaps in the compo-
nents increase. Worn components cause capacity losses and leakage risks.
• The hydraulic oil must chill and carry off the friction heat from
efficiency losses in the system.
Impurities, which enter the hydraulic oil, may damage the system.
• Air – Under normal pressure the hydraulic oil binds only a small amount
of air. However, under pressure, the hydraulic oil is capable of binding
much more air. Air is released when the pressure decreases and small air
bubbles are formed. In the tank, the air is separated from the hydraulic oil.
When hydraulic oil containing air, is pressurised, it turnes elastic and it will
take a longer time to reach the correct pressure. This may affect the
function of the system. Furthermore, air in the hydraulic oil will decrease
the possibility to build up a lubricating film, and thus reduce the lubrication
effect on the components.
• Water – Hydraulic oil naturally contains 0.01-0.02% of water. At higher
concentrations, the water may appear in a free state, which may damage the
system. The water may appear from condensation, leaking water coolers, or
leaking components.
Water in the hydraulic oil may cause corrosion on the components in the
system and decrease the capability to build up a lubricating film. When the
proportion of water in the hydraulic oil is high, the oil may get thicker and
thus block the filter.
• Solid impurities – Solid impurities in the hydraulic oil could cause
problems in pumps, valves and cylinders. The solid particles are filtered
out into two filters; one in the filling hose and one after the pump.
Safety The pressure must be discharged when working in hydraulic systems. An

accumulator is pressurised up to 70 Bar. When the system is to be vented,
the pressure must be reduced to a maximum of 40 bar, in order to decrease
the risk of splashing.
Furthermore, the handling instructions from the manufacturer must be
followed, since the hydraulic oil may be health hazardous and allergenic.
Symbols
The table below contains the symbols that normally are used in Tetra Pak
hydraulic system diagrams.
Symbol Meaning
Accumulator
Non-return valve
Valve, electrically operated
Valve, cam operated
Manual valve
Cylinder with oil return
Cylinder with spring return
Filter
Throttling
Cooler
Pump
Symbol Meaning
Tank
M Motor
Level transmitter
Temperature transmitter
Pressure gauge
Pressure indicator
Pressure regulator
Pressure reducing valve
Hydraulmodule
13
Water and pneumatic
systems

Water system TBA/8
FINAL FOLDER MACHINE BODY SUPERSTRUCTURE

H
DILUTION
L TANK
IN− SEPARATOR
FEED
DROP
M
CLEANING NOZZLES L
H
DRAINING
FILTER VALVE
GUARD VALVE KF2 COMPRESSOR
Y32 M5
PANEL J
M SEA−
H
CLEANING LING ZON HEATER
PUMP UNIT DELIMING
MAGNET J
Machine type
CLEANING TRAY
J
G L A5 A3 J J
A1
R2 R1 JL JR
TBA/8 100V
HYDRAULIC L J
COOLER A4 A2
J
Y33
CLEANING NOZZLES TUBE A8 Y36 PRESSURE JAW
FLUSHER TS SEALING
FLUSHER I
CONVEYOR JAW SYSTEM
COOLING QUICK K
ASSEMBLY COUPLING
G
Issue
O
1/9501
N M
Y29
M DETERGENT
PUMP
A9
A6
C A D B
OH 485
1 2 3 4 5 6 7 8
CONNECTIONS CONSUMTION WATER PIPE NO.

1 HOT WATER IN A (STANDARD ARRANGEMENT)
3 4−293201 4 5
2 COLD WATER (Max 20 C) IN

B
3
CONSUMTION WATER 3 PIPE NO. 5 PIPE NO.
4
5
MODULE CONNECTIONS VALVE PANEL C CIRCULATING COOLING WATER
4−436512
4
4−436512
6
6 MODULE CONNECTION ON BACKSIDE

7 CIRCULATING COOLING WATER IN ALTERNATIVE SYSTEM OF VALVE PANEL
8 COOLING WATER OUTLET
Pneumatic system TBA/8
SUPERSTRUCTURE
AIR SQUEE−GEE AIR INLET HEAT ELEMENT MOVEMENT LS − COUNTER PEROXIDE BATH
KNIFE ROLLER EJECTOR SUCTION VALVE VALVE EXCHANGER SA LS VACUUM SHORT STOP ELEMENTS ROLLER TOP FILLING
LEFT RIGHT DRYER / BATH VALVE VALVE MOVEMENT SHORT STOP
C24:2 AIR
SA LS
C21:1 C21:2 C21:3 54 C23 C44:1 C44:2 C24:1 F18 COMPENSATION
C26 VALVE
2
Y70
12
3
1
C86 C20:1 C20:2
C44:3 SUCTION VALVE
ASEPTIC CHAMBER
C71:1
PREHEATING VALVE
710 711
Y71
4
2
212 210 211 540 231 230 440 441 240 241 860 861 201 200 260 261 181
1
3
5
SPRAY TANK
JAW SYSTEM M21
Y35
12
AIR
2
C14 Y21 Y54 Y23 Y44 Y24 Y86 Y20 Y26 Y18 3
4
4
2
2
2
4
2
4
2
4
2
4
2
4
2
4
2
Machine type
1 2
RIGHT 1 41
1
1
1
1
3
3
3
3
5
5
5
5
R A B C D R T21
141 M4
STEAM BARRIER
121 Y14
4
2
VALVE C
131 90
B2 C7
1
Y102
3
5
T4
1
5
3
781 GUARD
PRODUCT
TBA/8
Port 14
4
2
681 VALVE A
Y12 F102 Y9
VALVE PANEL
4
2
4
2
R A B C D R
1020 C9
1
1
3
3
5
5
LEFT 1021
C13 M3 70
Y13 MACHINE BODY Y7

4
2
4
2
AUTO CORRECTION
STERILE AIR
1
1
3
3
5
5
C8 VALVE B
80
Y78 RT1 Y8
4
2
4
2
Issue
1
3
3
5
5
2/9904
A7 T1
1
1 T68 1 T84
M84 PT10 2
2 2 M1 T55
M68 Y6 Y5 Y17 Y47 Y45 Y46 Y2 Y27 Y28 Y1 1
1
1
5
3
5
3
5
3
5
3
5
3
5
3
5
3
5
3
5
3
5
3
Port 14
4
4
2
4
2
4
2
2
AIR
M55
OH 487
841 61 51 171 471 451 461 21 271 270 280 11 550
C2
C27 AIR FLAP FINAL
CLEANING
12 F6 12 F5 C47 TRAY DROP NOZZLE SEALING FOLDER
C45 C46:1 C46:2 DRAINING CHUTE AIR LOWER
1 2 1 2
M PART
PHOTO AIR SPLICER DRIVE UNIT DATING SPLICER

PEROXIDE PEROXIDE CENTRAL PRESSURE UNIT BRAKE
CELLS JET BATH BATH LUBRICATION PRESSURE
PISTOL JAW ROLL STOP
FILLING DRAINING PUMP
DRAINING
MACHINE BODY AUTOMATIC SPLICING UNIT FINAL FOLDER UNIT

Textbook
Pneumatic system
MT-83015-2

Lund, Sweden
This textbook has been compiled by the Technical
Training Centre in Lund.
Some of the pictures in the book are also available as
OH pictures.
For further information on training material, please contact
the Technical Training Centre.
Issue 1/9411
© 1994, Technical Training Centre

No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocop-
ying, recording or otherwise, without permission in writing from Technical Training Centre.
Pneumatic system
Training Document
used for other purpose.
equipment, and must not be used as such.
Note!

Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main air supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Function principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General
The technology of using compressed air to create movement is termed
Pneumatics. In the Tetra Pak packaging machines and distribution equipment,
compressed air is used to:make components move, operated by pneumatic
cylinders
• make components move, operated by pneumatic cylinders
• control and operate valves
• create vacuum and supply air nozzles with air
The pneumatic system consists of two parts. One part is located external to the
machine; in it, the required pressure is generated. The external pneumatics
include compressor, air conditioning unit, main air supply line, etc. The other
part is inside the machine and includes regulators, valves, cylinders, etc.
The air used in the pneumatic components must be clean and dry; pressure and
flow rate must also be as required. The recommended values are specified in
the installation manual (IM) for the machine concerned. In some systems, the
components are factory prelubricated once and for all, requiring no further oil
or grease; air for these components must be as free from oil as possible.
However, if such a component is once mist lubricated, it must always be mist
lubricated from then on.
The pneumatic system of each machine is documented in the form of a
diagram. In order to simplify its construction and make the diagram easier to
read, the various components are shown as symbols.
Pressure Shut–off Pressure regulator

source valve with gauge Valve Cylinder
As there are many models and versions of machines, and some of them have
been rebuilt or modified to differ from their original design, it is very
important that the correct, up–dated, and currently valid pneumatic diagram is
used when working with a particular machine.
Technical Training Centre 1/9411 Training Document. For training purpose only. 3
Components
Air conditioning units
The first unit the air passes through on its way to the machine is the air
conditioning unit. It consists of a separator, pressure regulator with pressure
gauge, and, on some machines, lubricator. Normally, a shut–off valve is built
into the conditioning unit.
Pressure regulator
Shut–off valve
Air conditioning unit symbol
Pressure gauge
Separator
Lubricator
The purpose of the separator is to remove water and other pollutants that might Separator
be present in the compressed air. The separator consists of a filter element and
a reservoir with a drain valve. The filter element may be made of sintered
bronze. The input air is made to rotate, so that water drops and the larger solid
particles are flung outwards against the inner surface of the reservoir.
Condensated liquid runs down to to bottom of the reservoir, where it is
removed through the drain valve when the input air is turned off.
The purpose of the pressure regulator is to provide air at a constant pressure, Pressure regulator
independent of the load on the system. It is a form of pressure reduction valve,
and its function will be explained under the heading of Valves.
The pressure gauge indicates the pressure setting. Pressure gauge
The lubricator (mist lubricator) provides the compressed air with oil. The Lubricator
injected amount of oil is proportional to the flow rate of the air and can be
preset. In systems whose components are factory prelubricated, no oil must be
added to the compressed air, as oil would wash out the grease in the
prelubricated components.
Valves
The purpose of valves is to regulate the flow rate and pressure of the
compressed air and control its flow direction. The valves are controlled and
operated either manually, by means of electrical signals from the PLC, or
pneumatically by other valves.
Valves are subdivided into two groups – seat valves and slide valves. These
groups differ in their design.
Seat valve The seat valve controls the flow of air by means of its valve head and seat. The
valve head only has to move a short distance to change over but needs
considerable change–over force.
Non–actuated Actuated
Seat
Valve head
Housing
Return spring
Slide valve The slide valve controls the air flow by means of a movable slide. To change
over, the slide has to move a relatively long distance, but the force needed for
it is small.
Non–actuated Actuated
Housing
Slide
Return spring
In respect of their purpose, valves are grouped as follows:

• directional valves, controlling the flow direction of the compressed air, for
instance to operate the reciprocating movement of the piston in a pneumatic
cylinder.
• flow rate regulating valves, controlling the amount of air per time unit, for
instance to control the speed of the piston in a pneumatic cylinder.
• pressure regulating valves, controlling the pressure in the pneumatic sys-
tem.
Before proceeding, we shall take a look at the symbols for the valves, and how
they are constructed and function.
The valve symbols denote the function of the valves but not their design. This Valve symbols
means that valves that look differently, due to the way they are designed and
constructed but function in the same manner, are shown with the same symbol.
The illustration shows the working principle of a slide valve, which may be in
either of two positions.
Outlet.
Port for output air Slide
Pilot air
Pilot air
Valve
housing
Inlet. Vent.
Port for input air Port for evacuation
Position 1 Position 2
The valve has received pilot air on the The valve has received pilot air on the
lefthand side. The passage between in- righthand side. The inlet is closed, and
let and outlet is open, and the vent is the passage between outlet and vent is
closed open.
This valve can be shown simplified as a symbol.

The symbol consists of a square, with the ducts through which the air is able
to pass shown as arrows. To the left and right of the square, the manner in
which the valve is controlled is symbolised, for instance with a horizontal line
for pneumatic control. The lines above and underneath the square represent the
ports connected to the input and output air lines.
Outlet Valve housing
Pilot air Pilot air
Inlet Vent
The valve symbol is shown with The valve symbol is shown with
open passage between inlet and open passage between outlet and
outlet, and closed vent. vent, and closed inlet.
The function of the valve is illustrated by means of symbols. Each position the
slide may be in is shown as a symbol, and the symbols are drawn after one
another. The ports are only shown on the symbol in active position in the
pneumatic diagram, which is the starting position of the valve.
Outlet
Active part of
symbol
Pilot air
Inlet Vent
Compressed air supply.
The pilot air is received on the lefthand side The pilot air is received on the right-
of the symbol, which means that the lefthand hand side of the symbol, which means
side of the symbol is active. Compressed air that the righthand side of the symbol is
passes through the valve and can actuate a active. The air in the
cylinder cylinder can be evacuated.
To make it easier to identify them, the ports are numbered: input air port – No
1; output air port – No 2; vent port – No 3. The pneumatic signal ports take
their numbers from the ports they provide passage between; for instance, port
No 12 connects input and output air.
2
12
1 3
As the valve in the example has three ports and a slide which may be in two
positions, it is termed a ”3/2 valve”. Similarly, a five–port valve with a three–
position slide becomes a ”5/3 valve”.
The valve may be operated in several ways. Other than pneumatically, it can
be operated manually, by a spring, or electrically. The different ways are
shown as symbols. In the following example, an electrically operated 5/2
valve with spring return operates a double-action pneumatic cylinder.
Cylinder
Control signal Outlet ports

4 2
14
5 1 3
Return spring
Vent port
Vent port
Inlet port
The control signal is received on the The control signal is discontinued, and
lefthand side of the symbol. Compressed the return spring moves the slide. The
air passes through the valve and into the compressed air is now directed to the mi-
plus compartment of the cylinder, while its nus compartment of the cylinder, while
minus compartment is vented. its plus compartment is vented.
The various forms of valve symbols used in our pneumatic diagrams are
explained in greater detail in the section of this text where the function of the
valves is described.
The monostable valve features spring return, i e in idle position, the slide is Monostable directional
always in the same position. One advantage of this type of valve is that it is valve
possible to operate a cylinder in both direction with only one control signal
output from the PLC.
Electrically controlled, monostable valves are used extensively in Tetra Pak
machines. The pilot air is controlled by means of an solenoid, powered by 24
or 48 V DC from a PLC output. The pilot air system is an integral part of the Electrically controlled,
directional valve. monostable directional
valve.
Cylinder
Electrically controlled,
monostable valve 4 2
Seal
Pilot valve
Solenoid
5 1 3
14
From PLC
In those cases where the valve receives air with a reduced pressure, which is
lower than the change–over pressure of the valve, the pilot valve can be
supplied separately with air from the pneumatic system. On some valves, for
instance Mecman Series 581, change–over is effected by turning the seal monostable directional
between the valve proper section and the control section upside down. Then valve with separate air
supply to pilot valve.
control port No 14 in the connection plate is connected directly to the
compressed air system.
Electrically controlled, monostable valve with sepa-
rately supplied solenoid valve
4 2
Seal
Pilot valve
Solenoid
5 1 3
14
Pressure regulator From PLC
Bistable directinal valve The valve has no spring return, and thus the slide can be in either of two idle
positions, depending on which one of the two solenoids was most recently
activated. Consequently, two outputs from the PLC are always required to
control a bistable valve.
bistable directional valve
4 2
5 1 3
12 14
From PLC
From PLC
Valves of the bistable type are used if, for instance, it is desirable that the
cylinder is to remain in the position it moved to as a result of the most recent
valve operation, even if the the output signal is discontinued. The same
standard principle for numbering the ports applies to this kind of valve. Pilot
air at port No 12 connects ports No 1 and No 2, pilot air at port No 14 connects
ports No 1 and No 4, in both cases admitting passage of input air.
This valve type is used, for instance when a cylinder is to remain in position 3-positioned directional
at an emergency stop. Below, an electrically controlled 5/3 valve is illustrated. valve
4 2
Electrically controlled, 3–
positions directional valve
with closed middle posi-
tion.
5 1 3
14 12
No control signal to ports No 12 and No 14 means that the return spring

positions the slide in the middle; all ports closed.
4 2
5 1 3
14 12
On port No 14 receiving a control signal, the slide moves to the right in the
picture. This means that port No 1 is connected to port No 4, and port
No 2 to port No 3.
4 2
5 1 3
14 12
On port No 12 receiving a control signal, the slide moves to the left in

the picture. This means that port No 1 is connected to port No 2, and
port No 4 to port No 5.
The valve can be in three positions. In addition to the two positions of a 2–

position valve, the 3–position valve has a middle position with all ports
closed(as exemplified above) or open for venting. Two PLC outputs are
required to control the valve. If there is no signal when the system is
depressurised, the return spring puts the valve in its middle position.
Soft-start valve This type of valve is used in order to make pressurisation of the pneumatic
system soft and smooth.
Variable stop Telescoping slide
1 2 3
12
Idle position.
In idle position, ports No 2 and No 3 have an
open connection. The pneumatic system is
depressurised.
1 2 3
12
Pressurisation phase.
During the pressurisation phase, the connection
between ports No 1 and No 2 is partly open, and
pressurisation has begun. The width of the open-
ing is regulated by means of a variable stop (limit
screw).
1 2 3
12
Full flow.
When the pressure has risen to approximately
75% of the pressure in the compressed air supply
line, the connection between ports No 1 and No
2 is opened all the way.
The three positions of the telescoping slide are illustrated, somewhat

simplified. When the control signal is received, the slide moves up against the
variable stop, opening a narrow connection between ports No 1 and No 2
(pressurisation phase). When the pressure has risen to approximately 75% of
the pressure in the compressed air supply line, the valve opens all the way. On
depressurisation or at an emergency stop, the valve provides full flow directly
between ports No 2 and No 3 (depressurisation).
This kind of valve is used to regulate the flow of air, which is restricted equally Throttle valve
much in both directions.
1 2
Throttle valve Throttle fitted in

directional valve
If throttles are incorporated in a directional valve, they are fitted in the outlet
ports and consist of brass screws. Normally, such throttles are factory fitted in
most of our directional valves. Normally, they provide adequate speed
regulation accuracy.
This kind of valve is used when the air is to be regulated in one flow direction Throttle check valve
only.
1 2 1 2
When the air flows from port No 1 If, on the other hand, the air flows from
to port No 2, it must pass through port No 2 to port No 1, it passes through
the throttle and can thus be regulat- the check valve without being regulat-
ed. ed.
In order to achieve better accuracy in speed regulation, throttle check valves

can be used, for instance fitted in the end sections of the cylinders. This is done
when the cylinder is located remote from the directional valve. If throttle
check valves are being used, the throttles integral with the directional valves
must be fully open; adjustment must only be made by means of the throttle
check valves.
This is a manually operated ball valve, used to shut the supply of air to the Shut-off valve
entire pneumatic system. Normally, it is built into the air conditioning unit.
The pressure switch triggers an alarm to the control system, if the pressure Pressure switch
drops below a preset value. This value can be adjusted.
Pressure regulator Correctly set pressure is a condition of correct speed control and correct force.
For this reason, a pressure regulator is a always fitted in the air conditioning
unit. To enable the pressure regulator to function well, there must be a pressure
difference between input and output air of not less than 0.8 bar. Some
machines have an extra pressure regulator within the pneumatic system for the
purpose of allowing the reduction of the air pressure to some of the cylinders.
Outlet pressure
set screw
Force spring
Diaphragm
Inlet port
Outlet port
Seat
Valve plate
The valve plate of the seat valve is operated by the diaphragm, which in its turn
is actuated by the outlet pressure of the pressure regulator. The force created
by this pressure is balanced by the spring force on the other side of the
diaphragm. By increasing the spring force by turning the set screw, the seat
valve is opened and is kept open until the outlet pressure exceeds the spring
force. Thus the diaphragm and the spring force together maintain a constant,
preset outlet pressure. If the pressure on the outlet side drops, for instance due
to air used in moving a cylinder, the seat valve opens again.
Vacuum ejector with valve This valve generates underpressure through its ejector effect. It is used, as an
example, to supply a vacuum to suction cups. There are two types of vacuum
valves. One type which is electrically controlled and generates a release pulse
when the direction of flow is reversed. The other type in entirely pneumatic
and generates the release pulse by means of a built–in accumulator.
1
3
1 3
2
Electrically controlled
vacuum ejector 2
Pneumatically controlled
vacuum ejector
Cylinders
The purpose of a pneumatic cylinder is to perform a movement, powered by
compressed air.
In simple terms, the pneumatic cylinder consists of a cylinder housing with
two end sections, a piston with piston rod, and two connections to the
pneumatic system.
Plus compartment Minus compartment
Piston rod
Rear end Connection Piston Cylinder housing Connection Front end

section section
The piston is provided with seal–rings, separating the two compartments. The
front end section has a piston rod guide and seal.
When compressed air is admitted into the plus compartment (pressurisation),
and the air in the minus compartment is vented, or evacuated
(depressurisation), the piston rod extends out of the cylinder – the piston
performs a plus stroke. If the flows of air are reversed, the piston rod is
withdrawn into the cylinder – the piston performs a minus stroke.
Plus stroke Minus stroke
The cylinder described above is a double–action cylinder with single–side Double-action cylinder
piston rod. This means that both the plus stroke and the minus stroke are
performed powered by compressed air, and that there is a piston rod at one end
only.
Single-action cylinder In the single–action cylinder, a spring effects the minus stroke.
Spring
Piston rod
Rod-less cylinder Such a cylinder is double–acting, but its piston rod has been replaced by an
attachment sliding along the outside of the cylinder shell. The movement may
be transferred to the attachment mechanically or by means of magnets.
Attachment
Connection Piston Cylinder Connection End section

End section housing
Magnetic piston sensor A magnetic piston sensor is fitted on the cylinder for the purpose of giving the
PLC information on the current piston position. This information is then
utilised by the PLC as a precondition of, for instance, the changing over a
directional valve etc.
Magnetic piston sensor
Fully electronic magnetic piston
sensor; when the magnetic field of
the piston alters the resistance in
a semiconductor element
inside the sensor, an output
signal is transmitted to the PLC;
the sensor has a switch–off delay
of 20–30 ms.
Magnetic piston
Double–action cylinder with mag-

netic piston
When replacing a cylinder with a magnetic piston, it is important that the
replacement cylinder also has a magnetic piston. A cylinder with the correct
length of stroke and diameter, but without magnetic piston, will not actuate the
magnetic piston sensors.
The direction, force, and speed of movement of the piston rod can be
controlled. To ensure that the piston rod stops moving softly and smoothly,
there are also end position dampers. The various functions are explained in the
following.
The direction of movement is controlled by directional valves.. Direction of movement
In order to control the movements of a double–action cylinder, a five–port

valve is required. As the valve is actuated by a control signal, its slide changes
over, and the compressed air is led to the plus compartment of the cylinder,
while the minus compartment is vented. The piston performs a plus stroke. If
the control signal is discontinued, the return spring of the valve moves the
slide back again, and the flow of air reverses direction; the minus compartment
is filled with air, the plus compartment is vented, and the piston makes a minus
stroke.
The force which the piston rod exerts on the load, is regulated by varying the Force
pressure of the air – reducing the pressure decreases the force. The pressure is
controlled by means of a pressure regulator.
Pressure regulator Valve Cylinder
Speed The speed of the piston is regulated by varying the flow of air on the return
side in the cylinder. This is done by means of the throttles in the valve, or with
throttle check valves fitted in the line between the valve and cylinder.
Throttle check
valve
Throttle in
valve outlet
port
Speed regulation by means

of throttles in valve
Speed regulation by means of
throttle check valves; throttles in
valve to be fully open
The reason why throttling is done on the return side of the cylinder is to make
the movement smooth.
Pressure
Correct (vented air throttled)
Wrong (input air throttled)
Time
If the cylinders used are small, or the air lines between cylinder and valve are
long, the alternative of employing throttle check valves offers better speed
regulation accuracy; the valve throttles must in this case always be fully open.
The movement of the piston is dampened at both end positions by built–in Dampening
dampers in the cylinder end sections. The dampening effect is regulated with
adjustment screws. The purpose of the dampers is to decelerate, i e slow down
and stop, the piston a smoothly. In this way, damage to the cylinders, caused
by the piston striking the cylinder end section with some force, is eliminated.
Double-action cylinder with vari-
Dampening also reduces vibrations in the machine. If, on the other hand, the able end position dampening
dampening effect is too great, the piston may bounce back and come to a stop
with a jerk.
Cylinder end Adjustment
section screw Piston
The air on the vent side of the cylinder passes through

the large, central opening in the cylinder end section
A protrusion on the piston closes the central opening in the

end section, so that the vented air is forced through the nar-
row duct, in which the adjustment screw enables the flow,
and thus dampening effect on the piston, to be regulated.
In order to successfully set both speed and dampening, it is important first to

make sure that the pressure in the system is correct. Thereafter, the cylinder
speed can be set, and lastly, the dampening effect.
Undamped
Piston
position
Damped too much
Correctly damped
Time
Main air supply line
Shut–off
valve
Pressure gauge
Air user
Air user
Condensate water
The main air supply line should form a ring main line through the premises;
this will allow the users of air to receive it from two directions. There should
be a drop of 5–10 mm per metre in the direction of flow. Underneath the
lowest point in the ring line, a condensate drain cock is to be fitted. The output
connections to the users should be fitted on the top side of the main line piping;
this will keep condensate water and dirt from following the air into the user
device. There should also be a pressure gauge to make it possible to check that
correct air pressure is being maintained.
The diameter of the main line piping depends on its length as well as the
number of pipe bends and elbows, connections, and valves in the line. The
larger the number of such components that the air must pass, the bigger the
pipe diameter must be to prevent excessive pressure drop up to the points
where the air is used.
The pipe–lines should be be installed so that they are easily accessible for
checking that they are tight.
Function principle
This is an example of a principle diagram of a pneumatic system:
Valve cabinet
Y08
1 3
U05 Suction cups

B06
Hot melt pump
T05
U04 C4
Z04
T04 Valve panel
Y03 C3
U03
T03
Y02
C2
24
5
4
1
22
3
Y01
C1
YO00
U1
Pressure
supply
Z2
A1 Z1 T1
The input compressed air passes through manual valve A1, water separation
filter Z1, and pressure regulator T1; pressure gauge U1 indicate the pressure.
If the pressure drops below a preset value, pressure switch B06 indicates a
warning by lighting a signal lamp on the control panel. The pressure switch
should be connected as the last component in the system in order to sense the
pressure drops created by the other components.
Pressurisation valve YO00 is used to make pressurisation of the system slow
in order to allow cylinders in wrong positions to return smoothly to their
correct idle positions. The pressurisation time can be adjusted by means of an
adjustment screw in this valve. Valve YO00 also has a safety function, for
instance if an emergency stop requires the system to be instantly
depressurised.
Valve Y01 is a 3–position valve with closed middle position. If, for instance,
the machine is emergency stopped, the valve moves to the middle position,
and cylinder C1 remains in the position it was in at the stop.
A manual valve
B cylinder Valve Y02 is monostable and electrically controlled. It has throttles in its
C cylinder outlet ports for regulating the speed of cylinder C2.
T pressure regulator
U pressure gauge Valve Y03 is also monostable and electrically controlled, but its pilot valve is
Y electrically controlled supplied with air separately from a line, connected before soft–start valve
valve
YO pressurisation valve YO00. This means that valve Y03 does not have to wait for the slow build–up
Z filter of pressure via the soft–start valve but changes over instantly as soon as valve
A1 opens. The separate supply of air also allows valve Y03 to be supplied with
air at a reduced pressure, for instance to limit the force of cylinder C3.
Pressure regulator T04 regulates the pressure to cylinder C4. This cylinder acts
Pressurisation as an air spring, and for this reason, an accumulator is connected to the air line.
Control line Pressure regulator T05 regulates the pressure to the hot melt pump and thus
Depressurisation controls the amount of hot melt adhesive to be extruded.
Vacuum line
Valve panel
Y08 consists of a vacuum ejector and two valves. When the righthand valve is
activated, compressed air flows from port 1 to port 3 and, due to the ejector
Valve cabinet
effect, a vacuum is generated at port 2, to which the suction cups are
connected. When the lefthand valve is activated, compressed air is supplied
directly to the suction cups, which thus are receive a blast of air, releasing their
suction and blowing their ducts clear.
Silencer Z2 is common to the whole pneumatic system.
The designations in the diagram follow a certain system, usually consisting of
a letter and a number. The components which the compressed air comes to first
are given the same number, in this case 1, but different letters to denote their
functions: A for manual valve, Z for filter, and T for pressure regulator. The
number of a valve, for instance Y02, determines the numbers of the following
components. The output lines from the valve are given numbers beginning
with 2, followed by the number of the outlet port, i e numbers 22 and 24. The
cylinder is designated C2.
Whenever setting is done in the pneumatic system, it is important to do it i the
right order:
1input pressure
2speed (throttle check valves or valve throttles)
3dampening (end position dampers in cylinders)
Symbols
The following table, which is an excerpt from the Tetra Pak Standards (DS
208.35), lists the symbols that are normally used in our pneumatic diagrams.
Symbol Meaning
Single–action cylinder with return

stroke by spring.
Double–action cylinder with

single–ended piston rod.
Double–action cylinder without pis-

ton rod.
Double–action cylinder without pis-

ton rod, with variable dampening at
both end positions.
Double–action cylinder with variab-

le dampening at both end positions.
Double–action cylinder with variab-

le dampening at both end positions
and magnetic piston.
Torque cylinder.
2/2 directional control valve,

controlled by pressure acting
against return spring.

controlled by solenoid with
return spring.
3/3 soft–start valve.


controlled by solenoid with return
spring.

controlled by solenoid valve with
separate air supply.

controlled by solenoid in both
directions.
5/3 directional control valve, closed

in middle position, controlled by
solenoid and return spring.
5/3 directional control valve, open

in middle position, controlled by
solenoid and return spring.
Variable throttle valve.
Non–return valve with variable

throttle check.
Rapid–exhaust avlve.
Pressure regulator with relief port,
spring controlled. Adjustable spring
force.
Shut–off valve with exhaust port.
Silencer
Accumulator
Separator with water trap and

automatic drain.
Lubricator.
Air conditioning unit,

consisting of filter, pressure regula-
tor, pressure gauge, and lubricator.
Pressure gauge.
Electric pressure switch with

change–over contact and
variable pressure setting.
Magnetic piston sensor.
Ejector.
14
Cleaning

Cleaning In Place
Introduction
Cleaning In Place is usually shortened CIP. It is a method used for cleaning of
filling machines and process equipment without having to disassemble them.
A production cycle is always completed with CIP. It is important to clean
directly after the end of the production in order to prevent the product from
getting dry and that the microbiological growth does not start.
What is cleaned with CIP?

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

C
Lower filling pipe
B A
Control valve
Cleaning device
Hot air
Preheated and
cooled air resp.
Steam
Product
The figure shows two filling machines. The upper
Detergent machine is in production and the lower one is
being cleaned.
The filling machine is cleaned separately, in most cases with a separate

cleaning device, intended only for cleaning of the filling machine.
On machines with a lower filling pipe, the lower filling pipe is cleaned
manually. This method is called COP which is an abbreviation of Cleaning
Out of Place.
What is required for cleaning?
There are four important cleaning factors
• Flow
A turbulent flow of water is required to remove product remnants. This is
achieved by the speed of the detergent which is 1.5-3.0 m/min. The flow
must be at least 8000 l/h in order to reach this speed in the AP-valve.
• Chemicals
Chemicals are used to dissolve the product remnants.
• Temperature
Correct temperature of the detergent is important to dissolve the product
remnants.
• Time
It is essential that the detergent maintains contact with the product remnants
long enough in order to be able to dissolve them.
The effects of the chemicals

The product remnants contain sugar, fat, protein, salt, and minerals. Warm
water is sufficient to dissolve sugar. But to dissolve fat and protein a strong
alkali is required. Salt and minerals are a very small part of the product and
they usually disappear with the other dissolved components of the product Alkali = NaOH
remnants. In cases where salt and minerals do not disappear, acid has to be NaOH = Caustic soda
used. The quantity of salt and mineral deposits varies due to the degree of
hardness of the rinsing water and the pH-value of the product.
WA
TE
ID
AC
Salt and
mineral Sugar
Protein Fat
ALK ALI
The figure shows applicable chemicals that dissolve

the product remnants. Water is used to dissolve
sugar. But to dissolve fat and protein alkali is
needed. When salt and mineral deposits remain,
acid is required.
The ladder in the cleaning programmes
The contents of a cleaning programme may vary. On the whole, however, two
cleaning programmes are used, daily cleaning and weekly cleaning.
Daily cleaning Daily cleaning is done once per day and includes the following steps:
1. Cold rinsing
Cold water forces product remnants out of the pipes.
2. Warm rinsing
Warm water dissolves sugar and heats the pipes before the alkali cleaning.
3. Alcali cleaning
Alcali dissolves fat and proteins.
4. Cold rinsing
Cold water forces alkali and product remnants out of the pipes.
5. Final rinsing
Final rinsing takes place until the pH-value of the rinsing water, which
comes out of the pipes, is equal to incoming water.
Weekly cleaning If too many lime deposits have been built up in the pipes, a weekly cleaning is
performed after the daily cleaning. This can be done as often as required.
Weekly cleaning includes the following steps:
6. Acid cleaning
Acid cleaning dissolves salt and minerals.
7. Cold rinsing
Cold water forces the acid out of the pipes.
8. Final rinsing
Final rinsing takes place until the pH-value of the rinsing water, which
comes out of the pipes, is equal to incoming water.
Final cleaning and intermediary cleaning

The worst that can happen in connection with the production of food is that
toxic components enter the product. Since strong alkalis and acids are used for
cleaning it is important to check that no detergent can leak into the product.
Final cleaning Before final cleaning can start, make sure that there is no product in the
product line. Then turn a key and choose final cleaning. This is one of the ac-
tions for the daily care. Tetra Pak recommends that final cleaning takes place
once per day.
Steam
A
Water
Air B
Detergent
AP-valve, cleaned by final cleaning.
Detergent
Intermediary cleaning is used only if you have to clean the filling machine Intermediary cleaning
while there is still product in the product line. The AP-valve has a steam bar-
rier which prevents the detergent from leaking into the product. This also
means, however, that the space in the steam barrier will not be cleaned. This
space will be cleaned only at the final rinsing procedure.
Steam A
Product
B
Water
Air AP-valve, cleaned by intermedi-
Detergent ary cleaning.
15
Sterile air system

Lund, Sweden
Aseptic food processing

Machine type
Sterilized
packaging
material
Sterile
surrounding
Issue
1/9501
Commercially Aseptic
sterile food transfer
OH 525
Aseptic packages
Sterile system overview
Lund, Sweden
Air
Peroxide
Aseptic chamber Product
Water
Machine type
TBA/8, 9, 19, 21
Packaging material
Issue
1/9610
Peroxide bath
OH 613
Compressor Peroxide tank

Tight tube
Air superheater
Scrubber
Water
Air

Lund, Sweden TBA/8, TBA/19 1/9501 OH 493
Principle of constant flow valve
Rubber ring Constant

flow rate
of water
Water with
fluctuating
pressure
Water at low Constant

pressure flow rate
Water at high
pressure Constant
flow rate

Lund, Sweden 1/9904 OH 819
Water separator
Water
Air

Lund, Sweden TBA/8, TBA/19 1/9501 OH 494
Sequence"Spray" Pos 3 TBA/8 1100
0 10 20 30 40 50 60 70 80 90 100 110 120
%R1039
120 sec.
Level Sensor
Fill Tank
Y 34
Spraying
Y 35
Filling Ch Fast
Level Spray *"0" Emp
Tank tying
0-19 5 24-45 Slow 60 * "0"
Preheating Air Inlet "2"
Heatexhanger
Valve Y 44
Alarm T0 "2"
Pos. Air Inlet Valve

M.B 71
Valve B
Y8
Pos. Valve B
M.B 53 Alarm T0 "2"
Hydr. Pump
K9
Bending Roller
%Q0174
Peroxide Pump
K 11
* Venting 15 Min
Sequence Diagram TBA/8 1100

Issue 9906
"Drying Time" Pos 3 TBA/8 1100
0 5 10 15 20 25 30 Min.
(300) (600) (900) (1200) (1500) (1800) Sec.
%R1100
1500 sec.
Bending Roller
%Q0174
Valve B
Y8 Alarm to "0" And Venting 15 Min.
Off 1.5 Min

Peroxide Pump
K11
On 3.5 Min
Lower
Suction Valve
Y71
Flap air + EL
LS Temp 2
300
%R1000
Sequence
Peroxide pump

Issue 9906
Sequence"Start" Pos 4-5 TBA/8 1100
0 5 6 7 8 9 10 12 14 16 18 20
11 13 15 17 19 Sec .
%R300
Peroxide Pump
K 11
(On = Closed)
Drain Bath
Y5
Fill Bath
Y6 (On = Closed)
Level drop
max 3 sec
Level Sensor Level check
M.B 34 16 sec "3"
Top Fill
Y 18 (On = Closed)
Upper
Suction Valve
Y 23
9.9 sec. Pos. Monitor M.B 47
Air Knife M.B 46
Squeezing Rollers Alarm "3"
Y 21
6.5 sec. 9.2 sec
Short Stop Element
Y 20
9.0 sec.
LS/SA Element
Y 24
6.0 sec. 9.9 sec.
Counter Roller
Y 26
Valve C
Y7
Drive Motor *
K2
Air Compensation
Valve
Y 70
Lower
Suction Valve
Y 71
9.5 sec. Temp. check M.B 61
Temp. Peroxide "3" Alarm
A 213
Issue 9906 * Bending roller start when K2 is energized .
"Production"
" Pos. 6 TBA/8 1100
*
0 1 2 3 4 5 6 7 8 9 10 Min.
300-0 300-0
%R1000
5 Min.
60 Sec. 60 Sec.
Peroxide pump
K11
Top Fill Valve 35-40 35-40

Y18
10 Sec + 28 packages
Valve A
Y9
Bending Roller
%Q0174
TS Sealing On
Air Compensation
Valve
Y70
Drive Motor
K2
* 18 sec. End of sequence start

Issue 9906
"Normal stop" Pos 5-4 TBA/8 1100
0 10 20 30 40 50 60 Sec.
8 sec.
Drive Motor
K2
8.1 sec.
Mech. Brake
K4
5 sec.
Valve C *1
Y7
8.5 sec.
LS/SA Element
Y24
Air Knife
9.0 sec.
Squeezingrollers
Y21
2,5 min
Peroxide Pump *2
K11 60 sec.
8 sec. 2,5 min

Drain Bath *2
Y5
8 sec. 2,5 min

Fill Bath *2
Y6
10 sec
Final Folder
%M1912
Lower Suction 8 sec.

Valve
Y71
Valve A
115¡ 8
Y9
315¡ 8
Air Compensation 8 sec.
Valve
Y70
3 packs
Trap Door
Y27
*1 Mechanical Delay 6-12 sec.

*2 Goes into %R1000 sequence after the 2.5 min.
1.5 min off. 3.5 min on
Issue 9906
"Short stop" Pos 6 TBA/8 1100
0 10 20 30 40 50 60 70 80 90 Sec .
Drive Motor
K2
0.4 sec.
Mech. Brake
K4
0.5 sec.
LS/SA Elements
Y24
Air Knife 1 sec.

Squeezingrollers
Y21
2.5 min
*1
Peroxide Pump 60 sec.
K11
2.5 min
Drain Bath *1
Y5 60 sec.
2.5 min
Fill Bath *1
60 sec.
Y6
10 sec.
Final Folder
%M1912
11 sec.
Upper
Suction Valve
Y 23
Lower
Suction Valve
Y 71
55-65 sec.
Air Compensation
Valve
Y70
Valve A
Y9
Trap Door
Y27
15 min.
Time Limit
Short Stop
%R0700 15 min.
*1 Goes into %R1000 sequence after the 2.5 min.
1.5 min off. 3.5 min on

Issue 9906
" Venting and Vacuum " Pos 7 TBA/8 1100
0 5 10 15 20 25 30 60 Min
%R1215
Compressor
K10
Venting
P.H 123
Cutting of packaging material

Door aseptic
chamber
P.H 124 Door open fixed
Vacuum valve
Y86
Evacuation
Y54
Pre heating
Air inlet
Heat exch
Y44
Peroxide pump
K11
Upper
Suction valve
Y 23
Step up
P.H 30 "Step up " flashes when doors are closed

Issue 9906
"Venting and Vacuum " Pos 3-0 TBA/8 1100
0 5 10 15 20 25 30 60 Min
%R1215
Compressor
K10
Venting
P.H 123
Door aseptic
chamber
P.H 124 Doors open fixed
Vacuum valve
Y86
Spray tank *
Filling 30 sec
Y 34
Pre heating
Air inlet
Heat exhanger
Y44
Peroxide pump
K11
Upper Suction
valve
Y 23
B-Valve
Y8
Step down
P.H 31
" Step down " flashes when doors are closed
* Spray tank air M.Y 35 on

Issue 9906
Sterile System
Sterile System
Issue 950131
159
Sterile System
1. Compressor 36. SA element

2. Water separator 37. SA fan
3. Level switch 38. Filter
4. Vacuum valve 39. Spray tank
5. Sterile air pressure 40. Valve, filling spray tank/spraying peroxide
6. Heat exchanger valve 41. Valve, overflow spray tank/compressed air
7. Heat exchanger 42. Filter
8. Air superheater temp. 43. Water bath heater
9. Air superheater 44. Peroxide bath temp.
10. Silencer 45. Pressure switch, level in water bath
11. Presterilization temp. 46. Venting pipe
12. Presterilization valve 47. Valve, refilling peroxide
13. Spray nozzle 48. Valve, filling peroxide bath
14. Steam trap 49. Valve, draining peroxide bath
15. Steam temperature 50. Safety cap
16. Sterile air valve 51. Peroxide pump
17. Steam barrier valve 52. Filter
18. Steam filter 53. Diluting tank
19. Product valve 54. Peroxide container
20. Aseptic chamber 55. Venting pipe diluting tank
21. Driven bending roller 56. Strainer
22. Air knife 57. Lower suction valve.
23. Squee-gee rollers 58. Preheating valve
24. Air knife temp. 59. Preset air inlet
25. Level sensor, peroxide bath 60. Air compensation valve
26. Seal 61. Lower filling pipe
27. Diaphragm valve 62. Upper filling pipe
28. Sterilization bath 63. Seal
29. Water bath temp. 64. LS counter roller
30. Valve, top filling peroxide bath 65. Ejector
31. Adjustment screw 66. Pressure relief valve
32. Upper suction valve 67. LS short stop element
33. SA pressure- and counter roller 68. LS element
34. SA short stop element 69. LS element temp.
35. SA element temp. 70. Scrubber

Sterile System
Issue 950131
159
Sterile system 24 A 13
TBA/8
Lund, Sweden
100V
22
21
A4 12 23 33
11 18 26 31
13
17 25 27
10 20 32 A 11 35
34
A6
14 36
Machine type
14 29
39
28
15 A5
40
13 13 37
41
19
TBA/8 100V
30
42
16
5 43 Water bath heater
MB18 38 44 Peroxide bath temp.
68 45 Pressure switch,
43
6 69 A 12 level in water bath
4 46 Venting pipe
46
47 Valve, refilling
9 peroxide
48 Valve, filling
64 peroxide bath
48
Issue
MB 61 44 49 Valve, draining
65
peroxide bath
1/9501
67
56
7 45 50 Safety cap
49
51 Peroxide pump
3 66 63
2
52 Filter
47
53 Diluting tank
62 54 Peroxide container
70 55 Venting pipe
58
61 57 diluting tank
50 52
54 56 Strainer
OH 483:1
57 Lower suction valve

58 Preheating valve
59 50 59 Preset air inlet
1 55 60 Air compensation
A 10 8 60 51
valve
61 Lower filling pipe
1 Compressor 10 Silencer 62 Upper filling pipe
2 Water separator 11 Presterilization temp. 53 63 Seal
3 Level switch 12 Presterilization valve 64 LS counter roller
4 Vacuum valve 13 Spray nozzle 65 Ejector
5 Sterile air pressure 14 Steam trap 19 Product valve 24 Air knife temp. 28 Sterilization bath 32 Upper suction valve 35 SA element temp. 40 Valve, filling spray tank/ 66 Pressure relief valve
6 Heat exchanger valve 15 Steam temperature 20 Aseptic chamber 25 Level sensor, 29 Water bath temp. (Diversion valve) 36 SA element spraying peroxide 67 LS short stop element
7 Heat exchanger 16 Sterile air valve 21 Driven bending roller peroxide bath 30 Valve, top filling 33 SA pressure− and 37 SA fan 41 Valve, overflow spray 68 LS element
8 Air superheater temp. 17 Steam barrier valve 22 Air knife 26 Seal peroxide bath counter roller 38 Filter tank/compressed air 69 LS element temp.
9 Air superheater 18 Steam filter 23 Squee−gee rollers 27 Diaphragm valve 31 Adjustment screw 34 SA short stop element 39 Spray tank 42 Filter 70 Scrubber
Sterile system TBA/8 100V
Preheating
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:2
Air Steam
Hot air Product Peroxide
Pre−heated air Water Compressed air
alt. cooled air
Sterilization 1
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:3
Air Steam
alt. cooled air
Sterilization 2
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:4
Air Steam
alt. cooled air
Production
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:5
Air Steam
alt. cooled air
Short stop
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:6
Air Steam
alt. cooled air
Ventilation
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:7
Air Steam
alt. cooled air
Vacuum
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:8
Air Steam
alt. cooled air
Intermediate cleaning
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:9
Steam Peroxide
Product Compressed air
Water Cleaning liquid
Final cleaning
Lund, Sweden
Machine type
TBA/8 100V
Issue
1/9501
OH 483:10
Steam Compressed air

Water Cleaning liquid
Peroxide Cleaning liquid
TETRA
Heat reduction in aseptic chamber, TBA/8

PAK
Valve positions
Lund, Sweden
Preheating Spraying Drying Start

Tight tube Drying Last 5 minutes Empty tube
Machine type
TBA/8 090V
Open until A−valve opens
Production Short stop Short stop Normal stop

Issue
From 11 to 60 seconds From 60 seconds

1/9210
OH 458
Open from Open 8 first seconds

55 to 65 seconds
16
Peroxide system

Peroxide system TBA/8 090V
1 Overflow tanks
2 Peroxide bath
3 Water bath
4 Level sensor, peroxide bath
5 Heating coil, peroxide
6 Level pipe
13 7 Water bath temp.
8 Valve, top filling peroxide bath
9 Water bath heater
10 Peroxide bath temp.
11 Valve, draining water bath
1
12 Pressure switch,
level in water bath
2 13 Spray nozzles
3
14 Spray tank
15 Spray tank, low level
16 15 16 Spray tank, high level
4 17 Valve, filling spray tank/
7 spraying peroxide
5 14 18 Valve, overflow spray
tank/compressed air
19 Filter
17 20 Valve, refilling peroxide
8 21 Venting pipe
6
18 22 Valve, filling peroxide bath
23 Valve, draining peroxide bath
24 Safety cap
19 25 Peroxide tank
26 Peroxide tank, high level
27 Peroxide tank, low level
28 Peroxide pump
29 Filter
30 Valve, draining peroxide tank
9 31 Valve, draining to diluting tank
32 Valve, draining diluting tank
33 Diluting tank
21 20 34 Peroxide container
10
22
11
12 23
26 24
Water 34 27 25 29
Peroxide
Compressed air 24
28
31
33 30
32

TETRA
PAK Lund, Sweden TBA/8 090V 1/9302 OH 452:1
Filling spray tank
Water
Peroxide
Compressed air

TETRA
Spraying
Water
Peroxide
Compressed air

TETRA
Filling peroxide bath
Water
Peroxide
Compressed air

TETRA
Top filling
Water
Peroxide
Compressed air

TETRA
Draining peroxide bath
Water
Peroxide
Compressed air

TETRA
Alarm spray system
Water
Peroxide
Compressed air

TETRA
Peroxide handling TBA/8 1100
PREHEATING
( Filling of H2 O2 tank )
1 3 5 7 9 11 13 15
0 2 4 6 8 10 12 14 16 28 Sec
Alarm
P.H 064
High level
M.B 83:2
Refilling H2O2
M.Y 38
PREHEATING
( Alarm )
1 3 5 7 9 11 13 15
Sec
0 2 4 6 8 10 12 14 16 28
Alarm
P.H 064
High level
M.B 83:2
New container
Refilling H 2O2
M.Y 38

Issue 9906
PRODUCTION
(Level OK no refilling)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Min
Alarm
P.H 64
28 sec sensor check
Low level
M.B 83:1
Refilling
M.Y 38
Peroxide
pump
%R1000
PRODUCTION
(Level low refilling)
0 1 2 3 Min
Alarm
P.H 64
Low level
M.B 83:1
Refilling
M.Y 38
Sensor check 28 sec

Peroxide
pump
%R1000
60 sec 28 Alarm

Issue 9906
PRODUCTION
(Level low empty container)
0 Min
Alarm
P.H 64
High level
M.B 83:2
Low level
M.B 83:1
New container
Refilling
M.Y 38
Peroxide
pump
%R1000
Short stop
60 Sec 28 Alarm 15 Min 60

Issue 9906
PRODUCTION
(Level to high)
0 Min
Drive motor
Alarm Flashing
Alarm Tank
High level Alarm off
Emptying bath
High level
M.B 83:2
Low level
M.B 83:1
Peroxide
Pump
Fill,Drain
Bath
M.Y 5
Drain
Bath
M.Y 6
Alarm
Reset
Man,draining
Tank
Sensor check 28 sec "3"

Issue 9906
Peroxide handling TBA/8
Draining diluting tank
Compressed air
Peroxide
Water
TETRA
Emptying peroxide tank
Compressed air
Peroxide
Water
TETRA
Filling new peroxide
Compressed air
Peroxide
Water
TETRA
TETRA

PAK
Diluting peroxide during compressor run

Lund, Sweden
Machine type
TBA/8 090V
A l/min B l/min
Issue
1/9208
approx. X l/min from

water separator
OH 454:4
Water
Peroxide
Compressed air
Peroxide filling station
Peroxide
Compressed air
Vacuum

Lund, Sweden Tetra Brik Aseptic 1/9609 OH 594
Tetra Brik Packaging Systems
General 1(26)
No: 1:3/96 (Issue 3)
Date: Oct 97
TECHNICAL BULLETIN Internal Information
Specifications of Hydrogen Peroxide in TBA packaging

machines
This Technical Bullettin replace the previous issues 1 and 2, recommending

new specifications for Hydrogen Peroxide suitable for Tetra Brik Aseptic
packaging machines.
The new specifications are in Table 1.
Hydrogen Peroxide must comply with the specifications at the delivery to the
customer; dilution or any other chemical manipulation at the food plant is
explicitly excluded from the specifications.
Issuer: Pollastri Marco

TB 1:3/96 (Issue 3) 2
Technical Specifications
Parameter Value
Chemical H2O2
designation
Quality Food Grade
Aseptic Grade
Packaging grade
Concentration 35% ÷ 40% w/w
Appearance Clear, Colourless
Density at 20°C (g/l) 1132 ÷ 1153
Stability ≤5%
(relative percentage (ISO method n.
of titration loss after 7161)
16 hours at 96 ˚C)
Acidity ≤ 5 meq/l
Phosphate ≤ 100 ppm
Phosphate as P ≤ 35 ppm
Arsenic (As) ≤ 1 ppm
Lead (Pb) ≤ 1 ppm
Copper (Cu) ≤ 1 ppm
Iron (Fe) ≤ 0.1 ppm
Tin (Sn) ≤ 10 ppm
Heavy metals ≤ 10 ppm
(as Pb)
Index of pH 2÷4
Chloride < 1 ppm
Non volatile matter ≤ 150 ppm
(at 105 °C)
Table 1
TB 1:3/96 (Issue 3) 3
The new specifications of Tetra Brik Packaging Systems are fully implemented
as of January 1st, 1997.
REASONS
The new specifications were introduced because of the new technologies to
produce Hydrogen Peroxide developed in the last years.
These technologies allow a purer product.
The use of purer Hydrogen Peroxide, while retaining stability, will reduce
residues on spray nozzles and on squeezing rollers, thus reducing the need
for maintenance operations on the filling machines.
In fact this is not a real change because most of products (Hydrogen Peroxide
Food Grade) currently on the market have values of the listed parameters
within the new Tetra Brik specifications (even if the technical schedule
normally attached to the product reports old Tetra Pak recommendations).
EXPLANATION OF ITEMS
In order to help our customers to choose the best product, here is some
general information about the most important parameters which are normally
found in the technical schedules given with the product.
This Technical Bullettin fixes a general reduction of stabilizers and residues

after ignition of Peroxide. Therefore, to be sure that the Peroxide has the right
features, a new parameter, the Stability, was introduced.
Stability This parameter gives an indication on stability against

decomposition of Hydrogen Peroxide.
The stability is measured as relative percentage of titration loss
by heating a sample of Peroxide for 16 hours at 96°C (Method n.
7161 by ISO). The more Hydrogen Peroxide is decomposed, the
more unstable the product is.
Therefore this parameter has to be as low as possible.
TB 1:3/96 (Issue 3) 4
Density: is strictly related to the concentration of Peroxide and to the

temperature.
The higher the density, the higher the concentration of Peroxide
is.
The higher the temperature, the lower the density of Peroxide is.
35% Hydrogen Peroxide at 20 °C has a density of 1.132 Kg/l
50% Hydrogen Peroxide at 20 °C has a density of 1.195 Kg/l
Check the density of Hydrogen Peroxide at temperatures
different from 20 °C by using the nomogram on the OM
Ortophosphate or Pyrophosphate or Phosphor:

These parameters are related to a family of stabilizers inside the
Peroxide.
A Peroxide quality with a low amount of Phosphate will give a
low amount of deposits in the filling machine.
The higher these values, the higher the amount of residues on
squeezing rollers and in spray nozzles (in the same operating
time of the machine).
However, with too low stabilized Hydrogen Peroxide it may be
difficult to keep a proper Hydrogen Peroxide concentration; be
sure that the Peroxide quality under exam is formulated for bath-
machines and not for spray-machines (those which use
Peroxide spray for package sterilisation). Spray-machines need
less stable Hydrogen Peroxide.
The new limits fixed by Tetra Pak for phosphor-based stabilizers
are:
Phosphor: ≤ 35 ppm
Phosphate: ≤ 100 ppm
Pyrophosphate: ≤ 100 ppm
Heavy metals (as Pb):

Heavy metals break down the Peroxide very quickly.
The decomposition of 35% w/w Peroxide is very dangerous
owing to the large volume (nearly 130 liters) of oxygen delivered
from every liter of decomposed Peroxide.
Therefore it is fundamental that this parameter is as low as
possible.
The words “as Pb” are related to the detection method.
TB 1:3/96 (Issue 3) 5
Heavy metals in question are Pb (Lead), Cu (Copper), Zn (Zinc),

Ni (Nickel), Cr (Chromium), Cd (Cadmium), Pd (Palladium), Hg
(Mercury).
Iron (Fe): Iron, as well as heavy metals, breaks down the Peroxide.
Therefore it is important that its concentration is as low as
possible.
It is separately considered because
- it is a very common element
- its catalytic decomposition activity is stronger than other
heavy metals
Tin (Sn): This parameter is related to another class of stabilizers

Its value has to be lower than 10 ppm.
Non volatile matter or Residue on Evaporation:

This parameter shows the total content of stabilizers and
impurities after complete evaporation of a known quantity of
Peroxide.
The higher this value, the higher the amount of residues on
squee gee rollers and in spray nozzles (in the same operating
time of the machine).
The new limit fixed for this parameter by Tetra Pak is 150 ppm
IMPORTANT: If it is needed to evaluate the quality of a product from the

analysis of the technical schedule it is very important to distinguish between
Specifications and Typical values:
Specifications: These values are guaranteed by the producer of

Hydrogen Peroxide.
This means that the parameters of the Hydrogen Peroxide
must correspond to the technical specification written on
technical schedule.
Typical values: These values are generally calculated as average values

over a certain period of production of the plant.
TB 1:3/96 (Issue 3) 6
In practice these values are not guaranteed: this means that

the producer is not to be held liable in case of non compliance
of the product with the technical schedule.
Should you have any doubt with regard to the matter, please contact:
Giacomo Tarzia c/o
Via Delfini 1, 41100 Modena, ITALY
Tel. +39 59 898632; Fax +39 59 898370
LIST OF PRODUCERS WITH COMPLYING GRADES

The following list contains names, addresses and telephone numbers of the
most important producers and distributors of Hydrogen Peroxide which have
Peroxide qualities whose specification match ours. Where known, the name of
the product has been reported.
The Hydrogen Peroxide qualities presented below, which are low stabilized,
have been thoroughly tested.
This list will updated:
- every time Tetra Brik Packaging Systems receives announcement on other
producers (or important distributors) and products;
- every time the producers in the list will report to T.B.P.S. any variation of
their product (name, formulation,...).
IMPORTANT
This list is not an unconditioned approval: producers on the list have
Hydrogen Peroxide of different qualities (Food grade, Technical grade,...).
The quality of the product suggested for the use on our machine has
always to be verified by the customer and specifications have to meet
Tetra Brik specifications as in Table 1.
Besides, this is not a restrictive list: Hydrogen Peroxide qualities from
other producers or distributors may be used, provided they meet the
specifications on Table 1.
The use of Hydrogen Peroxide qualities not complying with

the specifications of Table 1 is in any case under full
responsibility of the user.
TB 1:3/96 (Issue 3) 7
SUPPORT BY TETRA BRIK TO MARKET COMPANIES
Tetra Brik Packaging Systems, as product company, is globally responsible

towards the Market Companies for its products (among which packaging
machines) and for the chemicals suggested. Nevertheless, it is prerogative of
the responsibles of the Market Companies to suggest, U N D E R T H E I R T O T A L
RESPONSIBILITY , Hydrogen Peroxide qualities not in compliance with Tetra
Brik Packaging Systems.
Tetra Brik guarantees its complete availability and willingness to help Market
Companies in case their customers find problems possibly related to the
quality of Peroxide.
Tetra Brik will help by means of troubleshooting and analysis.
If some customer complains with a Market Company about Peroxide, the
Market Company may:
- call the responsible for chemical on use on Tetra Brik machines and/or
- send a sample of the Peroxide for analysis. Together with the sample
always send the following information. Samples which arrive without
these information, will not be analysed.
INFORMATION SCHEDULE
1. Market Company (address, telephone and fax number, contact person)

2. Hydrogen Peroxide supplier
3. Hydrogen Peroxide producer
4. Technical schedule of Peroxide
5. Reason for the choice
6. Frequency of Peroxide concentration control during production
7. Frequency of maintenance of spray nozzles and squee-gee rollers
8. Frequency of the total change of Peroxide in the tank (hours and
production hours)
9. Filled product
10. Type of packaging material
11. Type of problem
12. Frequency of problem
13. Date of the last Peroxide purchase
14. Peroxide drum size
TB 1:3/96 (Issue 3) 8
15. Information about Peroxide storage (Temperature, Bulk dimensions

and material, Exposure...)
16. Peroxide pouring system
17. Model and version of Packaging machine
18. Type(s) and P-Order(s) of packaging material
If there is other information which could be relevant, please attach it.

Always call before shipping a sample so it will be possible manage at best for
the analysis.
PEROXIDE SAMPLING AND SHIPPING INSTRUCTIONS

- Take a 0.5 liter sample in one 1000 ml PE bottle (PolyEthylene bottle).
- Important: Always take the sample from a new drum and carefully seal the
bottle.
- Place the bottles in a plastic envelope.
- Take a plywood box and fill it with 3 liters of absorbing material, which must
not be combustible.
- Place the bottles upright in the box and fill it up with chips to keep the bottles
steady.
- Place warnings for “CORROSIVE” and “OXIDIZING” on the plywood box and
marks for “THIS SIDE UP”.
- You have to write on the box that it is:
Hydrogen Peroxide aqueous solution 35% w/w, UN N° 2014.
- It is possible to send Hydrogen Peroxide by air, but it must be sent as
dangerous goods according to UN N° 2014 (Class 5.1; Sub. Risk 8;
Packaging group II; EPG 5EI).
- You also have to write a proforma invoice describing what it is and that it is
for the purpose of quality test with no commercial value.
- Do not forget the schedule with all information
Send to:
Giacomo Tarzia
c/o Tetra Brik Packaging Systems
Chemical Laboratory
Via Delfini, 1
41100 Modena
Italy
17
Electrical equipment

Level relay
Peroxide spray quantity
Filling tank
L 52 A1
L 50
A2
B1 B3 B2 18 16 15
L 11
To PLC
RM3 LA1
A1 A2
16
15
18
500k
26
25
Function 28 R−sector
25
30
1 35 (x0.1)
Time value s R−value (x10)

Lund, Sweden TBA/8 1/9905 OH 827:1
Level relay
Peroxide spray quantity
Spraying
L 52 A1
L 50
A2
B1 B3 B2 18 16 15
L 11
To PLC
RM3 LA1
A1 A2
16
15
18
500k
26
25
Function 28 R−sector
25
30
1 35 (x0.1)
Time value s R−value (x10)

Lund, Sweden TBA/8 1/9905 OH 827:2
Temperature controller
H − heating
(relay ON = yellow LED lit) C − without function
X − process value
W 2 lit with 2nd set point W − 1st set point
HCA − heating current error

LC1 − limit contact (current < limits = green LED lit)
(X within limits = green LED lit)
Selector key
Decrease value Increase value
N 16
27
15 Digital
230V
26 Mains Digital interface 14 Interface
115V 13
25
12
24 11
3 Alarm 1 Local (open) / remote L/R
23 10
1st set−point (open) 2nd set−point 9
W/W2
0/4...20mA
22 Continous output
2 Current converter 8
21 0/4 ... 20mA 9404 407 50001 7
Earth terminal 6
20 0 ... 10V
Voltage 5
4 Alarm 2 0/4 ... 20mV
19 Current 4
Pt 100 3
18 Heating (logic output) 0 2
1
0/>
_5V DC Typical 13 V DC
17
Thermocouple 1

Lund, Sweden 2/9910 OH 602
Temperature settings, principal
Temp °C
LOC
SPH
LCH 1
LCL 1
LCH 2
W2
LCL 2
SPL
Temperature regulator
Operator level
W Temperature 1 setpoint
Self turning
(To be done after change of any part, like cables or termocouple)
Press “selector key” and “increase key” simultaneously.
AdA will appear on the instrument during the operation (max 10 min)
Parameter level (Press selector key for 3 sec.)

SP 2 Temperature 2 setpoint
LCL 1 Lower OK limit setpoint 1
LCH 1 Upper OK limit setpoint 1
LCL 2 Lower OK limit setpoint 2
LCH 2 Upper OK limit setpoint 2
HCA Heating current limit
LOC 0 X and W display with adjustment, self turning permitted
LOC 1 X and W display with adjustment
LOC 2 X and W display but without adjustment
LOC 3 Only X display, W is off (on set-point adjustment)
SPL Lower setpoint limit 1, 2
SPH Upper setpoint limit 1, 2
Pb 1 Proportional Band Heating
ti Integral time
td Derivated time tv
t1 Cycle time heating
Configuration Level (Press selector key for 5 sec)

Con 1 Configuration (0230)
Con 2 Configuration (0000)
Error signals
FdF Sensor break
POL Wrong sensor polarity
AdF Self-tuning error
Thermocouple type K
Material: Nickel−Cromium v Nickel−Aluminium (NiCr − NiAl)

Voltage: DC 4mV / 100 C
Colour: Overall yellow
NiCr yellow positive
NiAl red negativ
Thermoelement
Temperatureregulator

Measurement correction
Measurement correction does not change the instrument calibration. However, the measured
value is modified by the amount of correction. The correction is valid for the overall measuring
range. Correction up and down is possible.
Caution:
During measurement correction, the controller outputs are switched off.
Perquisite for measurement correction: Measurement correction is only possible with a constant
measurement value. For this, a constant measurement value must be applied to the measurement
input (separate transducer).
In particular, the following steps are necessary:

1 Remove the instrument from the housing.
2 Close wire-hook switch A (near wire-hook LOCK)
3 Install the instrument in the housing.
4 After initialization, “CAL” is displayed in the upper display line, whereas the actual
measurement value with digit *) behind the decimal point, which shall be corrected by
a defined amount, is displayed in the lower line.
5 The display can be corrected by means of keys and .
6 After display of the required value, store by pressing key .

7 Remove the instrument from the hosing.
8 Open wire-hook switch A.
9 Install the instrument in housing.
After initialization, the controller starts controlling immediately, using of the corrected meas-
urement value.
Adjusting is possible at any time and as frequently as necessary.
To cancel the correction, repeat steps 1-4. Press keys and simultaneously to set cor-
rection value to 0. Now, continue with steps 7-9.
*) no digit behind the decimal point with thermocouple type R and type S.
After re-configuration, a new measurement correction is necessary.
KS 40 LOCK
Technical Training Centre 1/9610 TM-00040 Training Document. For training purpose only.
Solid state relay
4 1
Zero detection
Input Photo Trigger Power

And
circuit detector circuit circuit
+
3 2

Lund, Sweden TBA/21 TB/19 2/9812 OH 600
1 BE - LIST, ELECTRICAL EQUIPMENT
2 CE - LIST, ELECTRICAL CABINET
3 MACHINE
4 ELECTRICAL DOCUMENT
5 STANDARD EQUIPMENT
6 EXTRA EQUIPMENT
7 SPARE PARTS
8 CONTROL PANEL
9 SIDE PROTECTION
10 CIRCUIT DIAGRAM, POS. SUMMARY
11 DRAWINGS
12 LINE SUMMARY
AM: 19666
13 TERMINAL SUMMARY
14 PROTECTIVE BONDING
15 ALTERATION MESSAGES
Sign: BWM/JÅB
16
Date: 930630
PLC-DIAGRAM, LIST OF BLOCKS

17 LIST OF ADRESSES
18 VOLUME ADAPTION DOC.
19 FUNCTION DIAGRAM
TETRA PAK INDEX FOR TBA/8 - 100V
20 PROGRAM LIST
21 MOUNTING DRAWINGS
22 CONNECTION DIAGRAMS, DRAWINGS
23 MAINS CONNECTION
24 TERMINAL AND ALARMDISP. DRAWINGS
25 MACHINE DEVIATIONS
26 REBUILDING KITS
27
28
29
30
31
Date: 930630
TETRA PAK INDEX FOR TBA/8 - 100V AM: 19666
Sign: BWM/JÅB
8
5
4
2
9
7
6
3
1
11
18
13
31
30
29
28
27
26
25
21
20
17
15
14
12
24
23
22
19
16
10
6+((7,1 7(50,1$/6
/,1( 63$5(3$57 /2&$7,21
32612 &,5&8,7 )81&7,21 3/&,1287 &211(&7
92/7$*( 180%(5 210$&+,1(
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IS 960806 ELOVNING TBA-8

WB Tba8110v

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Course introduction 1

Automatic splicing unit 11

Hydraulic and lubrication systems 12

Water and pneumatic systems 13

Sterile air system 15

Technical Training Centre 19

Technical Training Centre

Technical Training Centre 1/9701 TM-00001

Technical Training Centre 2/9903 TM-00010 1

Valuables You are responsible for your own valuables.

Technical Training Centre 2/9903 TM-00010 2

Tetra Pak 1 Main Reception

Technical Training Centre 2/9903 TM-00010 3

Technical Training Centre

Long history, stable performance. The TBA/8 filling

Tetra Prisma Baseline Slimline Squareline

The Tetra Brik Aseptic system is based on the

Tetra Brik Aseptic packages offer a wide range of

Proper working environment

15. Element for the longitudinal sealing which

21 22. Discharge of finished packages.

The packaging material is supplied in standard or

The exterior of the filling machine is made entirely

Products in Tetra Brik Aseptic packages make

We reserve the right to introduce design modifications without

The machine packages liquid food in Tetra Brik Aseptic packages.

Capacity External cleaning system

Tetra Brik Aseptic packaging machine TBA/8 1100 (110V)

Dimension of package and packaging material

Package Packaging material

TBA 355 B 104 47 76 14000 185

B = Baseline S = Slimline Sq = Squareline

We reserve the right to introduce design modifications without

Workbook Tetra Brik TBA/8 100V

Workbook Tetra Brik TBA/8 100V

Workbook Tetra Brik TBA/8 100V

1. Door to valve panel

Workbook Tetra Brik TBA/8 100V

Workbook Tetra Brik TBA/8 100V

Workbook Tetra Brik TBA/8 100V

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

TBA/8 648022-110V. New development step.

Issuer: Pollastri Marco

OPTIONAL EQUIPMENT ................................................................................................................ 7

This new development step of TBA/8 named 1100 ( eleven

It is very important to be aware of that training is needed

A number of other improvements (below listed) are also

The first delivery date for this development step will be

We are convinced that this development step will make the

Steam pipe, protection plate

Knife holder spring (All volumes)

Single piece knife (All volumes)

Waved formed Volume flaps 500S

AUTOMATIC SPLICING UNIT

New knives holder

Paper holder improvement

Missed splice detector

Splice brake in Date unit

Adjustable strip guide

• GE FANUC replace TPMC

PLMS (Packaging Line Monitoring System)

PLMS Basic kit