BIBLE IG0174enV4

SIG Combibloc
Document on behalf of SIG Technology AG, CH-8212 Neuhausen am Rheinfall, Switzerland

Doc.-No.: I-G-0174-en lssue: 4 Pagel of 76
Title: Settings for 3~ Generation Aseptic Filling Machines
Distribution list
Direct distribution list (user, functions):

Receipt by distribution email resp. by direct supervisors:
GE&A Head of Equipment Egineering & Application — Theissen, Head of Global Microbiology-Laven
GR&D Head of Aseptic Technology- Geissler;
GM-GS Global Service Director-Klamke;
CBEU Head of Quality & EHS Europe- Flashar; Head of System Technology EU — R. Schmidt;
Head of Pre-sales & Engineering EU — L. Schneider
CBAM-S Head of Cluster- Hilst
CBAM-N Head of Cluster Service — Schneller
CBAP-S Head of Cluster Service - Kremp; Head of System Technology - Comsang
CBAP-N Head of Cluster AP-N — P. Shen ; Head of Regional Quality Management AP — J. Lee
CBME Chief Operating Officer — C. Alt
(If required direct users are not Iisted here, please forward the document to those users and inform
the owner)
Document owner (function) on basis of the organizational structure (must be filled out)
Owner: Head of Aseptic Technology
Process oriented ciassification on basis of the SIG process map (must be filled out‘J
Core-process: Business process

Primary-process Customer project management
Sub-process (level 1): Installation and handoverto customer
Sub-process (level 2):
Sub-process (level 3):
lssue Approval Registration 1 Release by Owner

formal approval
Date 25.09.201~9~ 20.2.2017 /IS.(23.1:? 3.2.2017
Signature ?~7j~ ~wo~/4 -
Name Christian Weiler Hanno i 1er Silke Kling Hanno G issler
Function GR&DI Competence GR&D/Head of Aseptic GR&D/ IAM 1 QM- GR&DIHead of Aseptic
Pool Aseptic Processing Technology Systems Technology
File: l-G-O1 74 Settings for 3rd Generation Aseptic Filling Machines

EDV Document pnntouts are not subject to the update information service
-
SIG
Schutzvermerk DIN ISO 16016 beachten.
The copying, distributon and utilization 01 this document as weil as the communication ot its contents 10 others without expressed authorization in prohibite
Offenders will be held hable tor the payment of damages. All nghts reserved in the event of Ihn grant of a patent, utility model or ornamental design registra
Document
Doc.-No.: I-G-0174-en Issue: 4 Page 2 of 76
Title: Settings for 3rd Generation Aseptic Filling Machines
Content
1 Aim, purpose ............................................................................................................................. 4

2 Scope ........................................................................................................................................ 4
3 Terms and abbreviations........................................................................................................... 4
4 Responsibilities ......................................................................................................................... 4
5 Description ................................................................................................................................ 5
5.1 General Notes ............................................................................................................... 6
5.1.1 Measuring of dynamic pressure with Prandtl tube in straight pipe segments.... 6
5.1.2 Measuring of dynamic pressure at preheating- and drying heads ....................... 7
5.1.3 Setting of static pressure at heater heads of bottom activation........................... 7
5.1.4 Procedure to set sterile air household .................................................................... 8
5.1.5 Procedure to set dedusting ...................................................................................... 9
5.1.5.1 Infeed Air (air pressure) .................................................................................................. 9
5.1.5.2 Dedusting with cyclone ................................................................................................. 10
5.1.6 Exhaust air ............................................................................................................... 11
5.1.7 Machine output ........................................................................................................ 11
5.2 Head Diagramm .......................................................................................................... 12
LCF 12
CFA 112 N001…N012 ............................................................................................................... 13
CFA 112 from N013 ................................................................................................................... 14
CFA 124 N001...N005 ................................................................................................................ 15
CFA 124 from N006 ................................................................................................................... 16
CFA 712-32 based on 112 ......................................................................................................... 17
CFA 724 N001............................................................................................................................ 18
CFA 724 from N002 ................................................................................................................... 19
CFA 1224 ................................................................................................................................... 20
CFA 310 und 312 ....................................................................................................................... 21
CFA 510, 510 FL und 512 .......................................................................................................... 22
CFA 810 ..................................................................................................................................... 23
CFA 812 ..................................................................................................................................... 24
CFA combidome 1012 N001, N002 and N005 ........................................................................... 25
CFA combidome 1012 N003, N004 and from N006................................................................... 26
CFA 612-31/32, 612-31 FL......................................................................................................... 27
CFA 612-35 ................................................................................................................................ 28
712-31, 712-31 FL based on 510 ............................................................................................... 29
CFA 505 FP................................................................................................................................ 30
CFA 706 FP und 606 FP ............................................................................................................ 31
CFA 812 Food ............................................................................................................................ 32
CFA 612 Food ............................................................................................................................ 33
CFA 512 Food ............................................................................................................................ 34
CFA 206 ..................................................................................................................................... 35
CFA 406 und 405 FP.................................................................................................................. 36
CFA 404 FP................................................................................................................................ 37
CFA 909 ..................................................................................................................................... 38
CFA 209 ..................................................................................................................................... 39
5.3 H2O2 – Dosing ............................................................................................................. 40
5.3.1 Spray values ............................................................................................................ 40
5.3.2 Spray air volumes ................................................................................................... 43
5.3.3 Spray air pressure ................................................................................................... 44
5.3.4 Monitoring of regulation ratio of H2O2-vaporisation heaters............................... 45
5.3.5 Temperatures of H2O2 vaporisation heaters, preheating, drying ........................ 47
SIG Combibloc Systems GmbH
Rurstraße 58, D - 52441 Linnich
Schutzvermerk DIN 16016 beachten.
Document
5.4 Parameter steam, condensate, pressure product tank........................................... 48

5.4.1 Sterilisation parameters, steam parameters, condensate barriers .................... 48
5.4.1.1Valve Assembly Aseptomag ......................................................................................... 48
5.4.1.2Valve Assembly Aseptomag, parameters for FL, FP.................................................... 49
5.4.1.3Valve Assembly Aseptomag Food................................................................................ 50
5.4.1.4Valve Assembly Rieger Standard ................................................................................. 51
5.4.1.5Valve Assembly Rieger, parameters for Condensate Barrier ....................................... 52
5.4.1.6Valve Assembly Rieger, parameters for Condensate Barrier at agitator ...................... 52
5.4.1.7Valve Assembly Aseptomag & Rieger, special parameters for Critical Factor Machines
(FDA) ............................................................................................................................ 53
5.4.2 Product tank pressure (valve assembly RIEGER and ASEPTOMAG) ................ 53
5.5 Production .................................................................................................................. 54
5.5.1 Parameter sterile product change ......................................................................... 54
5.5.2 Parameter drain product tank into cartons ........................................................... 55
5.6 Cleaning parameters .................................................................................................. 56
5.6.1 Temperatures cleaning media ................................................................................ 56
5.6.2 Flow rate ................................................................................................................... 57
5.7 Sterile air household .................................................................................................. 65
5.7.1 Settings for pressure differentials of filters .......................................................... 65
5.7.2 Limits and warning values sterile air pressure and exhaust air box.................. 66
5.7.3 Sterile- and Echaust Air Values ............................................................................. 68
6 Reference documents, appendix ............................................................................................ 76
7 Changes from preceding issue ............................................................................................... 76

Document
1 Aim, purpose
Instruction for Aseptic Settings of 3rd Generation machines.
2 Scope
The Instructions are applicable to:
 Global Technology
 GM – Global Service
 Global Assembly
3 Terms and abbreviations

PH Preheating
D Drying
HMI Human Machine Interface
FM Filling machine(s)
CT CombiTop activation tube
HST H2O2 sterilisation of the aseptic zone
NW Nominal width
A/AL high acid/low acid products
C Carton
L+/L- upper/lower limit value
A+/A- upper/lower alarm value
F Filling machine for food1) in general
FL Filling machine for liquid food1) (with inductive filling station)
FP Filling machine for particulate food1) (with product pumps)
1)
food (in this context): products different from juice and milk, e.g. with particulate
content or high viscosity
4 Responsibilities
Global Technology, Global Microbiology, Global Service

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5 Description
Setting for 3rd Generation Aseptic Filling

Machines
Note! Changes compaired to previous version are marked with grey background.
Attention! CONFIDENTIAL! For internal use only!

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5.1 General Notes
5.1.1 Measuring of dynamic pressure with Prandtl tube in straight pipe segments
A measuring shall only be carried out with a Prandtl tube (spare part n° 888 998 001) and
a U-pipe pressure gauge (spare part n° 820159453) connected therewith. In order to carry
out measuring, connect both outputs of Prandtl tube with U-pipe pressure gauge. Only
pressure checks with a Prandtl tube are allowed!
It is recommended to use the blue coloured liquid for measuring. This liquid has a low
surface tension and a density = 1. Use the liquid only one time, never backfill into the
bottle.
The measuring procedure is carried out with the pocket chain at standstill and with the
machine in operating mode "Aseptic production“.
Always carry out measuring across the pipe cross section, because flow conditions are
generally not uniform at all points.
More detailled information you can find in the document I-G-0191-de.
Note: 1 mbar = 10 mm WS = 100 Pa
Dynamic Pressure: p dyn  p ges  p stat


Pipe cross section:  
A m2 
4
 d 2 m
m 
 
 3
  4  Pdyn mmWS   A m  3600

2
Volume: V  h 

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5.1.2 Measuring of dynamic pressure at preheating- and drying heads
A measuring shall only be carried out with a Prandtl tube and a U-pipe pressure gauge
connected therewith. In order to carry out measuring, connect both outputs of Prandtl tube
with U-pipe pressure gauge. Only pressure checks with the Prandtl tube are allowed!
The measuring procedure is carried out with the pocket chain at standstill, with the
machine in operating mode "Aseptic production“ and with a temperature setting (HMI) of
the preheating- and drying heads of 100°C. (The preheating- and drying heads
automatically reduce their temperature to 100 °C at a standstill of the chain.)
Hold bent end of Prandtl tube slightly into head and move across cross section. Generate
an average value from the measured values. The tolerances amount to  2 mm wc.
Temperatures are correct when between default value and (default value -10 K).
5.1.3 Setting of static pressure at heater heads of bottom activation
In this case, the static pressure is checked. The measuring is carried out with the pocket
chain at standstill and with heaters „ON“ at 50 °C.
Test equipment:
 Measuring with U-pipe pressure gauge
Screw connecting piece onto heater head, which is connected to one output of a U-pipe
pressure gauge.
 Measuring with test device for bottom pressure
4 heater heads may be checked at the same time. A connecting piece is screwed onto
each heater head, where each one is connected to a pressure gauge with a tube.
Procedure:
see MI of filling machine

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5.1.4 Procedure to set sterile air household
Volume of infeed air

The pressure of infeed air is automatically controlled by a frequency drive at the sterile air
fan. The sterile air default pressure is set at the HMI (see Section 5.7, Sterile Air
Household). The measuring point for the sterile air pressure is located downstream the 2nd
sterile air filter.
The quantity of the infeed air is checked inside the infeed air tube using the Prandtl tube,
in order to ensure the volume of the air taken in. The result may deviate by approx.  100
m3/h from the value specified. Otherwise check, which sections have a surplus or lack of
air supplied to. Frequently, the reason is a lacking or incorrect sterile air orifice.
Setting of exhaust air volume

The following procedure is used to set the volume of exhaust air at the 3rd generation filling
machines:
1) Fully close HST flap at exhaust box
2) Fully open throttling flap at exhaust fan
3) Use the exhaust fan frequency to set total exhaust air volume specified for this filling
machine (see Section 5.7, Sterile Air Household)
4) Afterwards, open up HST flap, until the required volume flow (indicated by pressure
gauge at B-side of filling machine) is generated at the exhaust air box (settings see
Section 5.7, Sterile Air Household)*
5) Control the required volume at the exhaust air box by measuring with the Prandtl tube,
measuring point at vertical pipe between exhaust box and HST flap (settings see
following table)*
6) Check once again the required total exhaust air volume by measuring with the Prandtl
tube
FM Type(s) Pressure (see Measured value (using a
CFA pressure gauge) Prandtl-tube)
[mbar] [mmWS]
LCF, 505 FP, 706 FP, 606 FP 0,8 10
112, 712 (based on 112) (with 1,0 12
standard exhaust box), 206, 406,
405 FP
112, 712 (based on 112) (with 2,0 24
exhaust box containing 3 additional
holes)
310, 312, 510, 512, 510 FL, 810, 1,2 16
812, 612, 612 FL,
712 (based on 510), 712 FL,
812 Food , 612 Food,
512 Food, combidome 1012
209, 909 3,1 24/27
5,7 46/50
124, 724, 1224 4,6 35
* The difference of the values of 4) and 5) results from the turbulent flow
characteristics at the measuring point.

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5.1.5 Procedure to set dedusting
The settings for Cam ON/OFF and pressure have to be taken into the HMI. The pressure
is measured by the pressure monitor next to the valves. For adjusting the pressure (during
production) there ist a pressure reducing regulator on the other side of the valves.
The exhaust air volume can be measured inside the hoses from the exhaust hoods to the
exhaust piping by using the Prandtl-tube.
5.1.5.1 Infeed Air (air pressure)

FM- number of pressure Cam
Typ(en) valves (Setting HMI) Dedusting
CFA
ON OFF
112, 712 (on the 4 L+ 5000 mbar 60 ° 220 °
basis of 112) A+ 5000 mbar
Default value 4000 mbar
A- 3500 mbar
L- 3500 mbar
124, 724, 1224 6 L+ 5000 mbar 120 ° 340 °
A+ 5000 mbar
A- 3500 mbar
L- 3500 mbar
706 FP, 606 FP 2 L+ 5000 mbar 60 ° 220 °
A+ 5000 mbar
A- 3500 mbar
L- 3500 mbar
404 FP L+ 6100 mbar 30 ° 80 °
A+ 5900 mbar
A- 4900 mbar
L- 4700 mbar
812 Food, 4 L+ 5000 mbar 50 ° 150 °
612 Food, A+ 5000 mbar
512 Food Default value 4000 mbar
A- 3500 mbar
505 FP 2 L- 3500 mbar

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FM- number of pressure Cam

Typ(en) valves (Setting HMI) Dedusting
CFA
ON OFF
CFA combidome 4 L+ 6000 mbar 140° 170°
1012 A+ 5700 mbar
Sollwert 5200 mbar
A- 4700 mbar
L- 4500 mbar
5.1.5.2 Dedusting with cyclone
There are two points of dedusting.

1. magazine dedusting: just at the magazine the dust, which is driven over the edge oft
he magazin when opening up the sleeves, is caught with nozzles beneeth the open
sleeve
2. package dedusting: before the prefolding the dust in the packages is blown up by
infeed air and then sucked up by nozzles directly above the package
The dust-loaded air is collected and led to a cyclone seperator, to avoid spoilage of the
exhaust air with dust.
The collection bin of the cyclone should be emptied minimum once a week.
FM-Type(s) cyclone magazin package

CFA dedusting dedusting
112, 712 (auf inner diameter tube / pipe (mm) 80 40 40
Basis 112) dynamic pressure 1) (mmWS) 30
pressure gauge at HMI 2) (mbar) 5
frequency of fan3) (%) 100
124, 724, inner diameter tube / pipe (mm) 80 40 50
1)
1224 dynamic pressure (mmWS) 30
Combidome inner diameter tube / pipe (mm) 50 50 50
1012 dynamic pressure 1) (mmWS) 35
1)
determined with Prandtl tube in the pipe before the cyclone, if possible shortly above or
underneath the pressure gauge
2)
pressure gauge is located in the pipe before the cyclone
3)
setting in the HMI for frequency converter, only installed for first dedusting sets

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5.1.6 Exhaust air
FM-Type(s) B-side A-side

CFA
112, 712 (on the basis Inner diameter hose (mm) 40 40
of 112) Orifice (mm) none none
Volumen (m3/h)  75  75
124, 724, 1224 Inner diameter hose (mm)
Orifice (mm) none none
Volumen (m3/h)  
706 FP, 606 FP Inner diameter hose (mm) 40 not applicable
Orifice (mm) none
Volumen (m3/h)  95
404 FP Inner diameter hose (mm) 80
Orifice (mm) none
Volumen (m3/h) > 130
812 Food, Inner diameter hose (mm) 80 80
612 Food, Orifice (mm) 55 55
512 Food Volumen (m3/h) 300 300
5.1.7 Machine output
All setpoints in this instruction are referring to the standard machine output of each filling
machine type.
e.g.: CFA 612: Machine output 12.000 Packages/hour

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5.2 Head Diagramm
LCF
a b c d e f g
Direction of movement
of cartons
LCF
Head a B c d e f g
Function PH PH H2O2 H2O2 D D D
Diameter NW 15 NW 15 NW 15 NW 15 NW 15 NW 15 NW 15
Dyn. 28 28 28 28 28
pressure mmwc mmwc mmwc mmwc mmwc
Temp. 240 °C  5 200 °C  20 170 °C  5

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CFA 112 N001…N012

a b c d e f g
Direction of movement The head pattern

of cartons of tracks 3 and 4 is identical.
CFA 112, Mach. No. N001 to N012

Head a B c d e f g
Dyn. 22 22 20 20 20
Temp.
 200 ml 140 °C  5 270 °C  20 130 °C  5
250 ml 180 °C  5 160 °C  5
(1)
N002 in ECV (Linnich), Setting of Parameters after advise of GT / Aseptic Processing

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CFA 112 from N013

a b c d e f g

CFA 112, from Mach. No. N013 with old tunnel (870182752)
Head a B c d e f g
Dyn. 31 31 30 30 30
Temp.
125-150 ml 120 °C  5 270 °C  20 90 °C  5
200-250 ml 130 °C  5 120 °C  5
CFA 112, from Mach. No. N013 with new tunnel (870182041)
Head a B c d e f g
Dyn. 31 31 30 30 30
Temp.
125-150 ml 120 °C  5 270 °C  20 90 °C  5
200 ml 130 °C  5 120 °C  5
250 ml 160 °C  5 150 °C  5

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CFA 124 N001...N005

The head pattern
Direction of movement of cartons of tracks 4, 5 and 6 is inversely.
a b c d e f g
CFA 124 with H2O2 dosing A(F) 200 l/s (currently N003, N004)
Head A B c d e f g
Dyn. 31 31 30 30 30
Temp.
125 ml 120 °C  5 270 °C  20 90 °C  5
250 ml 130 °C  5 120 °C  5
CFA 124 with H2O2 dosing AL(F) 400 l/s (currently N001, N002, N005)
Head a B c d e f g
Dyn. 31 31 30 30 30
Temp.
125 ml 150 °C  5 270 °C  20 130 °C  5
250 ml 170 °C  5 160 °C  5

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CFA 124 from N006

The head pattern
a b c d e f g h
CFA 124 from Mach. No. N006 with old tunnel (873082410)
Head a B c d e f g
Dyn. 31 31 30 30 30
Temp.
125 ml 150 °C  5 270 °C  20 130 °C  5
200 ml 150 °C  5 130 °C  5
250 ml 170 °C  5 160 °C  5
CFA 124 from Mach. No. N006 with new tunnel (873082420)
Head a B c d e f g
Dyn. 31 31 30 30 30
Temp.
125 ml 120 °C  5 270 °C  20 110 °C  5
150 ml 130 °C  5 110 °C  5
180 ml 150 °C  5 130 °C  5
200 ml 150 °C  5 130 °C  5
250 ml 170 °C  5 160 °C  5

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CFA 712-32
based on 112
a b c d e f g

CFA 712 N001 to N004 are only approved for high acid
Head a b c d e f g
Dyn. 22 22 20 20 20
Temp.
150 ml 130 °C  5 270 °C  20 120 °C  5
200 ml 150 °C  5 130 °C  5
250 ml 180 °C  5 150 °C  5
300 ml 200 °C  5 160 °C  5
350 ml 220 °C  5 170 °C  5
CFA 712, from Mach. No. N005

Head a b c d e f g
Dyn. 31 31 30 30 30
Temp.
 200 ml 120 °C  5 270 °C  20 80 °C  5 (1)
250-300 ml 130 °C  5 120 °C  5
> 300 ml 160 °C  5 140 °C  5
(1)
It is allowed to change the temperature setting “pocket chain at standstill” from 100 °C to 80 °C
to avoid time of waiting after switch on of main drive.

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CFA 724 N001

The head pattern
a b c d e f g
CFA 724 N001

Head a b c d e f g
Dyn. 31 31 30 30 30
Temp.
150 ml °C  5 270 °C  20 °C  5
200..250 ml 150 °C  5 140 °C  5
350 ml 160 °C  5 140 °C  5

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CFA 724 from N002

The head pattern
a b c d e f g h
CFA 724 from Mach. No. N002

Head a b c d e f g
Dyn. 31 31 30 30 30
Temp.
150 ml 120 °C  5 270 °C  20 110 °C  5
200/250 ml 150 °C  5 140 °C  5
300/330/35 160 °C  5 140 °C  5
0 ml

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CFA 1224
The head pattern
a b c d e f g h
CFA 1224
Head a b c d e f g
Dyn. 31 31 30 30 30
Temp.
80… 90ml 130 °C  5 270 °C  20 120 °C  5
100.. 125ml 130 °C  5 120 °C  5
150ml 150 °C  5 140 °C  5
180ml 170 °C  5 160 °C  5

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CFA 310 und 312

a b c d e f g

CFA 310, 312

Head a b c d e f g
Diameter NW 19 NW19 NW 15 NW 15 NW 19 NW 19 NW 19
Dyn. 34 34 26 26 26
Temp.
 750 ml 170 °C  5 270 °C  20 140 °C  5
> 750 ml 230 °C  5 180 °C  5

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CFA 510, 510 FL und 512

a b c d e f g

CFA 510, Mach. No. N001 to N021

Head a b c d e f g
Dyn. 30 30 28 28 28
Temperatur
 750 ml 170 °C  5 270 °C  20 140 °C  5
> 750 ml 230 °C  51) 180 °C  51)
CFA 510, from Mach. No. N022, CFA 510 FL, CFA 512
Head a b c d e f g
Dyn. 34 34 26 26 26
Temp.
500 ml 100 °C  5 270 °C  20 100 °C  5
 750 ml 170 °C  5 140 °C  5
> 750 ml 230 °C  5 180 °C  5
1) If packaging material with laser CT shall be processed, the temperatures may be increased to
260°C for preheating and to 230°C for drying. When checking with the polarisation filter, the
inside surfaces of the cartons may be blue, but the bottom section shall not be overheated.

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CFA 810
a b c d e f g

CFA 810
Head a b c d e f g
Dyn. 34 34 26 26 26
Temp.
500 ml 130 °C  5 270 °C  20 120 °C  5
1) 1)
750 ml
1000 ml 170 °C  5 140 °C  5
CFA 810 mode Fresh

Head a b c d e f g
Dyn. 34 34 26 26 26
Temp.
ml 100 °C  5 270 °C  20 100 °C  5
1) Values must still be determined

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CFA 812
a b c d e f g

CFA 812 Mach. No. N001, N002

Head a b c d e f g
Dyn. 34 34 26 26 26
Temp.
500 ml 130 °C  5 270 °C  20 120 °C  5
1) 1)
750 ml
1000 ml 170 °C  5 170 °C  5
CFA 812 from Mach. No. N003

Head a b c d e f g
Dyn. 40 40 30 30 30
Temp.
500 ml 130 °C  5 270 °C  20 120 °C  5
750 ml 170 °C  5 170 °C  5
1000 ml 170 °C  5 170 °C  5
1)
Values must still be determined

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CFA combidome 1012

N001, N002 and N005
a b c d e f g

CFA combidome 1012 N001 bis N00X

Head a b c d e f g
Dyn. 35 35 23 23 23
Temp.
500 ml 170 °C  5 270 °C  20 170 °C  5
750 ml 200 °C  5 200 °C  5
960 ml 230 °C  5 230 °C  5
1000 ml 230 °C  5 230 °C  5

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CFA combidome 1012

N003, N004 and from N006
a b c d e f g

CFA combidome 1012 from N00Y

Head a b c d e f g
Dyn. 35 35 23 23 23
Temp.
500 ml 170 °C  5 270 °C  20 170 °C  5
750 ml 200 °C  5 200 °C  5
960 ml 230 °C  5 230 °C  5
1000 ml 230 °C  5 230 °C  5

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CFA 612-31/32, 612-31 FL

a b c d e f g

CFA 612-31/32 860651 001 to 012, CFA 612-31 FL 868651 001 and 002
Head a b c d e f g
Dyn. 30 30 26 26 26
Temp.
 250 ml 140 °C  5 270 °C  20 130 °C  5
> 250 ml 160 °C  5 160 °C  5
CFA 612-32 from 860651 013, CFA 612-31 FL from N003

Head a B c d e f g
Dyn. 38 38 32 32 32
Temp.
200 ml 120 °C  5 270 °C  20 110 °C  5
300..500 ml 140 °C  5 140 °C  5

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CFA 612-35
a b c d e f g

CFA 612-35 869651 001 to 004

Head a B c d e f g
Dyn. 38 38 32 32 32
Temp.
200 ml 120 °C  5 270 °C  20 110 °C  5
300..500 ml 140 °C  5 140 °C  5
CFA 612-35 from 869651 005

Head a b c d e f g
Dyn. 57 57 45 45 45
Temp.
200 ml 100 °C  5 100 °C  5
250..300 ml 120 °C  5 110 °C  5
350..375 ml 130 °C  5 270 °C  20 130 °C  5
400 ml 160 °C  5 160 °C  5
500 ml 200 °C  5 200 °C  5

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712-31, 712-31 FL
based on 510
a b c d e f g

CFA 712-31 and CFA 712-31 FL

Head a b c d e f g
Dyn. 30 30 26 26 26
Temp.
 250 ml 140 °C  5 270 °C  20 130 °C  5
> 250 ml 160 °C  5 160 °C  5

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CFA 505 FP
a b c d e f g
of cartons
CFA 505 FP
Head a b c d e f g
Dyn. 34 34 26 26 26
Temp.
 750 ml 170 °C  5 270 °C  20 140 °C  5
> 750 ml 230 °C  5 180 °C  5

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CFA 706 FP und 606 FP

a b c d e f g
of cartons
CFA 706 FP and CFA 606 FP Mach. No N001 to N003

Head a b c d e f g
Dyn. 28 28 26 26 26
Temp.
 250 ml 140 °C  5 270 °C  20 130 °C  5
> 250 ml 160 °C  5 160 °C  5
CFA 606 FP from Mach. No. N004

Head a b c d e f g
Dyn. 38 38 32 32 32
Temp.
1) 1)
 250 ml 270 °C  20
> 250 ml 220 °C  5 190 °C  5
1)
Values must still be determined

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CFA 812 Food

a b c d e f g

812 Food 8 000 P/h and 12 000P/h

Head a b c d e f g
Dyn. 34 34 25 25 25
Temp.
500 ml 130 °C  5 270 °C  20 120 °C  5
750 ml 155 °C  5 155 °C  5
1000 ml 155 °C  5 155 °C  5

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CFA 612 Food

a b c d e f g

CFA 612 Food

Head a b c d e f g
Dyn. 48 48 37 37 37
Temp.
200 - 400 ml 120 °C  5 270 °C  20 110 °C  5
500 ml 200 °C  5 220 °C  5

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CFA 512 Food

a b c d e f g

CFA 512 Food 10 000 P/h and 12 000 P/h

Head a b c d e f g
Dyn. 34 34 26 26 26
Temp.
500 ml 100 °C  5 270 °C  20 100 °C  5
 750 ml 170 °C  5 140 °C  5
> 750 ml 210 °C  5 170 °C  5

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CFA 206
a b c d e f g h i
Direction of movement of cartons
CFA 206
Head a b c d f g h i
Function PH PH PH H2O2 D D D CT2)
Diameter NW 21 NW 21 NW 21 NW 15 NW 21 NW 21 NW 21 NW 15
1)2)
Dyn. 36 36 36 36 36 36
pressure3) mmwc mmwc mmwc mmwc mmwc mmwc
1)2)
Temp. 120 °C  5 120 °C  5
500 ml
1)2)
Temp. 150 °C  5 270 °C 130 °C  5
750 ml  20
1)2)
Temp. 230 °C  5 180 °C  5
> 750 ml
1) Values must still be determined

2) from Mach. No. N013 CombiTop activation will be outside aseptic zone, head i will be removed
3) Values have been adapted, new values are averaged over cross section, see also section 5.1.2.
Measuring of dynamic pressure at preheating- and drying heads

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CFA 406 und 405 FP

a b c d e f g h
CFA 406 from Mach. No. N003 (on the basis of CFA 206)1)
Head a b c d e f g
Function PH PH PH H2O2 D D D
Dyn. 22 22 22 22 22 22
pressure mmwc mmwc mmwc mmwc mmwc mmwc
Temp.
1000 ml 130 °C  5 270°C 120 °C  5
1360 ml 130 °C  5 20 120 °C  5
1420 ml 140 °C  5 130 °C  5
1500 ml 140 °C  5 130 °C  5
1893 ml 190 °C  5 190 °C  5
2000 ml 190 °C  5 190 °C  5
1) N001 doesn´t exist, was rebuild to another type of filling machine, N002 prototype Casalasco
CFA 405 FP
Head a b c d e f g
Dyn. 22 22 22 22 22 22
Temp.
1000 ml 130 °C  5 120 °C  5
1400- 270°C
1500 ml 140 °C  5 20 130 °C  5
2000 ml 170 °C  5 150 °C  5

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CFA 404 FP
a b c d e f g h
CFA 404 FP 1)
Head a b c d e f g
Dyn. 28 28 28 28 28 28
Temp. 270°C
1000 ml - 20
2000 ml 170 °C  5 150 °C  5
1) 4000 P/h with package volume 46 oz - 2000ml; 6000 P/h with package volume 1000ml

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CFA 909
a b c d e f g h i
of cartons
CFA 909
Head a b c d e f g h i
Dyn. 26 34 26 26 34 26
Temp.
1000 ml 150 °C 5 270°C 130 °C 5
1500 ml 200 °C 5 20 150 °C 5
CFA 909 reduced output 8000 P/h

Dyn. 26 34 26 26 34 26
Temp. 270°C
1500 ml 150 °C 5 20 130 °C 5

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CFA 209
a b c d e f g h i
of cartons
CFA 209
Dyn. 44 44 44 44 44 44
Temp.
 750 ml 80 °C 5 270°C 80 °C 5
> 750 ml 180 °C 5 20 170 °C 5

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5.3 H2O2 – Dosing
5.3.1 Spray values

The spray quantities are specified in the HMI in microlitres per second [l/s] and per track. The spray quantity per cycle and track is calculated from the
length of a cycle (in seconds) multiplied with the spray quantity per second.
FM Type (s) Size Standard Pocket chain empty HST
CFA A AL Wine A AL Wine
112, 712 (on the basis of 112) all Default value 180 l/s 400 l/s1) 180 l/s 180 l/s 225 l/s 180 l/s 300 l/s
124 N001…N005, all Default value 200 l/s 400 l/s 200 l/s 2) 2) 2) 200 l/s
724 N001
124 from N006, 724 from N002, all Default value 200 l/s 400 l/s 200 l/s 2) 2) 2) 300 l/s
1224
310, 510, 810 250 ml Default value 200 l/s 275 l/s 200 l/s 200 l/s 225 l/s 200 l/s 300 l/s
 500 ml Default value 275 l/s 450 l/s 275 l/s 225 l/s 225 l/s 225 l/s 300 l/s
312, 512, 812 250 ml Default value 250 l/s 450 l/s 250 l/s 225 l/s 225 l/s 225 l/s 300 l/s
Combidome 1012 all Default value 400 µl/s 450 µl/s 400 µl/s 300 µl/s 300 µl/s 300 µl/s 300µl/s
810 mode Fresh all Default value 100 l/s 2) 2) 2)
300 l/s
505 FP, 510 FL 250 ml Default value 200 l/s 275 l/s 200 l/s 2) 2) 2)
300 l/s
 500 ml Default value 275 l/s 540 l/s 275 l/s 2) 2) 2)
300 l/s
612, 612 FL  300 ml Default value 160 l/s 400 l/s 160 l/s 160 l/s 225 l/s 160 l/s 300 l/s

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FM Type (s) Size Standard Pocket chain empty HST

CFA A AL Wine/W A AL Wine
712 (on the basis of 510),  250 ml Default value 160 l/s 400 l/s 160 l/s 2) 2) 2)
300 l/s
706 FP, 712 FL  300 ml Default value 250 l/s 400 l/s 250 l/s 2) 2) 2)
300 l/s
606 FP  300 ml Default value 160 l/s 450 l/s 160 l/s 2) 2) 2)
300 l/s
612 Food  330 ml Default value 250 l/s 450 l/s 250 l/s 2) 2) 2)
300 l/s
812 Food (8.000 + 12.000 P/h), all Default value 330 l/s 450 l/s 330 l/s 2) 2) 2) 300 l/s
512 Food (10.000 + 12.000 P/h)
206 all Default value 300 l/s 500 l/s 275 l/s 2) 2) 2)
300 l/s
406 all Default value 540 l/s 700 l/s 540 l/s 2) 2) 2)
300 l/s
405 FP all Default value 450 l/s 600 l/s 450 l/s 2) 2) 2)
300 l/s
404 FP all Default value 700 l/s 700 l/s 700 l/s 2) 2) 2)
300 l/s
909 all Default value 540 l/s 700 l/s 540 l/s 270 l/s 350 l/s 270 l/s 300 l/s
909 reduced output
8000 P/h 270 l/s 350 l/s 270 l/s
all Default value 600 l/s 300 l/s
209 all Default value 300 l/s 540 l/s 300 l/s 150 l/s 270 l/s 150 l/s 300 l/s
2) 2) 2)
LCF 1000 ml Default value 0.36 ml/P 0.70 ml/P 0.30 ml/P 0.70 ml/P
1)
CFA 712 (on the basis of 112): for baby milk 450 l/s
2)
not defined

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Limits and alarm values (valid for all default values, but no practical impact)
L+ = Default value + 50 l/s

A+ = Default value + 25 l/s
Default value = Default value, see chart
A- = Default value - 25 l/s
L- = Default value - 50 l/s
Only machines equipped with „analog H2O2 dosing“

The parameter pressure H2O2 medium has to be checked in addition to the usual H2O2
parameters.
FM Type (s) Parameter

All L+ 1,5 bar
with „analog Pressure H2O2 medium (1) Default value 1,2 bar
H2O2 dosing“ L- 1,0 bar
(1)
To be adjusted by pressure control valve in the line back to H2O2 circulation tank,
reading at pressure gauge behind H2O2 circulation pump

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5.3.2 Spray air volumes

FM Number of Number Spray air volume of each vaporiser
Type (s) tracks of heater
vaporiser
CFA heaters
L+ 183 l/min (=11 Nm3/h)
HST A+
all CFA - - Setpoint 166 l/min (=10 Nm3/h)
A-
L- 150 l/min (=9 Nm3/h)
Production
112, 310, 510, 810, 612,

612 FL, 712, (both), 712 FL, 4 2
612 Food
L+ 183 l/min (=11 Nm3/h)
706 FP, 606 FP 2 1 A+
Setpoint 166 l/min (=10 Nm3/h)
206, 406, 405 FP 2 2 A-
L- 150 l/min (=9 Nm3/h)
909, 209 3 3
124 from N006, 724 from N002, 6 3

1224
Production
L+ 220 l/min (=13 Nm3/h)
505 FP1) 2 1 A+
Setpoint 200 l/min (=12 Nm3/h)
510 FL1), 312, 512, 812, A-
812 Food, 512 Food, 4 2 L- 180 l/min (=11 Nm3/h)
Combidome 1012
Production L+ 250 l/min (=15 Nm3/h)
A+
124 N001…N005, 724 N001 6 2 Setpoint 240 l/min (=14 Nm3/h)
A-
L- 230 l/min (=14 Nm3/h)
ca. 6 Nm3/h
LCF 2 1 Setpoint adjust manually at the
pressure gauge
1) Inner diameter of pipe between dosing piston and vaporisation unit is increased to di = 8
mm.

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5.3.3 Spray air pressure

Sprai Air Pressure
FM Number of Number Analog Analog
Type (s) tracks of dosing piston2) H2O2 H2O2
CFA vaporiser 3)
dosing dosing
heaters 4)
2.0
HST L+ 2000 mbar 2700 mbar 4500 mbar
- - A+ 1800 mbar 2500 mbar 4000 mbar
all CFA, Setpoint 1000 mbar 1200 mbar 3000 mbar
except 124, 724, 1224 A- 600 mbar 600 mbar 1500 mbar
L- 500 mbar 500 mbar 1000 mbar
L+ 3200 mbar 4500 mbar
HST A+ 3000 mbar 4000 mbar
- - Setpoint 2500 mbar 3000 mbar
124, 724, 1224 A- 600 mbar 1500 mbar
L- 500 mbar 1000 mbar
Production
112, 712 (beide), 712

FL, 310, 510, 510 FL,
512, 810, 812, 312, 4 2
612, 612 FL, 612 L+ 2000 mbar 2700 mbar 4500 mbar
Food, 512 Food, 812 A+ 1800 mbar 2500 mbar 4000 mbar
Food, Combidome Setpoint 1000 mbar 1200 mbar 3000 mbar
1012 A- 600 mbar 600 mbar 1500 mbar
2 1 L- 500 mbar 500 mbar 1000 mbar
505 FP, 706 FP, 606
FP 2 2
206, 406, 405 FP 3 3
909, 209
Production L+ 3200 mbar 4500 mbar
6 3 A+ 3000 mbar 4000 mbar
124, 724, 1224 and and Setpoint 2500 mbar 3000 mbar
6 2 A- 600 mbar 1500 mbar
L- 500 mbar 1000 mbar
2) The monitoring of the transporting air pressure is designed to safeguard the dosing
piston against pressures exceeding 2 bars. This is not a setting, but solely a control
value. The transporting air pressure indicated increases in relation to the degree of
calcification of the vaporisation heaters.
3) Measuring of transportation air pressure here takes place within the Bürkert
transportation air pressure controller.
4) New designed compact H2O2 dosing unit with Bürkert instruments from 2015
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5.3.4 Monitoring of regulation ratio of H2O2-vaporisation heaters
The L- -values have now a range of tolerance. The lower limit of the range of tolerance is
the value written in brackets.
As hitherto the original settings have to be used at ALL machines.
Only in case the machine is not able to run efficiently with these settings and all other
causes for deviations (like e.g. problems with H2O2 dosing or leakages) can be ruled out
and after consultation of the department Global Microbiology, it´s allowed to use the range
of tolerance!!!!!
To find the right values in the tables, first find the right table for the relevant machine type:
the tables A – C are sorted according to the number of tracks supplied by one vaporisation
heater. Then choose the dosing quantity in the first row of the relevant table and find the
right values for the regulation ratio.
Table A: 1 heater for 1 track
Valid for CFA

206, 209,
404 FP, 405 FP, 406,
909
Regulation ratio
Dosing quantity
default A- L- L+ and A+
150 l/s 17 % 13% (11%) 10% (8%)
270 l/s 24 % 19 % (16 %) 15 % (12 %)
275 l/s 24 % 19 % (16 %) 15 % (12 %)
300 l/s 25 % 20 % (16 %) 16 % (12 %)
350 l/s 30 % 22 % (17 %) 18 % (13 %)
100%
450 l/s 30 % 25 % (20 %) 20 % (15 %)
500 l/s 35 % 30 % (24 %) 22 % (16 %)
540 l/s 40 % 30 % (24 %) 22 % (16 %)
600 l/s 40 % 30 % (24 %) 24 % (18 %)
700 l/s 45 % 32 % (25 %) 27 % (20 %)

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Table B: 1 heater for 2 tracks
Valid for CFA

112, 124 from N006, 1224
310, 312, 505 FP, 510, 510 FL,512, 512 Food,
606 FP, 612, 612 FL, 612 Food
706 FP, 712, 712 FL, 724 from N002
810, 812, 812 Food, combidome 1012
Regulation ratio
Dosing quantity
100 l/s
fresh mode
160 l/s 25% 20% (16%) 16% (12%)
180 l/s 30% 22% (17%) 18% (13%)
200 l/s 32% 24% (19%) 20% (15%)
225 l/s 33% 25% (20%) 21% (16%)
250 l/s 35% 30% (24%) 22% (16%) 100%
275 l/s 40% 30% (24%) 22% (16%)
300 l/s 40% 30% (24%) 25% (19%)
330 l/s 43% 32% (25%) 27% (20%)
400 l/s 50% 35% (27%) 30% (22%)
450 l/s 50% 35% (27%) 30% (22%)
540 l/s 60% 45% (35%) 40% (30%)
Table C: 1 heater for 3 tracks
Valid for CFA

124 N001…N005, 724 N001
Regulation ratio
Dosing quantity
200 l/s 40 % 30% (24%) 25% (19%)
100%
400 l/s 62% 47% (36%) 42% (31%)

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5.3.5 Temperatures of H2O2 vaporisation heaters, preheating, drying
H2O2 vaporisation heaters

FM-Typ(en) Parameter Temperaturen
L+ 290 °C
A+ 285 °C
all Medium temperature Default value 270 °C
except of LCF H2O2 vaporisation heaters A- 255 °C
L- 250 °C
L+ 180 °C
Temperature upper H2O2 A+ 180 °C
all vaporisation heaters 1) Default value 160 °C
except of LCF A- 140 °C
L- 140 °C
1)
Alarm and limit values are not supervised, when heaters are controlled with out coil sensores
Preheating, drying
FM-Typ(en) Parameter Temperaturen
L+ + 5 °C
A+ + 5 °C
all Preheating, drying Default value see head
diagrams
A- - 5 °C
L- - 5 °C
L+ 105 °C
A+ 105 °C
all Preheating, drying Default value 100 °C
Pocket chain at standstill A- 95 °C
L- 95 °C

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5.4 Parameter steam, condensate, pressure product tank
5.4.1 Sterilisation parameters, steam parameters, condensate barriers
The sterilisation parameters are secured with the highest priority and shall only be
changed in a production plant through departments CBSY/Aseptic Processing or Global
Microbiology.
5.4.1.1 Valve Assembly Aseptomag

Valid for all CFA with standard Aseptomag Valve Assembly
(If separation of parameters for SST part 1 and SST part 2 in the HMI: choose values below
for both)
Parameter State Temperatures

L+ A+ Default A- L-
Steam Supply 170°C 165°C 155°C 130°C 125 °C
Steam Barrier Sterilisation 140°C 135°C 125°C 121°C 115 °C
Steam Barrier 140°C 135°C 115°C 110°C 102°C
ON
Steam Injection Sterilisation 140°C 135°C 125°C 121°C 115 °C
Production 140°C 135°C 125°C 110°C 102
°C
Swivel Couplings Sterilisation 140°C 135°C 125°C 121°C 115 °C
Sterile Air Filters Sterilisation 140°C 135°C 125°C 121°C 115 °C
N2-Filters, N2-Injection Sterilisation 140°C 135°C 125°C 121°C 115 °C

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5.4.1.2 Valve Assembly Aseptomag, parameters for FL, FP

Valid for CFA
404 FP, 405 FP, 505 FP, 606 FP, 706 FP, 510 FL, 612 FL, 712 FL
Additional values for FL and FP machines, besides the values from 5.4.1.1 Valve
Assembly Aseptomag are valid

L+ A+ Default A- L-
Lower valve block Sterilisation 140°C 135°C 125°C 121°C 115 °C
Pump housing Sterilisation 135°C 130°C 115°C 110°C 105°C
Condensate Barrier Sterilisation 140°C 135°C 125°C 121°C 115 °C
Pump Produktion 140°C 100°C 60°C 30°C 20°C
Valves Production 140°C 100°C 60°C 30°C 20°C
Condensate Reservoir Sterilisation 140°C 135°C 125°C 121°C 115 °C
(Valves and Pump) Production 140°C 100°C 80°C 60°C 40°C

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5.4.1.3 Valve Assembly Aseptomag Food
Valid for CFA

512 Food, 612 Food, 812 Food
All parameters for New Food Series (since 2007)

L+ A+ Default A- L-
Steam supply 170°C 165°C 155°C 130°C 125 °C
Behind pressure controller Production 140°C 135°C 115°C 110°C 102 °C
ON
Fill pistons / Inlet valves Steam Barrier 140°C 135°C 115°C 110°C 102°C
V01.1, V23.1 ON
V01.2, V23.4 Condensate 140°C 100°C 60°C 30°C 20°C
Barrier
Lower valve block Sterilisation 140°C 135°C 130°C 125°C 121 °C
Swivel couplings Sterilisation 140°C 135°C 130°C 125°C 121 °C
Tank pressure filter Sterilisation 140°C 135°C 130°C 125°C 121 °C
Pump Production 140°C 100°C 60°C 30°C 20°C
Valves Production 140°C 100°C 60°C 30°C 20°C
Reservoir
(Valves and Pump) Production 140°C 100°C 80°C 60°C 40°C

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5.4.1.4 Valve Assembly Rieger Standard

(If separation of parameters for SST part 1 and SST part 2 in the HMI: choose values below
for both)
Name of the parameters according to SIG HMI / c’touch HMI

L+ A+ Default A- L-
Steam Supply 170°C 165°C 155°C 130°C 125 °C
Steam Barrier / Sterilisation 140°C 1) 135°C 1) 125°C 1) 121°C 115 °C
Steam Barrier Production 140°C 135°C 125°C 115°C 110 °C
behind controller Steam Barrier 140°C 135°C 125°C 115°C 102°C
ON
Steam Barrier outside Sterilisation 140°C 135°C 125°C 121°C 115 °C
Passive 140°C 135°C 40°C 30°C 25 °C
Steam Barrier
ON
Steam injection Sterilisation 140°C 135°C 125°C 121°C 115 °C
Production 140°C 135°C 125°C 110°C 102 °C
Swivel Couplings Sterilisation 140°C 135°C 125°C 121°C 115 °C
Sterile Air Filter / Sterilisation 140°C 135°C 125°C 121°C 115 °C
Tank pressure filter
N2-Filter, N2-Injection Sterilisation 140°C 135°C 125°C 121°C 115 °C
1)
with pneumatiic steam temperature controler +10°C

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5.4.1.5 Valve Assembly Rieger, parameters for Condensate Barrier
Condensate Barrier for Rieger Valve Assembly

The Condensate Barrier for Rieger Valve Assemblies is installed at machines, that are
used for filling milk products.

L+ A+ Default A- L-
Condensate Barrier Steam 140°C 135°C 115°C 110°C 102 °C
Flushing 135°C 130°C 90°C 80°C 75 °C
Condensate 75°C 1) 65°C 1) 35°C 25°C 20°C
1)
L+ / A+ have to be increased up to +5°C, depending on the environmental conditions
5.4.1.6 Valve Assembly Rieger, parameters for Condensate Barrier at agitator
Condensate Barrier at agitator for Rieger Valve Assembly during production

A tank with agitator is installed for special products with chuncks. The agitator is protected
by a condensate barrier. The condensate barrier is controlled with 2 temperature sensors
(before and after agitator).

L+ A+ Default A- L-
Condensate Barrier Flushing 95°C 90°C 80°C 70°C 65 °C
Before Agitator / Inlet Condensate 135°C 130°C 40°C 25°C 20 °C
Sterilisation 140°C 135°C 125°C 121°C 115 °C
Condensate Barrier Condensatw 70°C 1) 65°C 40°C 25°C 20°C
After Agitator / Outlet Sterilisation 140°C 135°C 125°C 121°C 115 °C
1
) can be increased upto 95°C, depending on the environmental conditions

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5.4.1.7 Valve Assembly Aseptomag & Rieger, special parameters for Critical Factor
Machines (FDA)
For machines producing under special regard to the critical factors (FDA conditions)
different values for steam sterilisation Part 1 and Part 2 have to be set:

L+ A+ Default A- L-
All steam temperatures, Sterilisation 140°C 135°C 125°C 121°C 115 °C
that are controlled Part 1
during SST (see 5.4.1.1or Sterilisation 140°C 135°C 125°C 123°C 121 °C
5.4.1.4) Part 2
5.4.2 Product tank pressure (valve assembly RIEGER and ASEPTOMAG)

L+ Default L-
Pressure Sterilisation 2000 mbars 250 mbars 0 mbars
product tank Cooling filling 100 mbars 60 mbars 10 mbars
heads
cleaning 3000 mbars 1200 mbars 50 mbars

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5.5 Production
5.5.1 Parameter sterile product change

Cam position pocket chain
FM Type(s) CAM ON CAM OFF
CFA 112, 712 60 ° 140 °
CFA 310, 312, 60 ° 140 °
510, 512, 810,
812
CFA 209, 909
CFA 124, 724, 150 ° 250 °
1224
FM Type(s)
CFA 112, 712, Time tank pressure on 60 s
124, 724, 310, after tank not empty
312, 510, 512,
810, 812, 209,
909

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5.5.2 Parameter drain product tank into cartons
Parameter unit CFA 112, 712 CFA 310, 312, 510, 512, CFA 209, 909
810, 812
Volume 0 to 100% Liter [l] 20 90 125
Volume under tank probe Liter [l] 15 20 80
No. of tracks when draining - 2 2 1
Tank pressure rise when draining Millibar per Liter * Factor 0 1) 0 1) 0 1)
[* 1/10 mbar/l]
Parameter Unit CFA 112, 712 CFA 310, 312, 510, 512, CFA 124, 724,
valve assembly RIEGER 810, 812 1224
Volume 0 to 100% Liter [l] 90 90 90

No. of tracks when draining - 4 2 4
[* 1/10 mbar/l]
Parameter Unit CFA 112, 712 CFA 310, 312, 510, 512, CFA 124, 724
valve assembly RIEGER 810, 812
& tank with agitator
Volume 0 to 100% Liter [l] 75 75 75
No. of tracks when draining -
[* 1/10 mbar/l]
1)
If function “Tank pressure rise when draining” is necessary, tests have to be done to find out this product-specific setting.
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5.6 Cleaning parameters
5.6.1 Temperatures cleaning media
FM Type (s)
L+ 80 °C
A+ 75 °C
1) 70 °C
all Temperature caustic soda Default value
A- 65 °C
L- 60 °C
L+ 75 °C
A+ 70 °C
all Temperature acid 1) Default value 65 °C
A- 60 °C
L- 55 °C
1) The values L+, A+ and A- have no practical impact on the program sequence. A falling-
below of L- results in a time stop of the running program step.

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5.6.2 Flow rate

FM Type (s) CFA
all (except of 404 FP, Total flow volume Default value 10,000 l/h
1)2) 8,000 l/h
812 Food, 612 Food, L-
512 Food)
404 FP Total flow volume Default value 15,000 l/h
1)2) 12,000 l/h
L-
812 Food, 612 Food, Total flow volume Default value 18,000 l/h
1)2) 15,000 l/h
512 Food L-
Flow rates per fill head
All flow rates for fill heads are meant for total flow volume 10,000 l/h.
The values L+, A+ and A- have no practical impact on the program sequence. A falling-
below of L- results in a time stop of the running program step.
FP / Food Machines are not listed, the monitoring of the total flow volume by a flow meter
in the backflow piping to the CIP.
Flow volume during the step of pre-rinsing
In the first step of cleaning program (pre-rinsing) the total flow flushes alternately each
single fill head. Only the fill head just flushed is inquired. The total flow volume during this
step (depending on the filling machine and the custumer conditions) is approximately
4,000…7000 l/h.
Some machines can be equipped with filling nozzles with reduced cross section. For these
filling nozzles, the values „Nozzle with reduced cross section“ have to be used. For the
other nozzles, the standard values are used, because they are not affected of the other
nozzles during single step rinsing.

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CFA 612, 312, 512, 812, 712 FL, 612 FL

4 tracks, 8 nozzles
Fill Station 1 Nozzle 1 / 3 / 5 / 7

Nozzles Valve Sealing Flow Single Step Flow all nozzles
Rod Cone Rinsing opened
Default L- Default L-
Standard Standard Standard 1250 1000 350 280
Reduced 850 700 230 180
strong 450 350
reduced

Standard + Standard Standard 1250 1000 450 370
FS 1 Reduc.
Standard + Standard Standard 1250 1000
FS 1 strong
reduc.

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CFA 612-36 Food, 512-36Food, 812-36 Food / 808-36 Food

4 tracks, 12 nozzles
Fill station 1 Positions 1 -8

Fill station 2
Piston fill station, no flow control
Fill station 3 Positions 9 / 10 / 11 / 12

Note for X12-36 Food machines:

The piston fill station has no flow meter, therefor the CIP flow is monitored via the flow meter in the
standard fill station during special cleaning steps.
Single Step Rinsing:

only one nozzle from the piston fill station (Step 1 und 2) is open,
all nozzles from the standard fill station (Step 3) are open.
All nozzles opened:

all nozzles from the piston fill station (Step 1 und 2) are open,
all nozzles from the standard fill station (Step 3) are open.

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CFA 206, 406

2 tracks, 8 nozzles
Fill Station 1 Nozzle 1 / 5

Reduced 850 700 230 180
strong 450 350
reduced
Fill Station Nozzle 2 / 3 / 4 / 6 / 7 / 8

2-4
Standard + 1250 1000 450 370
FS 1 Reduc.
Standard + Standard Standard 1250 1000
FS 1 strong
reduc.

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CFA 112, 712 (both)

4 tracks, 8 nozzles

Nozzles Valve Nozzles Flow Single Step Flow all nozzles
Rod Rinsing opened
Reduced 230 180
Standard with 2 grooves 650 550 350 280
(870118089)

Rod Rinsing opened
Standard + 1000 800 450 370
FS 1 Reduc.
Standard with 2 grooves 650 550 350 280
(870118089)

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CFA 124, CFA 724, CFA 1224

Step 1
Step 2
Fill Station 1 Nozzle 1 / 3 / 5 / 7 / 9 / 11

Rod Rinsing opened
873018206 873018008 870118031 750 600 230 185
Standard
873018208 873018009 870118205 600 300 230 110
angled nozzle
871218011 600 300 230 110
angled nozzle
4 tubes
Fill Station 2 Nozzle 2 / 4 / 6 / 8 / 10 / 12

Rod Rinsing opened
873018206 873018008 870118031 750 600 230 185
Standard
873018206 873018008 870118031 750 600 260 215
Standard
+ FS 1
angled nozzle
871218010 750 600 260 215
segment
reduzced +
FS1 angled
nozzle 4
tubes

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CFA 209, 909

1 5| 9 Step 1
2 6 | 10 Step 2
3 7 | 11 Step 3
4 8 | 12 Step 4
Fill Station 1 Nozzle 1 / 5 / 9

Rod Rinsing opened
Reduced 850 650 160 125
angled nozzle 850 650 100 50
Fill station Nozzel 2 / 3 / 4 / 6 / 7 / 8 / 9 / 10 / 11 / 12

2-4
Rod Rinsing opened
Standard + 1000 800 230 185
FS 1 Reduc.
Standard + 1000 800 230 185
FS 1 angled
nozzle

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CFA combidome 1012

Fill station Nozzle 1-3 / 5-7 / 9-11 / 13-15

1-3
Rod Rinsing opened
angled nozzle 1450 1200 165 115
Fill station 4 Nozzle 4 / 8 / 12 / 16

Rod Rinsing opened
Standard 2000 1750 255 205

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5.7 Sterille air household
5.7.1 Settings for pressure differentials of filters

FM-Typ(en) Parameter
L+ 8 mbar
Pressure A+ 6 mbar
all differential Default value 2 mbar
sterile air filter A-, L- 0 mbar
LCF, CFA 112, L+ 3 mbar
712 (on the basis of 112) Pressure A+ 2 mbar
706 FP, 606 FP differential Default value 1 mbar
505 FP prefilter A-, L- 0 mbar
310, 312, 510, 512, 810, 612, 612 FL L+ 5 mbar
712 (on the basis of 510), 510 FL, Pressure A+ 4 mbar
712 FL, 812, 124, 724, 206, 406, differential Default value 2 mbar
405 FP, 812 Food, 612 Food, 512 Food, prefilter A-, L- 0 mbar
combidome 1012
L+ 8 mbar
209, 909 Pressure A+ 7 mbar
differential Default value 5 mbar
prefilter A-, L- 0 mbar

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5.7.2 Limits and warning values sterile air pressure and exhaust air box
The limits and warning values refer to the settings of the individual filling machines in the
following Section 5.7.3, Sterile - and Exhaust Air Values.
FM Types
all L+ = Default value + 5 mbars
except for A+ = Default value + 2 mbars
812 Food Sterile air pressure Default value = Default value, see chart
612 Food A- = Default value - 2 mbars
512 Food) L- = Default value - 5 mbars
L+ = Default value + 5 mbars
CFA A+ = Default value + 2 mbars
812 Food Sterile air pressure Default value = Default value, see chart
612 Food A- = Default value - 2 mbars
512 Food L- = Default value - 2 mbars

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FM Types
L+ 10 mbar
A+ 7 mbar
all Sterile air pressure Default value 5 mbar
outside production A- 3 mbar
L- 0 mbar
All except L+ = Default value + 300 bars
of CFA 909 A+ = Default value + 200 bars
209, Exhaust air, exhaust box1) Default value = Default value, see chart
124, 724, A- = Default value - 400 bars
1224 L- = Default value - 500 bars
L+ = Default value + 800 bars
A+ = Default value + 300 bars
1)
CFA 209, Exhaust air, exhaust box Default value = Default value, see chart
909 A- = Default value - 700 bars
L- = Default value - 1100 bars
1)
Exhaust air, exhaust box A+ = Default value + 1000 bars
CFA 209, Exhaust box with Default value = Default value, see chart
909 perforated plate A- = Default value - 2400 bars
A+ = Default value + 900 bars
1)
CFA 124, Exhaust air, exhaust box Default value = Default value, see chart
724, 1224 A- = Default value - 1400 bars
124, 724, Frequency exhaust air fan Default value 100 %
1224,
Combidome
1012
124, 724, Reduced frequency exhaust Default value 60 %
1224, air fan
Combidome
1012
all Max. exhaust during HST Default value 100 bar
1) Measuring point at vertical pipe between exhaust box and HST flap
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5.7.3 Sterile- and Echaust Air Values

All footnotes gathered at the end of this chapter
FM Type Sterile Total Total Pipe Bottom Drying Drying Filling US Ear
air infeed exhaust exhaust-box acti- station heads4) station station station
CFA press. air air vation laminar laminar laminar
13) 14)
112, 712 (on Pressure (mbars) 30 1,0 /2,0 25 28
the basis of 112)  pipe/hose (mm) 125 40 40 40
Orifice (mm) 2x30+1x123) 3x20 3x18 none
13) 14)
Volume (m3/h) 1250 3000300 600 /850 320 240 300 220
124, 724 Pressure (mbars) 30 4,616) 28 28
 pipe/hose (mm) 125 40 40 40
Orifice (mm) 3x18 PH 2*23/ 2x20+3x2815) 3x25 none
D 2*40
Volume (m3/h) 1750 3500300 1050 300 480 400 400
1224 Pressure (mbars) 30 4,616) 28 28
 pipe/hose (mm) 125 40 40 40
Orifice (mm) 3x18 PH 2*18/ 2x20+3x2815) 3x25 none
D 2*23
Volume (m3/h) 1750 3500300 1050 300 480 400 400
SIG
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Document
FM Type Sterile Total Total Pipe Bottom Drying Drying Filling US US Ear
air infeed exhaust exhaust-box acti- station heads4) station station air station
CFA press. air air vation laminar laminar laminar cooling
5)
310, 312 Pressure (mbars) 30 1.2 21 20
 pipe/hose (mm) 125 40 50 40
Orifice (mm) 3x20 2x30 4x30 none none
Volume (m3/h) 1800 3500300 700 240 450 250 500 100 30
510, 512 Pressure (mbars) 30 1.25) 21 20
 pipe/hose (mm) 125 40 50 40
Orifice (mm) 14001)/ 3x20 2701)/ 2x30 4x30 none none
Volume (m3/h) 18002) 3500300 700 240 4502) 250 500 100 30
810 Pressure (mbars) 30 1.25) 24 23
 pipe/hose (mm) 125 40 50 40
Volume (m3/h) 1800 3500300 700 240 450 250 500 100 30
812 Pressure (mbars) 30 1.25) 24 23
 pipe/hose (mm) 125 40 60 50 40
Orifice (mm) 3x20 28/35 2x30 4x30 none none
Volume (m3/h) 1800 3500300 700 240 450 250 500 100 30
SIG
Document
air infeed exhaust exhaust-box acti- station heads4) station station air station
CFA press. air air vation laminar laminar laminar cooling
5)
612, 712 (on Pressure (mbars) 30 1.2 25 23
Orifice (mm) 3x20 none 4x30 none none
Volume (m3/h) 1400 3500300 700 240 270 230 500 100 30
612 N012 (on Pressure (mbars) 30 1.25) 20 21
Volume (m3/h) 1550 3500300 700 240 250 500 100 30
LCF Pressure (mbars) 31 0.85) 28
 pipe/hose (mm) 40 50 40
Orifice (mm) 1x35
Volume (m3/h) 950 1100 550 70 190 140 150 360 40 N/A
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Document
box infeed exhaust exhaust activation station heads4) station station air station
CFA air air box laminar laminar laminar cooling
510 FL Pressure (mbars) 30 1.25) 25 20
 pipe/hose (mm) 125 40 50 40
Volume (m3/h) 1900 3500300 700 240 450 400 500 100 30
712 FL, Pressure (mbars) 30 1.25) 28 23
612 FL  pipe/hose (mm) 125 40 50 40
Volume (m3/h) 1650 3500300 700 240 270 400 500 100 30
505 FP Pressure (mbars) 30 0.85) 26 25
 pipe/hose (mm) 125 40 50/40 40
Orifice (mm) none 1x35(none none none
Volume (m3/h) 950 2000300 550 100 220 370 230
706 FP, Pressure (mbars) 30 0.85) 30 22
606 FP  pipe/hose (mm) 125 40 50/40 40
Orifice (mm) none 1x35(none none none
Volume (m3/h) 950 2000300 550 100 140 370 230
SIG
Document
206 Pressure (mbars) 45 1.0 40  5 45
 pipe/hose (mm) 125 70/50 50 50
7)
Orifice (mm) 2x30/none none 1x44 none
Volume (m3/h) 1700 3000300 6006) 400 420 400 400
406 from Pressure (mbars) 45 1.0 33  5 37
N003  pipe/hose (mm) 125 70/50 50 50
7)
Orifice (mm) 2x30/none none 1x44 none
Volume (m3/h) 1500 3000300 6006) 470
405 FP Pressure (mbars) 45 1.0 35  5 38
 pipe/hose (mm) 125 50 50 50
7)
Orifice (mm) 4*34 2*32 1*42 none
Volume (m3/h) 1650 3200300 6006) 450 470 400 340
404 FP Pressure (mbars) 45 1.0 38  5 35
 pipe/hose (mm)
17)
125 50 40/50 2*40
7)
Orifice (mm) 2*25 PH 25 1*15/2*2817) 2*20 none
D 25
Volume (m3/h) 1700 3200300 6006) 440 450 500 380
SIG
Document
box infeed exhaustexhaust activation station heads4) station station air station
512 Food Pressure (mbars) 20 1,25) 30
 pipe/hose (mm) 125 (separa- 40 PH 45 40 40
Orifice (mm) te fan) 3*20 D 56 2*20/2*2018) 3*18 none none
Volume (m3/h) 1500 3500300 700
612 Food Pressure (mbars) 20 1,25) 30
 pipe/hose (mm) (separa- PH 45 40 40
Orifice (mm) 125 te fan) 40 D 45 2*20/2*2018) 3*18
Volume (m3/h) 3*20 none none
1500 3500300 700
812 Food Pressure (mbars) 20 1.25) 30
 pipe/hose (mm) 125 (separate 40 PH 38 40 40
Orifice (mm) fan) 3*25 D56 2*25/2*1818) 3*20 none none
Volume (m3/h) 1500 3500300 700
SIG
Document
909 Pressure (mbar) 40 3,18)9)/5,711)9) 33  5 37
Orifice (mm) 2x35 none 2x32 none none
Volume (m3/h) 2500 3500… 7508)9)/ 670 800 630 520 70
30010) 100010011)9)
209 Pressure (mbar) 40 3,18)9)/5,711)9) 34  5 35
Orifice (mm) 85 2x35 none 2x32 none None
Volume (m3/h) 2500 3500… 7508)9)/ 670 580 630 520 60
30010) 100010011)9)
Combi- Pressure (mbars) 25 1,25) 2519)
dome  pipe/hose (mm) 125 40 60 40 40 21)
1012 Orifice (mm) separate 3x20 2x32/ 2x30 / 4x20 none

fan) 2x35 2x35 / (separa-
3
Volume (m /h) 1800 3500… 700 240 430 3x1820) 100 te fan)
300
1) Machines N001 to N021 (preheating- and drying heads NW 15)

2) From machine N022 (preheating- and drying heads NW 19)
3) Outer connections 30 mm, middle connection 12 mm
4) The values at the drying heads are the total of all air flows in the heads.
5) For further information see section 5.1.4, Procedure to set sterile air household!
6) Modified exhaust box
7) No orifice in any exhaust pipe
8) exhaust box ROM, connected with 2 exhaust pipes DN 80, measuring points at both exhaust pipes from N003
9) pressure setpoint mentioned above is valid for every single measuring point and exhaust pipe DN 80; the volume mentioned
above is the summation of both exhaust pipes
SIG
Document
pressure of both pipes differ by 0,2…0,4 mbar caused by the construction of the pipes,
the adjustment of the HST flap has to be done like this: one pressure gauge value slightly above and one slightly below the
pressure setpoint
10) Distribution of exhaust air with orifices as following: (note: All orifices have to be in the TriClamp-connections directly at the
central exhaust box (which is situated next to sterile air filter housing)!!!)
Exhaust above sleeve infeed 2*50 ROM-Hood above prefolder: 2*none
Below valve block, above ejector discharge station: 1*50 ROM-Drall bottom activation: 2*none
ROM-hood above ejector discharge station: 2*55 2 exhaust pipes DN 80, exhaust box: 2*none
11) exhaust box with perforated plate, connected with 2 exhaust pipes DN 80, measuring points at both exhaust pipes
12) ---
13) for standard exhaust box; For further information see section 5.1.4, Procedure to set sterile air household
14) increased exhaust air volume at exhaust box: exhaust box with 3 holes in the side face directed to the prefolder and orifices
(di=20) in the hoses of the ROM-hood above the prefolder (orifices have to be fixed directly at the ROM-hood);
Please remove the di=20 orifices at machines which are not installed in regions with tropical climate conditions!
Please see section 5.1.4 Procedure to set sterile air household for further information!
15) For further information see “aseptic acceptance certificate for combibloc filling machines CFA X24”
16) exhaust box with 3 holes in the side face directed to the prefolder and orifices (di=25) in the hoses of the ROM-hood above the
prefolder (orifices have to be fixed directly at the ROM-hood);
Please remove the di=25 orifices at machines which are not installed in regions with tropical climate conditions!
Please see section 5.1.4 Procedure to set sterile air household for further information!
17) Filling station 1 for sterile air supply of panes aseptic zone: NW 40 with orifice 15 mm;
Filling station 1 and 2 Laminar flow: each NW 50 with orifice 28 mm
18) 2 hoses for supply of swivel couplings: each orifice 18 mm; remaining 2 hoses: each orifice 25 mm
19) bottom sealing after ultra sonic station
20) 2 hoses supply swivel coupling front / 2 hoses supply swivel coupling back /
3 hoses supply laminar flow fill station
21) sealing of the dome on the mandrel wheel
SIG
Document
6 Reference documents, appendix

Dok. Nr. I-G-0191-de Theoretische Grundlagen der Messung von Luftmengen
Dok. Nr. I-G-0173-en Settings for 1st/2nd Generation Aseptic Filling Machines
7 Changes from preceding issue

- CFA combidome 1012 – Preheating & dryingactualized, package volume 960 ml
released
- Reduced infeed air pressure for dedusting parameters
- Settings for dedusting unit with cyclone
- Settings for CFA 1224- 150ml package volume released
- Settings for CFA 812- 750 ml package volume released
- Settings for CFA 406- 1420 ml and 1893 ml released
- Settings for CFA 312 - 500, 750 und 969 ml actualized
- Settings for CFA 612-31/32/35 actualized
- Spray air volume for HST set to 166l/min for all CFA
- harmonized spray air pressure for all machines
- spray air pressure for analogue H2O2 dosing unit 2.0 (compact Bürkert unit)
- Settings for passive steam barrier for Rieger valve assembly
- in chapter 5.1.1 acutalised order numbers for prandtl tube and u-pipe pressure gauge
- Remaining tank volume “under tank level probe” for Rieger Valve cluster corrected
- Corrections:Distribution list actualized

head diagram CFA 206
Drying temperature CFA 112, from machine No. 013 with new tunnel
diameter nozzles pre-heating and drying CFA 612 Food
CIP flow rate diagram for CFA combidome 1012
Peroxide dosing values for CFA 312/512/812 for all package formats
adjusted
The document substitutes I-G-0174-en Issue 3
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Direct distribution list (user, functions):

Owner: Head of Aseptic Technology

Core-process: Business process

lssue Approval Registration 1 Release by Owner

Name Christian Weiler Hanno i 1er Silke Kling Hanno G issler

File: l-G-O1 74 Settings for 3rd Generation Aseptic Filling Machines

Title: Settings for 3rd Generation Aseptic Filling Machines

1 Aim, purpose ............................................................................................................................. 4

Title: Settings for 3rd Generation Aseptic Filling Machines

5.4 Parameter steam, condensate, pressure product tank........................................... 48

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

3 Terms and abbreviations

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

Setting for 3rd Generation Aseptic Filling

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

5.1 General Notes

Note: 1 mbar = 10 mm WS = 100 Pa

Dynamic Pressure: p dyn  p ges  p stat

  4  Pdyn mmWS   A m  3600

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

5.1.2 Measuring of dynamic pressure at preheating- and drying heads

5.1.3 Setting of static pressure at heater heads of bottom activation

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

5.1.4 Procedure to set sterile air household

Volume of infeed air

Setting of exhaust air volume

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

5.1.5 Procedure to set dedusting

5.1.5.1 Infeed Air (air pressure)

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

FM- number of pressure Cam

5.1.5.2 Dedusting with cyclone

There are two points of dedusting.

FM-Type(s) cyclone magazin package

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

5.1.6 Exhaust air

FM-Type(s) B-side A-side

5.1.7 Machine output

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

5.2 Head Diagramm

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

CFA 112 N001…N012

Direction of movement The head pattern

CFA 112, Mach. No. N001 to N012

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

CFA 112 from N013

Direction of movement The head pattern

SIG Combibloc Systems GmbH

Title: Settings for 3rd Generation Aseptic Filling Machines

CFA 124 N001...N005