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TBA/19 030V Maintenance: Training Document

This training document provides an overview of the TBA/19 030V maintenance and conversion courses, aimed at Tetra Pak and customer technicians. It outlines course objectives, content, and methods, emphasizing the importance of prior knowledge and practical skills. Additionally, it includes instructions for using digital workbooks and commenting tools in Adobe Reader for effective note-taking during training sessions.

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dkboss7351980

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0% found this document useful (0 votes)

104 views258 pages

TBA/19 030V Maintenance: Training Document

Uploaded by

dkboss7351980

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

 Course Introduction 1

 TBA/19 Introduction 2
TBA/19 030V  Supply System 3
Maintenance
 Superstructure 4
Training Document
This Training Document is intended for
 Drive Unit 5
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace  Jaw System 6
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
 Final Folder Unit 7
For safe and proper procedures, refer to
the equipment specific documentation.
 ASSU 8

 ASU/PMI 9
Name:

................................................................................................................
 Design Control 10
................................................................................................................

 Filling Control System 11

 Temperature Controlled Steam Barrier 12

 Cleaning In Place 13
 Package Check 14
 PLMS 15
 TPMS 16

Technical Training Centre 19

Lund, Sweden
WB-199-01
Issue 3/0903 20
1
Course
Introduction

Technical Training Centre

   
TC-0103 - TBA/19 030V Maintenance
Course Length 3 weeks

Target Group Tetra Pak Technicians

Customer Technicians

Previous To be able to operate a TBA/19 with help of an

Knowledge Operator Manual.
Good mechanical skills and basic electrical
knowledge.
Study "TBA basic course" material.
Perform "TBA basic course" as a self test

Course Objectives To achieve common basic TBA knowledge.

To achieve a basic understanding of how the
machine's different components work, individually
and together.
To be able to locate and replace defective
components.
To be able to carry out a 1000h TPMS service.

Course- Start-up machine in accordance with the OM.

Content/Subjects An introduction to the machine's function.
Ability to use the technical documentation for the
machine.
Function and basic settings of the sterile air system.
Understanding of the tube forming and package
forming.
Function and settings of the Drive system.
Function and basic settings of the Jaw system.
Function and settings of the Final folder.
Function and settings of the ASSU.
Function and basic settings of the Design correction
system.
Function and basic setting of the Filling system.
Function and settings of the different Supply
systems.
Basic setting of the sealing systems.
Package integrity and package checks.
Hygiene when working with the machine.
Performing a TPMS service.

Questionnaires There will be written questionnaires during the

course.

   
Course Methods Approximately 25/75 theory/practical time ratio.
Individual as well as group work will be used.
Homework can be expected.

Last modified: Aug 24, 2006

   
TC-0104 - TBA/19 030V Conversion
Course Length • 2 weeks

Target Group • Tetra Pak Technicians

• Customer Technicians

Previous • Participants must have participated in a TTC course

Knowledge on another TBA system.
• The participants must have at least 12 months
experience of TBA machines in order to understand
the background and to be able to take part in the
discussions during the course.
• To be able to operate a TBA/19 030V with help of an
OM.

Course Objectives • To achieve a basic understanding of how the

machine's different components work individually
and together.
• To be able to carry out a 1000h TPMS service.
• To be able to locate and replace defective
components.

Course- • Start-up machine in accordance with the OM.

Content/Subjects • An introduction to the machine's function.
• Function of the different Supply systems.
• Function and basic settings of the sterile air system.
• Understanding of the tube forming and package
forming.
• Function and settings of the Drive unit.
• Function and basic settings of the Jaw system.
• Function and settings of the Final folder.
• Function and settings of the ASSU and PMI/ASU.
• Function and basic settings of the Design correction
system.
• Function and basic setting of the Filling system.

Course Methods • Approximately 25/75-theory/practical-time ratio.

• Individual as well as group work will be used.
• Homework can be expected.

Last modified: Aug 24, 2006

   
Making Notes in the Digital Workbook


You have received a workbook in a digital format (PDF).
Our intention is that you shall be able to use it the same way as the usual paper
based workbook.

Technical Training Centre 1/0809

It is possible to make notes in the digital workbook by using the commenting
and markup tools and the typewriter tool in Adobe Reader. In case you are
not already familiar with these tools, a short introduction follows below.
The introduction is based on the interface of Adobe Reader 9.0 and covers:


• Instructions on how to display the toolbars

TM-01559
• An overview of the function of commenting and markup tools
Add a comment
Delete a comment
Edit a comment
Customise the look of a comment
• An introduction to some tools in the Comment &Markup toolbar


Sticky Note tool
Stamp tool
Create a stamp of your own
The paper based workbook
Add a stamp to the Favourites list

Training Document. For training purpose only.

Highlight Text tool
Text Box tool
Customise the text box properties


Arrow tool
Rectangle tool
Pencil tool
• An introduction to the typewriter tool
Add text using the typewriter tool
Change the typewriter properties
Customise the typewriter properties

1
How to display the toolbars
The Comment & Markup toolbar and the Typewriter toolbar may not be
displayed when you first start Adobe Reader. To show them as floating palettes
in the work area choose View>Toolbars.
A check mark next to the toolbar name indicates that the toolbar is displayed.


Choose Comment & Markup.
Then do it all over again and choose Typewriter further down the menu.

Technical Training Centre 1/0809


TM-01559
Comment & Markup toolbar


check mark

Typewriter toolbar

Training Document. For training purpose only.


2
Commenting and Markup tools
Overview


The Comment & Markup toolbar

Technical Training Centre 1/0809

You use commenting and markup tools to add notes to your PDF-document.


Most comments include two parts:
• the markup, that appears on the page, and

TM-01559
• the pop-up note that appears when you double-click the markup.

markup

pop-up note


Training Document. For training purpose only.


3
Add a comment
Choose the tool you want to use in the Comment & Markup toolbar and click Sticky Note cursor
on the page where you want to place the comment.

Stamp cursor


Highlight Text and Text Box cursor

Technical Training Centre 1/0809

Arrow, Rectangle and Pencil cursor


Delete a comment

TM-01559
Click the markup to select the comment. Right-click and choose Delete


Training Document. For training purpose only.


4
Edit a comment edit handle
blue halo (rotation)
Click the markup to select a comment.
A selected comment is highlighted with a blue halo to help you find the markup edit handle
(size and shape)
on the page. Some comments are equipped with edit handles to let you adjust
size, shape and rotation.


When you roll over the markup and the cursor changes to cross-arrows, click-
hold and drag to move the markup to another position cross-arrows cursor

Technical Training Centre 1/0809

Stamp tool


Double-click the markup to show the pop-up note.
Edit the message in the pop-up note

TM-01559


markup

pop-up note

Training Document. For training purpose only.


The comment remains selected until you click elsewhere on the page.

5
Customise the look of a comment
Click the markup to select it. Use the Properties bar (ctrl+E) to change the
markup properties
Properties bar


Technical Training Centre 1/0809
markup

pop-up note


TM-01559
Double-click the markup to select the pop-up note. Use the Properties bar
(Ctrl+E) to change the pop-up note’s properties


Properties bar

Training Document. For training purpose only.


markup

pop-up note

6
When you are happy with the result and want to make your settings default, right-
click and choose Make Current Properties Default


Technical Training Centre 1/0809


TM-01559


Training Document. For training purpose only.


7
Commenting and markup tools


1 2 3 4 5 6 7

Technical Training Centre 1/0809

There are several tools in the Comment & Markup toolbar. This user guide
will only deal with a few of them, the ones we consider most useful in a class-
room situation.


TM-01559
1. Sticky Note tool Add a sticky note comment

2. Stamp tool Add a stamp comment

3. Highlight Text tool Highlight text


4. Text Box tool Create a box that contains text

5. Arrow tool Draw an arrow

6. Rectangle tool Draw a rectangle

Training Document. For training purpose only.

7. Pencil tool Create free-form drawings


8
Sticky note tool

The most common type of comment is the Sticky Note.

markup
A sticky note has a markup that appears on the page and a pop-up note for your
text message. You can add a sticky note anywhere on the page or in the document


area.
pop-up note

Technical Training Centre 1/0809

Sticky Note tool


Stamp tool

TM-01559
You apply a stamp to a PDF in much the same way as you apply a rubber stamp
to a paper document. You can choose from a list of pre-defined stamps, or you
can create your own stamps.
markup


Training Document. For training purpose only.
pop-up note


Stamp tool

9
Create a stamp of your own
You can create custom stamps from a number of different formats, including
PDF, JPEG,BMP, Adobe Illustrator (AI) and Adobe Photoshop (PSD).
In the Comment & Markup toolbar, click the arrow beside the stamp and
choose Show Stamps Palette.


Technical Training Centre 1/0809


TM-01559
Click the Import button.


Training Document. For training purpose only.


10
Click the Browse button to locate the file you want to use as a stamp, select it
and then click OK.
Choose a Category from the menu or type a new category name. Give your new
stamp a Name, and then click OK.


Technical Training Centre 1/0809


TM-01559


Training Document. For training purpose only.


11
Add a stamp to the Favourites list
Select a stamp markup on the page.


Technical Training Centre 1/0809
In the Comment & Markup toolbar, click the arrow beside the stamp and
choose Favourites > Add Current Stamp To Favourites.


TM-01559


Training Document. For training purpose only.


12
Highlight Text tool

With this tool you can highlight text and add a note to it. Click-drag from the
beginning of the text you want to highlight.


If you’re marking up a lot of text, Ctrl+click-drag to mark up a rectangular area

Technical Training Centre 1/0809

of text. This is especially useful when marking up all text in a column.


TM-01559
markup


pop-up note

Highlight Text tool

Training Document. For training purpose only.


13
Text Box tool

You can use the Text Box tool to create a box that contains text. You can
position it anywhere on the page and adjust it to any size. The text box remains
visible on the document page; it doesn’t close like a pop-up note.


Note! The Text box tool does not include a pop-up note!
Simply click on the page and start typing. Text wraps automatically when it
reaches the right edge of the box.

Technical Training Centre 1/0809

Double-click the text box to edit the text. Text Box tool
markup


Customise the text box properties
Click to select the text box. Use the Properties bar (ctrl+E) to change the

TM-01559
border and fill options.


Training Document. For training purpose only.
Double-click the text box and click-drag across the text to select it. Then use the
Properties bar (ctrl+E) to change the text properties.


14
When you are happy with the result and want to make your settings default, select
the text box, right-click and choose Make Current Properties Default.


Technical Training Centre 1/0809
Arrow tool


To draw an arrow, either drag across the area where you want the markup to ap-

TM-01559
pear, or click twice: once to create the start point and once to create the end point
of the arrow. markup


pop-up note

Training Document. For training purpose only.


Arrow tool

15
Rectangle tool

To draw a rectangle, either drag across the area where you want the markup to
appear, or click twice: once to create the start point and once to create the end
point of the rectangle.


To draw a square, press Shift while you draw.

Technical Training Centre 1/0809


TM-01559
markup


Training Document. For training purpose only.
pop-up note


16
Pencil tool

To draw free-form lines using the Pencil tool, drag where you want to
begin drawing. You can release the mouse button, move the pointer to a
new location, and continue drawing.


markup

Technical Training Centre 1/0809


pop-up note

TM-01559


Training Document. For training purpose only.


17
Typewriter tool
Add text using the Typewriter
Use the Typewriter to type text anywhere on a PDF page. The typewriter tool
provides a simple solution for filling out forms, for example. The typewriter tool


is similar to the text box tool, but includes a somewhat limited set of properties.

Technical Training Centre 1/0809

Customise the Typewriter properties
Double-click the typed text and click-drag to select it. Change properties directly
in the Typewriter toolbar.
When you are happy with the result and want to make your settings default, use


the Properties bar (Ctrl+E). Tick the Make Properties Default box and
then click OK.

TM-01559


Training Document. For training purpose only.


18
2
TBA/19
Introduction

Technical Training Centre

   
TBA 250 S Straw

Package volume
Related Pack. Mat. Drawing: 479641-1
Size code: 565

Nominal volume (ml) 250.0

Theoretical crease volume (ml) 263.8
Underfilling (ml) 13.8
Underfilling (%) 5.2

Web width (mm) 188.0 ± 1

Repeated length (mm) 185.0 ± 0.3
Theoretical LS-Overlap (mm) 6.0

Related documents
Packaging material specification S001
Choice of Packaging material FDM or
Sales Manual G001
Distribution See ORBIS;
Pallet Pattern

Additional material
Type Quality Consumption/pack Order number

LS-strip LHL 7.5x0.1 mm 0.129 g 8891-952-01

8893-952-01

PPP 7.5x0.080 mm 0.100 g 8840-951-01

8842-951-01

Wine 7.5x0.080 mm 0.100 g 8841-951-01

8843-951-01

LSE 7.5x0.080 mm 0.096 g 8868-951-01

Straw FDM or See ORBIS

Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 1.2

   
Package Data
TBA 250 S Straw

D W

Package dimensions
W D H
Width Depth Height
(mm) (mm) (mm)

Crease measurements 53.0 38.0 131.0

Package measurements 56.2 38.9 133.3

Filling machine
(reference filling machine is the one used during the develop-
ment phase)

Filling machine TBA/19 & TBA/21

Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 2.2

   
TBA 250 S
Packing Pattern 3x9
Distribution Unit Tray

Pallet Type Euro (1200 x 800 mm)

Opening Straw Ø 4 mm

Weight Load Tray

Gross 613 kg 7 kg
Volume 1,06 m3

1109,0

1200,0
800,0

This Pallet Pattern is theoretical only. Tests should be made with packages
in the right kind of material and filled with the right product to get the final
pattern.
Packages / pallet 2268 Litres / pallet 567 Trays / pallet 84
Trays / layer 12 Layers / pallet 7 Area efficiency 82,5 %

For more information: Sara Sjöström Tel. +46 46 364503 November 01, 2000

   
TBA 250 S
Packing Pattern 3x9
Distribution Unit Tray

Pallet Type Eurohalf (800 x 600 mm)

Opening

Weight Load Tray

Gross 306 kg 7 kg
Volume 0,53 m3

1100,0

600,0 800,0

This Pallet Pattern is theoretical only. Tests should be made with packages
in the right kind of material and filled with the right product to get the final
pattern.

Packages / pallet 1134 Litres / pallet 283,5 Trays / pallet 42

Trays / layer 6 Layers / pallet 7 Area efficiency 78,5

For more information: Sara Sjöström Tel. +46 46 364503 November 01, 2000

   
TBA 250 S
Packing Pattern 3x9
Distribution Unit TRAY

Pallet Type UK (1000 x 1200 mm)

Opening

Weight Load Tray

Gross 956 kg 7 kg
Volume 1,33 m3

1109,0

1200,0
1000,0

This Pallet Pattern is theoretical only. Tests should be made with packages
in the right kind of material and filled with the right product to get the final
pattern.

Packages / pallet 3591 Litres / pallet 897,8 Trays / pallet 133

Trays / layer 19 Layers / pallet 7 Area efficiency 93,3 %

For more information: Sara Sjöström Tel. +46 46 364503 March 01, 2000

   
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3
Supply System

Technical Training Centre

   
X034 Valve panel
MY182


MY177
MY129
MY020
MY021

Lund, Sweden
MY024
MY026
MY027

Technical Training Centre

X035


MY001, MY002

Machine type
MY915
MY002, MY003
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TBA/19 030V
MY023
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Issue
2/0903
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Air diagram

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 3/0903 OH 1848:1
   
Air diagram

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0903 OH 1848:2
   
Air diagram

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0903 OH 1848:3
   
Air diagram, ASU

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 2/0903 OH 1833
   
Air diagram, PT19

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 2/0903 OH 1849
   
Festo CDVI
CDVI overview ................................................. 2

CDVI parts ....................................................... 3

CDVI combinations .......................................... 4

Type of valve ................................................... 5

Valve numbering .............................................. 6

Sealing plates .................................................. 7

Sealing plates example .................................... 8

End plates ....................................................... 9

End plate supply ............................................ 10

Main and expansion sub-base ...................... 11

Technical Training Centre 1/0607 TM-01059 Training Document. For training purpose only. 1

   
CDVI overview

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2 TM-01059 Training Document. For training purpose only. Technical Training Centre 1/0607

   
CDVI parts
Denomination Type Tetra Pak no. Festo no. Festo code

Main valves Monostable valve, 5/2 90458-1194 196657 M

Bistable valve, 5/2 90458-1197 196659 J

Valve pressurized in mid-position, 5/3 90458-1198 196655 D

Valve closed in mid-position, 5/3 90458-1199 196651 G

Valve open in mid-position, 5/3 90458-1200 196653 E

Valves 2x3/2, open 90458-1201 196663 N

Valves 2x3/2, closed 90458-1202 196661 K

Valves 2x3/2, 1 open, 1 closed 90458-1203 196665 H

Basic sub-base For 4 valves 90458-1204 196714 4

For 8 valves 90458-1205 196690 8

Expansion sub-base Expansion for 2 valves 90458-1206 196711

Expansion for 2 valves with separate 90458-2956 528609

supply pressure

Sealing plates Standard 90458-1207 196700

Channel 1 blocked 90458-1208 196702

Channel 3/5 blocked 90458-1209 196704

All channels blocked and separated 90458-1210 196706

End plates Left endplate, 5 mm cable 90458-1211 196692

Left endplate, 10 mm cable 90458-1212 196694

Right endplate, internal pilot air 90458-1213 196696

Right endplate, external pilot air 90458-1214 196698

Accessories Cover plate for empty valve 90458-1215 196667

Mounting kit (4 spacers) 90458-1216 196718 A

Technical Training Centre 1/0607 TM-01059 Training Document. For training purpose only. 3

   
CDVI combinations

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4 TM-01059 Training Document. For training purpose only. Technical Training Centre 1/0607

   

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Type of valve

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8 TM-01059 Training Document. For training purpose only. Technical Training Centre 1/0607

   

End plates

Technical Training Centre 1/0607

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Technical Training Centre 1/0607 TM-01059 Training Document. For training purpose only. 11

   
   
Multi-Pin cable
Pin assignment


Lund, Sweden
Valve / coil Pin number Core colour Valve / coil Pin number Core colour

Technical Training Centre

1 / 14 A01 white 9 / 14 C05 white-pink
1 / 12 A02 green 9 / 12 C06 pink-brown


2 / 14 B01 yellow 10 / 14 A07 white-blue
2 / 12 B02 gray 10 / 12 A08 brown-blue
3 / 14 C01 pink 11 / 14 B07 white-red

Machine type
3 / 12 C02 blue 11 / 12 B08 brown-red
4 / 14 A03 red 12 / 14 C07 white-black
4 / 12 A04 purple 12 / 12 C08 brown-black
5 / 14 B03 gray-pink COM B10 brown


5 / 12 B04 red-blues COM C10 black
6 / 14 C03 white-green NC A09
6 / 12 C04 brown-green NC A10

Issue
7 / 14 A05 white-yellow NC B09
7 / 12 A06 yellow-brown NC C09

1/0903
8 / 14 B05 white-gray
8 / 12 B06 gray-brown


Cable testing standard FN 942 042

OH 2100
diagram
Hydraulic

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 2/0804 OH 1834
   
Pressure regulation

Reduction valve

Cutting pressure

Jaw pressure

Releif valve

To tank

From pump

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V, 030V 1/0601 OH 1767
   
diagram
Water

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 2/0804 OH 1835
   
diagram
Lubrication

-ACHINE TYPE )SSUE

4ECHNICAL 4RAINING #ENTRE
,UND 3WEDEN 4"! 6 /(
   
Central lubrication system

Lubrication oil
Compressed air

PLC

Technical Training Centre Machine type Issue

Lund, Sweden 1/9905 OH 820
   
Central lubrication pump
and dosing valve
Rest position

Lubrication oil
Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden 1/9905 OH 821:1
   
Central lubrication pump
and dosing valve
Pressure stroke

Lubrication oil
Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden 1/9905 OH 821:2
   
Central lubrication pump
and dosing valve
Discharge pressure

Lubrication oil
Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden 1/9905 OH 821:3
   
Lubrication cycles

Lund, Sweden


Single lubrication pulse

Technical Training Centre

15 min

10 s 10 s

Machine type


TBA/19
Long lubrication cycle


Issue
10 s 30 s 10 s 30 s 10 s 30 s 10 s 30 s 10 s

1/0011

Lubrication

OH 1022
Check for no oil pressure
Check for oil pressure
4
Superstructure

Technical Training Centre

   
Aseptic food processing

Lund, Sweden


Technical Training Centre
Sterilized

Machine type
packaging


material

Sterile


surrounding

Issue
1/9501
Commercially Aseptic
sterile food transfer


Aseptic packages

OH 525
Aseptic Production Cycle

Lund, Sweden


Preparation of filling machine

Technical Training Centre

No production planned time
Sterilisation of filling machine

Machine type


Weekly care

TBA
Production
Daily care


Issue
1/0106
External cleaning


CIP

OH 1065
Aseptic Machine Sterilisation

Lund, Sweden


Technical Training Centre
Machine type
Evaporated peroxide The peroxide is The aseptic environment


is sprayed into an condensed and then is kept with an overpressure

TBA
enclosed area. dried with hot sterile air. of cooled sterile air.


Issue
1/0106

OH 1066
Sterile system overview

Lund, Sweden
Air


Peroxide

Technical Training Centre

Aseptic chamber Product
Water

Machine type


Packaging material

TBA/8, 9, 19, 21

Issue
1/9610
Peroxide bath


Compressor Peroxide tank
Tight tube

OH 613
Air superheater
33 Safety valve
34 Pressure expansion
65
030V 49 tank
50
Sterile system TBA/19 56 18
35 Filling valve,
peroxide bath
36 Draining valve,
19 48 peroxide bath
20 21 37 Safety cap
46 38 Peroxide pump
39 Peroxide filter
9 47 40 Filling peroxide
pump
41 Peroxide container

Lund, Sweden
54 13
45 42 Peroxide tank
22


43 Diluting tank
55 44 Chamber pressure valve
58
45 Peroxide filter

Technical Training Centre

68 46 Filling spray tank valve
11
47 spraying peroxide valve
10 1 1 48 Spray tank
8 49 Air valve, spraying
57 50 Air filter
51 Water level sensor
59 52 Pressure switch
23 53 Air superheater temperature
27 60 54 Presterilization temperature


12

Machine type
55 Steam temperature
24 56 Air knife temperature
5 61
57 Water bath level sensor
58 Peroxide bath level sensor
28 59 LS temperature, production
14 25
60 LS temperature, tube sealing
66 61 LS short stop temperature
26

TBA/19 030V
62 Water bath temperature
63 Peroxide bath temperature
62 45
64 Peroxide tank level sensor
52 65 Spray tank level sensor


30 66 Leakage sensor
29
67 Tube folding device
63 36 68 Deaerator

Issue
7
4
68
35
31 39

2/0612
67 40
16
32 41

38
33
17 37
15


44
51 34
2
1 42
6

53 39 64
3

OH 1844:1
18 Air knife
43
7 Heat exchanger valve 19 Driven bending roller
8 Peroxide evaporator 13 Steam barrier valve (C) 20 Pendulum roller
9 Air inlet valve 14 Regulating valve 21 Calender roller 25 Peroxide bath 29 Product level probe
1 Compressor 4 Venting valve 10 Steam trap 15 Compressor water valve 22 Filling pipe 26 Water bath 30 Product level float
2 Water separator 5 Air superheater 11 Product valve (A) 16 Constant flow valve 23 Suction valve 27 LS element 31 Water bath heater
3 Float unit 6 Heat exchanger 12 Sterile air valve (B) 17 Scrubber 24 Top filling valve 28 LS short stop element 32 Water circulation pump
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

Technical Training Centre Machine type Issue

Lund, Sweden 1/9904 OH 819
   
Scrubber

Water
Air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8, TBA/19 1/9501 OH 493
   
Sterile System
Water ring compressor


Lund, Sweden
Technical Training Centre


Machine type


Issue
3/0505

OH 104
Rotating water ring
Air mixed with water
Water separator

Water
Air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8, TBA/19 1/9501 OH 494
   
   
Insulating material
Pre−heated air
Hot air
Air
Air superheater

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 TBA/21 TBA/22 3/9508 OH 107
   
Sterile system
Peroxide evaporator

Peroxide
Compressed air
Hot air

Technical Training Centre Machine type Issue


Water

Machine type
Peroxide
Compressed air

TBA/19 030V

Issue
2/0612

OH 1844:5
Sterile system TBA/19 030V

Filling spray tank

Lund, Sweden


Low temperature

Technical Training Centre

Air
Hot air
Pre−heated air
1 1 alt. cooled air
Steam
Product


Water

Machine type
Peroxide
Compressed air

TBA/19 030V

Issue
2/0612

OH 1844:6
,EVEL RELAY
0EROXIDE SPRAY QUANTITY 4"!

, !

,
!


43 Diluting tank
44 Chamber pressure valve
45 Peroxide filter

Technical Training Centre

46 Filling spray tank valve
47 spraying peroxide valve
1 1 48 Spray tank
49 Air valve, spraying
50 Air filter
51 Water level sensor
52 Pressure switch
53 Air superheater temperature
54 Presterilization temperature


Machine type
55 Steam temperature
56 Air knife temperature
57 Water bath level sensor
58 Peroxide bath level sensor
59 LS temperature, production
60 LS temperature, tube sealing
61 LS short stop temperature

TBA/19 030V
62 Water bath temperature
63 Peroxide bath temperature
64 Peroxide tank level sensor
65 Spray tank level sensor


66 Leakage sensor
67 Tube folding device
68 Deaerator

Issue
2/0612

18 Air knife

OH 1844:20
7 Heat exchanger valve 19 Driven bending roller
8 Peroxide evaporator 13 Steam barrier valve (C) 20 Pendulum roller
9 Air inlet valve 14 Regulating valve 21 Calender roller 25 Peroxide bath 29 Product level probe
1 Compressor 4 Venting valve 10 Steam trap 15 Compressor water valve 22 Filling pipe 26 Water bath 30 Product level float
2 Water separator 5 Air superheater 11 Product valve (A) 16 Constant flow valve 23 Suction valve 27 LS element 31 Water bath heater
3 Float unit 6 Heat exchanger 12 Sterile air valve (B) 17 Scrubber 24 Top filling valve 28 LS short stop element 32 Water circulation pump
Program steps, TBA/19 030V
Symbol Name Criteria Function

SIGNAL FROM Signal from steriliser

STERILISER

SIGNAL TO Signal to steriliser

STERILISER 20 minutes
DRYING, 20 minutes
Air inlet valve directs air to aseptic chamber
LS heating ON (set-point 1)
B-valve closes after 18 minutes of Drying
DRYING Bending roller rotates during the last minute of Drying
PAUSE, 52 - 112 s
Air inlet valve directs air to scrubber
Peroxide condensates on surfaces in aceptic chamber
Heat exchanger valve to cooling (air to heat exchanger)
Bending roller rotates
SPRAY, 11 - 52 s
If spraying fails (<21 s, >52 s) machine to Venting
Bending roller rotates
FILL, 3 - 11 s
Spray container fills up with peroxide
If spray container not filled at 11 s machine steps
SPRAYING to Preheating III

Pre-sterilization temperature
Drying spray container with compressed air
Heat exchanger valve to by-pass
Air inlet valve directs air to scrubber
Suction-valve switches (air from peroxide bath and air knife)
Pressure chamber valve opens (increases air inlet)
PREHEATING III Air superheater ON (set-point 1)
B-valve closes
Heat exchanger valve to cooling (air to heat exchanger)
Main motor high-speed (ejects packages past SA)
TIGHT TUBE Automatic step-up to Preheating III
LS temperature
Compressor starts / Water valve opens
Heat exchanger valve to by-pass (until air knife temp OK)
Air superheater ON (set-point 2)
LS heating ON (set-point 2)
Peroxide circulation ON
PREHEATING II LRF-valve sterile pressure
Peroxide tank level, Steam temperature

Water circulation and water heating ON (set-point 2)

PREHEATING I Peroxide filling from container to tank

Air, water, and power on

Technical Training Centre 1/0610 TM-01085 Training Document. For training purpose only. 1

   
Program steps, TBA/19 030V
3YMBOL .AME #RITERIA &UNCTION

CIP Key-switch selection of final or intermediate cleaning

LRF-valve cleaning pressure

EXTERNAL CLEANING Cleaning with hot water and detergent

Manual cleaning of lower filling pipe

PREPARATION Connect cleaning pipe for CIP
FOR CIP

Operator to cut of packaging material

PREPARATION FOR Operator to inch out packaging material from superstructure
EXTERNAL CLEANING
Venting valve opens
READY FOR DOORS (to create underpressure in the Aseptic chamber)
TO BE OPENED
Venting after production and if spraying or drying fails
Suction from peroxide bath
VENTING All heaters OFF

A-valve closes and tube empties from product,

8 packages ejected
C-valve opens for steam to flush filling pipe from product,
16 packages ejected
PRODUCTION Possible to restart production within 2 minutes
FINISHED
Peroxide is drained from bath to tank
A-valve closes
Jaw system stops in design
Air knife and calendar rollers returns to “up” position
SHORT STOP Machine steps to drying completed after 5 minutes

Packages to final folder when correct design position is found

PRODUCTION Top filling of peroxide bath (1 minute ON, 5 minutes OFF)

A-valve opens when correct filling position is found

FILLING ON Filling system controls the level in tube

LS Short stop heater ON

Synchronization of final folder and jaw system
Filling of peroxide bath
LS, LS Short stop, and counter roller moves into position
MOTOR START Air knife and calendar rollers moves into position
Main motor starts

READY FOR
PRODUCTION

Technical Training Centre 1/0610 TM-01085 Training Document. For training purpose only. 2

   
Peroxide filling station

Peroxide
Compressed air
Vacuum

Technical Training Centre Machine type Issue

Lund, Sweden Tetra Brik Aseptic 1/9609 OH 594
   
Forming of the tube
1

2
1
2

4
5

Technical Training Centre Machine type Issue

Lund, Sweden TBA/9, TBA/19 1/9509 OH 554
   
5
Drive Unit

Technical Training Centre

   
Drive system
Overview

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0301 OH 1104
   
Final folder
Drive

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0301 OH 1098
   
   
Drive unit
Electrical clutch
Disengaged

Rotating
Stationary
Shim

Engaged

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0211 OH 1248
   
Drive unit
Electrical clutch,
cranking Disengaged

Rotating
Stationary
Shim

Engaged

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0302 OH 1249
   
   
Drive unit
Crank mechanism

Disengaged position

Engaged position

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0212 OH 1100
   
6
Jaw System

Technical Training Centre

   
Drive
Jaw system

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0301 OH 1099
   
Jaw movement and functions

Jaws moves apart

Cutting

Volume flaps

Folding flaps

Sealing pulse Cooling

Jaw pressure

Jaw gap measurement

Jaws catch tube

Technical Training Centre Machine type Issue

Lund, Sweden TBA 3/0302 OH 892
   
   
   
   
Basic Jaw System Setting
TBA/19 030V
4.4-6 Yoke - Set 4-3 Jaw System - 4-2 Jaw System - Set
Turning Position Check Jaw Over Jaw Jaw Gap

4-12 Jaw System - NO 4-4 Jaw System - Set

Set Cam Support OK?
Jaw Over Jaw
Rollers YES
4-8 Jaw System -
4-5 Jaw System - Check T-
Check Stroke measurement

NO 4-6 Jaw System - Set 4.3-3 MDCS - Set

OK? Stroke Cylinder
YES
4-9 Jaw System - Set 4.1-1 Cutting Jaw -
4-2 Jaw System - Set
Cutting Jaw and Set Folding Flap
Jaw Gap
Pressure Jaw Parallelism

4.1-6 Cutting Jaw -

4.4-5 Yoke - Set
Check Folding Flap
Symmetry
Mechanism

Install volume flaps

4.8-3 Volume
and springs on
Adjustment - Set
cutting jaw

4.7-2 Volume Flap - 4.2-7 Pressure Jaw -

Alignment Set Pivot Spring

4.1-5 Cutting Jaw -

4.5-1 Support Roller -
Bleed and 4.2-4
Set
Pressure Jaw - Bleed

Remove volume 4-13 Jaw System -

flaps and springs on Set Catch Lifter
cutting jaw Cams and Rollers

4.2-2 Pressure Jaw -

4-2 Jaw System - Set
Check Catches and
Jaw Gap
Catch Clearance

4-10 Jaw System -

3.6-2 Disconnection
Check Parallelism in
Link - Set
Movement

NO 4-11 Jaw System - 4-7 Jaw System -

OK? Set Parallelism in Check Stroke During
Movement Production
YES

Technical Training Centre 2/0903 TM-01058 Training Document. For training purpose only.

   
Lower turning position
TBA/19 020V

Technical Training Centre 1/0602 TM-01013 Training Document. For training purpose only.

   
Stroke
TBA/19 020V

Technical Training Centre 1/0602 TM-01014 Training Document. For training purpose only.

   
Jaw alignment
TBA/19 020V

Technical Training Centre 1/0602 TM-01015 Training Document. For training purpose only.

   
Jaw symmetry
TBA/19 020V

Technical Training Centre 1/0602 TM-01016 Training Document. For training purpose only.

   
Volume cams
Volume adjustment

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0212 OH 1105
   
Jaw gap / parallelism
TBA/19 020V

Technical Training Centre 1/0602 TM-01017 Training Document. For training purpose only.

   
Jaw above jaw
TBA/19 020V

Technical Training Centre 1/0602 TM-01018 Training Document. For training purpose only.

   
Disconnecting link

-ACHINE TYPE )SSUE

4ECHNICAL 4RAINING #ENTRE
,UND 3WEDEN 4"! /(
   
7
Final Folder Unit

Technical Training Centre

   
Final Folder
Overview

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 2/0704 OH 1859:1
   
Final Folder
Packages

Air for heating

Movement
Pressure

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 2/0704 OH 1859:2
   
Final folder
Drive

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0301 OH 1098
   
Final Folder
Drop Chute

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 1/0610 OH 1851
   
Compressed air
Final Folder
Drop Chute

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 1/0610 OH 1850
   
Final folder
Station chain

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0701 OH 1857
   
Final folder
Pivot frame

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0701 OH 1858
   
Pull−down device
Final folder

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0612 OH 1852
   
PE
N
L
Final folder
Flap heating

Hot air
element

Air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0612 OH 1856
   
Final folder
Upper position
Pressure unit

Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0402 OH 1051:1
   
Final folder
Middle position
Pressure unit

Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0402 OH 1051:2
   
Final folder
Lower position
Pressure unit

Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0402 OH 1051:3
   
Cam connection
Final folder
Pressure unit

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0402 OH 1051:4
   
Final folder
Outfeed unit

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0301 OH 1308
   
8
ASSU

Technical Training Centre

   
Splice Sequence
Strip splice prepared
ASSU

Technical Training Centre Machine type Issue

Lund, Sweden ASSU 1/0508 OH 1705: 1
   
Splice Sequence
ASSU

Splicing

Technical Training Centre Machine type Issue

Lund, Sweden ASSU 1/0508 OH 1705: 2
   
Splice Sequence
Cooling and unlocking
ASSU

Technical Training Centre Machine type Issue

Lund, Sweden ASSU 1/0508 OH 1705: 3
   
Splice Sequence
Splice sequence completed
ASSU

Technical Training Centre Machine type Issue

Lund, Sweden ASSU 1/0508 OH 1705: 4
   
Automatic Strip Splicing Unit

The Automatic Strip Splicing Unit, ASSU, facilitates changing of LS strip

from a consumed reel to a new one by joining the strips together. The package
with the strip splice will be automatically ejected.

Strip magazine There are two reels of strip material in the strip magazine. One reel is in
production and one reel is prepared for splicing. The reels are mounted on
reel holders equipped with a brake function to prevent unintentional
unreeling. During splicing the filling machine continues running, consuming
strip material from the splicing magazine.
An “empty reel detector” for each reel initiates a splice sequence when a reel is
empty. The splice sequence can also be inititiated by pushing the manual strip
splice button.
A strip rotation detecor senses if the strip is broken and sends a signal, which
will cause the machine to stop automatically.

Empty reel detector Strip rotation detector

Strip magazine

Splicing magazine

Technical Training Centre 1/0508. TM-00910 Training Document. For training purpose only. 1

   
Splicing device The splicing device consists of a movable heating device with a sealing plate
and a fixed dolly side. There are also two heated wires that work like knives
to cut off both the old and the new strip.
Heated wires Sealing plate

Heating
device

Splicing device

Strip sealing with The strip is sealed to the packaging material through induction heating.
induction heating An inductor heats the packaging material and the strip is pressed and sealed by
two springloaded pressure rollers. The strip guide ensures that the strip is ap-
plied at the correct position on the packaging material.

Strip guide
Outer
pressure
roller

Inductor

Strip sealing unit

Technical Training Centre 1/0508. TM-00910 Training Document. For training purpose only. 2

   
Splice sequence
Strip splice prepared

The operator must prepare a splice by threading the strip from the new reel
according to the OM.

Technical Training Centre 1/0508. TM-00910 Training Document. For training purpose only. 3

   
Splicing

Heated wires

Sealing plate

When the reel in production is consumed, or the manual splice button is

pushed, a splice will be performed. The sealing plate joins the old and the new
strip material by a heating pulse. At the same time a heated wire system will
cut off the old and the new strip.

Technical Training Centre 1/0508. TM-00910 Training Document. For training purpose only. 4

   
Cooling and unlocking

Springloaded
plunger

Airflow from a small nozzle below the sealing plate is used to cool the seal.
A springloaded plunger will hold the strip in place while the splicing head is
retracting, to extend the cooling time slightly.

Technical Training Centre 1/0508. TM-00910 Training Document. For training purpose only. 5

   
Splice sequence completed

An alarm is triggered on the operator panel when the splice sequence is

completed. The alarm indicates to the operator to prepare a new reel of strip.
If a new strip is not prepared, the machine will stop the next time a strip level
sensor is activated.

Technical Training Centre 1/0508. TM-00910 Training Document. For training purpose only. 6

   
9
ASU/PMI

Technical Training Centre

   
Automatic Splicing Unit
Overview

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0309 OH 1449
   
ASU
Automatic Splicing Unit

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:1
   
ASU
Starting splice sequence

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:2
   
ASU
Register code found

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:3
   
ASU
Cutting packaging
material

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:4
   
ASU
Cylinder retraction

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 10403 OH 1409: 5
   
ASU
Changing packaging
material reel

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:6
   
ASU
Sealing

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:7
   
ASU
Splicing sequence
completed

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0403 OH 1409:8
   
Packaging Material
Infeed

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 3/0610 OH 1382
   
10
Design Control

Technical Training Centre

   
Motorised Design Control System
TBA/19


Photocells TMCC

Read
Photocells

Technical Training Centre 4/0601

Angle encoder
Read Pendulum


Angle Encoder I/P Transducer
Manometer

TM-00338
TPOP / Design adjustment
Calculation
(PID)

Cylinder


Output to
I/P Transducer, Step
PC motor and Folding flaps

Step motor
Communication drive
with PLC Step motor - left

Training Document. For training purpose only.

and terminal


PLC

Parameter Step motor

settings drive
Step motor - right
TMCC
TMCC2
559810

Lund, Sweden
+ 24 VDC 1
Motorised Design Control System


DC common 2

Technical Training Centre

Design adjustment potentiometer 3
(MUPP)

6 6 U/P transducer

Machine type
RCM photocell 3 bars 7


RCM photocell 4 bars 8 OFF ON

Register code detection

Angle encoder 9−16

TBA/19 030V
Design OK in production
RH/LH stepper motor pulse
RH/LH motor direction CCW RH/LH motor direction CW


RCM photocell 3 bars comm. 17
Cylinder position 19−25
RCM photocell 4 bars comm. 18
25 Right step pulse Cylinder position 12−18

Issue
MDCS right sensor home 19 Cylinder position 6−11
RS232 RS485 26 Left step pulse
CAN Cylinder position 0−5

3/0903
MDCS left sensor home 20
27 Direction
Design enable 21 28 MDCS Alarm


22 30 Request volume values
Volume enable
23 31 RCM pulse
Volume clock
24 32 Design OK
Volume data

OH 1114
Register code reading
26 bits

10
01

11010001111011010001111000
11010001111011010001111000

Technical Training Centre Machine type Issue

Lund, Sweden 1/9906 OH 858
   
TMCC

FAULT
POWER
S1
S2
S3
S4
Register mark reading S5
S6
S7
S8

SW 1

Old New
RS232
Dynamic Threshold


White
255
I I

Lund, Sweden
o o

o o

=24V

Technical Training Centre

o o


A

Machine type
TB/TBA

Issue
1/0506
>XX
1 0 1 D.T


0
Black

OH 1673
0,15V 0,8V 1,4V 2.1V
Black White
0
Design correction

Lund, Sweden


Technical Training Centre
Pre correction Position 0

Machine type


TBA/19 020V

Correction Position 1

Issue
1/0304

OH 1379
Full paper feed Position 25
Web Tension Control

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 030V 1/0701 OH 1839
   
Constant web tension
Increase motor speed Decrease motor speed

Lund, Sweden


Technical Training Centre
Machine type


TBA/22

Issue
1/9909

Motor Motor

OH 835
PLC Drive PLC Drive
Control M Control M
Compressed air Motor, Driven roller
Tube regulation
by web tension

High web tension

(low product pressure)
Low web tension
(high product pressure)

Technical Training Centre Machine type Issue

Lund, Sweden TB/TBA 2/0506 OH 818
   
MDCS

Lund, Sweden


Output Signal Diagram

Technical Training Centre

Cylinder I/P transducer
position pressure

Machine type


25 2.5 bar (max)

TBA/19 020V

Issue
2/0304

1 0.5 bar (min)

OH 1368
Output value
1 10 255
11
Filling Control System

Technical Training Centre

   
Leakage
detector

TMCC2
559810
Level
probe

TMCC

RS232 RS485
CAN
GSZ

I/P Transducer
Tube Folding
device

Product
Compressed air

PC
PLC TPOP

Principle of
filling system
Technical Training Centre Machine type Issue
Lund, Sweden TBA/19 020V 2/0301 OH 1106
   
TMCC
TMCC2

Lund, Sweden
559810 Filling Control System


+ 24 VDC 1

Technical Training Centre

Ground 2

Level detector 3
5 U/P transducer signal

Machine type
6 Filtered Level Output


Sterilisation 9
Flashing ON
Production 10

Cleaning 11 Normal or Prefilling starts Production

TBA/19 020V
12 Cleaning
Prefilling
Sterilisation


High level alarm Level higher than 83%

PLC data / PLC clock 14 Level higher than 66%

Issue
Level higher than 50%
Level higher than 33%
RS232 RS485

4/0903
CAN Low level alarm Level higher than 16%
Main motor low speed 17 25 High level alarm


26 Low level alarm
27 Filling OK
28 Handshake / TMCC data

OH 1108
Level Probe
9,6 V DC Signal Out (1,8 V DC)

0,6 V

90°
0,6 V

0,6 V

1,8 V DC 0,6 V

0,6 V

0 V DC

Technical Training Centre Machine type Issue

Lund, Sweden 2/0408 OH 1107
   
Regulating

Lund, Sweden
valve


Technical Training Centre
Machine type



Issue
Product

6/0110
Compressed air
Non−conductive part


of the regulator
Conductive layer
in the diaphragm

OH 497
Non−conductive layer
in the diaphragm
Disengaged position

Engaged position
Tube folding device

Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0302 OH 1311
   
C
A

AP−Valve
440630−020V
(Aseptic Product Valve)

Technical Training Centre Machine type Issue

TETRA
PAK Lund, Sweden 1/9208 OH 453:1
   
AP-Valve
440630-020V
(Aseptic Product Valve)
C

Technical Training Centre Machine type Issue

Lund, Sweden 1/0003 OH 453:2
   
(The function is
identical with
Aseptic Product Valve 440630-101/102 valve 90 207-40/41)


Lund, Sweden
Technical Training Centre


Machine type


Issue
2/0601

OH 1:7
12
Temperature Controlled
Steam Barrier

Technical Training Centre

   
Temperature Controlled
Steam Barrier - TCSB19
2.2c [Link]

Tetra Pak Doc No. 591098-0102 15

   
Temperature Controlled Steam Barrier

Overview

2.2c [Link]
This rebuilding kit is valid for the following machine types:
Machine Development step Volume/
Package shape
TBA/19 TBA 648160-0100 All except for
Square
TBA/19 TPA 648160-0100 All
TBA/19 TWA 648160-0100 All

16 Doc No. 591098-0102 Tetra Pak

   
Temperature Controlled Steam Barrier

Functional description
This kit allows to set the steam pressure according to technical data directly
on the filling machine. The kit is installed between the APV valve group and
the steam supply (1).

1 Steam supply 2.5 bar 1

2 Shut-off valve
3 Filter 2
4 Pressure regulator (high)
5 Pressure regulator (low)
6 Steam trap 11 12 13
7 Temperature regulator
3
8 Steam trap
9 Thermocouple
10 Non-return valve
11 Solenoid valve 4
12 Selector 10
13 Manometer
14 APV valve
14 5
2.2c [Link]

9
6

8 7
The solenoid valve (11) is activated (closed) at the end of the Spraying
phase and stays in this condition until the Drying phase is completed. This
creates a steam barrier in the area of the APV valve (14) at 130° C. If during
this phase the temperature goes out of tolerances (130° C -5° C +25° C) for
more than 1 minute, the machine jumps to step Power On (step 0).
For the rest of the machine cycle, the temperature is kept at 110° C. If the
temperature goes out of tolerances (110° C -5° C +10° C) for more than 1
minute, an alarm is shown. After 5 minutes in wrong temperature conditions,
the machine jumps to position. 40 (stop in sequence without step up
condition). In this case, it is not possible to resume production.
(Cont'd)

Tetra Pak Doc No. 591098-0102 17

   
Temperature Controlled Steam Barrier

(Cont'd)
To set the pressure values proceed as follows:
a) Turn the selector (12) to position Line. The value on the manometer (13)
corresponds to the steam pressure in line.
b) Turn the selector (12) to position Low (Pressure during production). Set
the steam pressure to 0.4 - 0.5 bar turning the pressure regulator (4). This
pressure value range corresponds to a temperature range of 109- 111°C.
c) Turn the selector (12) to position High (Pressure during sterilisation).
Set the steam pressure to 1.7 - 1.8 bar turning the pressure regulator (5).
This pressure value range correspond to a temperature range of
130- 131°C.
d) Turn the selector (12) in position Off. Start to run the machine.
z

4 5

2.2c [Link]
High Low
Pressure Pressure

High

Low Line

Off

12 13

4 Pressure regulator - High

5 Pressure regulator - Low
12 Selector
13 Manometer

18 Doc No. 591098-0102 Tetra Pak

   
Temperature Controlled Steam Barrier

Enclosed documentation
Mechanical documents
Description Document No
SPC pages SPC-DF-591098-0102
Modification drawing 1334843-1

Electrical documents
The electrical documentation is delivered as a separate document together
with the kit.
Note! Always add the rebuilding information to the machine card.
A white machine card defining the development state of the equipment is
located in the electrical cabinet.
All the alterations are outlined with a heavy dashed line to facilitate
comparison of new documentation with existing documentation.

Rebuilding time
Total man/hours Recommended
personnel
Mechanics 4 1
Electricians 4 1
2.2c [Link]

For further information, please contact Tetra Pak Carton Ambient Liaison
Centre.

Preparation
Machine status Power Off
Water Off
Steam Off
Air Off

Before start any operation on the machine check the following items:
• that this folder is correct for the machine according to the demands
• that all parts for the rebuilding are delivered according to the bill of
material.

Tetra Pak Doc No. 591098-0102 19

   
Steam pressure
Low temperature

Y1281
OFF
Line
Low

High

High Low

Y1280

High temperature

Y1281
OFF
Line
Low

High

High Low

Y1280
Steam Product
Water Sterile air
Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 050V 5/0802 OH 1236
   
13
Cleaning In Place

Technical Training Centre

   
Cleaning
what product component is
removed by
what solution

TE
ID

Salt
AC

and R
mineral Sugar

Protein Fat

A LK AL I

Technical Training Centre Machine type Issue

Lund, Sweden 1/9810 OH 799
   
Cleaning in Place
Final
Cleaning steps To restore Ph in the return pipe rinsing


Rinsing

Technical Training Centre 1/9910

To force out the Acid cold water
Acid
To dissolve mineral deposits cleaning


Final
rinsing To restore Ph in the return pipe

TM-00135
Rinsing
cold water To force out the Alkali

Alkali


cleaning Cleaning with Alkali

Rinsing
warm water Rinsing the pipes and melting any fat built-ups

Training Document. For training purpose only.

Rinsing
cold water To force out product, remaning in the product pipe


Daily cleaning

Weekly cleaning ( or when required)

1
Intermediate cleaning
TBA/19

Lund, Sweden


Technical Training Centre
Machine type


TBA/19

Issue
2/9804

Hot air
Pre−heated air
alt. cooled air
Steam

OH 533:1
Product
Cleaning liquid
Final cleaning
TBA/19

Cleaning liquid
Cleaning liquid
Steam

Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 2/9804 OH 533:2
   
14
Package Check

Technical Training Centre

   
Notebook

Package Evaluation
TBA

MT-83112-1
Technical Training Centre
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 1/0805

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 photo-
copying, recording or otherwise, without permission in writing from Technical Training
Centre.

   
Package Evaluation
TBA

Training Document
This Training Document is intended for
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to
the equipment specific documentation.

Technical Training Centre

Lund, Sweden
   
Contents

Package Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Package Forming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crease Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LS-Overlap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Volume (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flap Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Date Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transversal Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rough Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accurate Check (Tear Down Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dissolving of Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Red Ink in Dissolved Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Longitudinal Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Longitudinal Sealing Tearing (LS Tear Down) . . . . . . . . . . . . . . . . . . . . . 9
Red Ink Injection in Air Gap of the LS-strip . . . . . . . . . . . . . . . . . . . . . . 10
Inside Layer Ruptures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conductivity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Red Ink Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Copper Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pull Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Red Ink Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

   
Package Evaluation
TBA
Introduction
This textbook is intended to be used together with instructor led training.
A wide variety of tests are described briefly, but you are only supposed to fo-
cus on the tests selected by the instructor. Pay attention and write notes for the
selected tests.

General
A tight package is a precondition for an aseptic package. A tight package is
achieved by tight seals and the microbiological barrier of the packaging mate-
rial. The package integrity tests will verify that the condition of the package is
according to the needs.
The transversal and longitudinal seals are produced by the sealing components
in the filling machine, and tests to verify them are described in the dedicated
chapters.
The packages microbiological barrier is composed by the inner plastic layers,
the aluminium foil and the lamination layer between the aluminium foil and
paper board. All three layers have to be broken before the microbiological bar-
rier is lost.

Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 3

   
Package Forming
Crease Lines
This test is a visual inspection to verify that the creases are correctly posi-
tioned. Incorrect crease positions will have an impact on package forming, and
could cause mechanical tension, particularly in the corners.

_____________________________________________________________

LS-overlap
By measuring the LS-overlap, you can check the tube diameter dimension and
the packaging material width. These are important parameters to produce well
shaped packages.

_____________________________________________________________

4 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
Design
This test is a visual inspection to verify that the packages are correctly formed.
Badly formed packages could cause mechanical tension in the packaging ma-
terial.

_____________________________________________________________

Volume (weight)
The package should contain at least what it's labelled, since it is a legal demand
in most countries. By weighing the filled package you can check its volume,
since weight and volume are linked by the product's density.

_____________________________________________________________

Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 5

   
Flap Sealing
Flap sealing is an important factor in the line efficiency and package integrity.
Unsealed flaps can cause unnecessary stops and waste, if they get caught in the
final folder, conveyor or distribution equipment.

_____________________________________________________________

Date Printing
Date printing is a legal demand. In most countries, at least the best before date
must be stated on the package.

_____________________________________________________________

6 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
Transversal Sealing
Rough Check
The rough check will give a quick indication if there is any severe malfunction
in the sealing components of the machine, for example missing rubber dollies
or an inductor failure.

_____________________________________________________________

Accurate Check (Tear Down Test)

This is a test to assess the quality of the transversal seal. By manually tearing
the seal, you can evaluate that the seal is mechanically more resistant than the
packaging material. If the sealing is weaker than the packaging material, we
have a blocked seal, which is a defective seal.
The only way to detect a blocked transversal seal is to manually tear the seal
directly when the packages leave the machine. Other tests, such as the conduc-
tivity test and the red ink test will not detect a blocked seal.

_____________________________________________________________

Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 7

   
Dissolving of Packages
By dissolving the packages, you can assess the heat pattern of the transversal
seal. The method involves chemicals and requires laboratory personnel. This
test is often used as a quality control method, or during troubleshooting.

_____________________________________________________________

Red Ink in Dissolved Packages

This is the next step after evaluating the heat pattern of a dissolved package.
Red ink will enable the detection of micro channels through the transversal
seal.

_____________________________________________________________

8 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
Longitudinal Sealing
Visual Check
By visually examining the LS-strip, you will get a quick indication if there is
any severe malfunction in the sealing components. You can detect obvious
faults such as scratches, stretch marks, overheated areas and badly positioned
strip.

_____________________________________________________________

Longitudinal Seal Tearing (LS Tear Down)

This is a test to assess the quality of the longitudinal seal. By manually tearing
the seal, you can evaluate that the seal is mechanically more resistant than the
packaging material. If the sealing is weaker than the packaging material we
have a blocked seal, which is a defective seal.
The only way to detect a blocked longitudinal seal is to manually tear the seal
directly when the packages leave the machine. Other tests, such as the conduc-
tivity test and the red ink test will not detect a blocked seal.

_____________________________________________________________

Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 9

   
Red Ink Injection in Air Gap of the LS-strip
This test will determine if the package is leaking underneath the LS-strip.

_____________________________________________________________

10 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
Inside Layer Ruptures
Visual Check
By visually examining the inside surface of the packaging material, you can
detect scratches and damages on the inner layers. Even if the scratches are
shallow and do not result in defective packages, it is an indication of some-
thing being wrong and should lead to preventive actions.

_____________________________________________________________

Conductivity Test
This test will determine if there is a breakage in the inner plastic layers of the
packaging material, which results in product coming in contact with the alu-
minium foil.
A positive reading on this test indicates that the package could be defective,
and that a red ink test should be performed.

_____________________________________________________________

Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 11

   
Red Ink Test
This test will determine if there is a leakage to the paperboard through the in-
ner plastic layers of the packaging material. Contact to the paperboard means
a risk of microbiological contamination.

_____________________________________________________________

Copper Test
This test can be used when you have established that there is a breakage in the
inner plastic layers and you want to know exactly where it is. The test will
show where the product is in contact with the aluminium foil.

_____________________________________________________________

12 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
Pull Tab
Position
The PullTab opening is made in three steps. First a hole is punched, then it is
sealed with an inner patch on the inside and the tab on the outside. This test
verifies that all three; the hole, inner patch and tab, are correctly positioned. If
any of them are badly positioned, the seal of the package is compromised.
A badly positioned tab could also get caught under the cap, making it difficult
for the consumer to open it.

_____________________________________________________________

Visual Check
This is a visual inspection to detect damages on the inner patch, which could
cause leakages.

_____________________________________________________________

Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 13

   
Red Ink Test
This test will determine if the package is leaking around the punched and
sealed hole.

_____________________________________________________________

14 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
Technical Training Centre 1/0805 MT-83112-1 Training Document. For training purpose only. 15

   
16 MT-83112-1 Training Document. For training purpose only. Technical Training Centre 1/0805

   
   
   
15
PLMS

Technical Training Centre

   

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TPMS

Technical Training Centre

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Maintenance
Routines
Operator Maintenance
Care and maintenance of the machine is important in order to produce a good
product and to avoid unintentional stops.
Recommended maintenance routines for the machine are fully described in the
Operation Manual (OM). Care and maintenance that is to be performed by the
machine operator can be divided into two parts:
• Care after finished production includes among other things cleaning of
CIP = Cleaning In Place the machine; manual cleaning and CIP. Checking for possible damages due
to normal wear and tear are further examples of the daily care.
• Weekly care and maintenance covers a more extensive cleaning and
maintenance than care after finished production.

Maintenance techniques
Maintenance includes a wide range of activities. We can divide them into three
main categories: Corrective, Preventive and Improvement maintenance.

Corrective Maintenance Preventive Maintenance Improvement Maintenance

Condition Life Time

Unplanned Planned Monitoring Direct PM Design Out Extension

+ objective FTM

subjective Lubrication,
cleaning
etc.

Maintenance techniques

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Corrective maintenance is equivalent to repairing or restoring. A failure is cor- Corrective maintenance
rected when it occurs. Corrective maintenance is mainly carried out on com-
ponents where the failure occurs instantly. This category can be divided into
two sub categories, “Planned” and “Unplanned” maintenance.
Unplanned maintenance
Breakdowns and other unpredicted stops are typical incidents that require un-
planned maintenance. Because of the large costs that often are related to this
category, it’s of great interest to minimise the unplanned maintenance by op-
timizing the planned and preventive maintenance.
Planned maintenance
A good way to avoid unpleasant breakdowns and improve the predictability is
to implement condition monitoring. Some electrical components however are
very difficult or nearly impossible to monitor with condition measuring devic-
es.

The main purpose of Preventive Maintenance (PM) is to prevent breakdowns Preventive maintenance
or standstills. Preventive maintenance is used where the faults can be prede-
termined, set to an interval or detected with condition monitoring devices.
Preventive maintenance is usually categorised as “Condition Monitoring” (In-
direct PM). and “Direct PM”. Activities that are carried out in order to prevent
occurrence of failure are called “Direct PM”, because the activity will have a
direct impact on the condition of the equipment.
Condition Monitoring (CM)
is carried out in order to detect failures in the early stage of the failure devel-
opment and has consequently no direct impact on the condition of the equip-
ment. All CM actions will eventually lead to corrective maintenance actions
(see the figure above)
Condition based maintenance (CBM)
is another, more used, term for indirect PM. The general idea of CBM is that
a replacement is initiated by some kind of check. The check could be either
subjective or objective. The TPMS checklists mainly consist of subjective
checks, which means by using ones senses: sight, hearing, feeling etc. Objec-
tive checks are used when monitoring some physical parameters like vibra-
tions, pressure drops and are often initiated by planned maintenance. More
complicated equipment is sometimes provided with on-line measuring devices
like SPM (Shock Pulse Method) and vibration level indicators.
Fixed Time Maintenance (FTM)
is another term for direct PM and is basically a time-scheduled maintenance
that is applied in cases, where it’s possible to predict the failure rate of the
component. The lifetime of the components are often based upon experience.
Planned maintenance could be applied to most of the well-known mechanical
components (bearings, bushings etc.).

Improvement maintenance is one of the best methods to reduce the mainte- Improvement maintenance
nance costs for equipment. Input from experienced maintenance personnel and
maintenance reports represent a valuable information base, which is used in
the development of new or rebuilding of existing production units. The
participation of TPMS in development projects from an early start is proven to
have a high impact on the end result.

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Tetra Pak Maintenance System (TPMS)
The principle of TPMS is to ensure maximum performance and to minimise
the number of unpredicted stops. This is achieved by providing carefully
prepared maintenance recommendations. TPMS has been practised by Tetra
Pak since 1989.
The major difference between TPMS and other maintenance systems is that
TPMS is used as a tool and that the need of maintenance is estimated already
in the development phase of the machine.

Idea Design Test Operation

MCC = Maintenance Cost

Calculation MCC Maintenance
DRM MCC Evaluation
(MCC)
DRM = Design Review Documents Improvements
Meeting Checklists Feedback

Development & Engineering Market Companies

Care and maintenance are involved in the development phase of the machine. This way
machine design that could cause service problems, can be avoided.

Maintenance The central part of TPMS is the maintenance recommendations provided by

recommendations Development & Engineering. The recommendations are used by Market com-
panies, which enables:
• Maintenance recommendations for a machine type
• Administrating when the machines should be serviced
• Generating checklists
• Reporting results of service
• Following-up on reported results

Development & Engineering Market Company

(TPMS responsible)

SMA SMA

• Maintenance recommendations • Checklist (unique)

• Service parts • Service parts list (unique)
• Maintenance units • Tools/templates list (unique)
• Tools/templates • Planning
• Statistics

The central part in TPMS is the maintenance recommendations.

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A streamlined production unit requires high availability. This is made possible Availability
by TPMS, which implies the following advantages:
• Reduction of downtime - TPMS is designed to reduce the downtime due
to maintenance. TPMS will inform about the approximate point of time for
the service, so that it can be scheduled together with the production man-
agement, in order to have the least interference possible on the production.
• Avoiding breakdown - A breakdown can have many different causes, for
example incorrect handling or lack of maintenance. A breakdown will
always lead to loss of production.
• Predicting maintenance cost - Since less breakdowns due to the lack of
maintenance will occur, it is possible to calculate maintenance costs more
exactly.
• Optimizing spare parts handling - Spare parts are expensive to stock. As
a consequence of less breakdowns and the possibility to plan the use of
maintenance spare parts, it will be possible to reduce the stock of spare
parts. A safety stock is however always required.
The availability is depending upon Reliability, Maintainability and Supporta-
bility:

Reliability describes how often the machine is stopped due to [Link] Reliability
ensure a high reliability it is important to consider the maintenance need of the
components selected and that they withstand the conditions in which the
machine is operated.

Maintainability describes how long time it takes to correct the average failure. Maintainability
One way of improving the maintainability is to design a machine with easy
access to parts that need to be replaced. A fault detection system can reduce
the time consuming trouble shooting.

Supportability is a measure of how long time it takes until repair is started. Supportability
This is a measure of how well the maintenance organisation works. Mainte-
nance staff knowledge, documentation, spare parts supply etc. are factors that
affect the supportability of the equipment.

Overviews of the service life of different components are based on information Service life
from the suppliers, as well as from people with personal experience. The first
step when creating maintenance recommendations is to collect this informa-
tion.
Items
Items

Bushing
Bushing
Axle
Axle
Cuttingjaw
Cutting jaw
Motor
Motor
Filter
Filter
Roller
Roller
Damper
Damper
Arm
Arm
Compressor
Compressor
Bearing
Bearing Production
Production
hours
hours

00 3000
3000 6000
6000 9000
9000 12000
12000

The diagram shows the recommended maintenace intervals for various components.

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Service intervals TPMS is based on two different service intervals:
• The short service interval is performed every 500 hours (or when
required, every 250 hours) and is used for filling and distribution machines.
Normally this service is performed by the customer.
• The expanded service interval is performed every 1000 hours and is
normally performed by Tetra Pak. But this is just a recommendation. Each
customer decides together with Tetra Pak, how much of the service they
want to perform themselves. Service differs from one customer to another.
hours
Maintenance Specialists
Specialists
hours
Customer
Customer

Production
hours

500 1500 2500 3500 4500

1000 2000 3000 4000

TPMS is based on two different service intervals: every 500 (250) hours
and every 1000 hours.

TPMS cycle
Basically TPMS consists of four main actions:
• Maintain
• Report
• Evaluate
• Improve

Maintain Report

TPMS

Improve Evaluate

TPMS involves a continuous evaluation of the maintenance system itself, based on

recurrent feed back from the customers.

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Maintain
The core of TPMS is the preventive maintenance and the common tool for the
maintenance activities in that matter is the checklist. Every planned mainte-
SPC = Spare Parts Catalogue
nance occasion has a specific checklist including spare parts recommendations OM = Operation Manual
and linked documentation: SPC, OM, MM, EM etc. Checklists are beneficial MM = Maintenance Manual
in many ways, and below we present some of them. EM = Electrical Manual
• Enable a uniform way of performing the services.
• Offer possibilities to plan the service in advance, because of the high pre-
dictability.
• Provide an information exchange base.

The checklist overview is a list containing all maintenance recommendations Checklist overview
for the machine.

A checklist is a list of all the work that should be performed during one main- Checklist
tenance occasion. The checklist refer to all technical documentation, for
example the MM and the SPC.

Tailor made checklists are machine specific checklists. Based on an agreement Tailor made checklists
between the customer and Tetra Pak, more or less of the maintenance work can
be put on the customer’s checklist.

Maintenance units, service boxes, tools and spare parts are important for a Connected items lists
good maintenance program. In addition to the maintenance checklists, custom-
ers receive lists of the items required at each maintenance occasion. This en-
sures that everything is available on site when it is needed.
• Maintenance units are isolated sub-assemblies that contain components or
parts that require frequent maintenance actions. Maintenance units are
replaced in their entity in the field and the old one is returned to the work-
shop where it is reconditioned and updated.
• A service box is a “container” with the spare parts that are to be used or
might be needed at one maintenance occasion. The service box can be sent
from a Tetra Pak store or put together by the customer from his stock. The
use of service boxes is not the same in all countries.
• Using special tools might speed up the work. These tools are listed, but
ordinary hand tools like wrenches, screw drivers etc. are not included
in the list.
• The spare parts required for each maintenance occasion are listed.

The APM list is a supplement to after production and weekly care procedures APM list
described in the OM. It contains all items that should be performed according APM = After Production
to a shorter interval, normally 250 hours. This list is static and all items are Maintenance
performed every time.

TPMS covers all components that are crucial for the production line. Most of Line maintenance
the components, from the milk intake to the palletisers, are made according to
maintenance recommendations.

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Report
When a service has been performed, either by Tetra Pak or the customer, the
service results are entered into SMA or SAP R/3. Statistical reports are
extracted from SMA or SAP R/3 and used as input for update meetings. The
notes and comments, made by the service technicians, constitute valuable in-
formation for the next maintenance occasion. Thus, experience gained from
using the maintenance recommendations is conveyed back to Development &
Engineering, where it is used as an input for further improvements.

Evaluate
Update meetings Evaluation takes place on two different levels:
• In the Market companies, the TPMS responsibles regularly hold local
update meetings on a regional level, where local service engineers and
systems specialists, among others, discuss the performed service and how it
can be improved. The reported service results provide a valuable input.
It is recommended and important that the customers are involved in the
updating in one way or another, as it will contribute to better TPMS per-
formance. The outcome of the local meetings most often results in
improved maintenance recommendations, which further on will result in
better equipment performance.
• On an international level and a regular basis the business areas arrange cen-
tral update meetings where representatives from different countries get
together to discuss machine performance and service results. Such meetings
generally result in updated maintenance recommendations and influence on
the machine development.

Local Update Meeting

Evaluation
• Checklist statistics
• Reports
• Engineer and
Customer experience

Market Company

Improvement Feedback
Locally and globally improved
Maintenance recommendations

Global Update Meeting

Improvement
Input to
Machine development Development & Engineering

Evaluation is a continuous process that takes place on two different levels - national
and international.

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Improve
The results of discussions at the update meetings are used to improve the Maintenance
maintenance recommendations. recommendations
The statistical results of the TPMS system play a key role in the development Machine design
of new machines. It is in the development phase that the maintenance needs
are estimated.

The third feature that Tetra Pak constantly improves is of course the TPMS TPMS concept
concept in itself. This is done in close cooperation with the TPMS users.

TPMS 2
The first release of the TPMS 2 project will be deployed in the autumn of 2008. Deployment
It includes filling machines at a number of selected sites. The second release,
which will include all remaining filling machines, distribution equipment and
sites is scheduled for the autumn of 2009.
Both installed base and future equipment are in focus. Only packaging lines
are in question at present but processing lines are under discussion.

TPMS 2 is based on Reliability Centred Maintenance (RCM) instead of the Reliability Centred
Time based Preventive Maintenance approach of today. Maintenance (RCM)
The following aspects will ensure maintenance optimization and process im-
provement:
Maintenance Recommendations are configured as separate tasks and linked to
the relevant equipment in the IT system. This allows updates and corrections
to be made quicker and with less administration.
Maintenance Events (services) are generated for each machine depending on
the actual work performed, or work not performed yet, and the actual meter
readings obtained directly from the machine’s control system.
Additionally the maintenance events can be tailored for customers' operations
to ensure minimal impact on production. The aim is to create, for example,
maintenance events that take a few hours every 14 days instead of an event
which last 2-3 days.
Feedback is electronically captured directly into the global database which fa-
cilitates analysis and continuous improvement. Information can also be shared
with the customer electronically instead of paper reports that are mailed today.

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How to read the SMA checklists
The checklists contains all the check items (position numbers) for an
individual machine and a specific maintenance occasion.
All information about what and how to maintain the equipment is originally
created by Tetra Pak Development & Engineering. The Checklist overviews
are sometimes adjusted by the Tetra Pak Market company due to local needs
and conditions.
The checklists are generated from the SMA database and are normally printed
at the local service station. After a completed maintenance service the result
of the work can be reported back into the SMA application. The information
is used, later on, when both the equipment and the maintenance recommenda-
tions are updated and improved.
The last page of the checklist is a “Comments Page” where it is possible to
note items that could not be included in the prior pages (remaining work, sug-
gested rebuildings, etc.).
Below are examples of different sections of the checklists. Each section is
followed by a list where the marked fields are explained.

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SMA Checklist - Front page

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1 Customer Customer specification.
2 Equipment/ Equipment/ machine specification.
machine
3 Installed Variants the current equipment/ machine is
Variants equipped with.
Variant beginning with an asterisk ‘*’ are
valid for lists converted from SAP R/3.
4 Installed Options the current equipment/ machine is
Options equipped with.
This field is not used for lists converted from
SAP R/3.
5 Installed Rebuildings the current equipment/machine is
Rebuildings equipped with.
Rebuildings beginning with an asterisk ‘*’
are valid for lists converted from SAP R/3.
‘*N’ means that the rebuilding is not installed,
‘*R’ means that the rebuilding is installed.
6 Issued By Name of the person who created the mainte-
nance recommendations
7 Issue Date Date when maintenance recommendations
were created.
8 Approved By The name of the person who is Product
Responsible.
9 Overview Showing documents the checklist refers to.
Referring to
Document
10 Printing When and by whom the list is printed. Same on all pages
information
11 Equipment/ E.g 1234/1234. Same on all pages
machine
identity
12 Responsible Customer, Tetra Pak, or All (both). Same on all pages
13 Interval The interval the checklist is valid for, e.g. Same on all pages
5000 h.
14 Page No 1/ if more pages will follow, Same on all pages
2. if last page.

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SMA Checklist - Check items

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15 Selection/ Describes the location of the check item on the equipment. Name of
Description details selected from the SMA 3 phrase library.
16 Action Defines what to do with the check item. Check, change, clean, etc. -
22 pre defined action codes to select.
The Document Reference below (pos 18) refers to the correct page
in the Maintenance Manual for further information.
17 S (selection Possibility to define the amount of work selected for Customer (3)
code) and Tetra Pak (7).
18 Document Where to find further information in Maintenance Manual (MM) or
Reference equivalent.
Unique key if list is converted from SAP R/3.
19 Time The expected time, in minutes, it will take a trained technician to
perform the check item. This time is used when planning the work-
and down-time for the maintenance.
20 Interval At what interval the check item should be performed.
21 Pos No Position number is the check item’s identity. Used when evaluating
statistical results and to identify the check items when lists are
printed in different languages.
22 Result Code Here is where the technician fills in the result of the maintenance.
A=Satisfactory, B=Adjusted, C=Replaced, D=Remaining
It is mandatory to set a C if the action code is set to “Change”. If D,
there has to be a comment on the last page regarding the reason.
23 C (notes on If the performer has made a comment for a position number on the
the last page) last page, he should make a mark in this column.
24 Notes Here the measurements should be noted, e.g. 62 volts, 34 mm., etc.
If the check item is connected to a “Rotator on request” the question
“Replace next time? (Yes/No)” appears here.
25 Total Expected The expected time it is supposed to take to perform this mainte-
Worktime nance.
26 Total Expected This time is set to either the same time as Total Expected Worktime
Downtime or to zero. The later means that it is possible to perform the check
item while the equipment/ machine is in operation.
27 Info - Result This is information about the possible result codes that is mandatory
Code to fill in.

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SMA Checklist - Comments page

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28 Pos No The position number that the comment is valid for.
Note! It is also possible to make general comments about the equip-
ment, or parts of it.
29 Comment E.g. notes about recommended rebuildings, problems on the equip-
ment, etc.
30 Start Date The date the maintenance was started.
31 Start Time The time the maintenance was started.
32 Engineer The signature from the one who performed the maintenance (Cus-
Signature tomer or Tetra Pak). If more than one person, name the responsible
for the work.
33 Completion The date the maintenance was completed.
Date
34 Completion The time the maintenance was completed.
Time
35 Total Used The man hours it took to perform the maintenance excluding lunch
Worktime breaks and other activities etc.
36 Total Used Total downtime used to perform the service.
Downtime
37 Hour Meter The value of the hour meter on the filling equipment/machine when
the maintenance was started.
38 Adjusted Running hours when the hour meter was replaced.
Hour meter
39 Customer Signature form the person responsible for the maintenance at the
Signature plant.
40 Workorder No Field use manually.

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SMA Checklist - Connected items list

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41 Pos No The position number of the check item, where the spare part, tool, or
Maintenance Unit is connected.
42 Description The description of the spare part, tool, or Maintenance Unit.
43 Item Identity The part number of the spare part, tool, or Maintenance Unit.
44 Used Quantity The amount of spare parts, tools, or Maintenance Units needed for
this check item.
45 Action The action to take for this check item.

How to read the SAP R/3 checklist

The checklist contains all the check items (operation numbers) for an individ-
ual equipment/ machine and a specific maintenance occasion.
All information about what and how to maintain the equipment is originally
created by the Tetra Pak Development & Engineering. The Task lists are
sometimes adjusted by the Tetra Pak Market company due to local needs and
conditions.
The checklists are generated from SAP R/3 and are normally printed at the lo-
cal service station. After a completed maintenance service the result of the
work can be reported back. The information is used, later on, when both the
equipment and the maintenance recommendations are updated and improved.
The last page of the checklist is a “Comments Page” where it is possible to
note items that could not be included in the prior pages (remaining work, sug-
gested rebuildings, etc.).
Below are examples of different sections of the checklists. Each section is
followed by a list where the marked fields are explained.

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SAP R/3 Checklist - Front page

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1 Customer Customer specification and contact details.
details
2 Market Tetra Pak Market Company details.
company
details
3 Contact Contact details for responsible Tetra Pak staff.
details
4 Planned date/ Date and time when the maintenance is planned
start time to be performed.
5 Work Description on Service Order.
Description
6 Equipment/ Equipment/ machine specification.
machine
7 Task list Group, Group counter, and Description of the
Specification maintenance recommendation that the checklist
is based on.
8 Task list Name of the person who created the mainte-
Issued by nance recommendations.
9 Issue Date Date when maintenance recommendations were
created.
10 Approved by The name of the person who has approved the
maintenance recommendation.
11 Task list Shows documents (MM, OM, SPC, etc.).
referring to
document
12 Serial number Identity of the equipment/ machine, e.g. 1234/ Same on all pages
1234.
13 Line The line at the customer site. Same on all pages

14 Responsible Customer, Tetra Pak, or All (both). Same on all pages

15 Service Order The number of the service order that the check- Same on all pages
list refers to.
16 Interval The interval the checklist is valid for, e.g. 5000 Same on all pages
h.
17 Printing Same on all pages
details

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SAP R/3 Checklist - Second page

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18 Equipment Characteristics (options, variants, etc.) that are valid for the current
Specification equipment/ machine.
19 Rebuilding Kit Rebuilding kits that the current equipment/ machine is equipped
with.

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SAP R/3 Checklist - Check items page

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20 Op No: Operation number is the check item’s [Link] to identify the
operation when lists are printed in different languages
Selection code defines the amount of work selected for Customer
(C) and Tetra Pak (TP), or indicates that operation is an “On
Request only” (OR).
21 Doc Ref./ Doc ref. defines where to find further information in Maintenance
C-Group Manual (MM) or equivalent.
If C-group number is entered on the operation, the description of the
C-group is printed.
This column also lists the spare part number.
22 Description Defines what to do with the check item. Check, change, clean, etc. -
22 pre-defined action codes to select.
Describes the location of the operation (operation text).
Name of details selected from the SAP R/3 global phrase library.
Description of the spare part, tool, or maintenance unit used in the
operation.
23 Cycle At what interval the check item should be performed.
24 Time The expected time, in minutes, it will take a trained technician to
perform the check item. This time is used when planning the work-
and down-time for the maintenance.
25 Done Here is where the technician fills in the result of the maintenance.
If the operation is “On Request only” (OR) - 15 (operation not per-
formed next maintenance event, no parts ordered) or 20 (operation
will be performed next maintenance event, parts ordered).
26 Qty The amount of spare parts, tools, or Maintenance Unit s needed for
this operation.
27 Rel This parameter (Relevancy for planning) impacts the ordering proc-
ess of spare parts, tools, and Maintenance Units.
1 = Not ordered, Blank = Ordered.
28 Used Q-ty The amount of spare parts, tools, or Maintenance Units used for this
operation.
29 Total Expected The expected time it is supposed to take to perform this mainte-
Work-time nance.
30 Total Expected The expected time the machine is down, while doing maintenance.
Down-time This time is set to either the same time as Total Expected Work-time
or to zero.

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SAP R/3 Checklist - Comments page

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31 Pos No The operation number that the comment is valid for. Note! It is also
possible to make general comments about the equipment or parts of
it.
32 Comments E.g. notes about the recommended rebuildings, problems on the
equipment, etc.
33 Customer Signature form the person responsible for the maintenance at the
Signature plant.
34 Service The signature from the one who performed the maintenance (Cus-
Engineer tomer or Tetra Pak). If more than one person, name the responsible
Signature for the work.
35 Date The date the maintenance was completed.

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Tetra Pak Carton Ambient Tetra Pak Maintenance System

Check List

Customer No: Customer Name:

Customer:
001-0001 Technical Service
Line No: Plant Name:

A1 TTC Technical Training Center

Machine: Machine Type No: Machine Type Text:

648160 Tetra Brik Aseptic TBA/19

Machine Identity:

21204/7
List Variant: List Text:

030VTTC TBA/19 + SA, ASU

Volume: Dev. Step:

250 030V
El. Control System:

GE FANUC

Installed Variants: Installed Options: Installed

Rebuildings:
50HZ PT
7500P/H MK C Pneumatic &
ASU Software
SA
MK S Condensation
SLIM
water

Checklist Overview Used:

Overview Refering to Document:
Issued By:
MM 2771721-0105 TBA/19 + SA
Eli Jönsson
Issue Date:

2008.11.26
Approved By:

Charles C.
Machine Identity: Responsible: Interval:

21204/7 Tetra Pak 6000

Page No:
(Not to be reported back) 1 / ...
Printed 2004.03.09 at08:40 by System Administrator using Windows ZP310900

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Tetra Pak Carton Ambient Tetra Pak Maintenance System
Section/Description Action S Document Time Inter Pos No Result C Notes
Reference val Code

00. Pre-Maintenance Checks

SPC 2771717-0106 TBA/19-030V Check 7 [ 5] 1000 15

WARNING! Before starting any service Check 7 MM [ 5] 1000 40

work, read the safety precaution in the
corresponding Maintenance Manual.
Doc No:

Go through the lists carried out by the Check 7 [ 5] 1000 60

customer since the last service, discuss
with customer technician

Filling system- first package. Check 7 14.7-6 [ 5] 1000 80

Hydraulic system- Accumulator Check 7 6.4-4 [ 10] 1000 320

Spray system- Leaks Check 7 1.13-2 [ 5] 1000 340

Result Code: A = Satisfactory, B = Adjusted, C = Replaced, and D = Remaining.

S = Selection Code needed for a checkpoint.
C = If you have made a comment for a position number on the last page, you should make a mark in this column.

Machine Identity: Responsible: Interval:

21204/7 Tetra Pak 6000

Page No:

2 / ...
Printed 2004.03.09 at08:40 by System Administrator using Windows ZP310900

   
Tetra Pak Carton Ambient Tetra Pak Maintenance System
Section/Description Action S Document Time Inter Pos No Result C Notes
Reference val Code

00. Pre-Maintenance Checks

Peroxide / Sterile air system- Leaks Check 7 6.2-1 [ 10] 1000 360

01. Superstructure
Calender roller- Bearings Change 7 1.3-3 60 2000 10280

Heat exchanger- Tightness Check 7 1.8-1 120 3000 10580

06. Service unit

Peroxide tank- Pump Overhaul 7 6.2.2-2 60 2000 60320

60. Start-up checks

Safety functions Check 7 15.2 10 1000 600020

Connection box- Sterile air pressure Check 7 2.1-1 10 1000 600040

Switch

95. After-Maintenance Checks

Filling system- first package. Check 7 14.7-6 [ 5] 1000 950020

Package - check package according to Check 7 OM [ 5] 1000 950040

OM.

Hot air element LS SS- Package Check 7 1.12-1 [ 5] 1000 950060

Valve plate- Sterile air pressure Check & 7 6.1-1 [ 5] 1000 950080
Record

Calender roller- Function Check 7 1.3-2 [ 5] 1000 950100

Superstructure- Pressures Check 7 1-3 [ 15] 1000 950120

LS nozzle- Pressure Check & 7 1.14-2 [ 5] 1000 950140

Record

Filling system- Parameters Check 7 14.7-7 [ 5] 1000 950180

TPIH Power settings Check & 7 14.4.-7 [ 5] 1000 950200

Record

If pre-maintenance checks have not Check 7 [ 5] 1000 950240

been done-do them now

Total Expected Worktime 7 Hrs 5 Min

Total expected downtime 4 Hrs 20 Min

Result Code: A = Satisfactory, B = Adjusted, C = Replaced, and D = Remaining.

S = Selection Code needed for a checkpoint.
C = If you have made a comment for a position number on the last page, you should make a mark in this column.

Machine Identity: Responsible: Interval:

21204/7 Tetra Pak 6000

Page No:

3 / ...
Printed 2004.03.09 at08:40 by System Administrator using Windows ZP310900

   
Tetra Pak Carton Ambient Tetra Pak Maintenance System
Pos No Comments

Start Date: Completion Date: Total Used Worktime: Hour Meter: Workorder No:

Start Time: Completion Time: Total Used Downtime: Adjusted Hourmeter:

Engineer Signature: Customer Signature:

Machine Identity: Responsible: Interval:

21204/7 Tetra Pak 6000

Page No:

4
Printed 2004.03.09 at08:40 by System Administrator using Windows ZP310900

   
Tetra Pak Carton Ambient Tetra Pak Maintenance System
Pos No Description Item Identity Used Action
Quantity

Rotators
60320 Peroxide pump 1284017-007 1 Overhaul

Spare Parts
10280 Ball bearing 1523209 4 Change
10580 Gasket 315229-203 2 Check
10580 Heat exchanger 978838 1 Check
600040 Pressure guard 90274-45 1 Check

Tools
180 Pressure gauge 90243-137 1 Measure & Record
10580 Hydrostatic test equip. 565536 1 Check
10580 Flange 979951 1 Check
10580 Flange 979952 1 Check
950120 Pressure gauge 90243-137 1 Check

End of connected items

Machine Identity: Responsible: Interval:

21204/7 Tetra Pak 6000

Page No:

1
Printed 2004.03.09 at08:40 by System Administrator using Windows ZREPORT

   

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TBA/19 030V Maintenance: Training Document

Uploaded by

TBA/19 030V Maintenance: Training Document

Uploaded by

 Course Introduction 1

 Filling Control System 11

Technical Training Centre 19

Technical Training Centre

Target Group Tetra Pak Technicians

Previous To be able to operate a TBA/19 with help of an

Course Objectives To achieve common basic TBA knowledge.

Course- Start-up machine in accordance with the OM.

Questionnaires There will be written questionnaires during the

Last modified: Aug 24, 2006

Target Group • Tetra Pak Technicians

Previous • Participants must have participated in a TTC course

Course Objectives • To achieve a basic understanding of how the

Course- • Start-up machine in accordance with the OM.

Course Methods • Approximately 25/75-theory/practical-time ratio.

Last modified: Aug 24, 2006

Technical Training Centre 1/0809

Training Document. For training purpose only.

Technical Training Centre 1/0809

Training Document. For training purpose only.

Technical Training Centre 1/0809

Technical Training Centre 1/0809

Technical Training Centre 1/0809

Training Document. For training purpose only.

Training Document. For training purpose only.

Technical Training Centre 1/0809

2. Stamp tool Add a stamp comment

3. Highlight Text tool Highlight text

5. Arrow tool Draw an arrow

6. Rectangle tool Draw a rectangle

Training Document. For training purpose only.

The most common type of comment is the Sticky Note.

Technical Training Centre 1/0809

Technical Training Centre 1/0809

Highlight Text tool

Training Document. For training purpose only.

Technical Training Centre 1/0809

Training Document. For training purpose only.

Technical Training Centre 1/0809

Technical Training Centre 1/0809

Technical Training Centre 1/0809

Technical Training Centre

Nominal volume (ml) 250.0

Web width (mm) 188.0 ± 1

LS-strip LHL 7.5x0.1 mm 0.129 g 8891-952-01

PPP 7.5x0.080 mm 0.100 g 8840-951-01

Wine 7.5x0.080 mm 0.100 g 8841-951-01

LSE 7.5x0.080 mm 0.096 g 8868-951-01

Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 1.2

Crease measurements 53.0 38.0 131.0

Filling machine TBA/19 & TBA/21

Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 2.2

Pallet Type Euro (1200 x 800 mm)

Weight Load Tray

Pallet Type Eurohalf (800 x 600 mm)

Weight Load Tray

Packages / pallet 1134 Litres / pallet 283,5 Trays / pallet 42

Pallet Type UK (1000 x 1200 mm)

Weight Load Tray

Packages / pallet 3591 Litres / pallet 897,8 Trays / pallet 133

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Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

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