OM

Operation Manual

Tetra Alex® 30
2.235781-01.fro

Doc No. OM-1235781-01

This document is valid for:

Series No/ Machine No

OM
Operation Manual

Tetra Alex® 30

2.235781-01.fro

Doc No. OM-1235781-01

Issue 2008-03

Tetra Pak Processing Components AB

 Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of hazard information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Handling of cleaning solution. . . . . . . . . . . . . . . . . . . . . . . . 5
Emergency precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Process description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Denominations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.235781-01.toc

Cooling water system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sterilisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check during production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Recommended oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Table of contents

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ii Tetra Alex® 30
 Introduction
Introduction
This section contains basic information about this manual and the
Tetra Pak equipment described.

WARNING! To ensure maximum safety, always read the section Safety precautions
before carrying out any work on the unit.

Equipment
Intended use of this Tetra Pak equipment
This unit is intended for use according to the specifications in Technical data
(see Technical Manual) and related documents.
Tetra Pak will not be held responsible for injury or damage if the equipment is
used for any other purpose.

Service
If problems are encountered when operating the unit, contact the nearest
Tetra Pak service station.

Manufacturer
This Tetra Pak equipment was produced by:
2.2 tf201628.en

Tetra Pak Processing Components AB

Bryggaregatan
S-221 00 LUND
Sweden

Unit identification
All units carries a machine plate stating:
– unit identification
– data unique to the unit
Have this information available before contacting Tetra Pak concerning this
particular unit.

Tetra Pak
Machine Type
Drawing Spec.
Machine No.
Manufacturer

Year of manufacture

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Tetra Alex® 30 1
Introduction
Document
Operation Manual (OM)
The purpose of this Operation Manual is to provide the operator with
information on how to operate the machine.
Tetra Pak recommend that you study it carefully, and - above all - ensure its
availability to those who will be operating the unit.
Furthermore, it is important that you:
– keep the manual for the life of the equipment
– pass the manual on to any subsequent owner or user of the equipment.
Tetra Pak will not be held responsible for any breakdown of the equipment
caused by the owner’s failure to follow the instructions given in this manual.

Design modifications
The information given in this document is in accordance with the design and
construction of the machine at the time it was delivered by the Tetra Pak
machine production facility.

Further copies
Additional copies can be ordered from the nearest Tetra Pak service station.
When ordering technical publications, always quote the document number

2.2 tf201628.en
printed on the front cover of the document concerned.

Document producer
This document was produced by:
Tetra Pak Processing Components AB
Bryggaregatan
S-221 00 LUND
Sweden

Number of pages
This document contains a total of 24 pages.

Copyright © 2008
Tetra Pak Processing Systems Division
All rights reserved. No part of this document may be reproduced or copied in
any form or by any means without the written permission of
Tetra Pak Processing Systems Division.

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2 Tetra Alex® 30
 Safety precautions
Safety precautions
To ensure maximum safety for the operator, always read this section
carefully before carrying out any work on the equipment.

Use of hazard information

Hazard information in this documentation is defined as follows:

DANGER! Failure to observe this information results in immediate danger to life.

WARNING! Failure to observe this information can result in major personal injury or
loss of life

Caution! Failure to observe this information can result in minor personal injury or
damage to the equipment.
2.2 tf201472.en

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Tetra Alex® 30 3
Safety precautions
General
Only trained personnel are allowed to operate the machine. The machine may
only be used in accordance with the instructions given in the manuals delivered
with the equipment.
If the Safety precautions are not followed, there is risk of personal injury.
The machine is normally started by an external signal, therefore:
• always keep all covers closed during operation, rotating wheels and moving
pistons may cause severe injuries
• make sure the mains power is turned off and secured before the service
covers are opened/removed
• regard all electrical equipment as live, make sure the doors for the starter
panel are closed

During operation:
• stay outside the safety area
(approximately 1m (3 feet) around the machine)
• regard all pipes including pulsation dampers as hot
• watch out for leakage/blasts from hot media at pipe connections and from
pressurized parts of the machine
• always use hearing protection

2.2 tf201472.en
• never throttle down the product flow to or from the machine
DANGER! Risk of explosion - Immediate danger to life
Make sure that the product outlet pipes not are blocked in any way.
Due to high pressure, this will make a high risk of exploded pipes and
dampers.
WARNING! Risk of scalds
This machine works under pressurised conditions and high
temperatures. To avoid jets of hot liquid, steam or cleaning solution,
make sure that any operation sequence is finalised, the machine is
cooled down and without pressure before disassembling any parts.

Before carrying out maintenance and repair:

• read the Safety precautions in the Technical Manual and follow
instructions given

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4 Tetra Alex® 30
 Safety precautions
Cleaning solution

Handling of cleaning solution

Cleaning solutions normally contain caustic soda (NaOH) or nitric acid
(HNO3). These chemicals may cause burning to skin and eyes. Follow the
instructions given by the supplier.
Whenever there is a risk of exposure to these chemicals, always wear:
• safety glasses
• protective gloves
• shoes made of PVC or PE plastic, or rubber
• apron.

In the case of an accident involving cleaning solution, the basic rule is to rinse
the affected area as soon as possible with as much water as possible.
For this reason, always make sure that the showers work, that there are
additional washing facilities, and that an eyewash device is available at or near
each machine site.

Emergency precautions
If swallowed
2.2 tf201472.en

If you happen to swallow cleaning solution:

• drink large amounts of lukewarm water (in order to dilute the cleaning
solution); then seek medical attention immediately.

Contact with eyes

If cleaning solution is splashed into your eyes:
• wash the eyes thoroughly with lukewarm water for 15 minutes (keep
eyelids widely apart); then seek medical attention immediately.

Contact with skin or clothes

If cleaning solution comes into contact with skin or clothes:
• rinse immediately with plenty of water
• thoroughly wash the clothes before they are worn again. If skin burns
appear, seek medical advice immediately.

If inhaled
If you experience irritation or pain due to having inhaled vaporized cleaning
solution:
• leave the affected area to get fresh air. If the symptoms become worse, seek
medical advice.

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Safety precautions

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6 Tetra Alex® 30
 General description
General description
Applications
High pressure homogenisation of liquid food.

DAIRY OTHER
Pasteurized milk Beverages

UHT milk Concentrates

Cream Fruit juices

Yoghurt Baby food

Condensed milk Dressings

Tomato juice and ketchup

Process description
The high pressure homogeniser functions as a positive displacement pump.
It forces the product through a narrow adjustable gap under high pressure.
The resulting high velocity and turbulence in the gap effectively reduce the size
of liquid droplets.
2.2 tf201339.en

GF201506

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Tetra Alex® 30 7
General description
Denominations

Main components

2 1
3

1 Drive motor
2 Reducing gearbox
3 Crankcase
4 Wetend
7 5 Homogenising head
6 Hydraulic unit
7 Control panel

4 GF201504

5 6

2.2 tf208688.en
Control panel

1
4 2
5 - 1
3
+

6
7
- 2
+

GF202663

1 Start button
2 Stop button
3 Emergency stop button
4 Homogenisation pressure gauge
5 Pressure adjusting valve, 1st stage (Remote control as option)
6 Pressure adjusting valve, 2nd stage (Remote control as option)
7 Hour meter

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8 Tetra Alex® 30
 General description
Cooling water system

1
2
3
4
4
5

1b 2
1a

5
2.2 tf201372.en

GF201613

Description Function
1a Cooling water valve, solenoid (standard) Shut of valve,
controlled by electrical signal
1b Cooling water valve, pneumatic (optional) Shut of valve,
controlled by compressed air
2 Cooling water flow meter (optional) Indicates flow rate and accumulated value
Flow rate, see Technical Data in the Technical Manual
3 Cooling water regulating valve Regulation of crankcase oil temperature
Max. 55 °C (131 °F)
4 Cooling water regulator (optional) Automatic control of crankcase oil temperature
5 Cooling water regulating valve Regulation of gearbox oil temperature

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General description

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2.2 tf201372.en

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10 Tetra Alex® 30
 Operation
Operation
Preparations
• Check that the mains power switch is turned off
• Check oil levels and top up if required
– Crank case
1
– Reducing gear box
– Hydraulic unit
Type of oil: see Lubricants
• Drain the dampers (1)
90 • Close all covers
• Open external cooling water valve
GF201447 • Turn on the external mains power switch

DANGER! Risk of explosion - Immediate danger to life

Make sure that the outlet pipes not are blocked in any way.
Due to high pressure, this will make a high risk of exploded pipes and
dampers.
2.2 tf201631.en

WARNING! Risk of scalds

This machine works under pressurised conditions and high
temperatures. To avoid jets of hot liquid, steam or cleaning solution,
make sure that any operation sequence is finalised, the machine is
cooled down and without pressure before disassembling any parts.

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Tetra Alex® 30 11
Operation
Start
• Start the product feed pump / Start by external signal
Check that the inlet pressure corresponds to the table below:

Recommended inlet pressures

Product P1 bar (psi)

Low viscous products 3 - 10
e.g. milk, juice (45 - 150)
High viscous products 4 - 10
e.g. sauces, ketchups (60 - 150)

• Push the start button / Start by external signal

– The drive motor starts
– The coling water valve opens
– The hydraulic unit starts
Check for flow at cooling water outlet.

Sterilisation

2.2 tf201631.en
Before production the machine must be sterilized.
This is done in line with the surrounding process systems.

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12 Tetra Alex® 30
 Operation
Production
• Activate the pressure relief valves
If the homogenising pressure is not pre-set:
a) Adjust the 2nd stage pressure adjusting valve to desired value or 20% of
the homogenisation pressure.
b) Adjust the 1st stage pressure valve to the decided value.

Check during production

• Homogenising pressure
Fine tune by help of the 1st stage pressure adjusting valve.
• Crank case oil temperature, maximum 55 ºC (131 ºF)
WARNING! Risk of jam
Avoid getting in contact with the pistons

• Product inlet pressure

• If a fault occurs, see section Trouble shooting in the Technical Manual.

Stop
• De-activate the pressure relief valves
or
• Turn off the pressure adjusting valves for
2.2 tf201324.en

a) 1st stage
b) 2nd stage
• Push the stop button / Stop by external signal

Emergency stop
• Push the emergency stop button only if there is a risk of damage to
personnel or property.

Emergency stopped
WARNING! The machine may contain hot liquid
or cleaning solution. Handle with outmost
care to avoid exposure.

• Eliminate the cause for the emergency stop.

• De-activate the pressure relief valves
or
• Turn off the pressure adjusting valves for
a) 1st stage
b) 2nd stage
• Release the emergency stop button and perform a normal start according
Start and Production.

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Operation

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2.2 tf201324.en

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14 Tetra Alex® 30
 Cleaning
Cleaning
Check the cleaning of the pulsation damper after cleaning and clean manually if
required. The pulsation damper should always be drained after cleaning.
The minimal required cleaning flow is 100 % of maximal requested production
flow.

90

GF201447

WARNING! Risk of scalds

This machine works under pressurised conditions and high
temperatures. To avoid jets of hot liquid, steam or cleaning solution,
make sure that any operation sequence is finalised, the machine is
cooled down and without pressure before disassembling any parts.
2.2 tf201633.en

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Tetra Alex® 30 15
Cleaning

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16 Tetra Alex® 30
 Lubrication
Lubrication
Recommended oil

Crankcase

Recommended oil: Cirkulation/gearbox oils with EP additives which do not

harm slidebearings (yellow metals)

Mineral Type
Producer Type Viscosity*
BP/Castrol Energol GR-XP 220 220
Exxon/Mobil Mobilgear 600 XP 220
Shell Omala Oil 220

Synthetic Type**
Producer Type Viscosity*
BP/Castrol Alphasyn EP 220 220
Exxon/Mobil SHC 630 220
Shell Omala RL 220

Food GradeType***
2.2 tf208716.en

Producer Type Viscosity*

BP/Castrol Optileb GT 220 220
Exxon/Mobil DTE FM 220 220
Shell DTE FM 220 220

* Viscosity in mm2/sec (cSt) at 40°C (104°F)

** A synthetic oil for the crank case must be of PAO ( poly alfa olefine)
type , like the Omala, that is mixable with mineral oils and does not
affect rubber, sealings and paint.
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
Note! Green oils is for the time beeing not availabe, but for some viscosities, and their
lubricacion performance is not yet good enough for use in our type of heavy
duty machines.
(Cont'd)

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Tetra Alex® 30 17
Lubrication
(Cont'd)

Gearbox

Recommended oil: Gearbox oil

Mineral Type
Producer Type Viscosity*
BP/Castrol Energol GR-XP 320 320
Exxon/Mobil Mobilgear 600 XP 320
Shell Omala Oil 320

Synthetic Type**
Producer Type Viscosity*
BP/Castrol Enersyn HTX 220-320
Exxon/Mobil SHC 630-632 220-320
Shell Omala RL 220-320

Food GradeType***
Producer Type Viscosity*
BP/Castrol Optileb GT 220 220-320

2.2 tf208716.en
Exxon/Mobil DTE FM 220-320 220-320
Shell Cassida GL 220-320

* Viscosity in mm2/sec (cSt) at 40°C (104°F)

If the gear box temperatur is kept to max. 70 °C ( 158°F),
220 cSt is sufficient.
** A synthetic oil for the gear box must be of PAO ( poly alfa olefine)
type, like the Omala, that is mixable with mineral oils and does not
affect rubber, sealings and paint.
(Cont'd)

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18 Tetra Alex® 30
 Lubrication
(Cont'd)

Hydraulic unit

Recommended oil: Hydraulic oil

Mineral Type
Producer Type Viscosity*
BP/Castrol Bartran 68 68
Exxon/Mobil Mobil DTE Excel 68 68
Shell Tellus 68

Synthetic Type**
Producer Type Viscosity*
BP/Castrol - -
Exxon/Mobil Mobil SHC 526 68
Shell Tellus 68

Food GradeType***
Producer Type Viscosity*
BP/Castrol Optileb HY 68
2.2 tf208716.en

Exxon/Mobil Mobil DET FM 68 68

Shell Cassida HF 68

* Viscosity in mm2/sec (cSt) at 40°C (104°F)

** A synthetic oil for the hydraulic unit must be of PAO ( poly alfa
olefine) type , like the Omala, that is mixable with mineral oils and
does not affect rubber, sealings and paint.
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
(Cont'd)

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Tetra Alex® 30 19
Lubrication
(Cont'd)

Main drive motor

Recommended grease

Producer Type Viscosity*

BP/Castrol Energrease LS EP 1 115
Exxon/Mobil Mobilith SHC 100 100
Shell Alvania grease RL3 100

Food GradeType***
Producer Type Viscosity*
BP/Castrol -
Exxon/Mobil Mobil grease FM 101 100
Shell Cassida RLS 2 150

* Viscosity in mm2/sec (c.st) at 40°C (104°F)

*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.

2.2 tf208716.en

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20 Tetra Alex® 30
 Oil amount

Crankcase Gearbox Hydraulic unit

Approx. 63 litres Approx. 8 litres Approx. 6 litres
(16.6 U.S. gallons) (2.1 U.S. gallons) (1.6 U.S. gallons)

GF200599

GF200326 GF200601
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Tetra Pak