Course Introduction 1

TBA/22 Introduction 2
TPMS Service system 3
TBA/22 Packaging material/package integrity 4
050V Supply systems 5
Tube forming 6
Training Document Sterile system components 7
This Training Document is intended for
Training purposes only, and must not be Sterile system 8
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
DMC 9
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such. Jaw system 10
Note!
For safe and proper procedures, refer to
Design control system 11
the equipment specific documentation.
Final folder 12
ASU 13
Sealing 14
Name:
Filling system 15
................................................................................................................

................................................................................................................
Line automation 16
Temperatures 17
Safety relays 18
Waste of packages, TPOP 19
Cleaning system 20
Headspace by Injection 21
22
23
24
25
26
27
28
29
Technical Training Centre
Lund, Sweden 30
WB-135-01
Issue 6/0507 31
 1
Course
Introduction

Technical Training Centre

 Information regarding
Safety Regulations at the
Technical Training Centre in Lund
This list summarizes a number of items which may concern you, as a
participant in this training course. Read the list, and if anything re-
mains less than clear, or if you have any questions, feel free to contact
your instructor.

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

Technical Training Centre 1/9701 TM-00001

 
   
 
  



 
  

 
   
 



  
     

 

 


 
     
  

 

   
   
  
 

 

 


 

 


 


 

 
  
    
 


  
      
 

    
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 2
TBA/22 introduction

Technical Training Centre

 Electrical cabinet Strip applicator (ASU RH side)

Lund, Sweden
Superstructure

Technical Training Centre

Service unit

Machine type
TBA/22
Issue
1/9905
OH 828
Automatic splicing unit Drive Jaw system Main groups
Machine body Final folder
Tetra Brik Aseptic
filling machine
TBA/22
High speed packaging system
for portion packages
TB A/22 High speed packaging system
High speed that adds value
TB A/22 creates an entirely new standard of capacity in the aseptic packaging of
liquid food. It provides a highly competitive solution for achieving lower operating
costs, higher productivity and greater space efficiency.

The capacity is remarkable; 20,000 packages per hour for the Tetra B rik¨ Aseptic
200 and 250 B aseline, 200 Midline and 200 S limline with straw openings and
secondary packaging solutions. The system offers a high speed straw applicator
and a high speed cardboard packer.

The beauty of the system is that it is not only fast, it is simple too. The higher
capacity has been achieved by increasing the speed of the filling machine and
designing innovative solutions for the new jaw unit and the new final folder.

C ost-effective, productive
and space-efficient
TB A/22 has been designed with the specific purpose of
reducing costs and raising the productivity of producers.

C os t-effec tive
S avings on packaging operating costs are achieved through lower
capital costs, lower utility consumption, lower operator costs,
improved space utilisation and less waste on a per package basis.

High produc tivity and s pac e effic ienc y

An unparalleled capacity of 20,000 packages per hour combined
with a very compact footprint makes the machine extremely cost-
effective. Producers can expand capacity in the space they already
have available, without having to invest in major extensions or
new plants.

Us er-friendly
S ignificant steps have been made to increase user-friendliness
for operators and service technicians. TB A/22 provides:
∗ easy access,
* ef ficient handling of consumables such
as packaging material and the LS-strip,
* an interactive operator interface.
 TB A/22 machine functions
8

10
11
1
4

12

5
9

1. P ac kaging material s upply 3. As eptic s ys tem 4. J aw unit

Two reels of packaging material are placed in S terilis ation of the pac kaging material is The jaw unit consists of 2 chains opposite
an integrated section of the machine. The achieved by letting the packaging material each other and are driven at a constant speed
reels are s pliced automatically by means pass through a deep bath of heated hydro- by a servo-motor. E ach chain is made of 10
of induction heat. The two-reel concept en- gen peroxide. R ollers remove the hydrogen links which move agains t fixed cams . No
ables the next reel to be spliced before the peroxide from the packaging material and hydraulics are needed.
one currently in use is finished …an ideal fea- remaining residues of H 2O 2 are evaporated
ture for contract packing and s hort pro- by hot s terile air. The temperature in the 5. S ingle final folder
aseptic chamber is monitored so that it will The final folder consists of a single chain dri-
duction runs of the same product with diffe-
not exceed 100° C . P roblems caus ed by ven at cons tant s peed by a s ervo-motor.
rent designs.
polyethylene sticking during short stops are There are no hydraulics. Use of lubrication
thus avoided. The aseptic chamber has been grease is minimal in order to avoid the risk of
2. L ongitudinal s ealing designed with a minimum of slots and screws, lea ka ges on the pa c ka ges . Individua l
Induction heat is used for sealing the longitu- and the surfaces are angled to enable efficient temperature-regulated air nozzles for the flap
dinal seam of the packages. Preheating is not cleaning. sealing improve the sealing.
needed, as the inductor applies the s trip TB A/22 has a self-balanced sterile air
immediately. overpressure that is automatically monitored
thus permitting reliable operation.
6. P roduc t filling s ys tem 11. S ervic e unit P ackaging Line Monitoring S ys tem (P LMS )
The product filling system has a level probe The service unit for the closed cooling sys- Automatic recording of line efficiency is made
that measures the liquid level very precisely tem and foam cleaning is located at the front possible by the PLMS . The system records
and controls it with an electronic system and of the machine. E asy connection of all utilities data about stoppages i.e. duration, frequency
a regulating valve. simplifies installation. and waste. The data can be analysed off-line
by transferring it to a P C via a modem or
7. P latforms 12. Interac tive operatorÕs panel diskette.
The spacious platforms and stairway make TB A/22 has an interactive operatorÕ s panel
the machine very accessible and provide a at floor level with a touch sensitive display. It F oam c leaning
s afe working environment. T he des ign contains very extensive alarm functions and Alkali foam cleaning is standard for external
complies with the directives for C E-marking. it is also possible to switch between different cleaning (cleaning of jaw system, final folder
languages very quickly. and aseptic chamber). Foam is dynamic and
8. Air c ooling of the elec tric al c abinet The operator guidance supports the ope- penetrates unseen surfaces to give a very
The electrical cabinet has a compres s or- rator with detailed instructions, such as what
hygenic environment.
controlled air cooler so that the temperature actions to take to reset the machine into the
will not exceed 40°C , even if the maximum production position. This feature helps save
C IP c leaning
number of options are built in. labour and reduce downtime.
The operator can easily adjust the most The cleaning-in-place function (cleaning of
important sealing parameters, centering of the produc t va lves a nd produc t piping) is
9. Was te c onveyor
longitudinal seal, package volume etc. automatically switched between production
R ejected packages are discharged at the front and the cleaning configuration by a group of
of the machine, which improves waste hand- P eroxide c ontainer s ys tem valves. This feature also records the C IP para-
ling and does not affect the operatorÕ
s working meters, i.e. the concentration, temperature
TB A/22 has a closed water system for heating
area. and flow of the cleaning media, which are
the hydrogen peroxide. The tank is insulated.
To avoid overfilling, the maximum level in the presented on a chart diagram.
10. Integrated c los ed water c ooling
tank is supervised by a level probe.
s ys tem
TB A/22 has an integrated c los ed water
L ongitudinal s eal s trip applic ation
cooling system to cool down IH transform-
The longitudinal seal strip applicator is located
ers and final folder guides. About 10% of the
at floor level to allow easy access.
water is continously purified through an ion
S ealing is done by induction heat. Two jumbo
exc hange filter whic h means that lime
reels are s plic ed automatic aly. If 250 B
deposits are eliminated in the cooling sys-
packaging material is used then one jumbo
tem.
strip lasts for about 1 hour.

TB A/22 packaging line

F illing mac hine Ac c umulator S traw applic ator C ardboard pac ker
F illing mac hine TB A/22 creates an Tetra Helix 22 has Tetra S traw Tetra C ardboard
entirely new been designed to Applicator 22 HS Packer 71 is
standard of capacity respond and adapt applies a drinking designed for the
in the aseptic itself to the straw to the high speed system
Ink jet date printer packaging of liquid changing needs of package. and makes
food. the production lines. S traw types: S -, distribution units
Its role is to keep T- and U-straws. of 3x8,3x9, 3x10,
production running 4x8, 4x9 and 4x10.
smoothly during a
stoppage and
prevent a shutdown
of the filling
machine.
Ac c umulator

S traw applic ator

Tray s hrink

Dis tributor

P allet s ys tem
C ardboard pac ker
Tetra Helix 22
Tetra Helix 22 consists of two parallel conveyors, which
operate at related speeds yet, are independent of one
another. The one conveyor is for infeed, the other for
outfeed, and at the hearth of the system, is a floating
gear.

Tetra S traw Applic ator 22 HS

The applicator is small and compact, making it easy
to integrate the machine with the packaging lines.

T he applic ator works with the flow princ iple.

To ens ure a precis e application of the s traw, the
packages are lifted up from the conveyor chain to
a transport belt when passing through the application
area.

The applicator head, containing the ladder band,

is mec ha nic a lly c onnec ted a nd driven by a
servo-motor. The straw is applied with the help of
pressure pads that move with the packages.

Tetra C ardboard P ac ker 71

Tetra C ardboard Packer 71 packs Tetra B rik¨ and Tetra B rik¨
Aseptic packages into cardboard trays in the 3x8, 3x9,
3x10, 4x8, 4x9 and 4x10 packing patterns. The machine
is easy to adjust from one packing pattern to another.

The packages are fed through a dis tributor that

separates the flow of packages into three parallel lines.
The packages are then fed into the packer and
grouped in the required packing pattern.
Technical Data: Tetra B rik ¨ Aseptic filling machine TB A/22 - 0500
C apac ity filling mac hine Water s upply (c old)
Packages per hour: 20,000 for TB A 200 B , TB A 250 B C onnection pressure, kPa (bar): 300-450 (3-4.5)
TB A 200 M and TB A 200 S Temperature, °C (°F): Max. 20 (68)
C onsumption, production:
F illed produc t type S terile air compressor, l/min: 8
S terile air compressor plus cooling
High and low acid product only
system compressor, l/min: 14-16
Non viscous product only
Water s upply (hot)
P roduc t s upply
C onnection pressure, kPa (bar): 300-450 (3-4.5)
C onnection pressure, kPa (bar): 160±40 (1.6±0.4) Temperature, °C (°F): 55-60 (130-140)
C onsumption
S team production: 0
E xternal cleaning, l/cycle: 120
C onnection pressure, kPa (bar): 170±30 (1.7±0.3)
Temperature, °C (°F): 130 (266) C ompres s ed air
C onsumption, kg/h: 3.5
C onnection presssure, kPa (bar): 550Ð600 (5.5 Ð6)
E lec tric ity C onsumption, production, Nl/min: 420

C onnection: Detergent (external c leaning)

Voltage, V: 400/230±10%
Frequency, Hz: 50/60±2% Alkali, l/cycle: 1.2 (1.8*)
R ecommended main fuse, A * If external cleaning superstructure is also running.
(To obtain selectivity): 100
C onsumption: C leaning in plac e (C IP )
Pre-heating, kW: 29
C onnection pressure, kPa (bar): Max. 350 (3.5)
S terilisation, spraying, kW: 34
Flow, l/h: Min. 8000
S terilisation, drying, kW: 20
Production, kW: 30.5
Nois e level
C leaning, kW: 10
S ound pressure level, Lp dB (A): 77
Hydrogen peroxide, (H 2O 2)
Ins tallation drawing No.
C oncentration: 35%
C onsumption, l/h: 4 2514257-3
T B A 21 MAC HINE P ULL TAB
IK OS MODE NA 5/98
F R IZIO

3621

© 2002 Tetra Pak Carton Ambient S.p.A./ AD Ikos. Produced by Tetra Pak Marketing Services AB. Code 8201en. 2002-09
589
5
2300
5054

75
16
49
17 00
11
85
80

Measurements in mm

www.tetrapak.com We reserve the right to introduce modifications without prior

notice.Tetra Pak, More than the package and Tetra Brik
are trademarks belonging to the Tetra Pak Group.
 3
TPMS service system

Technical Training Centre

Tetra Pak Maintenance
System
The methodology of preventive maintenance
Planned production requires planned
maintenance

A modern facility for processing and packaging food, milk or fruit

juice is a highly complex installation. Professional maintenance makes
it possible to maintain the high standards of reliability, hygiene and
consistent quality called for when working with sensitive products.
Minimal downtime and high machine availability have an immediate,
positive impact on the plant’s profitability.

By systematically applying preventive maintenance routines, pro-

duction downtime can be kept to a minimum. With the Tetra Pak
Maintenance System (TPMS) we can share with you all the experi-
ence we have acquired. Together we can achieve our common goal
– a reliable, profitable production plant.
A limited approach – or a limited attitude – to maintenance brings
only limited results. To be truly effective, maintenance must include
all the actions necessary to maximise plant efficiency.

That is why TPMS takes a holistic approach to maintenance – an

approach that consists of the following essential areas: maintenance
management, preventive maintenance, documentation, training, parts
logistics and tools facilities.

Tools
Facilities

Parts
Logistics
n
Documentatio

e
Preventiv
e
ain e
enanc
Maint ment
ge
Mana
Training
 TPMS – integrating maintenance starts at
the design phase

The best way of reducing maintenance costs is at the design stage.

Tetra Pak machines/equipment are designed to be easily maintained.
This is done by:

• involving service staff in the development work at the start of

the design phase of a new machine/equipment model

• ensuring designers participate in customers’ maintenance work,

in order to gain experience

When a prototype machine is designed, the first maintenance

checklists are complied by the designers in collaboration with
maintenance engineers. TPMS includes engagement in the product
development stage, applying unique tools to ensure minimised
maintenance needs, and securing a high level of availability for our
products.

Maintenance specialists work closely with The experience gained from maintaining
design engineers. The maintenance aspect Tetra Pak systems is incorporated into new
of each function is carefully evaluated. development projects.
 Innovation

Industrialisation

TPMS
View of Order Fulfilment Capital Equipment
Maintenance

Order Fulfilment Consumables

Traditional
Customer System Performance View of
Maintenance

Many of the machine functions are assessed Each Tetra Pak equipment development
on test rigs to ensure compliance with main- project receives input from our design,
tenance specifications. testing, production and service personnel.
Constantly updated—by the people
who actually use it

The Tetra Pak Maintenance System is constantly improved by input

from hundreds of users worldwide. This input is based on users’
real, hands-on experience. It helps make the system as effective
and easy-to-use as possible. It also contributes to continuous
equipment/machine innovation and improvement.

Maintain
A maintenance activity is performed when and where
specified by the TPMS. The actual work is carried out
either by your staff, Tetra Pak Technical Service staff,
or a combination of both.

Improve
The updated TPMS database is then used to formulate
new, more effective maintenance recommendations.
These recommendations make up part of new main-
tenance checklists, incorporating the lessons learned
from previous maintenance activities.
Report
Following the maintenance activity, a Maintenance
Report is filled in. This report is then forwarded to
Tetra Pak Technical Service.

Evaluate
Each Maintenance Report is analysed and evaluated
by TPMS experts within Tetra Pak Technical Service.
The results of these evaluations are fed into the
TPMS database as updates.
Documentation ensures consistency

Regularly updated documents support your work with TPMS. Detailed main-
tenance manuals help ensure the consistency of all maintenance work, whether
carried out by your staff or Tetra Pak staff.
Checklists ensure the correct work is performed at the correct intervals.
Maintenance reports give feedback and influence the ongoing development of
TPMS.

Maintenance Manuals Spare Parts Catalogues

Maintenance manuals give technicians Spare parts catalogues inform when, how and
information on the maintenance of each item where to order maintenance parts.
of Tetra Pak equipment.

Operation Manuals
Operation manuals contain everything
operators need to know about running a
particular machine – before, during and after
production.
Tetra Pak Technical Service / Code 9922 en. 2004-03

www.tetrapak.com
 Maintenance
Routines
Operator Maintenance

             
      
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14-4 TM-00079 Training Document. For training purpose only. Technical Training Centre 2/0310
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Technical Training Centre 2/0310 TM-00079 Training Document. For training purpose only. 14-7
Checklist - Front page

14-8 TM-00079 Training Document. For training purpose only. Technical Training Centre 2/0310
 1 Customer
 
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6 Issued by 8    &  
 
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Checklist - Check items

14-10 TM-00079 Training Document. For training purpose only. Technical Training Centre 2/0310
 15 Selection/Description /#        
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Technical Training Centre 2/0310 TM-00079 Training Document. For training purpose only. 14-11
Checklist - Comments page

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 28 Pos no 0  #      
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Technical Training Centre 2/0310 TM-00079 Training Document. For training purpose only. 14-13
Checklist - Connected items list

14-14 TM-00079 Training Document. For training purpose only. Technical Training Centre 2/0310
 41 Pos no 0  #    - &  
    
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Technical Training Centre 2/0310 TM-00079 Training Document. For training purpose only. 14-15
14-16 TM-00079 Training Document. For training purpose only. Technical Training Centre 2/0310
 4
Packaging material/
package integrity

Technical Training Centre

 Packaging Material
Introduction
Besides constituting a container, giving the steadiness needed to shape and
maintain the shape of the package, the packaging material protects the product
from being affected by the environment.
Furthermore, the packaging material gives information about the contents of
the package, and makes it easy to transport and handle.

Construction
The packaging material is a laminate, which means that it is built by several
layers. The structure of the packaging material varies depending on the
product being packed. Further information is given in section Different
material for different products, page 15-5.
TBA = Tetra Brik Aseptic A typical TBA material is built, from outside and inwards, as shown in the
picture and description below.

1
2

3:1

3:2

4
5
6
7
Construction of the packaging material.

1. Outer coating protects the package against external humidity.

2. Printing
3. Paper board 1; printside, offers a smooth printing surface.
2; reverse side, offers strength to the package.
4. Lamination a plastic layer which enables the paper board to stick
to the aluminium layer.
5. Aluminium protects against oxygen and light.
6. Internal coating 1 offers adhesion against the aluminium layer.
7. Internal coating 2 offers tightening against the product and enables
package sealing.

Technical Training Centre 5/0506 TM-00080 Training Document. For training purpose only. 15-1
The picture below describes what type of effects the different layers in the
material protects against.
Moisture Micro-
of water Light organisms Oxygen Odours

Outer coating
Printing
Paper board, bleached
with or without claycoat

Paperboard, bleached or
unbleached
Lamination
Aluminium
Internal coating 1
Internal coating 2

Product Flavour

The converting process

The converting process is what takes place when the paper board is trans-
formed into packaging material, ready to use. The process can be divided into
three phases:
• Printing and creasing.
The design is printed on the paperboard which continues through the
creasing tools. The creasing tools create creases, which means the folding
instructions on the package, as well as opening perforations and holes for
straws and screwcaps.

Printing press, flexography Printing

Creasing

Straw hole
Crease pattern
Opening perforation

Crease pattern, opening perforation and straw hole on the

packaging material

15-2 TM-00080 Training Document. For training purpose only. Technical Training Centre 5/0506
 • Lamination
The roll will be transported to the laminator. In the laminator different
layers will be added to the printed paperboard. First the paperboard passes
through a flame treating unit in order to burn off dust and to make it easier
for the plastic layer to stick. When all layers have been applied on the
paperboard, the thickness of the different plastic layers, and the surface
pureness is checked by in-line equipment.

Lamination

• Slitting
Roll = Roll of packaging material; After lamination, the roll is transferred to the slitter where it is slit into
several packages wide. reels. The slitting process is almost fully automatic. Reels with defect pack-
aging material will be sent to rewinding; the faulty part will be cut off, and
the reel will be spliced. Each approved reel is wrapped in shrinking film
Reel = Reel of packaging
material; one package wide
and stacked on a pallet.

Slitting

The raw materials

Paperboard Paperboard is used as main support to strengthen the package and maintain its
shape, and to sustain a certain amount of physical exposure.
All types of paperboard can be claycoated. This means that the board is coated
with a thin layer of white clay offering an even and white surface with excel-
lent printing properties.
The type of paperboard used varies due to type and size of the package and
Duplex
printing technique involved. The most common types of paperboard are
duplex, duplex claycoated and bleached claycoated:
• Duplex consists of different layers of paperboard; a thin
bleached (white) layer, to print on, and an unbleached
Duplex claycoated (brown) layer, which strengthens the material. Duplex
is the most common material and a standard for TBA
packages.
• Duplex claycoated consists of a Duplex board coated with a layer of white
clay, offering excellent printing properties.
Bleached • Bleached material merely consists of bleached (white) paper-
board.
• Bleached claycoated consists of a bleached board coated with a layer of
white clay, offering excellent printing properties.

Bleached claycoated

Technical Training Centre 5/0506 TM-00080 Training Document. For training purpose only. 15-3
Aluminium offers good barrier qualities. It protects the product against light, Aluminium
oxygen, odour and external humidity. It is manufactured in very thin layers.
The thinkness used in TBA packages is between 6 and 9 microns.
Furthermore, aluminium possesses good conductivity, which enables sealing
by induction heating. Packaging material without an aluminium layer cannot
be sealed by this method.

The plastic used in the packaging material is a PolyEthylene. PolyEthylene is Plastic

thermoplastic, which means that it can be melted and shaped more than once.
There are different kinds of PolyEthylene. The most common ones in our
packaging materials are:
• LDPE Low Density PolyEthylene
• mPE Mix of metallocene Linear low Density PolyEthylene (mLLDPE) and LDPE
Positive properties are:
• It is water proof.
• It enables sealing of the package.
• It is possible to apply in thin layers.
• It is transparent and thus does not affect the printed design.
• It is neutral, meaning that it does not affect the product.
• It is chemically resistant, meaning that it does not react with other
substances.
A limitation is:
• It does not protect the product against oxygen.
In wide coating mPE is used as the inner-most layer.

In all j-materials, for example TBA/j, the packaging material contains a type Adhesion plastic
of adhesive plastic as internal coating 1, see page 15-1, that offers a strong and
durable adhesion to the aluminium. This prevents the product from detoriating
the bond between the aluminum foil and the inside coating layers.

Metallised or Transparent OPP (Oriented polypropylene) film, or metallised Outer coating film
PET (Polyester) film, can be used as outer coating to improve apperance of the
package and to enhance the package shape.

Packaging material containing K-film in the innermost layer is used when K-film
packing aggressive products and products that are sensitive to residual
flavours. Examples of aggressive products are: tomato products, alcohol, oil,
and feta cheese. Water, and other low-tasting products, are sensitive to
residual flavours.
K-film is manufactured through film blowing techniques. This method means
that the plastic is stretched and oriented in length as well as transversal direc-
tion. K-film is applied to the material as ready-made film, unlike other plastic
coatings which are applied by extruding a thin layer of melted plastic onto the
packaging material.
K-film decreases the possibility for residual flavours to affect the product. It is
also tighter than extruded film, which makes it more difficult for aggressive
products to penetrate the plastic and cause microscopic cracks. When using
K-film, there is no risk of corrosion in the aluminium layer.

15-4 TM-00080 Training Document. For training purpose only. Technical Training Centre 5/0506
Pre-laminated hole (PLH) PLH packaging material is a packaging material where a hole is punched in the
paperboard during the printing process. When laminating the paperboard the
Pre-laminated hole
hole will be covered with aluminium foil and plastic.This kind of packaging
Post-applied cap material will be laminated with the thicker aluminium foil and plastic layers.
Paperboard Pre-laminated hole

PLH packaging material

PLH packaging material is used for packages with post-applied caps, which
means caps that are applied after filling.

Different materials for different products

The type of packaging material chosen depends on what product is to be
packaged. The different types of packaging material provided for TBA
packages are:
• TBA/m Used for UHT milk products.
• TBA/j Used for juice and drinks, flavoured milk products, soya bean
drinks, tea and coffee.
Outside LDPE layer, 12 g/m2

Paperboard and printing

Lamination layer LDPE, 20 g/m2

Aluminium foil, 17 g/m2

Adhesive polymers, 6 g/m2

Inside LDPE layer, 29 g/m2

Example of TBA/j material for 1000 ml packages
• TBA/w Used for wine and alcoholic drinks with less than 20%
alcohol.
k = the innermost layer consists • TBA/jk Used for products that will be heated in their package.
of k-film
• TBA/wk Used for alcoholic drinks with more than 20% alcohol.
• TBA/ok Used for eatable oil.
• TBA/tk Used for tomato products, dressings, soups and sauces.
• TBA/aqk Used for water.
• TBA/lk Used for products with fibres and seeds, can be used instead of
any TBA material with k-film.
The number of packaging material types will be decreased for the next
generation of TBA packages. This has already been introduced, and will be
completed in 2007.
• TBA/ml TBA Wide, replaces TBA/m.
• TBA/jl TBA Wide, replaces TBA/j, TBA/w and to some extent
material with k-film (/jk, /wk, /ok, /tk).
• TBA/jk For aggressive products and products that will be heated in
TPA = Tetra Prisma Aseptic their package, where TBA/jl will not be sufficient.
TWA = Tetra Wedge Aseptic • TBA/aqk For water.
• TBA/lk For products with fibres and seeds.
TFA = Tetra Fino Aseptic
The packaging material is chosen the same way for other packages i.e,
TCA = Tetra Classic Aseptic
TPA, TWA, TFA and TCA.

Technical Training Centre 5/0506 TM-00080 Training Document. For training purpose only. 15-5
Strips
Four types of strips are used in Tetra Pak packages: Longitudinal seal strip,
generally called LS-strip, Tab strip, Inner strip and Outer protection strip.

The longitudinal seal strip is applied on the inside of the packaging material, LS-strip
covering the edge of the longitudinal seal. It prevents the product from soaking
into the packaging material. The strip also ensures protection against oxygen
and contributes to the sealing of the tube.

Packaging material

Longitudinal seal strip

mPE mPE
LDPE
LDPE LDPE
Primer Primer Primer

PET PET EVOH

Primer Primer Primer

LDPE LDPE
LDPE mPE mPE

PPP MPM/MWM MSE

Longitudinal seal and different types of LS strips.

Tetra Pak uses two different strip core polymers, depending on the oxygen
permeability desired:
• PET PolyEthylene Terephtalate
• EVOH Ethylene Vinyl Acetate with Alcohol groups
From these polymers three basic types of LS strips are available:
• PPP has a core of PET, coated with primed layers of LDPE. This LDPE = Low Density PolyEthylene
strip is suitable for products that require a dense oxygen
barrier.
• MPM/MWMhas a core of PET, coated with primed layers of LDPE. The mPE = Mix of mLLDPE and LDPE
outermost layers consist of mPE. This strip has to be used
mLLDPE = metallocene Linear Low
together with Tetra Wide packaging material but is also
Density PolyEthylene
suitable for standard materials. MPM/MWM is suitable for
aggressive and alcoholic products. It also constitutes a tougher
seal.
• MSE has a core of EVOH, coated with primed layers of LDPE. The
outermost layers consists of mPE. This strip is suitable for
products that require a high oxygen barrier.

When producing packages with PullTab openings, a hole is punched into the Tab and Inner strip
packaging material in the filling machine. The inner strip patch is applied on
the inside and the tab strip on the outside of the hole.

PullTab opening

15-6 TM-00080 Training Document. For training purpose only. Technical Training Centre 5/0506
 To enable this opening, the inner strip patch and the tab strip must consist of
different materials. The inner strip patch is made of a multi layer blown film,
composed with a core of EVOH, coated with layers of LDPE. This gives a
dense barrier against oxygen and a thin enough patch to make the PullTab easy
to open. The tab strip is made of a laminated foil, composed of printed alumin-
ium, which provides mechanical strength and aesthetics, and LDPE which en-
ables sealing to the inner patch and the packaging material. For TPA portion
packages an outer protection strip patch is applied before punching the hole.
The outer patch improves the feeling when drinking directly from the package.

LDPE Al LDPE
Primer Primer

EVOH LDPE OPP

Primer

LDPE

Inner strip Tab Strip Outer protection strip

(Inner patch) (Tab) (Outer patch)

Different printing methods

Printing is the process of applying ink to create colours, words and designs.
Tetra Pak uses two different printing methods: Flexo and Offset.

Flexo Flexo has become the most common printing method and it is today used for
all types of designs.
Flexo is a relief printing method. One roller collects the ink, transfers it to the
Relief printing = Printing method
where the cliche’ sections, which ink transfer roller (anilox roller), which applies the ink onto the cliché. The
transfer the ink, are raised. cliché applies the design directly onto the board or other material.
The plates used for flexo printing are flexible and are made of mouldable
natural or synthetic rubber compounds or of photo polymer materials.

Counter
Anilox roller = A laser engraved Cliche pressure
roller that has a specific pattern roller
of holes or “cups”.
Ink transfer roller
(anilox)

Roller, collecting
the ink

Packaging material

Function principle for Flexo

Technical Training Centre 5/0506 TM-00080 Training Document. For training purpose only. 15-7
There are two types of flexo printing:
• Lineflexo Used for more simple designs without any photos.
• Flexo process Used for photographic designs.
Screen pattern = small dots
The main difference between lineflexo and flexo process is that process is a
four-colour print method. The design is built by screen patterns. Using the four
process colours; yellow, magenta, cyan and black, applied one after another in
balanced amounts, makes it possible to represent any tint. As for line printing,
Yellow Cyan
the desired tint is first prepared in a bucket and then poured into the printing
machine.
The pictures below show examples of a typical line design and a typical
process design.

Magenta

Line design Process design

Offset is used for designs with photographic pictures. Compared to flexo Offset
process, offset yields a somewhat better quality of the picture.
Dampening roller

Ink roller Printing plate

Packaging material

Rubber roller

Counter pressure
roller

Function principle for Offset

Offset is a flat printing method. An ink roller applies the ink on the printing Flat printing = Printing method,
plate. The ink is then transferred to a rubber roller, which applies the design where the sections which transfer
the colour are in level with the
onto the board or other material. plate.
The principle of offset printing is that certain parts of the printing plate are
water-repelling while other parts absorb the water. Damp is continuously
transferred to the printing plate from the dampening roller. As the printing
colour contains a certain amount of grease, it will not stick to the wet surfaces.
The colour will only stick to the water-repelling surfaces.
The offset printing plate is made from a sheet of aluminium.
Offset, like flexo process, is a four-colour print method. The design is built by
screen patterns. Using the four process colours; yellow, magenta, cyan and
black, applied one after another in balanced amounts, makes it possible to
represent any tint.

15-8 TM-00080 Training Document. For training purpose only. Technical Training Centre 5/0506
 Production Order Label and Pallet Label
Production order label and Pallet label are labels on the packaging material
reel and on the pallet containing reels. These labels contain information about
the content and are used, as an example, for claims.

Production order label

2
Tetra Pak Argentina
TP ORDER TP PRODUCT
10
3 01234567 D10-2701-03
CUST No CUSTOMER
11
4 Milk Lovers Ltd
987-6543 REMARKS
ID No
12
5 123-456789
TYPE

TBA/J
6 VOLUME REEL/PARCEL/BOX No CUSTOMER EAN

7
1000 ml 100015
QUANTITY PROD. DATE

08200 2000-09-15 8 711900 040479

8 13

1010123456710001508200

Production order label

The Production order label contains the following information:

1. Place of production
2. TP order No
3. Customer No
4. ID No
5. Material type
6. Volume
7. Quantity
8. Reel, parcel, box No
9. Production date
10. TP product code
11. Customer
12. Remarks
13. The two barcodes (according to standard)

Technical Training Centre 5/0506 TM-00080 Training Document. For training purpose only. 15-9
 Pallet label
1
Tetra Pak Argentina
Design Material no. ID No.
2
D99-9999-99 123-456789 6
PALLET CONTENTS
TP-ORDER Pallet no.
3 03-0025 / 8200
02-0025 / 8200 P999-1234567 0015

1010123456700150410000
02-0024 / 8200
Extra row 1
Extra row 2
Extra row 3
Extra row 4
4 Extra row 5
TOTAL QUANTITY

024600
5 PALLET WEIGHT

1415 kg
TYPE
TBA/J SL 8 711900 040479

24-Jan-2002 1010123456700150410000

Ritad av / Drawn by Skala / Scale Datum / Date Anmärkning / Remark

EH/ISP 1:1 2002-01-29 Final
Ritn Nr. / Drawing No.

PALLET LABEL
Tetra Pak GENERAL; TEXT PLG-4-01-T

The Pallet label contains the following information:

1. ID No
2. TP order No
3. Reel No
4. Quantity of packages on the reel
5. Total quantity
6. Pallet No

Packaging Material Claims

Packaging material claims, usually cost a lot of money. Therefore, every effort
must be made to use the packaging material produced and delivered. As a rule,
a claim will not be accepted by Tetra Pak if the packaging material was pro-
duced and delivered within specification.
One condition for accepting a packaging material claim, is that the filling
machine is upgraded to recommended standard and adequately maintained.
Packaging material claims will not be accepted if the material has not been
stored in accordance with local recommendations or recommended storage
conditions in the Installation Manual.
Below follows a description of how a packaging material claim is handled:
1. The customer makes his complaint to the Area Technical Service
Manager, on a packaging material report form, or in accordance with the
local producer.
2. The Area Technical Service Manager confirms the complaint by returning
a copy of the packaging material report form to the customer.
3. As a first step, the Technical Service Department sends a service engineer
to the customer to investigate the nature of the complaint.

15-10 TM-00080 Training Document. For training purpose only. Technical Training Centre 5/0506
 4. The packaging material on hold is moved to a separate location and
clearly marked. When the complaints are involving suspicious packaging
material, the producer is contacted and the responsible market is informed.
5. A detailed description of the fault in accordance with the Fault Code List
Packaging Material, the disturbances occurred on the packaging machine
and the name of the person who inspected the goods, are given on the
claim report form. The original of the completed claim report form is sent
to the receiver at the producing plant together with representative samples
of the faulty packaging material, two meters from each reel.

Fault Code List The Fault Code List consists of seven head groups. Within these groups there
Packaging Material are ten sub groups, each sub group consists of ten detailed fault denomina-
L009 tions. The head group, 900 Filling machine, is intended to be used by Techni-
cal Service as an indication to the producer of how the packaging material
behaves in the filling machine. The codes 100-800 are used to give a more pre-
cise direction of where the fault occurs on the packaging material. This to en-
able faster handling of the claim.

Tetra Pak Carton Packaging Division Carton Support

Fault Code List Packaging Material L 009

4. Fault Code List Packaging Material

More detailed information are available on the Tetra Pak intranet, Orbis, in the
following documents:
General Rules For Packaging Material Claims, G007
Packaging Material Claims and Complaints, I011
Fault Code List Packaging Material, L009

Recommendations
Storage Tetra Brik packaging material is supplied in protected and palletised reels,
which are sufficiently resistant to any damage it might be exposed to in the
course of normal handling and storage.
Below follows some advice to ensure maximum utilisation of the packaging
material:
1. Keep the storage premises clean and use them exclusively for the
packaging material.
2. The optimal temperature range for storing the packaging material is
between 10 and 30 °C. Do not allow the temperature to fall below 0 °C.
3. Maintain a relative humidity between 40 and 65%. Do not store the
packaging material in excessively damp or moist areas. No pipes etc.

Technical Training Centre 5/0506 TM-00080 Training Document. For training purpose only. 15-11
 which may produce condensation should run through the storage
premises.
4. It is important that the packaging material attains a temperature close to
that of the packaging room. Therefore it is advisable to withdraw it from
the storage premises one day before use and keep it in a suitable place
inside the packaging room.
5. Under normal circumstances, reels of packaging material are double-
wrapped. Each reel is tightly shrink-wrapped and each pallet is enclosed in
shrink material. Do not remove this until shortly before the reel is placed
in the machine.
6. Always store the reels on pallets and not directly on the floor. Position the
pallets at a sufficient distance from the walls to ensure efficient handling
of the pallets.
7. Pallets can be stacked three high provided a rigid divider board is placed
on top of the lower pallets. The transportation pallet is only a one-way unit
and its strength has limitations, therefore avoid excessive scuffing and
chafing.

Always take the greatest care when handling the packaging material. Below Handling
follows some advice:
1. Before touching the packaging material, disinfect your hands.
2. The packaging material must never touch the floor.
3. Do not remove the shrink wrapping from the reel until you have placed it
in the trolley.
4. Unwind one revolution of the packaging material from the reel and check
for damages. If damages are found on the packaging material, be sure to
remove enough packaging material to avoid this to enter the filling
machine.
5. Keep the Production order label.

For the latest updates please visit our website: cartonambient.tetrapak.com

15-12 TM-00080 Training Document. For training purpose only. Technical Training Centre 5/0506
 Tetra Brik Aseptic
Transversal Sealing
Evaluation

Tetra Pak
Issue 2 English
Doc. No. TM-00433
 Preparations
This spread shows how to prepare samples for transversal sealing
Stretch-Test and evaluation. The ”Strech-Test” can be done either
by hand or with Stretch-Pliers.
The everyday term for Transversal Sealing is TS.

Commence preparations with Empty both packages.

1 removing two consecutive packages
from the packaging machine
2
conveyor line.

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

2
 Cut off both TS from both Trim a narrow strip, no more than
3 packages to a width of 25 mm to
accommodate the Stretch-Pliers.
4 1 mm from the ends of each
sample.

Cut wider when stretching by hand.

Rinse samples and dry. Preparations concluded, four

5 6 samples from two consecutive
packages are now ready.

Good light conditions are essential

for evaluation.

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

3
 Stretch-Test
Stretch-Test can be done either with Stretch-Pliers or by hand.
Evaluation method of seal quality is the same. Evaluation is car-
ried out while stretching.

When using Stretch-

7 Pliers, insert sample
into the gripping jaws
and squeeze handles to
stretch the seal.

When stretching by
hand, apply force and
stretch perpendicular
to the seal.

Gently tension the seal by Observe how the seal area stretches
8 stretching it. 9 and breaks. Stretching slowly,
makes evaluation easier.

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

4
 On the following two spreads examples of
”Good” seals and ”Bad” seals are shown.

All four samples have

12 to be stretched and
evaluated along the
entire seal. Pay special
attention to the TS
ends and where the TS
meets the longitudinal
sealing (TS/LS cross).

Continue stretching. In this case Continue stretching until the

10 there is stretched plastic film
visible in the seal area.
11 sample has opened completely.

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

5
 Good Seal
The first sign of a good seal when testing, is a stretched film of
plastic.

Plastic film

Intact seal

On this sample the plastic film has been stretched to the

point where it starts to break (two holes). Since the plastic
film has stretched along the whole seal it is consequently a
good seal.

Stretched plastic film or breakage in packaging material

indicate that the seal is stronger than the packaging
material. The seal is good.

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

6
 These four samples are also good, although the stretched plastic film
was broken at an earlier stage and did not become clearly visible.
Other indications on these samples will tell that the seals are good.

Sample 1, broke in the packaging material Sample 2, shows a breakage in the plastic
during testing. Notice the paper fibres part of the packaging material, since
along the whole seal. uncovered shiny aluminiumfoil (1), can
be observed. Notice also the remnants of
stretched and broken plastic film (2).

Sample 3, has a clear indication of the Sample 4. This TS/LS cross is also broken
packaging material breaking along the in the packaking material. Like sample 3,
seal. It is a combination of samples 1 it is a combination of shiny aluminium
and 2. foil and breakage in paper fibres.

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

7
 Bad Seal
Separation in the seal

When testing this sample,

the seal separated at the mar-
ked area, without the plastic
film stretching and without
breaking the packaging
material. This is a bad seal.

A commonly used term for

this type of fault is a
”Blocked Seal”.

In a Blocked area the seal is

weaker than the packaging
material.

If a seal is Blocked somew-

here along its length, it is a
bad seal. Independent of
how small the Blocking is, it
is still a bad seal.

A Blocked seal can only be detected

with a Stretch-Test.
A Blocked seal seldom leaks product.
A Blocked seal is usually caused by
either insufficient heat or insufficient
pressure during sealing.

This is also a Blocked seal, but the

Blocked area (marked) is small.

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

8
 Bad Seal
Plastic lumps

This is a different type of

bad seal. The sample has
hard lumps of plastic
squeezed out during sealing.

Plastic lumps can puncture the

package from inside during handling.
Plastic lumps are usually caused by
too much heat or too high pressure
during sealing.

Check for lumps by running a finger along

the seal before Stretch-Testing the sample.

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

9
 Exercise
Mark the box that applies, and fill in reason for
choice. Point with arrow where needed. Other obser-
vations can be treated as a supplementary study.

❑ Good Seal ❑ Bad seal ❑ Good Seal ❑ Bad seal

Reason: Reason:
Other observations: Other observations:

❑ Good Seal ❑ Bad seal ❑ Good Seal ❑ Bad seal

Reason: Reason:
Other observations: Other observations:

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

10
 Answer
key

❑ Good Seal ❑ Bad seal ❑ Good Seal ❑ Bad seal

Reason: Reason:
Other observations: Other observations:

❑ Good Seal ❑ Bad seal ❑ Good Seal ❑ Bad seal

Reason: Reason:
Other observations: Other observations:

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

11
 Answer key

✘
❑ Good Seal ❑ Bad seal ❑ Good Seal ✘
❑ Bad seal
Reason: Stretched plastic film (1). Reason: Blocking (1).
Other observations: Plastic film starts to Other observations: Breakage in paper
break (2). Seal (3). fibres (2).

❑ Good Seal ✘
❑ Bad seal ✘
❑ Good Seal ❑ Bad seal
Reason: Plastic lumps (1). Reason: Shiny aluminium foil (1).
Other observations: Stretched plastic film Other observations: Remnants of
(2). Breakage in paper fibres (3). stretched and broken plastic film (2).

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

12
✘
❑ Good Seal ❑ Bad seal ❑ Good Seal ✘
❑ Bad seal
Reason: Stretched plastic film along seal. Reason: Blocking (1).
Other observations: Seal (1). Holes where Other observations: Stretched plastic film
plastic film starts to break (2). (2).

❑ Good Seal ✘
❑ Bad seal ✘
❑ Good Seal ❑ Bad seal
Reason: Blocking (1). Reason: Packaging material broken
Other observations: Remnants of along seal.
stretched and broken plastic film (2). Other observations: Shiny aluminiumfoil
Breakage in paper fibres (3). (1). Plastic film (2). Breakage in paper
fibres (3).

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

13
 Suggested tools for
Transversal Sealing evaluation

Stretch-pliers; makes the

stretching easier to control. It also
ensures that stretching is perpen-
dicular to the seal.
Spare part No. 78073-101

Circular fluorescent lamp 220 V, *

with built in magnifying lens.
Magnification x1.75. Delivered
with table clamp. Extra
accessories; table plate, clip on
lens for magnification x3.5.

Scissors, right hand.

Spare part No. 90243-129

Scissors, left hand. *

Paper knife.
Spare part No. 777502-101

Pocket size magnifyer, *

foldable. Magnification x6.

* When ordering these items contact

your local Tetra Pak office.

TM-00433 Training Document. For training purpose only. Technical Training Centre 2/0206

14
Notes

Technical Training Centre 2/0206 TM-00433 Training Document. For training purpose only.

15
 Issue 2/0206
© 1991, 2002 Tetra Pak Global Technical Support AB, Technical Training Centre
All rights reserved. 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 photocopying, recording or otherwise, without permission in writing
from Technical Training Centre.

Technical Training Centre

 5
Supply systems

Technical Training Centre

 Pneumatic panel

Y 3112
Y 3111
Y 3110

T 3109 Y 3103

U 3109 Y 3109

Y 2201
B 2201

5
A 2201
T 2201
U 2201
Z 2201

Connection block
Air
2
Ice water, inlet

Cold water

Ice water, outlet

3 Supply HI−HL
4 1 Air inlet
2 Air jet gun
Central refilling of
3 FFU, A and B valves
hydrogen peroxide
4 ASU, superstructure
and machine body
5 Service unit Hot water

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 2/0303 OH 830
 T3109
Y2104
T4200

Y3110

Y3109
Y3103
Y3111
Y3112
Y5504
T4210
Service Unit
Y5501
T4220

Lund, Sweden
Y1220
T4230

Y1221 T2201 A2201 Valve panels

Technical Training Centre

B2201 Y2201
P2

T4301

Y4230

U2201
Y4220 P1

Machine type
Y4210 Y1501 Y1303
Z2201
Y4200 Y1502
Air Supply Unit T1501
Machine Body Y1301 Y1401

TBA/22 050V
T1502
Y1302 Y1405
T1326

T1231
Y1114:4
Y1111
Y1114:2

Issue
Y1107 Y1241

1/0303
Y1325 Y1108

Y3116 Y1280

Y7420
Y7421
Y7414
Y7415
Y7303
Y6203
Y7315
Y6205
Y6201
Y1281
T01

T7425

Y7425

OH 1215
Y7413
Y7412
Y7408
Y7410
Y7407
Superstructure
ASU
 Pneumatic system
Overview

Lund, Sweden
Valve panel ASU

Technical Training Centre

Machine type
Valve panel Valve panel
Superstructure Machine body

Valve panel

TBA/22 050V
Service unit

P2 B2201

Air supply unit

Issue
P1

1/0303
Y2201

Flow line P1
Flow line P2
Control flow line
Return flow line

Air jet gun

OH 1216:1
 Pneumatic system
Service unit

Lund, Sweden
Aseptic
Foaming Flushing chamber Jaw system Final folder
cleaning cleaning cleaning
F3112
F3103 F3110 F3111

Technical Training Centre

Y3109 Y3103 Y3110 Y3111 Y3112

Machine type
TBA/22 050V
U3109
T3109

Issue
Flow line

1/0303
Control flow line
P1 Return flow line

OH 1216:4
 Pneumatic system
Machine body Design correction photocell

Z43012

Lund, Sweden
Filling H2 O2 tank

Z43011 U1210
Y1210

Technical Training Centre

U4200 U4210 U4220 U4230 U4301 T1210

Machine type
Z1210
T4200 T4210 T4220 T4230 T4301

TBA/22 050V
Flap heating bottom Flap heating top Draining Filling bath Waste box Outfeed of Flushing Tube
Right Left Right Left peroxide bath waste in front F.F. flusher
F1221 F1220 C5501 C5504 S21041 S21042

Issue
1/0303
Y4200 Y4210 Y4220 Y4230 Y1221 Y1220 Y5501 Y5504 Y2104

P1 P2

OH 1216:3
 Z13261 Z13262

F1231
Pneumatic system Spraying

U1231 U1326 U1502 U1501

Superstructure

Lund, Sweden
T1231 T1326 T1502 T1501

Colum ball / lid Bucket

cleaning cleaning
F13252
C31162

Technical Training Centre

Heat exchanger Preheating B−valve A−valve Squee−gee Pendulum
Cleaning valve Step 2 Step 2 roller roller
sleeve
C31161 F13251 C1107 C1114 F1302 F1301 C1502 C1501

Machine type
Y3116 Y1325 Y1107 Y1114:4 Y1114:2 Y1302 Y1301 Y1502 Y1501

TBA/22 050V
TCSB Steam Heat exchanger Butterfly Preheating Bending roller Movable lower C−valve
trap valve Step 1 valve Step 1 rotation forming ring

Issue
F1281 F1280 C1108 C1241 C1111 C1405 C1401 F1303

1/0303
S1303

Y1281 Y1280 Y1108 Y1241 Y1111 Y1405 Y1401 Y1303

OH 1216:2
Regulating valve

Y1304 F1304
P2 P1
 Textbook

Pneumatic system

MT-83015-2

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 1/9411

© 1994, Technical Training Centre

No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocop-
ying, recording or otherwise, without permission in writing from Technical Training Centre.
Pneumatic system

Training Document
This Training Document is intended for
Training purpose only, and must not be
used for other purpose.
The Training Document is not replacing
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

Contents

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

Pressure Shut–off Pressure regulator

source valve with gauge Valve Cylinder

As there are many models and versions of machines, and some of them have
been rebuilt or modified to differ from their original design, it is very
important that the correct, up–dated, and currently valid pneumatic diagram is
used when working with a particular machine.

Technical Training Centre 1/9411 Training Document. For training purpose only. 3
Components
Air conditioning units
The first unit the air passes through on its way to the machine is the air
conditioning unit. It consists of a separator, pressure regulator with pressure
gauge, and, on some machines, lubricator. Normally, a shut–off valve is built
into the conditioning unit.

Pressure regulator
Shut–off valve

Air conditioning unit symbol

Pressure gauge

Separator
Lubricator

The purpose of the separator is to remove water and other pollutants that might Separator
be present in the compressed air. The separator consists of a filter element and
a reservoir with a drain valve. The filter element may be made of sintered
bronze. The input air is made to rotate, so that water drops and the larger solid
particles are flung outwards against the inner surface of the reservoir.
Condensated liquid runs down to to bottom of the reservoir, where it is
removed through the drain valve when the input air is turned off.

The purpose of the pressure regulator is to provide air at a constant pressure, Pressure regulator
independent of the load on the system. It is a form of pressure reduction valve,
and its function will be explained under the heading of Valves.

The pressure gauge indicates the pressure setting. Pressure gauge

The lubricator (mist lubricator) provides the compressed air with oil. The Lubricator
injected amount of oil is proportional to the flow rate of the air and can be
preset. In systems whose components are factory prelubricated, no oil must be
added to the compressed air, as oil would wash out the grease in the
prelubricated components.

4 Training Document. For training purpose only. Technical Training Centre 1/9411
 Valves
The purpose of valves is to regulate the flow rate and pressure of the
compressed air and control its flow direction. The valves are controlled and
operated either manually, by means of electrical signals from the PLC, or
pneumatically by other valves.
Valves are subdivided into two groups – seat valves and slide valves. These
groups differ in their design.

Seat valve The seat valve controls the flow of air by means of its valve head and seat. The
valve head only has to move a short distance to change over but needs
considerable change–over force.
Non–actuated Actuated

Seat
Valve head
Housing
Return spring

Slide valve The slide valve controls the air flow by means of a movable slide. To change
over, the slide has to move a relatively long distance, but the force needed for
it is small.

Non–actuated Actuated

Housing
Slide

Return spring

In respect of their purpose, valves are grouped as follows:

• directional valves, controlling the flow direction of the compressed air, for
instance to operate the reciprocating movement of the piston in a pneumatic
cylinder.
• flow rate regulating valves, controlling the amount of air per time unit, for
instance to control the speed of the piston in a pneumatic cylinder.
• pressure regulating valves, controlling the pressure in the pneumatic sys-
tem.
Before proceeding, we shall take a look at the symbols for the valves, and how
they are constructed and function.

Technical Training Centre 1/9411 Training Document. For training purpose only. 5
The valve symbols denote the function of the valves but not their design. This Valve symbols
means that valves that look differently, due to the way they are designed and
constructed but function in the same manner, are shown with the same symbol.
The illustration shows the working principle of a slide valve, which may be in
either of two positions.
Outlet.
Port for output air Slide
Pilot air
Pilot air

Valve
housing
Inlet. Vent.
Port for input air Port for evacuation

Position 1 Position 2
The valve has received pilot air on the The valve has received pilot air on the
lefthand side. The passage between in- righthand side. The inlet is closed, and
let and outlet is open, and the vent is the passage between outlet and vent is
closed open.

This valve can be shown simplified as a symbol.

The symbol consists of a square, with the ducts through which the air is able
to pass shown as arrows. To the left and right of the square, the manner in
which the valve is controlled is symbolised, for instance with a horizontal line
for pneumatic control. The lines above and underneath the square represent the
ports connected to the input and output air lines.
Outlet Valve housing

Pilot air Pilot air

Inlet Vent

Position 1 Position 2
The valve symbol is shown with The valve symbol is shown with
open passage between inlet and open passage between outlet and
outlet, and closed vent. vent, and closed inlet.

6 Training Document. For training purpose only. Technical Training Centre 1/9411
 The function of the valve is illustrated by means of symbols. Each position the
slide may be in is shown as a symbol, and the symbols are drawn after one
another. The ports are only shown on the symbol in active position in the
pneumatic diagram, which is the starting position of the valve.
Outlet
Active part of
symbol

Pilot air
Inlet Vent
Compressed air supply.
Position 1 Position 2
The pilot air is received on the lefthand side The pilot air is received on the right-
of the symbol, which means that the lefthand hand side of the symbol, which means
side of the symbol is active. Compressed air that the righthand side of the symbol is
passes through the valve and can actuate a active. The air in the
cylinder cylinder can be evacuated.

To make it easier to identify them, the ports are numbered: input air port – No
1; output air port – No 2; vent port – No 3. The pneumatic signal ports take
their numbers from the ports they provide passage between; for instance, port
No 12 connects input and output air.
2

12

1 3

As the valve in the example has three ports and a slide which may be in two
positions, it is termed a ”3/2 valve”. Similarly, a five–port valve with a three–
position slide becomes a ”5/3 valve”.
The valve may be operated in several ways. Other than pneumatically, it can
be operated manually, by a spring, or electrically. The different ways are
shown as symbols. In the following example, an electrically operated 5/2
valve with spring return operates a double-action pneumatic cylinder.

Cylinder

Control signal Outlet ports

4 2

14
5 1 3
Return spring
Vent port
Vent port
Inlet port
The control signal is received on the The control signal is discontinued, and
lefthand side of the symbol. Compressed the return spring moves the slide. The
air passes through the valve and into the compressed air is now directed to the mi-
plus compartment of the cylinder, while its nus compartment of the cylinder, while
minus compartment is vented. its plus compartment is vented.

The various forms of valve symbols used in our pneumatic diagrams are
explained in greater detail in the section of this text where the function of the
valves is described.

Technical Training Centre 1/9411 Training Document. For training purpose only. 7
The monostable valve features spring return, i e in idle position, the slide is Monostable directional
always in the same position. One advantage of this type of valve is that it is valve
possible to operate a cylinder in both direction with only one control signal
output from the PLC.
Electrically controlled, monostable valves are used extensively in Tetra Pak
machines. The pilot air is controlled by means of an solenoid, powered by 24
or 48 V DC from a PLC output. The pilot air system is an integral part of the Electrically controlled,
directional valve. monostable directional
valve.

Cylinder

Electrically controlled,
monostable valve 4 2

Seal
Pilot valve
Solenoid

5 1 3
14

From PLC

In those cases where the valve receives air with a reduced pressure, which is
lower than the change–over pressure of the valve, the pilot valve can be
supplied separately with air from the pneumatic system. On some valves, for
Electrically controlled,
instance Mecman Series 581, change–over is effected by turning the seal monostable directional
between the valve proper section and the control section upside down. Then valve with separate air
supply to pilot valve.
control port No 14 in the connection plate is connected directly to the
compressed air system.
Electrically controlled, monostable valve with sepa-
rately supplied solenoid valve
4 2

Seal
Pilot valve
Solenoid

5 1 3
14

Pressure regulator From PLC

8 Training Document. For training purpose only. Technical Training Centre 1/9411
Bistable directinal valve The valve has no spring return, and thus the slide can be in either of two idle
positions, depending on which one of the two solenoids was most recently
activated. Consequently, two outputs from the PLC are always required to
control a bistable valve.
Electrically controlled,
bistable directional valve

4 2

5 1 3
12 14

From PLC
From PLC

Valves of the bistable type are used if, for instance, it is desirable that the
cylinder is to remain in the position it moved to as a result of the most recent
valve operation, even if the the output signal is discontinued. The same
standard principle for numbering the ports applies to this kind of valve. Pilot
air at port No 12 connects ports No 1 and No 2, pilot air at port No 14 connects
ports No 1 and No 4, in both cases admitting passage of input air.

Technical Training Centre 1/9411 Training Document. For training purpose only. 9
This valve type is used, for instance when a cylinder is to remain in position 3-positioned directional
at an emergency stop. Below, an electrically controlled 5/3 valve is illustrated. valve
4 2

Electrically controlled, 3–
positions directional valve
with closed middle posi-
tion.
5 1 3

14 12

No control signal to ports No 12 and No 14 means that the return spring

positions the slide in the middle; all ports closed.

4 2

5 1 3

14 12

On port No 14 receiving a control signal, the slide moves to the right in the
picture. This means that port No 1 is connected to port No 4, and port
No 2 to port No 3.
4 2

5 1 3

14 12

On port No 12 receiving a control signal, the slide moves to the left in

the picture. This means that port No 1 is connected to port No 2, and
port No 4 to port No 5.

The valve can be in three positions. In addition to the two positions of a 2–

position valve, the 3–position valve has a middle position with all ports
closed(as exemplified above) or open for venting. Two PLC outputs are
required to control the valve. If there is no signal when the system is
depressurised, the return spring puts the valve in its middle position.

10 Training Document. For training purpose only. Technical Training Centre 1/9411
 Soft-start valve This type of valve is used in order to make pressurisation of the pneumatic
system soft and smooth.
Variable stop Telescoping slide

1 2 3
12
Idle position.
In idle position, ports No 2 and No 3 have an
open connection. The pneumatic system is
depressurised.

1 2 3
12
Pressurisation phase.
During the pressurisation phase, the connection
between ports No 1 and No 2 is partly open, and
pressurisation has begun. The width of the open-
ing is regulated by means of a variable stop (limit
screw).

1 2 3
12
Full flow.
When the pressure has risen to approximately
75% of the pressure in the compressed air supply
line, the connection between ports No 1 and No
2 is opened all the way.

The three positions of the telescoping slide are illustrated, somewhat

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

Technical Training Centre 1/9411 Training Document. For training purpose only. 11
This kind of valve is used to regulate the flow of air, which is restricted equally Throttle valve
much in both directions.

1 2

Throttle valve Throttle fitted in

directional valve

If throttles are incorporated in a directional valve, they are fitted in the outlet
ports and consist of brass screws. Normally, such throttles are factory fitted in
most of our directional valves. Normally, they provide adequate speed
regulation accuracy.

This kind of valve is used when the air is to be regulated in one flow direction Throttle check valve
only.

1 2 1 2

When the air flows from port No 1 If, on the other hand, the air flows from
to port No 2, it must pass through port No 2 to port No 1, it passes through
the throttle and can thus be regulat- the check valve without being regulat-
ed. ed.

In order to achieve better accuracy in speed regulation, throttle check valves

can be used, for instance fitted in the end sections of the cylinders. This is done
when the cylinder is located remote from the directional valve. If throttle
check valves are being used, the throttles integral with the directional valves
must be fully open; adjustment must only be made by means of the throttle
check valves.

This is a manually operated ball valve, used to shut the supply of air to the Shut-off valve
entire pneumatic system. Normally, it is built into the air conditioning unit.

The pressure switch triggers an alarm to the control system, if the pressure Pressure switch
drops below a preset value. This value can be adjusted.

12 Training Document. For training purpose only. Technical Training Centre 1/9411
 Pressure regulator Correctly set pressure is a condition of correct speed control and correct force.
For this reason, a pressure regulator is a always fitted in the air conditioning
unit. To enable the pressure regulator to function well, there must be a pressure
difference between input and output air of not less than 0.8 bar. Some
machines have an extra pressure regulator within the pneumatic system for the
purpose of allowing the reduction of the air pressure to some of the cylinders.

Outlet pressure
set screw
Force spring

Diaphragm
Inlet port
Outlet port
Seat
Valve plate

The valve plate of the seat valve is operated by the diaphragm, which in its turn
is actuated by the outlet pressure of the pressure regulator. The force created
by this pressure is balanced by the spring force on the other side of the
diaphragm. By increasing the spring force by turning the set screw, the seat
valve is opened and is kept open until the outlet pressure exceeds the spring
force. Thus the diaphragm and the spring force together maintain a constant,
preset outlet pressure. If the pressure on the outlet side drops, for instance due
to air used in moving a cylinder, the seat valve opens again.

Vacuum ejector with valve This valve generates underpressure through its ejector effect. It is used, as an
example, to supply a vacuum to suction cups. There are two types of vacuum
valves. One type which is electrically controlled and generates a release pulse
when the direction of flow is reversed. The other type in entirely pneumatic
and generates the release pulse by means of a built–in accumulator.

1
3

1 3
2

Electrically controlled
vacuum ejector 2
Pneumatically controlled
vacuum ejector

Technical Training Centre 1/9411 Training Document. For training purpose only. 13
Cylinders
The purpose of a pneumatic cylinder is to perform a movement, powered by
compressed air.
In simple terms, the pneumatic cylinder consists of a cylinder housing with
two end sections, a piston with piston rod, and two connections to the
pneumatic system.
Plus compartment Minus compartment
Piston rod

Rear end Connection Piston Cylinder housing Connection Front end

section section

The piston is provided with seal–rings, separating the two compartments. The
front end section has a piston rod guide and seal.
When compressed air is admitted into the plus compartment (pressurisation),
and the air in the minus compartment is vented, or evacuated
(depressurisation), the piston rod extends out of the cylinder – the piston
performs a plus stroke. If the flows of air are reversed, the piston rod is
withdrawn into the cylinder – the piston performs a minus stroke.
Plus stroke Minus stroke

The cylinder described above is a double–action cylinder with single–side Double-action cylinder
piston rod. This means that both the plus stroke and the minus stroke are
performed powered by compressed air, and that there is a piston rod at one end
only.

14 Training Document. For training purpose only. Technical Training Centre 1/9411
 Single-action cylinder In the single–action cylinder, a spring effects the minus stroke.
Spring

Piston rod

Rod-less cylinder Such a cylinder is double–acting, but its piston rod has been replaced by an
attachment sliding along the outside of the cylinder shell. The movement may
be transferred to the attachment mechanically or by means of magnets.
Attachment

Connection Piston Cylinder Connection End section

End section housing

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

Magnetic piston

Double–action cylinder with mag-

netic piston
When replacing a cylinder with a magnetic piston, it is important that the
replacement cylinder also has a magnetic piston. A cylinder with the correct
length of stroke and diameter, but without magnetic piston, will not actuate the
magnetic piston sensors.

Technical Training Centre 1/9411 Training Document. For training purpose only. 15
The direction, force, and speed of movement of the piston rod can be
controlled. To ensure that the piston rod stops moving softly and smoothly,
there are also end position dampers. The various functions are explained in the
following.

The direction of movement is controlled by directional valves.. Direction of movement

In order to control the movements of a double–action cylinder, a five–port

valve is required. As the valve is actuated by a control signal, its slide changes
over, and the compressed air is led to the plus compartment of the cylinder,
while the minus compartment is vented. The piston performs a plus stroke. If
the control signal is discontinued, the return spring of the valve moves the
slide back again, and the flow of air reverses direction; the minus compartment
is filled with air, the plus compartment is vented, and the piston makes a minus
stroke.

The force which the piston rod exerts on the load, is regulated by varying the Force
pressure of the air – reducing the pressure decreases the force. The pressure is
controlled by means of a pressure regulator.

Pressure regulator Valve Cylinder

16 Training Document. For training purpose only. Technical Training Centre 1/9411
 Speed The speed of the piston is regulated by varying the flow of air on the return
side in the cylinder. This is done by means of the throttles in the valve, or with
throttle check valves fitted in the line between the valve and cylinder.

Throttle check
valve

Throttle in
valve outlet
port

Speed regulation by means

of throttles in valve
Speed regulation by means of
throttle check valves; throttles in
valve to be fully open

The reason why throttling is done on the return side of the cylinder is to make
the movement smooth.

Pressure
Correct (vented air throttled)

Wrong (input air throttled)

Time

If the cylinders used are small, or the air lines between cylinder and valve are
long, the alternative of employing throttle check valves offers better speed
regulation accuracy; the valve throttles must in this case always be fully open.

Technical Training Centre 1/9411 Training Document. For training purpose only. 17
The movement of the piston is dampened at both end positions by built–in Dampening
dampers in the cylinder end sections. The dampening effect is regulated with
adjustment screws. The purpose of the dampers is to decelerate, i e slow down
and stop, the piston a smoothly. In this way, damage to the cylinders, caused
by the piston striking the cylinder end section with some force, is eliminated.
Double-action cylinder with vari-
Dampening also reduces vibrations in the machine. If, on the other hand, the able end position dampening
dampening effect is too great, the piston may bounce back and come to a stop
with a jerk.
Cylinder end Adjustment
section screw Piston

The air on the vent side of the cylinder passes through

the large, central opening in the cylinder end section

A protrusion on the piston closes the central opening in the

end section, so that the vented air is forced through the nar-
row duct, in which the adjustment screw enables the flow,
and thus dampening effect on the piston, to be regulated.

In order to successfully set both speed and dampening, it is important first to

make sure that the pressure in the system is correct. Thereafter, the cylinder
speed can be set, and lastly, the dampening effect.
Undamped
Piston
position

Damped too much

Correctly damped

Time

18 Training Document. For training purpose only. Technical Training Centre 1/9411
 Main air supply line

Shut–off
valve
Pressure gauge
Air user

Air user
Condensate water

The main air supply line should form a ring main line through the premises;
this will allow the users of air to receive it from two directions. There should
be a drop of 5–10 mm per metre in the direction of flow. Underneath the
lowest point in the ring line, a condensate drain cock is to be fitted. The output
connections to the users should be fitted on the top side of the main line piping;
this will keep condensate water and dirt from following the air into the user
device. There should also be a pressure gauge to make it possible to check that
correct air pressure is being maintained.
The diameter of the main line piping depends on its length as well as the
number of pipe bends and elbows, connections, and valves in the line. The
larger the number of such components that the air must pass, the bigger the
pipe diameter must be to prevent excessive pressure drop up to the points
where the air is used.
The pipe–lines should be be installed so that they are easily accessible for
checking that they are tight.

Technical Training Centre 1/9411 Training Document. For training purpose only. 19
Function principle
This is an example of a principle diagram of a pneumatic system:

Valve cabinet
Y08
1 3

U05 Suction cups

B06
Hot melt pump

T05

U04 C4

Z04
T04 Valve panel

Y03 C3
U03

T03

Y02
C2
24
5

4
1

22
3

Y01
C1

YO00

U1
Pressure
supply
Z2

A1 Z1 T1

The input compressed air passes through manual valve A1, water separation
filter Z1, and pressure regulator T1; pressure gauge U1 indicate the pressure.
If the pressure drops below a preset value, pressure switch B06 indicates a
warning by lighting a signal lamp on the control panel. The pressure switch
should be connected as the last component in the system in order to sense the
pressure drops created by the other components.

20 Training Document. For training purpose only. Technical Training Centre 1/9411
 Pressurisation valve YO00 is used to make pressurisation of the system slow
in order to allow cylinders in wrong positions to return smoothly to their
correct idle positions. The pressurisation time can be adjusted by means of an
adjustment screw in this valve. Valve YO00 also has a safety function, for
instance if an emergency stop requires the system to be instantly
depressurised.
Valve Y01 is a 3–position valve with closed middle position. If, for instance,
the machine is emergency stopped, the valve moves to the middle position,
and cylinder C1 remains in the position it was in at the stop.
A manual valve
B cylinder Valve Y02 is monostable and electrically controlled. It has throttles in its
C cylinder outlet ports for regulating the speed of cylinder C2.
T pressure regulator
U pressure gauge Valve Y03 is also monostable and electrically controlled, but its pilot valve is
Y electrically controlled supplied with air separately from a line, connected before soft–start valve
valve
YO pressurisation valve YO00. This means that valve Y03 does not have to wait for the slow build–up
Z filter of pressure via the soft–start valve but changes over instantly as soon as valve
A1 opens. The separate supply of air also allows valve Y03 to be supplied with
air at a reduced pressure, for instance to limit the force of cylinder C3.
Pressure regulator T04 regulates the pressure to cylinder C4. This cylinder acts
Pressurisation as an air spring, and for this reason, an accumulator is connected to the air line.
Control line Pressure regulator T05 regulates the pressure to the hot melt pump and thus
Depressurisation controls the amount of hot melt adhesive to be extruded.
Vacuum line
Valve panel
Y08 consists of a vacuum ejector and two valves. When the righthand valve is
activated, compressed air flows from port 1 to port 3 and, due to the ejector
Valve cabinet
effect, a vacuum is generated at port 2, to which the suction cups are
connected. When the lefthand valve is activated, compressed air is supplied
directly to the suction cups, which thus are receive a blast of air, releasing their
suction and blowing their ducts clear.
Silencer Z2 is common to the whole pneumatic system.
The designations in the diagram follow a certain system, usually consisting of
a letter and a number. The components which the compressed air comes to first
are given the same number, in this case 1, but different letters to denote their
functions: A for manual valve, Z for filter, and T for pressure regulator. The
number of a valve, for instance Y02, determines the numbers of the following
components. The output lines from the valve are given numbers beginning
with 2, followed by the number of the outlet port, i e numbers 22 and 24. The
cylinder is designated C2.
Whenever setting is done in the pneumatic system, it is important to do it i the
right order:
1input pressure
2speed (throttle check valves or valve throttles)
3dampening (end position dampers in cylinders)

Technical Training Centre 1/9411 Training Document. For training purpose only. 21
Symbols
The following table, which is an excerpt from the Tetra Pak Standards (DS
208.35), lists the symbols that are normally used in our pneumatic diagrams.

Symbol Meaning

Single–action cylinder with return

stroke by spring.

Double–action cylinder with

single–ended piston rod.

Double–action cylinder without pis-

ton rod.

Double–action cylinder without pis-

ton rod, with variable dampening at
both end positions.

Double–action cylinder with variab-

le dampening at both end positions.

Double–action cylinder with variab-

le dampening at both end positions
and magnetic piston.

Torque cylinder.

2/2 directional control valve,

controlled by pressure acting
against return spring.

3/2 directional control valve,

controlled by pressure acting
against return spring.

22 Training Document. For training purpose only. Technical Training Centre 1/9411
 3/2 directional control valve,
controlled by solenoid with
return spring.

3/3 soft–start valve.

5/2 directional control valve,

controlled by pressure acting
against return spring.

5/2 directional control valve,

controlled by solenoid with return
spring.

5/2 directional control valve,

controlled by solenoid valve with
separate air supply.

5/2 directional control valve,

controlled by solenoid in both
directions.

5/3 directional control valve, closed

in middle position, controlled by
solenoid and return spring.

5/3 directional control valve, open

in middle position, controlled by
solenoid and return spring.

Variable throttle valve.

Non–return valve with variable

throttle check.

Rapid–exhaust avlve.

Technical Training Centre 1/9411 Training Document. For training purpose only. 23
 Pressure regulator with relief port,
spring controlled. Adjustable spring
force.

Shut–off valve with exhaust port.

Silencer

Accumulator

Separator with water trap and

automatic drain.

Lubricator.

Air conditioning unit,

consisting of filter, pressure regula-
tor, pressure gauge, and lubricator.

Pressure gauge.

Electric pressure switch with

change–over contact and
variable pressure setting.

Magnetic piston sensor.

Ejector.

24 Training Document. For training purpose only. Technical Training Centre 1/9411
 Water panel

Filter

1
Ball valve

Pressure gauge

Pressure switch
B 2102

Solenoide valve
Y 2108

Connection block
Air

5 Ice water, inlet

4
3 Cold water
2
Ice water, outlet

Supply HI

1 Cold water inlet Central refilling of

2 Flushing final folder hydrogen peroxide
3 Superstructure
4 Spray gun
Hot water
5 Cooling water system

Technical Training Centre Machine type Issue

Lund, Sweden TBA/21 TBA/22 2/0108 OH 778
 Cooling water system
1
2
3
29 4

28

27

26

25

24 5

23 6

22

21 7

20 8

19 9

18

17

16

15
14
13
12
1 Expansion wessel (O 2530) 11
2 Pressure gauge (U 2501)
3 Temperature sensor (B 2510) 10
4 Conductivity sensor (B 2520)
5 Ion exchanger (O 2520)
6 Filte (Z2520) 15 Regulating valve, capacity (S 2514)
7 Ball valve (A 2530) 16 High pressure transmitter (B 2540)
8 Non−return valve (J 2530) 17 Low pressure transmitter (B 2541) 23 Flow meter, ion exchanger (S 2520)
9 Heat exchanger (K 2550) 18 Cooling compressor (P 2540) 24 Flow meter, LS transormer (S 2320)
10 Water saving valve (S 2550) 19 Pressure switch (B 2501) 25 Bleeding valve (A 2501)
11 Sight glass (U 2560) 20 Security valve (F 2530) 26 Flow meter, final folder (S 5305)
12 Filter (O 2560) 21 Cooling water pump (P 2501) 27 Flow meter, TS transformer left (S 4309)
13 Heat exchanger (K 2510) 22 Flow meter, SA transformer (S 8404) 28 Flow meter, TS transformer right (S 4310)
14 Expansion valve (S 2513) (unused in TBA/21) 29 Ball valve (A 2520)

Technical Training Centre Machine type Issue

Lund, Sweden TBA/21 TBA/22 2/0001 OH 832
 F.F. Tube
flusher flusher Rails−TS Rails−TS

Infeed
Peroxide Sterile slider
Cooling
T6101 T1402 system system Air Air plate TS
Strip Guide T4309 T4310
LS−sealing, IH−transf. cooling Transf. Transf.
applicator

Lund, Sweden
Bracket of upper bending roller F.F. left right
transf. Bracket of stepper motor A1201
Y1104

Technical Training Centre

Y2106 Y2109

Machine type
Water cooling unit Flushing
O2530
Spray gun final folder
A2520 B2520

Q A2107
B2501 F2530
M2501 U2501

TBA/22 050V
LEAK
A2501
M
O2520 C/A Y2108
B2510
P2501 T
A2530

Cold water
J2530
Z2520

S2320
S2520

S4309
T

S4310
S8404

S2505

Issue
A21022 Z2102 A21021
B2102

B2540 B2541

1/0303
A21032 Z2103 A21031

LEAK
LEAK
S2514
P2540
O2560
U2560
K2550

K2510
M T U2102 Hot water
P

Heat exchanger
Heat exchanger

M2540
Water panel
S2550
Compressor unit S2513

Hygenic cleaning system

OH 1217:1
Water system
Alternative refrigeratory
 F.F. Tube
flusher flusher Rails−TS Rails−TS

Infeed
Peroxide Sterile slider
Cooling
T6101 T1402 system system Air Air plate TS
Strip Guide T4309 T4310
LS−sealing, IH−transf. cooling Transf. Transf.
applicator

Lund, Sweden
Bracket of upper bending roller F.F. left right
transf. Bracket of stepper motor A1201
Y1104

Technical Training Centre

Y2106 Y2109

Machine type
Water cooling unit Flushing
O2530
Spray gun final folder
A2520 B2520

Q A2107
B2501 F2530
M2501 U2501

TBA/22 050V
LEAK
A2501
M
O2520 C/A Y2108
B2510
P2501 T
A2530

Cold water
J2530
Z2520

S2320
S2520

S4309
T

S4310
S8404

S2505

Issue
A21022 Z2102 A21021
B2102

1/0303
Ice water in
A21032 Z2103 A21031

Ice water out

U2102 Hot water

Heat exchanger
Water panel
Compressor unit

Hygenic cleaning system

OH 1217:2
Water system
Alternative ice water
 Cooling Water
System
General
Tetra Brik filling machines use water to cool different components, like:
• inductors in the jaw system
• guide rails in the final folder
• oil in the hydraulic system
• air in the electrical cabinet
The cooling water system can either be open or circulating. Circulating
cooling water is used when the temperature of the ordinary water supply
is too high, over 20 ˚C. In an open system, the water is consumed, while
a circulating system uses the same water over and over again.

Chilled unit Chilled unit

From cooler

Cooler

Drain Return to cooler

Open cooling water system Circulating cooling water system

Many machines have a separate water cooling system. This means that there
is some kind of heat exchanger between incoming water and water to be
cooled. In an open separate water cooling system, the cooler is part of the
machine.

Chilled unit Chilled unit

Cold water Chilled cold water
Heat exchanger

Heat exchanger
Heat exchanger

Cooler

Open separate cooling water system Circulating separate cooling water system

The cooling system of the machine is documented by means of a diagram.

To simplify the construction and make it easier to understand, the diagram is
made up of symbols for the different components. The design of the cooling
water system varies depending on machine type, development step and
rebuilds. Thus it is important to use the correct cooling water diagram when
working on the machine.

Technical Training Centre 1/9902 TM-00075 Training Document. For training purpose only. 10-1
In order to be able to cool efficiently, the water must be of adequate quality Cooling water
and temperature. Data on water quality to be used for the different machines
can be found in the IM, MM or OM.

The kind and quality of the water differs. Below some examples:
• Raw water is a surface or ground water. Depending on where it is taken, it
contains different ingredients and impurities.
• Drinking water is produced from raw water. Drinking water must not
contain components that may cause illness.
• Deionized water is produced from drinking water. In deionized water you
control the amount of hardening ions.
• Totally desalinated water is also produced from drinking water. All salt
ions, both positively and negatively charged ions, are removed.

Components
A cooling water system is built up of many components. The most important
and frequent ones, are described below.

Manual valves are opened and closed manually. Manual valve

An electrically controlled valve receives a control signal from the machine Electrically controlled
control system when to open and close. valve
A pressure gauge displays the pressure in the cooling water system. Pressure gauge
In order to protect the cooling water system, there might be an over-pressure Over-pressure valve
valve included in the system.
Overpressure valve

The overpressure valve opens up if the pressure in the cooling water system
exceeds a preset pressure. Water is then released, causing the pressure to
decrease in order to avoid damages to the cooling water system.

The filter is used to filter off solid particles and other impurities which may Filter
clog valves and narrow passages, or in any other way affect functions in the
cooling water system.

10-2 TM-00075 Training Document. For training purpose only. Technical Training Centre 1/9902
 Magnet device The magnet device prevents forming of lime deposits in the cooling water
system. It is built up of a mechanical filter and a magnet device.

3
4

1
2

• Mechanical filter - The filter basket (1) collects any solid impurities in the
water. Inserted in the filter basket there is a magnet rod (2), collecting any
magnetic impurities like iron chips. The magnet has a plastic cover to
prevent corrosion.
• Magnet separator - This consists of two permanent magnets (4) forming
a gap (3), through which the water flows.
The function of the magnet separator can be described like this:
Between the magnets (4) there is a heavy magnet field. The magnet field
affects the lime in the flowing water so that the lime deposit formed in the
cooling water system does not adhere to the cooling water channels. Instead
the lime deposit will follow the cooling water out to the return line. The
function of the magnet device is temporary.
Magnet field
4

Untreated water. The crystals gather Magnetically treated water. The

and stick easily on surfaces. crystals do not gather and do not stick
on surfaces.

Water tank There is a water tank in some machines, and it works as a reservoir for
the water.

Technical Training Centre 1/9902 TM-00075 Training Document. For training purpose only. 10-3
The accumulator is a vessel containing air. The air can be compressed, to take Accumulator
up any pressure variations caused by temperature variations.

A temperature sensor monitors the temperature and signals the control system Temperature sensor
if the temperature raises above or falls under the preset values.

The thermostat is used to keep a constant temperature by regulating the flow Thermostat
and thus the supply of colling water to a component.

A pressure guard monitors the pressure and signals the control system if the Pressure guard
pressure raises above or falls under the preset values.

Heat exchangers are used in a cooling water system to transfer heat from one Heat exchanger
circuit to another, without any direct contact between the medias. The two
main types used are tube heat exchanger and plate heat exchanger.

Cold water

Hot water
Plate heat exchanger

The water pump circulates cooling water, used to cool various components. Water pump
Non-return valves are used in the cooling water system to direct the flows. Non-return valve
A throttle is used to set a desired flow through a component or a part of the Throttle
cooling water system. The throttle can be fixed or adjustable.

The flow meter is a floating body meter used to measure small liquid flows Flow meter
with high accuracy.

10-4 TM-00075 Training Document. For training purpose only. Technical Training Centre 1/9902
 In the valve housing of the flow meter, made of transparent plastic, there is a
conical passage with its narrowest part turned downwards. In the passage there
is a ball affected by the flow of the water.
Low water flow High water flow

When the flow increases, the ball is lifted. Due to the fact that the passage is
conical, the ball will stabilise in a specific position, and the flow can be read
on the graduated scale.

Constant flow valve In order to make the water flow to the water ring compressor independent of
the pressure in the water line, there is a constant flow valve fitted just before
the compressor.
The constant flow valve is designed for a fixed flow.

The acting part of the valve is a soft rubber washer. In the middle of the washer
there is a hole, through which the water flows. The size of the hole varies
depending on the water pressure, and thus keeps the water flow through the
valve constant.
Low water flow High water flow

The shape of the rubber washer at low and high water pressure, respectively in a
constant flow valve.
• Low water pressure - The shape of the rubber washer makes the hole in
the middle relatively large, i e water with low pressure flows through a
large hole.
• High water pressure - The rubber washer is deformed so the diameter of
the hole is small. This will cause the rubber washer to reduce the water jet,
but as the water pressure is high, the same amount of water will flow
through the valve as when the pressure is low.

Technical Training Centre 1/9902 TM-00075 Training Document. For training purpose only. 10-5
The conductivity sensor monitors the electrical conductivity in the water, and Conductivity sensor
signals the control system if the conductivity raises above or falls under the
preset values.

A softening filter is a container with a bed material, often consisting of small Softening filter
polystyrene balls. When the water gets in contact with the bed material, there
is an exchange of ions. Thus the amount of hardening ions in the water is
reduced and you get a soft, so called dehardened water.

Function
The cooling water is used to cool the inductors, the guides in the final folder,
the hydraulic oil and the sterile air. The diagram below describes a system that
may be run both open and recirculated.
Simplified cooling water system for a TBA/19 Separator

SERVICE UNIT

Scrubber Compressor M (M7) Drain

B4
Z1
VALVE PANEL
A GUARD
Cirk. cold
water inlet B7
A4
M5 Y32
B A1 Z3 Z5 FINAL FOLDER
Cold water
LIME SEPARATOR
C
E
Cirk. cold
water outlet
Sealing
JAW SYSTEM unit

(K50)
L TS− R
sealing
Cooler
hydraulic
FM2 FM3 system

A2

Water connection B shall always be connected and valve A1 open, as there

is always a need for consumption water to cool components in the service unit.
For circulated cooling water, the water connections A and E shall also be
connected, and the valves A2 and A4 be closed.
The circulating water enters the system at connection A, is filtered in filter Z1
and flows further on to the jaw system and final folder. The pressure is
monitored by the pressure guard B7. The water flow through the inductors
in the jaw system can be read on flow meters FM2 and FM3. At point D the
circulated cooling water turns back and flows out at outlet E.
For an open cooling water system only water connection B shall be
connected and the valves A1, A2 and A4 be open. The cooling water enters at
connection B, is filtered in filter Z3 and flows through the lime separator
Z5.

10-6 TM-00075 Training Document. For training purpose only. Technical Training Centre 1/9902
 At point C the water flow is branched and the consumption water flows on to
the service unit. The remaining water flows pass the open valve A4 and into
the system. The pressure is indicated on the pressure gauge M5. At branching
point D the cooling water is drained through valve A2.
The following is a separate closed cooling system with three separate circuits
Simplified cooling water diagram for a TBA/21

Inductor
Jaw unit Final folder Pull Tab

TS−sealing Guide cooling

Z2
B1 O2
Water panel Q
V

Cold water C/A

T
B2
P O1 T
Heat exchanger

Heat exchanger
K2
K1

B4 B3
P P Water cooling unit

P2 B5 F1
M1 U1
M P
A2
M
M2
Compressor unit P1

One circuit is cooling the heat sources on the machine and it is called the water
cooling unit. It is a closed circuit. The water used in this circuit must be totally
deionized in order to remove all particles that could clog the cooling pipes in
the transversal sealing inductors. Approximately 10% of the total flow is
circulated through a total deionizing filter C/A.
The second circuit is called compressor unit. It is a closed circuit and it is
actually the cooler in the machine. In this system, which is identical to a
refrigerator, gas is used as media.
The third circuit is an open circuit, meaning that the water is drained off after
being used to cool the compressor unit.
When the water cooling unit is filled with water, valve V is open and the
water flows through the deionizing filter, C/A. The temperature of the water
in this circuit should be 12 ˚C. This is monitored by sensor B2 after the heat
exchanger K2. To maintain that temperature, the compressor unit takes up
the heat energy needed from the water cooling unit in the heat exchanger K2
(evaporator) in which the gas will be evaporated. This energy will then be
transferred by the gas to another heat exchanger K1 (condenser), where the
energy will be transferred to the water in the open circuit. The gas will be
condensed after the condenser.

Technical Training Centre 1/9902 TM-00075 Training Document. For training purpose only. 10-7
Symbols
The table below contains the symbols that normally are used in Tetra Pak
cooling water system diagrams.

Symbol Meaning

Accumulator

Deionizing filter
C/A

Non-return valve

Electrically controlled valve

Manual valve

Filter

Throttle, adjustable

Constant flow valve

Cooler

Water pump

M Motor

Water tank

10-8 TM-00075 Training Document. For training purpose only. Technical Training Centre 1/9902
 Symbol Meaning

Heat exchanger

Cooling coil

Deaerator

Flow meter

Pressure gauge

Q Conductivity sensor

T Temperature sensor

P Pressure guard

Pressure regulator

Technical Training Centre 1/9902 TM-00075 Training Document. For training purpose only. 10-9
10-10 TM-00075 Training Document. For training purpose only. Technical Training Centre 1/9902
 Grease lubrication system

Jaw System

Final folder

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 050V 1/0303 OH 1253
 Grease lubrication
B
Jaw system
Z
Y4265

Final folder
Y4263

U T T

U U
M1122
M

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 050V 2/0502 OH 1254
 6
Tube forming

Technical Training Centre

 Packaging material web

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 050V 1/0303 OH 1255
 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
 PENDULUM ROLLER : SPEED REGULATION
( exemple valid for 200 Slim )

The speed is controlled by the analog output AQ11.

If the sensor is activated more than 0,2 sec both high and low speeds are increased (the
value of AQ11 is increased by 10)
If the sensor is de-activated more than 0,2 sec both high and low speeds are decreased (the
value of AQ11 is decreased by 10)

Inching at high speed

- if the sensor is ON : AQ11 = 20900

- if the sensor is OFF : AQ11 = 18900

Production

- if the sensor is ON : AQ11 = 21700

- if the sensor is OFF : AQ11 = 19700

If the sensor if ON ( higher position ) more than 4 sec an alarm is triggered.

For the two cases below the speed is never adjusted and if the sensor if ON (higher position)
more than 14 sec there is an alarm.

Main motor at low speed

- if the sensor is ON : AQ11 = 5400

- if the sensor is OFF : AQ11 = 4700

Threading the paper

- if the sensor is ON : AQ11 = 5250

- if the sensor is OFF : AQ11 = 0

Note : The values of the analog register AQ11 are default values which can be found in the
program, but on the machine, they change all the time automatically.

AG 18-6-2003
 Lund, Sweden
Technical Training Centre
Upper bending roller rotation

Machine type
1 sec ON, 1 sec OFF 5 sec ON
ON
Y1405

TBA/22 050V
OFF
0 0 3 min 6 min 9 min 12 min
position 5 position 6

Issue
1/0209
Alarm if:
− in position 5 there are more than 4 sec without a pulse from B1405
− in Low Speed there are more than 0.5 sec without a pulse from B1405
− in High Speed there are more than 0.2 sec without a pulse from B1405

OH 1233
 7
Sterile system
components

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
 Sterile System
Water ring compressor

Lund, Sweden
Technical Training Centre
Machine type
Issue
3/0505
OH 104
Rotating water ring
Air mixed with water
 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

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Technical Training Centre, Lund, Sweden TBA/21 TBA/22 1/9410 OH 503
 Water separator

Water
Air

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Technical Training Centre, Lund, Sweden TBA/21 TBA/22 1/9410 OH 504
 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
Spray nozzle

Compressed air
Peroxide

Technical Training Centre Machine type Issue

Lund, Sweden TBA/21 1/0104 OH 1045
 Heat
exchanger
valve
Y 1107 : 2 bar
Y 1107 Y 1108 Y 1108 : 6 bar

0 0 By pass

B y pas s
0.0

S tatus
cycle
1.0 1.1
Min. Max.
cooling cooling
Y 1107 Y 1108

1 0 Min. cooling

Y 1107 Y 1108
Max. cooling
1 1

T echnical T raining C entre 1/0212 T M-00509 T raining Document. F or training purpos e only.
 Preheating valve
Y1111: 6 bar
Y1114: 2 bar

B1112 B1111

By pass

Y1111 Y1114:4 Y1114:2

ON ON OFF

B1112 B1111

Min. heating

Y1111 Y1114:4 Y1114:2

ON OFF ON

B1112 B1111

Max. heating

Y1111 Y1114:4 Y1114:2

OFF OFF ON

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 050V 1/0303 OH 1280
 Steam pressure
Low pressure

Y1281
OFF
Line
Low

High

High Low

Y1280

High pressure

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 3/0501 OH 1236
 Lund, Sweden
Peroxide concentration, %

Technical Training Centre

50

Machine type
45

TBA/22 050V
Good conditions
40

Issue
Prel.
35
Dirty system

30

OH 1357
0 30 60 90 120 Time (hours)
 UR-20 Digital refractometer

Refracted Light
Product
Media "B"

Measuring Prisma
Media "A"

Entrance Lens

Reflected Light

Optical Condenser

Image Detector

Light Source

Lighted Area Shadow Area

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22 050V 1/0303 OH 1358
 PEROXIDE MONITOR

The concentration and the temperature can be displayed on the TPOP by

means of an analogue input AI 7 and the relay K140. When it is activated, the
temperature is checked. The signals are refreshed on the the TPOP every
minute.

In PREPARATION, during 10 minutes, the pump runs and the concentration

is checked. If it is not within the range, it is not possible to step up the
programme.

Basically, there are 3 alarms :

MALFUNCTION PEROXYDE METER ( M460 )

PEROXIDE CONCENTRATION OUT OF LIMITS ( M461 )
PEROXIDE CONCENTRATION CLOSE TO LIMITS ( M462 )

During PRODUCTION, if the concentration is less than 32% but more than
30%, it will appear the blue alarm “PEROXIDE CONCENTRATION CLOSE
TO LIMITS” but the machine will continue in PRODUCTION. If one of the two
other alarms appear it will be yellow and the machine stops immediately in
normal stop.

During PREPARATION and FLAP HEATERS, if one of the three alarms

appear it will be yellow and the stepping up of the program will be impossible.
If this occurs during HEAT STERILISATION the program will be stepped
down to step OFF after 5 minutes.

The concentration is correct during PREPARATION and HEAT

STERILISATION if it is within 32% and 50%. During DRYING and above, it
must be within 30% and 50%. If it is between 30% and 32% it is closed to
limits.
The refractometer is faulty if the measure of the concentration is negative or if
the difference between the temperature in the tank and in the refractometer is
higher than 10°C.

In addition, if there is an internal fault in the refractometer, there is a blue

alarm “MALFUNCTION PEROXIDE METER WARNING” ( M 463 and Input
421 )

AG/5-3-2003
Level relay
Peroxide spray quantity
Heat sterilisation

L 51 A1

L 50
A2

B1 B3 B2 15 16 18

To PLC INPUT
L 11 (24 VDC)

Air to spraytank

Filter

Air to spray nozzle

Y1230
Y1231

Air to spray nozzle

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22, Tetra Pak A3/Speed 3/0310 OH 1221:1
Level relay
Peroxide spray quantity
Filling tank

L 51 A1

L 50
A2

B1 B3 B2 15 16 18

To PLC INPUT
L 11 (24 VDC)

Filter

Y1230
Y1231

Peroxide from tank

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22, Tetra Pak A3/Speed 3/0310 OH 1221:2
Level relay
Peroxide spray quantity
Spraying

L 51 A1

L 50
A2

B1 B3 B2 15 16 18

To PLC INPUT
L 11 (24 VDC)

Air to spraytank

Filter

Air to spray nozzle

Y1230
Y1231

Peroxide to spray nozzle

Technical Training Centre Machine type Issue

Lund, Sweden TBA/22, Tetra Pak A3/Speed 3/0310 OH 1221:3
 1. A1
2. A1
Level relay
230V 230V
Latch function
A2 A2

Lund, Sweden
B1 B3 B2 15 16 18 B1 B3 B2 15 16 18

Technical Training Centre

To PLC INPUT To PLC INPUT
L 11 (24 VDC) L 11 (24 VDC)

Machine type
3. A1
4. A1

230V 230V

Issue
A2 A2

2/0405
B1 B3 B2 15 16 18 B1 B3 B2 15 16 18

To PLC INPUT To PLC INPUT

L 11 (24 VDC) L 11 (24 VDC)

OH 1223
 Tetra Brik TBA/21 TBA/22
Level control in peroxide tank
A306 A307

A1 A1

A2 A2

B1 B2 B3 15 16 18 B1 B2 B3 15 16 18

PLC input A308 PLC input

L11 L11
A1

A2

B1 B2 B3 15 16 18

PLC input
L11

Level sonds
1 Maximum level when bath is empty
and when service switch is on.
2. Maximum level when bath is filled
3. Start filling when bath is filled
4. Supervising if the level is to high.
Stops filling. ALARM

Y1210 4
2
3

Tetra Brik
Level control in Peroxide tank
Issue 2/0101
 8
Sterile system

Technical Training Centre

 Ladder diagram TBA/22 TPOP
10:Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design OK.
Temperature in AC. is regulated at 95 °C.
Packages made from material that was in the H2O2 bath and AC are ejected.
After 2 sec A valve opens and design control starts.
After 12 sec motor start.
After 9.9 sec must H2O2 temp. and level be right.
After 3 sec starts peroxide bath filling.
After 1 sec synchronization FFU-JUM.
For first start, design pulse fall on filling sector, this enable the FCS.
Normal start; depending on the level in the tube, pre-filling will start.
Sound alarm for 10 sec.

9:Motor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right temp on flap sealing element. Right temp in H2O2 tank. All doors closed.
If no start attempt within 90 sec steps down to 7.

8:Flap heaters on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product at A-valve.

7:Signals to Sterilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All. doors closed. Right temp in H2O2 tank. Drying time ended 15 min.
Sterile inching is possible.
After 14 min B-valve closes.
Sterile air pressure reads on both separator and aseptic chamber.
Preheating valve open. Heat exchanger valve in minimum cooling position.
Heat and circulation in water bath.
B valve is closed during the first minute (pause).

6:Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The filling spray tank has to be emptied after 30 sec and before 45 sec.
The filling spray tank has to be filled after 3 sec and before 10.

5:Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre.ster.temp 280 °C. All doors chamber closed. Steam temperature.
When 280 °C is obtained, spraying starts automatically after 10 sec.
Heat exhanger in bypass.
Preheating valve in bypass until 280°C is obtained. However temporary
opens to keep A.C. temp at 39-40 °C.
B-valve and reg. valve opens.
Circulation on H2O2.
Air superheater at 360 °C.
Compressor on, reads on separator pressure switch.

4:Heat sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water separator low level. Cleaning pipes disconnect. All doors closed.
Inching packaging material.
3:Tube sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling. water pressure and cleanness. All doors closed. DMC ready.
Power to motors to help when threading packaging material.
Strip applicator on.
Possible to slow inch without LS, drying 3 min.
Concentration of peroxyde betwween 32 % and 50 %.

2:Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power. Air pressure. Water pressure. All doors closed.

Technical Training Centre 2/0506 TM-00510 Training Document. For training purpose only. 1
 1:Step 0

Ladder diagram TBA/22 TPOP

15 CIP Blowing

14:2 External cleaning

14:1 CIP cleaning

13 Doors, Aseptic chamber

12 Venting Aseptic chamber

11 Production ended

Technical Training Centre 2/0506 TM-00510 Training Document. For training purpose only. 2