Tba19 Im-82109-0103

IM
Installation Manual
TBA/19 0101
Tetra Brik Aseptic Tetra Bri

k Aseptic
2.28210903.fro
Tetra Pak
Tetra Pak
Doc. No. IM-82109-0103
This document is valid for:
Series No/ Machine No Sign.
Tetra Brik Aseptic

TBA/19 0101
648160-0101
Equipment included:
Strip Applicator
648107-110V
Headspace by gas Injection

HI19 010V
979320-010V
2.28210903.fro
Issue 9609
Doc. No. IM-82109-0103
Tetra Brik Packaging Systems

Table of contents
Introduction
Equipment information . . . . . . . . . . . . . . . . . . . . . . . . . 2
Document information . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety precautions
Hazard information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mandatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Danger and warning signs . . . . . . . . . . . . . . . . . . . 14
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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General safety precautions . . . . . . . . . . . . . . . . . . . . . 17

Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . 19

Emergency stop buttons . . . . . . . . . . . . . . . . . . . . 19
Doors, covers and guards . . . . . . . . . . . . . . . . . . . 20
Chemical products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Personal protective equipment . . . . . . . . . . . . . . . 21
General emergency procedures . . . . . . . . . . . . . . . 21
Hydrogen peroxide . . . . . . . . . . . . . . . . . . . . . . . . 22
Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Equipment for lifting and moving loads . . . . . . . . . . . 25
Tetra Pak Doc. No. IM-82109-0103 i

Table of contents
3 Drawings and Technical Data

3.1 Installation drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Basic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Mass (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5 Emissions and thermal load . . . . . . . . . . . . . . . . . . . . 38
3.6 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.7 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.9 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.10 Outfeed conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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4
5 Crate handling
5.1 Crate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Unloading the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3.2 Using an overhead gantry or mobile crane . . . . . . 53
5.3.3 Using a fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4 Moving and storing the crate . . . . . . . . . . . . . . . . . . . 55

5.4.1 Moving the crate . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5 4.2 Storing the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ii Doc. No. IM-82109-0103 Tetra Pak

Table of contents
6 Positioning, assembly, and connections

6.1 General requirements. . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.2 Opening the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.3 Unpacking the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.3.1 Uncrating separate components . . . . . . . . . . . . . . 61
6.3.2 Uncrating the machine body with an
overhead gantry or mobile crane . . . . . . . . . . . . . . 62
6.3.3 Uncrating the machine body with a fork lift . . . . . 65
6.4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.5 Disposal/return of packing . . . . . . . . . . . . . . . . . . . . . 71
6.6 Fitting the transporter . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.7 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.8 Approximate levelling. . . . . . . . . . . . . . . . . . . . . . . . . . 76

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6.9 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.9.1 Platform, ladder, and handrail . . . . . . . . . . . . . . . . 78
6.9.2 Electrical cabinet cooler . . . . . . . . . . . . . . . . . . . . 84
6.9.3 Strip applicator (SA) . . . . . . . . . . . . . . . . . . . . . . . 86
6.9.4 Drying chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.9.5 Hydrogen peroxide generator . . . . . . . . . . . . . . . . 97
6.9.6 Large diameter pipes . . . . . . . . . . . . . . . . . . . . . . . 98
6.9.7 Aseptic product valve (APV) and
remaining large pipes . . . . . . . . . . . . . . . . . . . . . 104
6.9.8 Small diameter pipes . . . . . . . . . . . . . . . . . . . . . . 112
6.9.9 Electrical connections . . . . . . . . . . . . . . . . . . . . . 119
6.9.10 Covers and guards . . . . . . . . . . . . . . . . . . . . . . . . 123
6.10 Precision levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.11 Conveyor connections . . . . . . . . . . . . . . . . . . . . . . . . 128
6.12 Utility, product, and drain connections. . . . . . . . . . . 129
6.13 Other operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Tetra Pak Doc. No. IM-82109-0103 iii

Table of contents
7 Final installation checks

7.1 Installation and connection checks . . . . . . . . . . . . . 138
7.2 Lubricant level checks . . . . . . . . . . . . . . . . . . . . . . . . 139
7.3 Valve checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.4 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8 Preparation for commissioning

8.1 Presence and correctness checks . . . . . . . . . . . . . . 145
8.2 Product and utility value checks. . . . . . . . . . . . . . . . 147
8.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

8.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.3.2 Normal operating checks . . . . . . . . . . . . . . . . . . . 149
8.3.3 Changing PLC parameters . . . . . . . . . . . . . . . . . . 151
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8.4 Health and safety checks. . . . . . . . . . . . . . . . . . . . . . 153
8.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9 Disassembly and removal

9.1 Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.1.1 Draining methods. . . . . . . . . . . . . . . . . . . . . . . . . 157
9.1.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.1.3 Draining procedure . . . . . . . . . . . . . . . . . . . . . . . 160
9.2 Moving and transporting the equipment . . . . . . . . . 173

9.2.1 Short moves and short term storage . . . . . . . . . . . 173
9.2.2 Long moves and long term storage . . . . . . . . . . . 175
9.3 Return to the manufacturer . . . . . . . . . . . . . . . . . . . . 177
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
iv Doc. No. IM-82109-0103 Tetra Pak

Introduction
To ensure maximum safety, always read the Safety precautions section
before doing any work on the equipment or making any adjustments.
2.28210903.int
Tetra Pak Doc. No. IM-82109-0103 1

Introduction
Equipment information
Intended use
This Tetra Pak equipment is designed to package liquid products.
Manufacturer
This Tetra Pak equipment has been manufactured by:
Tetra Brik Packaging Systems AB
Ruben Rausings gata
22186 LUND
Sweden
or by:
Tetra Brik Packaging Systems S.p.A.
Via Delfini 1
41100 MODENA
Italy
Service
Contact the nearest Tetra Pak service station.
(Cont'd)
2.28210903.int
2 Doc. No. IM-82109-0103 Tetra Pak

Introduction
(Cont'd)
Identification
The figure below shows an example of the equipment data plate. The plate
carries data needed when contacting Tetra Pak concerning this specific
equipment.
CE marking
This equipment complies with the basic health and safety regulations of the
European Economic Area (EEA).
1 2 1 Machine type
2 Volume
Machine type 3 3 Drawing specifications
Drawing Spec. 4 Machine serial number
Machine No. 4 5 Manufacturer
Manufacturer
6 CE mark
Year of manufacture 5 7 Year of manufacture
7 6
2.28210903.int

Introduction
Document information
Purpose of Installation Manual (IM)
The purpose of this Installation Manual is to provide service technicians with
information on how to safely install this Tetra Pak equipment.
It is important to:
• keep the manual for the life of the equipment
• pass the manual on to any subsequent holder or user of the equipment.
Design modifications
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Tetra Pak
production plant.
Document producer
Tetra Brik Packaging Systems S.p.A.
via Delfini, 1
41100 MODENA
Italy
Number of pages
This document contains a total of 180 pages.
Copyright  1996
2.28210903.int
Tetra Brik Packaging Systems
All rights reserved. No parts of this document may be reproduced or copied
in any form or by any means without the written permission of Tetra Brik
Packaging Systems.
Technical publications
The technical publications for this equipment are:
• Electrical Manual (EM)
• Installation Manual (IM)
• Maintenance Manual (MM)
• Operation Manual (OM)
• Spare Parts Catalogue (SPC)
Additional copies can be ordered from the nearest Tetra Pak service station.
When ordering technical publications, always quote the document number
that can be found in the machine specification document.

Introduction
Main parts
Throughout this manual the terms LH and RH refer to the equipment and all
its parts as seen from the front.
Front view
3
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LH RH
1 Drying chamber
2 APV
3 Operator panel
4 Final folder
(Cont'd)

Introduction
(Cont'd)
LH view (filling machine without HI)
1 2 3 4
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7 6 5
1 TPIH cabinet
2 Mains power switch
3 Hydrogen peroxide bath
4 Column
5 Electrical cabinet
6 Service unit
7 Splicing table
(Cont'd)

Introduction
(Cont'd)
LH view (filling machine with HI)
1 2 3 4
2.28210903.int
8 7 6 5
1 TPIH cabinet
2 Mains power switch
3 Hydrogen peroxide bath
4 Column
5 HI unit
6 Electrical cabinet
7 Service unit
8 Splicing table
(Cont'd)

Introduction
(Cont'd)
RH view
1 2 3
2.28210903.int
8 7 6 5 4
1 APV
2 Strip applicator
3 Dating unit
4 Packaging material
cassette unit
5 Connections panel
6 Drive unit
7 Jaw system
8 Final folder

Introduction
Other documents
The following documents are attached to the crate:
• Packing List
• Declaration of EC conformity (for equipment delivered in the EEA only)
• Installation Manual (this manual)
The following documents are located on the equipment itself, behind the rear
LH door of the service unit:
View of filling machine

without HI
2.28210903.int
• Machine Specification Document

• Final Inspection Report
• Machine Deviation Report (if relevant)
• Start-up Machine Quality Report (including Transport Damage Report)
• Feedback from MC form
• System drawings

Introduction
Abbreviations
The following abbreviations are used in this Installation Manual.
Abbreviation Meaning
Approx. Approximately
APV Aseptic Product Valve
CIP Cleaning In Place
h Hour, Hours, Height
HI Headspace by gas Injection
IS Inner Strip
L Length
LH Left hand
LS Longitudinal Seal(ing)
min Minimum
max Maximum
p/h Packages per Hour
Recirc Recirculation, Recirculated
RH Right Hand
SA Strip Applicator
TMCC Tetra Pak Multi-purpose Compact Controller
2.28210903.int
TPIH Tetra Pak Induction Heating
TPMC Tetra Pak Machine Control
TS Transversal Seal(ing)
Standard International System abbreviations are used for all measurement

values.

Safety precautions
To ensure maximum safety, always read this document carefully before
doing any work on the equipment or making any adjustments.
2.28210903.sp

Safety precautions
Hazard information
General
Failure to observe information marked “DANGER!” puts your life in
danger.
DANGER!
Failure to observe information marked “WARNING!” can result in

personal injury and/or serious damage to or destruction of
equipment.
WARNING!
Caution! Failure to observe information marked “Caution!” can result in

damage to equipment.
2.28210903.sp

Safety precautions
Mandatory signs
Wear eye protection Wear hearing protection
Wear head protection Wear protective gloves

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D I SI N F E C
Disinfect hands/gloves

Safety precautions
Danger and warning signs
Risk of entanglement! Risk of cutting/amputation!
Risk of burns! Risk of corrosion!
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Risk of intoxication! Risk of electrocution!
(Cont'd)

Safety precautions
(Cont'd)
Risk of crushing! Risk of crushing!
Risk of falling!
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Safety precautions
Personnel
Only skilled or instructed persons are allowed to work on the equipment.
The manufacturer declines all responsibility for injury or damage if the
instructions in this manual are not followed.
Personnel are responsible for:
• the equipment and the work area around the equipment
• all personnel in the vicinity of the equipment
• making sure that all safety devices are fully operational
Personnel must regard all electrical equipment as live. Before carrying out
maintenance or repair work, switch the equipment off at the mains power and
padlock the switch.
Electricians should be certified according to local regulations and have
experience of similar types of installations, proven skills in reading and
working from drawings and cable lists, and knowledge of local safety
regulations regarding power and automation. Work with the electrical
equipment must be performed only by skilled or instructed technicians.
According to EN 60204.3,55 a skilled person is:
– An individual with technical knowledge or sufficient experience to
enable that individual to avoid hazards which electricity can create.
2.28210903.sp

Safety precautions
General safety precautions

Wear hearing protection while the equipment is running.
Hygiene
It is important to keep hands and/or gloves clean.
Disinfect hands and/or gloves before touching the packaging material, the
strip(s) or any other equipment part that may come into contact with the
product.
Clean the platforms, the ladder and the area around the equipment.
To avoid production faults, it is important that the packaging material and the
strip(s) never touch the floor, the platform or the area around the equipment.
High voltage
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Work with parts marked with this symbol must be performed by skilled or
instructed persons only.
Make sure that the mains power is disconnected before starting any work on
electrical equipment marked with this symbol.
In case of accident, call for medical attention immediately.

Safety precautions
Electrical cabinet
There is high voltage in the electrical cabinet (up to 400 V).
Work inside the electrical cabinet must be performed by skilled or instructed

DANGER! persons only.
Electrical cabinet doors locked with screws may be opened only by skilled or
instructed persons.
LH side
without HI
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RH side

Safety precautions
Machine safety devices

Emergency stop buttons
Learn the position of the Emergency stop buttons in order to stop the
equipment immediately in case of danger to people or damage to the
equipment.
The Emergency stop buttons do not switch off the power at the mains power
switch.
Pushing the Emergency stop buttons will reset the equipment program to
Zero position and deactivate all pneumatic cylinders.
LH side
without HI
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RH side

Safety precautions
Doors, covers and guards

Make sure that all doors, covers and guards are in place and
functioning.
WARNING! Never remove covers or guards while the equipment is operating.
Certain doors, covers and guards are fitted with safety switches. These
switches are part of the safety system and must never be bridged, by-passed
or otherwise made non-operational.
Never stop the equipment by opening a door or cover with a safety switch.
WARNING!
The equipment may perform a reciprocating movement during the first few
seconds after a stop. Some equipment parts may also be hot.
In case of accident, call for medical attention.
LH side
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without HI
RH side

Safety precautions
Chemical products
Risk of personal injury!
Certain chemical products are toxic and/or inflammable. Carefully
follow the instructions on the container label.
WARNING!
Follow the supplier’s instructions for handling and disposal of chemical
products.
Personal protective equipment

• Safety goggles, TP No. 779130-102
• Apron, TP No. 90303-5
• Shoes made of PVC, PE plastic or rubber
• Protective gloves made of neoprene, TP No. 90303-4
Before starting work with any chemical products, make sure that:
• the showers work
• a portable, TP No. 90303-6, or wall-mounted eyewash device is available
at or near each machine site
• there are additional washing facilities
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General emergency procedures

If you accidentally swallow chemical products, drink large amounts of
lukewarm water.
If you get splashes or vapour from chemical products in your eyes, wash
your eyes thoroughly with lukewarm water for 15 minutes (keeping eyelids
wide apart).
If chemical products comes into contact with skin or clothes:
• rinse immediately with plenty of water
• if skin burns appear, call for medical attention immediately
• thoroughly wash clothes before wearing them again
If you experience irritation or pain due to having inhaled chemical products

vapour:
• leave the affected area and breathe fresh air
• if the symptoms get worse, call for medical attention

Safety precautions
Hydrogen peroxide
The liquid used for sterilising the packaging material consists of 35%
hydrogen peroxide (H2O2).
Hydrogen peroxide in liquid and gas form can cause irritation and
injury if it comes into contact with the skin, mucous membranes, the
eyes or clothes. Carefully follow the instructions on the can label.
WARNING! Hydrogen peroxide can

HYDROGEN PEROXIDE:
• 35% w/w Aqueous Solution UN No. 2014
• Corrosive
• Oxidizing
• Causes burns. Contact with combustible materials may cause fire.
• Keep in a cool place away from sources of heat.
• Avoid contamination.
• Wear suitable protective clothing, gloves, and eye/face protection.
• After contact with skin, wash immediately with plenty of water and call
for medical attention.
• In case of contact with eyes, rinse immediately with plenty of water and
call for medical attention.
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• In case of spillage or fire, drench with water.
Reference: TP document No. M 1751.80.
Example of can label
(Cont'd)

Safety precautions
(Cont'd)
Storage of hydrogen peroxide
Make sure that the area or room used for storage is:
• cool, clean and well ventilated
• shielded from direct sunlight
• free from combustible materials
Hydrogen peroxide must be stored only in its original container as delivered
by the supplier.
Keep the container upright and closed with a proper ventilation cap which
allows oxygen to escape.
Pumps and other equipment used for hydrogen peroxide must be used for
this purpose only.
Never put used hydrogen peroxide back into storage.
Disposal of hydrogen peroxide
Hydrogen peroxide should be sent for destruction by waste disposal
specialists.
Risk of explosion!
Do not pour surplus hydrogen peroxide back into its original container.
Hydrogen peroxide may decompose. In case of accident, call for
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medical attention immediately.

WARNING!
In some countries it is permitted to dilute hydrogen peroxide with water to a
concentration below 1% and to dispose of it in the normal waste water drain.
Hydrogen peroxide with a concentration below 1% is considered harmless.

Safety precautions
Ink
Risk of personal injury!
Ink is inflammable and can be harmful if it comes into contact with the
eyes or skin. Carefully follow the instructions on the container label.
WARNING! Ink container

• INFLAMMABLE
• Avoid direct contact with the product
• Use gloves and goggles
• Care for good ventilation
• Propylene glycol mono methyl ether >30%
• Ethanol 1-5%
• SHAKE BEFORE USE
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BLACK MARKFLEX
MF 7011
INFLAMMABLE
Avoid direct contact with

the product
Use gloves and goggles
Care for good ventilation
Propylene glycol mono
methyl ether >30%
Ethanol 1 - 5%
Manufacturer:
G-man AB
tel. 0410-59200
Trelleborg
SWEDEN
TP No. 90299-72
SHAKE BEFORE USE

Safety precautions
Equipment for lifting and moving

loads
Make sure that the capacity of lifting equipment is adequate and that
the equipment itself is in good working order.
If lifting tackle has to be joined to make up the necessary lengths, make sure
WARNING! that the joins are secure and have the same lifting capacity as the rest of the
tackle.
Always engage the safety clip on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.
2.28210903.sp

Safety precautions
This page intentionally left blank
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3 Drawings and Technical
Data
2.2TB031093.en

3.1 Installation drawings

The following drawings provide machine dimensions, connection positions
and dimensions, and access dimensions. These dimensions must be
respected. All dimensions are in millimetres unless otherwise stated.
Note! The following drawings show the filling machine without HI equipment
installed. The dimensions are not affected by the presence of the HI
equipment.
(Cont'd)
2.2TB031093.en

(Cont'd)
Top view
1 150
681
4 747
4 625
2.2TB031093.en
2 300
(Cont'd)

(Cont'd)
Front view
2.2TB031093.en
588
190 235
Min 1 250 810 528 Min 850
1 338
2 348
2 987
(Cont'd)

2.2TB031093.en
Tetra Pak
(Cont'd)
LH view
Packaging material
min 4 600
reel trolley
Doc. No. IM-82109-0103

Power supply
3 600
Tool locker
2754
85
136
150±20
No lifting Cleaning & cooling

min 3 000 3 480 water outlet,
Min 3 300 recommended when more Ø51 mm
than one machine is in the line
(Cont'd)
31
(Cont'd)
RH view
2 1
2 770
2 529
1 2 3 2 288
3 038, Ø51
3 143, Ø12
2 846, Ø38
2.2TB031093.en
1 286
1 226
1 166
1 106
661
1 640
290
173
1 670
1 700
4 1 800
5
9 1 Steam connection
6 2 Product connection
3 CIP connection
7 8 4 Cold water inlet
5 Recirculated cooling
water inlet
6 Recirculated cooling
water outlet
7 Compressed air inlet
8 Hot water inlet
9 Nitrogen inlet (HI only)
(Cont'd)

(Cont'd)
System drawings
The system drawings are attached inside the rear LH door of the filling
machine. These include:
• hydraulic system
• water system
• lubrication system
• compressed air system
• aseptic system
• valve panel
• extra equipment (if relevant)
2.2TB031093.en

3.2 Basic machine data

Characteristic Value Notes
Machine type TBA/19 0101
Production capacity 6000 or 7500 p/h, To be specified on order.
+4%, -0%
2.2TB031093.en

3.3 Mass (weight)

Weight Approx. 5 600 kg
(12 400 lbs)
Centre of gravity
Location of centre of gravity:
• Height: 1 172 mm from the bottom of the machine body
• Longitudinal position: 1 970 mm back from the front edge of the final
folder
• Transverse position: 497 mm from the RH edge of the machine body
2.2TB031093.en
(Cont'd)

(Cont'd)
Static load
Note! The minimum system for static load distribution requires three points of
support. A four point system is used here because the machine frame cannot
be considered as a rigid structure. The loads given represent the maximum
possible loads at the feet. Real loads will be significantly less since total
machine weight is distributed over ten feet.
1 4
2 3
2.2TB031093.en
Leg Static load (kg)
1 1 800 - 1 900
2 1 500 - 1 600
3 1 600 - 1 700
4 500 - 600

3.4 Noise
Risk of impaired hearing!
Use hearing protection while the equipment is running.
The table below gives the noise level measurements for the machine under
WARNING! the following conditions:
• machine on a concrete floor supported by standard feet
• production under normal operating conditions at 7500 p/h
Characteristic Symbol Declared Rounded Notes

Value
Corrected LpA 77.5 dB(A) 0.5 dB(A) Measured in
equivalent sound (oper.) accordance with
pressure level, ISO 11204.
operator position LpA corrected =
LpA measured
– K1A – K3A.
Background noise K1A 0 dB 0.1 dB Measured in
correction factor, accordance with
average value ISO 3746
Environmental K3A 0.4 dB 0.1 dB Measured in
2.2TB031093.en
correction factor, accordance with

operator position ISO 11204.
Sound power level LwA 92.0 dB(A) 1 dB(A) Measured in
accordance with
ISO 3746.

3.5 Emissions and thermal load

Hydrogen peroxide <1 ppm TLV - Time Weighted
fumes in operator’s Average value
environment
Hydrogen peroxide ≤1%
concentration at outlet
to drain
Oil fumes in operator’s None
environment
Oil spillages None
Detergent spillages None
Water spillages None Except during startup
and external cleaning
Product spillages None
Thermal load 15.4 kW
2.2TB031093.en

3.6 Product
Supply pressure 50 - 350 kPa
(0.5 - 3.5 bar)
[7.2 - 50.7 psi]
Max pressure 100 kPa
fluctuation (1 bar)
[14.3 psi]
Max calculated 150 kPa Calculated between
pressure drop (1.5 bar) product inlet and product
(viscosity index) [22 psi] outlet with regulating
valve fully open.
Inlet temperature 5 - 50°C
(41 - 122°F)
Filling temperature 5 - 50°C Varies from inlet
(41 - 122°F) temperature by +1-2°C
(2-4°F)
Hard particles Absent Product must leave no
hard residue on a
600 µm mesh.
Citrus fibres ≤5% w/w Measured as fibre
residue on a 600 µm
mesh.
2.2TB031093.en
pH 2.5 - 8

3.7 Utilities
Electrical power

Supply voltage to 400/230 VAC, Other voltages available
machine 3 phase +N + earth to order with transformer.
Max voltage -10%, +10%
fluctuation
Frequency 50/60 Hz To be specified on order.
Recommended main 100 A Value for optimum
fuse selectivity at 400/230
VAC.
Consumption during 9 - 29 kW
preheating
Consumption during 12 - 18 kW
sterilisation
Consumption during 5 kW
external cleaning
Consumption during 22 kW
production
Control circuits voltage 24 VDC
2.2TB031093.en
Compressed air

(6 - 7 bar)
[87 - 102 psi]
Consumption during Approx. 130 Nl/min
production (Approx. 4.6 cu.ft/mim)
Peak consumption Approx. 450 Nl/min Peak duration:
(Approx. 16.8 cu.ft/min) < 2 seconds
Max particle size 20 µm
Max particle content 25 mg/m3
Dew point 2°C
(35.6°F)
Oil content 0.01 mg/m3
(Cont'd)

(Cont'd)
Cooling water

(3 - 4.5 bar)
[43.5 - 65 psi]
Max inlet temperature 20°C
(68°F)
Consumption 10 l/min Approximately 5 l/min
(2.2 imp.galls/min) (1.1 imp.galls/min) of
total consumption can be
recirculated.
pH 5-8
Steam

Water quality Drinking water Boiler additives must be
suitable for use with
drinking water.
Supply pressure 170 kPa
(1.7 bar)
2.2TB031093.en
[25 psi]
Max pressure 30 kPa
fluctuation (0.3 bar)
[4.5 psi]
Inlet temperature 130 ±4°C Measured after APV.
(266±7°F)
Consumption 2.4 kg/h
(5.3 lbs/h)
(Cont'd)

(Cont'd)
Hydrogen peroxide

Quality Aseptic grade
Concentration 35%
Consumption 0.7 - 1.2 l/h
Nitrogen (HI equipment only)

Quality High purity Min. purity 99.5%.
No solid particles.
No oil particles.
(4 - 7 bar)
[60 - 100 psi]
Consumption 2 - 5 + headspace Depends on headspace
volume Nl/min volume setting.
2.2TB031093.en

3.8 Cleaning
Cleaning in place (CIP)

Max inlet pressure 350 kPa
(3.5 bar)
[50.7 psi]
Min flow 8 000 l/h
External cleaning (hot water connection)

(3 - 4.5 bar)
[43.5 -65 psi]
Inlet temperature 60 - 70°C
(140 - 158°F)
Hot water consumption 300 l/cycle Per complete cleaning
cycle.
Detergent pH 8 - 12
Detergent consumption 0.8 l/cycle Per complete cleaning
cycle.
2.2TB031093.en

3.9 Ambient temperature

Minimum ambient 5°C
temperature (41°F)
Maximum ambient 50°C
temperature (122°F)
Recommended ambient 15°C to 30°C
temperature (59°F to 86°F)
2.2TB031093.en

3.10 Outfeed conveyor

Recommended conveyor See PIM Conveyors Width varies according
make/model manual. to package volume.
Contact Service
organisation if
necessary.
Recommended conveyor 25 m/min
speed
2.2TB031093.en

2.2TB031093.en

4
2.2TB041093.en
This section intentionally left empty.

4
2.2TB041093.en

5 Crate handling
2.2TB051093.en

5 Crate handling
5.1 Crate data

The TBA/19 0101 is shipped in one crate.
Crate specifications
Crate Gross Net Length Width Height

Identifier weight weight mm mm mm
kg (lbs) kg (lbs) (ft-in) (ft-in) (ft-in)
1/1 7 000 5 600 4 850 2 150 3 200
(15 400) (12 400) (16’) (7’ ) (10’ 6’’)
Crate contents
Crate identifier Contents

1/2 Machine body
Strip applicator
Electrical cabinet cooler
Drying chamber
APV group
Hydrogen peroxide generator
Pipes
Packaging material reel holder
Packaging material covers
Packaging material reel lifting trolley
2.2TB051093.en
Platform frame and plates
Lateral signs
End signs
Warning beacon
Ladder
Handrails
Guards
Legs and feet
Tools
Spare parts
Accessories
Lifting unit
Machine documents
Packaging material
LS strip reel
See the Packing List for further details.

5 Crate handling
5.2 Lifting equipment

Types of lifting equipment
The following types of equipment can be used to lift and move the crate:
• overhead gantry
• mobile crane
• fork lift
The most practical equipment is an overhead gantry.

Lifting capacities
Make sure that the lifting capacities of the equipment and tackle comply with
the minimum values given in the following table.
Equipment or Lifting Notes

tackle capacity
kg (lbs)
Overhead gantry 8 000 9 000 kg (20 000 lbs) required if gantry
(18 000) does not have gradual acceleration/
deceleration ramps.
Mobile crane 8 000 9 000 kg (20 000 lbs) required if crane does
(18 000) not have gradual acceleration/
deceleration ramps.
2.2TB051093.en
Lifting chains, 8 000 9 000 kg (20 000 lbs) required if lifting

cables, ropes or (18 000) equipment does not have gradual
slings acceleration/deceleration ramps.
Min. length hook to hook: 15 m (50’)
Fork lift 9 000 Higher capacity required to allow for reach
(20 000) to centre of gravity of 1 000 - 1 500 mm (3’
to 5’).
Lifting forks 9 000 Min length 2 000 mm (6’6’’).
(20 000) Min setting width 2 000 mm (6’6’’).

5 Crate handling
5.3 Unloading the crate

Make sure that everybody understands all the symbols and warnings on the
crate before starting to lift or move it.
Symbol Meaning
Centre of gravity
Lifting points for chains, cables, ropes, or

slings
This way up
Fragile
Keep dry
Top of crate
‘Fragile’ warning
2.2TB051093.en
‘Handle with care’ warning
‘Not to be dropped’ warning
‘Gross weight’ value
‘Net weight’ value
5.3.1 Inspection
a) Examine the outside of the crate before starting to unload, and record
any damage. This information must later be recorded on the Transport
Damage Report (a section of the Startup Machine Quality report).
b) Record the readings of the humidity indicators and tipping indicator
attached to the outside of the crate (if present). This information must
later be recorded on the Transport Damage Report (a section of the
Startup Machine Quality report).

5 Crate handling
5.3.2 Using an overhead gantry or mobile crane

If using a fork lift, see section 5.3.3 Using a fork lift.
a) Make sure that the lifting capacity of the equipment and tackle is
adequate and that the tackle is of the correct length for the crate being
lifted. See section 5.2 Lifting equipment.
b) Manoeuvre the hook to one side of the crate.
c) Pass the lifting tackle under the crate at the points shown in the figure
below.
d) Secure the tackle to the lifting hook and fit the safety clip on the hook.
e) Manoeuvre the hook over the centre of the crate.
f) Slowly take up the slack in the lifting tackle. Make sure that the tackle is
secure at the crate and hook. If necessary, adjust the tackle to distribute
the load evenly.
L = min. 15 000 mm
2.2TB051093.en
g) Prepare ropes or poles to steady and manoeuvre the load. Do not use
hands or feet.
h) Lift the crate only enough to clear the platform of the vehicle.
i) If possible, have the vehicle driven away from under the crate.
j) Lower the crate gently to the floor.
DANGER!
k) Make sure that the crate is firmly supported. Place blocks or plates under
it if necessary.
l) Lower the lifting hook and remove the lifting tackle.

5 Crate handling
5.3.3 Using a fork lift

If using an overhead gantry or mobile crane, see section 5.3.2 Using an
overhead gantry or mobile crane.
a) Make sure that the lifting capacity of the fork lift and forks is adequate
and that the fork length is correct for the crate being lifted. See section
5.2 Lifting equipment.
b) Set the lifting forks to the correct width. See section 5.2 Lifting
equipment.
c) Manoeuvre the fork lift so that the forks engage the crate no further apart
than the points shown in the figure below, and at equal distances from the
centre of gravity symbol. If the crate is fitted with fork tubes, manoeuvre
the forks inside these to lift the crate.
2.2TB051093.en
= =
d) Lift the crate only enough to clear the platform of the vehicle.
e) If possible, have the vehicle driven away from under the crate.
f) Lower the crate gently to the floor.
DANGER!
g) Make sure that the crate is firmly supported. Place blocks or plates under
it if necessary.
h) Remove the forks from under the crate.

5 Crate handling
5.4 Moving and storing the crate

If the crate has to be stored before the equipment can be installed, make sure
that the storage area complies with specifications before taking the crate
there. See section 5 4.2 Storing the crate.
If installation is to start immediately, check whether it is possible to move the
crate to the installation site. Uncrating and installation can then be performed
together.
When moving the crate to the installation site, deposit it so that the
equipment can be lifted out and positioned without being turned around.
Open the customs inspection panel to see inside the crate.
Wait until installation can start before unpacking the crate.
5.4.1 Moving the crate

a) Lift the crate as instructed above, only enough to clear the floor. See
section 5.3 Unloading the crate.
b) Make sure that the crate remains stable on the lifting equipment.
Caution! Move the crate slowly and gently.
c) Move the crate to its destination.
2.2TB051093.en
d) Look through the customs inspection panel to see in which direction the
contents are facing. Position the crate to face in the most convenient
direction.
e) Lower the crate gently to the floor, leaving enough room around it for
easy access to all sides.
f) Make sure that the crate is firmly supported. Place blocks or plates under
it if necessary.
g) Remove the lifting equipment.

5 Crate handling
5 4.2 Storing the crate

Caution! Store the crate indoors. Exposure to damp or to high or low
temperatures may damage the equipment.
a) Make sure that the storage area has the following approximate
dimensions:
7 000 x 4 000 x 4 000 h mm
Note! These dimensions allow about 1 000 mm (3 ft) of free space around and
above the crate for access and ventilation.
b) Make sure that the storage environment respects the following
conditions:

Min and max 5 - 40 If the water system is drained,
temperatures °C (°F) (40 - 105) the equipment can withstand
freezing conditions.
Max relative humidity % 80 Non-condensing.
c) Manoeuvre the crate into position, leaving about 1 000 mm (3 ft) of free
access space around it if possible.
d) If the floor under the crate is uneven, place blocks or plates under it to
provide a steady support.
2.2TB051093.en
e) Make sure that the crate is stable and remove the lifting equipment.

6 Positioning, assembly, and
connections
2.2TB061093.en

6.1 General requirements

Personnel
Only skilled or instructed Tetra Pak installation personnel are allowed to
assemble the machine.
Personnel must know how to use the portable PC computer programs for
modifying GE Fanuc program parameters and downloading the TMCC
program.
Lifting equipment, tools and materials
The equipment used for lifting and moving the crate can also be used for
unpacking the crate and installing the filling machine. See section 5.2 Lifting
equipment for further details.
The following tools and materials are needed to move and install the filling
machine:
• lifting unit, TP No. 2-579899 (supplied)
• hydraulic jack, min. capacity 3 tons
• pallet trolley, capacity 800 kg
• spirit level, TP No. 90243-163
• spirit level, TP No. 90243-165
• 2 m step ladder
2.2TB061093.en
• min. four wooden blocks, min. 150 - max. 200 mm in height
• cable ties
• insulating tape
• hydraulic sealing tape
The following special tools may also be available from the local Service
Organisation:
• wheeled transporter unit, TP No. 271635-401
• drying chamber lifting tool, TP No. 76500-101
(Cont'd)

(Cont'd)
The following equipment will be needed only if the GE Fanuc PLC
parameters (for example filling sector parameters) need to be changed:
• portable PC running GE Fanuc LM90 software, V 6.01 or later
• GE Fanuc PLC serial cable, TP No. 90031-300
The following equipment will be needed only if a new TMCC PLC program
needs to be downloaded:
• TMCC PLC serial cable (9-pin M-F, pinned F2-M3, F3-M2, F5-M5)
• TMCC program and communications diskette
Unpacking area
The unpacking area must be at least twice the size of the crate:
7 000 x 7 000 x 4 000 mm (23’ x 23’ x 13’ h)
Installation area
a) Clear all obstacles away from the installation site and, if necessary, clean
the floor of the site before starting to install the machine.
b) Make sure that there is sufficient room to move safely around the
installation site. If machines around the site cannot be stopped, place
guards around them to prevent accidental contact.
2.2TB061093.en
WARNING! c) Make sure that lighting is adequate. Arrange additional portable lights if
necessary.

6.2 Opening the crate

Do not open the crate until you are ready to start installation.
a) Remove the top of the crate and the reinforcement cross-beams.
b) Unscrew any screws fixing the contents to the front of the crate and
remove the front of the crate.
WARNING! c) Unscrew any screws fixing the contents to the back of the crate and
remove the back of the crate.
d) Unscrew any screws fixing the contents to the sides of the crate and
remove the sides of the crate.
a)
b)
2.2TB061093.en
c) d)
e) Remove all loose boxes and packages.

6.3 Unpacking the crate

6.3.1 Uncrating separate components
a) Remove all loose components from the floor of the crate.
Take care when working on machine platforms without railings.
WARNING!
The components fixed to the filling machine and crate weigh up to 300
Kg.
b) Remove all the components fixed to the top of the platform.

WARNING! c) Remove all the components fixed to the underside of the platform and/or
to the sides of the filling machine.
d) Remove all the components fixed to the floor of the crate.
2.2TB061093.en

6.3.2 Uncrating the machine body with an

overhead gantry or mobile crane
If using a fork lift, see section 6.3.3 Uncrating the machine body with a fork
lift.
a) Place the wooden blocks on the floor to support the machine.
b) Make sure that the lifting eyebolts on the machine are secure and are not
damaged.
c) Secure the lifting unit (1) to the hook and fit the safety clip on the hook.
Risk of tipping!
Use four separate lifting lines. Respect minimum lengths.
d) Fit two separate lines to the two eyebolts (2) on the electrical cabinet.
WARNING! Fit another two separate lines to the two eyebolts (3) on the platform
frame.
1
2 1 3
L1 L2
2
2.2TB061093.en
3
1 Lifting unit TP No 579899

L1 = min 1 650 mm (5’5’’)
2 Eyebolt on electrical cabinet
3 Eyebolt on platform frame
L2 = min 1 700 mm (5’7’’)
(Cont'd)

(Cont'd)
Caution! Do not start lifting yet.
e) Slowly take up the slack in the lifting tackle.
f) Unscrew the screws fixing the transport frame to the floor of the crate
(six screws).
Rear Front
g) Remove the longitudinal bars (two bars, six screws each).

2.2TB061093.en
Rear Front
(Cont'd)

(Cont'd)
The filling machine body weighs approximately 5 000 Kg.
WARNING!
h) Lift the machine complete with the cross bars of the transport frame only
enough to clear the crate.
i) Manoeuvre the machine out of the crate.
DANGER!
Caution! Make sure that the wooden blocks support the frame members on
both sides of the machine.
j) Lower the machine complete with the cross bars of the transport frame
gently on to the wooden blocks (4). The blocks must support the bottom
of the machine, leaving the cross bars (5) free.
2.2TB061093.en
5 4 5
4 Wooden block
5 Cross bar
(Cont'd)

(Cont'd)
k) Remove the cross bars (rear and middle bars, three screws each; front
bar, two screws).
Rear Front
l) Make sure that the machine is stable and remove the lifting equipment.
6.3.3 Uncrating the machine body with a fork lift

If using an overhead gantry or mobile crane, see section 6.3.2 Uncrating the
machine body with an overhead gantry or mobile crane.
a) Place the wooden blocks on the floor to support the machine.
b) Unscrew the screws fixing the transport frame to the floor of the crate
(six screws).
2.2TB061093.en
Rear Front
(Cont'd)

(Cont'd)
c) Remove the longitudinal bars (two bars, six screws each).
Rear Front
d) Remove the angle brackets behind the front cross bar (two brackets, two
screws each).
2.2TB061093.en
Rear Front
(Cont'd)

(Cont'd)
The filling machine body weighs approximately 5 000 Kg.
e) Lift the machine gently while manoeuvring the forks under it at the
points shown in the figure below.
WARNING!
Note! Position the forks where they will not interfere with the wooden blocks.
2.2TB061093.en
f) Lift the machine complete with the cross bars of the transport frame only
enough to clear the crate.
g) Manoeuvre the machine out of the crate.
DANGER! (Cont'd)

(Cont'd)
Caution! Make sure that the wooden blocks support the frame members on
both sides of the machine.
h) Lower the machine complete with the cross bars of the transport frame
gently on to the wooden blocks (1). The blocks must support the bottom
of the machine, leaving the cross bars (2) free.
2.2TB061093.en
2 1 2
1 Wooden block
2 Cross bar
i) Remove the cross bars (rear and middle bars, three screws each; front
bar, two screws).
Rear Front
j) Make sure that the machine is stable and remove the lifting equipment.

6.4 Inspection
a) Use the Packing List to check that nothing is missing from the crate.
b) Inspect the machine, the SA, the drying chamber, the electrical cabinet
cooler, and all other machine parts for damage.
c) Open the boxes containing the smaller machine components and inspect
these for damage.
d) Open the Machine Documents box and check the documentation.
MACHINE DOCUMENTS
NOT TO BE REMOVED
MACH. NR.................. Tetra Pak
(Cont'd)
2.2TB061093.en

(Cont'd)
e) Open the rear LH door of the service unit. Check that the following
documents are present and that they correspond to the machine in
question:
– Machine Specification Document
– Final Inspection Report
– Machine Deviation Report (if relevant).
– Start-up Machine Quality Report (including the Transport Damage
Report)
– Feedback from MC form
– System drawings
2.2TB061093.en
f) Take the spare parts to the spare parts stores.
g) Fill in the Transport Damage Report (a section of the Machine Startup
Quality Report).

6.5 Disposal/return of packing

Note! Packing materials (including the crates, wrapping, and boxes) are not
normally returned to the manufacturer.
a) Check with the customer if there is a special agreement for the return of
packing to the manufacturer.
b) If packing must be returned to the manufacturer, prepare an area to store
the crates and other returnable packing.
c) Check with the customer if there is a special arrangement for recycling
packing.
d) If packing is not to be returned or recycled, check with the customer how
to separate and dispose of packing (wood, plastic, paper, etc.).
e) Dispose of pollutant waste (bubble wrapping, plastic bags, expanded
polystyrene, etc.) in accordance with local regulations.
WARNING!
2.2TB061093.en

6.6 Fitting the transporter

Note! The transporter, TP No. 271635-401, must be obtained from the local
Service Organisation.
a) Place a hydraulic jack centrally at the rear of the machine body at the
point shown in the figure below.
Make sure that the jack is positioned in the centre of the machine and
under the structural frame member.
b) Slowly jack up the rear of the machine only enough to fit the rear
DANGER! transporter.
c) Fit the rear transporter (eight screws).
2.2TB061093.en
d) Remove the wooden blocks from under the rear of the machine.
Gently lower the machine until the rear wheels support its weight.
(Cont'd)

(Cont'd)
e) Place the jack centrally at the front of the machine body at the point
shown in the figure below.
Make sure that the jack is positioned in the centre of the machine and
under the structural frame member.
f) Slowly jack up the front of the machine only enough to fit the front
DANGER! transporter.
g) Move the wooden blocks towards the front of the machine if necessary,
but do not remove them yet.
h) Fit the front transporter to the bottom of the drive unit (eight screws).
2.2TB061093.en
i) Remove the wooden blocks from under the front of the machine.
Gently lower the machine until the front wheels support its weight.
Note! Block the wheels if the machine must be left on the transporter.
Removing the transporter
Follow the procedure for fitting the transporter in the reverse order to remove
the transporter.

6.7 Positioning
a) Move the machine to the installation position and support it on wooden
blocks.
Take care when working on machines without legs and feet.
b) Fit all ten legs (four screws and washers per leg).
WARNING!
Note! If space under the machine is limited, screw the legs fully up, or use larger
wooden blocks.
c) Screw all non-structural legs up towards the machine frame so that they
will not interfere with levelling.
2.2TB061093.en
(Cont'd)

(Cont'd)
d) Check that the machine is correctly positioned with respect to the
customer’s plant. See section 3.1 Installation drawings.
e) Position four feet under the structural legs.
Do not unscrew the legs more than the maximum specified.
f) Screw down the four structural legs until they engage the recesses in the
WARNING! feet.
g) Screw down the four structural legs again just enough to lift the
machine off the wooden blocks.
2.2TB061093.en
max 190 mm
h) Make sure that the machine is supported and stable on all four structural
legs and feet. Remove the wooden blocks.

6.8 Approximate levelling

Note! Approximate levelling must be performed before assembly to ensure that the
machine is stable and that there are no torsional forces on the frame.
Precision levelling must be performed when assembly is complete.
a) Screw all four structural legs in or out until the machine, measured at the
bottom panel, is 150 mm ±20 mm from the floor.
150 ±20 mm
2.2TB061093.en
(Cont'd)

(Cont'd)
b) Crank the machine to raise the outer LH guide of the jaw system and fit
the spirit level TP No. 90243-163 to it.
c) Adjust all four structural legs until the machine is approximately level
transversely and longitudinally.
d) Place feet under all the non-structural legs.
2.2TB061093.en
e) Screw down all the non-structural legs until they just start to take the
weight of the machine.
Note! Do not screw down too much. This could alter the levelling of the machine.
f) Make sure that the levelling of the machine has not changed.
Remove the spirit level.

6.9 Assembly
Packing
Leave the bubble wrapping on parts until they are ready for use.
Leave the plastic plugs in the pipes until they are ready to be connected, but
do not forget to remove them before connecting the pipes.
Leave ties in place until tied parts are ready to be used or connected.
6.9.1 Platform, ladder, and handrail

Take care when working on machine platforms without railings.
RH side platform
Insert the four tongues of the RH side frame into the main platform frame.
WARNING! Align the screw holes. Insert the fixing screws and tighten firmly (four
screws).
2.2TB061093.en
(Cont'd)

(Cont'd)
Ladder
Fix the top of the ladder to the underside of the platform (two brackets, two
screws each). Adjust the feet so that the ladder is firmly supported. Tighten
the foot lock nuts.
(Cont'd)
2.2TB061093.en

(Cont'd)
Completing the platform
a) Place the LH sign holder on the platform frame.
Fit the ladder safety hoop (two screws).
Fit the ladder handrails (two handrails, two screws and one ring nut
each).
2.2TB061093.en
b) Remove the four lifting eyebolts .
Note! The eyebolts are machine accessories (TP No. 318301-128). Keep them safe.
Front view
(Cont'd)

(Cont'd)
c) Fit the RH platform panels (1) and (2) (six screws and brackets each).
Fit the RH platform panel (3) (four screws and brackets).
Fit the front LH platform panel (4) (six screws and brackets).
1 2 3
4
1 Platform panel
2 Platform panel
3 Platform panel
2.2TB061093.en
4 Platform panel
(Cont'd)

(Cont'd)
d) Fit the signs in the sign holders (if not already in place).
e) Fit the handrail all around the machine, taking care to position the sign
holders and corner pieces as required.
Note! The sign holders are fixed on top of the platform frame by the handrails.
The signs are fixed in the sign holders by the corner pieces.
The corner pieces are fixed in place by the sign holders to either side.
2.2TB061093.en
(Cont'd)

(Cont'd)
Warning beacon
a) Thread the warning beacon cables through the support post (1).
Caution! Take care not to jam the cables when tightening the screws.
b) Fit the support post to the bracket at the front of the platform (two
screws).
c) Connect the cables to the bulb holder. Fit the warning beacon glass (2) to
the support post (1).
1 2
1 Support post
2 Warning beacon glass
2.2TB061093.en

6.9.2 Electrical cabinet cooler

a) Remove the RH side panel (1) of the electrical cabinet cooler (four
screws).
Disconnect the temperature display cables and remove the side panel.
b) Fit an eyebolt (2) to the top of the electrical cabinet cooler. Fit suitable
lifting tackle to the lifting eyebolt.
Lift the cooler into place over the air inlet (3) and cable duct (4) on the
top of the electrical cabinet.
c) Guide the cables from the electrical cabinet into the cable duct inside the
cooler.
2.2TB061093.en
4 3 2 1 RH side panel
2 Lifting eyebolt
3 Air inlet
4 Cable duct
(Cont'd)

(Cont'd)
Caution! Take care not to jam any cables between the cooler and the electrical
cabinet.
d) Insert the fixing screws from below through the holes in the top of the
electrical cabinet (six screws). Tighten the screws to fix the cooler in
place. Remove the lifting tackle and the lifting eyebolt.
View without cooler
e) Make the necessary electrical connections. See the EM for further

details.
f) Connect the temperature display cables and fit the RH side panel of the
2.2TB061093.en
cooler (four screws).

g) Fit the condensate drain pipe between the connection at the rear of the
electrical cabinet cooler and the connection at the front of the electrical
cabinet. Fix the bracket at the front LH side of the electrical cabinet.

6.9.3 Strip applicator (SA)

a) Open the top covers on the SA and fit the lifting tackle to the SA frame at
the points shown in the figure below.
2.2TB061093.en
(Cont'd)

(Cont'd)
Caution! Secure the doors of the SA when you are manoeuvring it.
Take care not to damage the electrical cabinet cooler, the condensate
drain pipe, or the pneumatic pipes.
b) Lift the SA into position on top of the electrical cabinet.
2.2TB061093.en
(Cont'd)

(Cont'd)
c) Make sure that the pins in the top of the electrical cabinet engage in the
holes in the feet of the SA frame. Fit the pins if necessary.
2.2TB061093.en
(Cont'd)

(Cont'd)
d) Place the shim packs (if present) under the feet of the SA.
Note! The shim packs are attached to the feet with which they are associated.
e) Fit and tighten the SA frame fixing screws (five screws).
2.2TB061093.en
f) Fit the two door microswitches to the top of the electrical cabinet.
Adjust the microswitches so that the SA doors engage them correctly.
Tighten the microswitches in place.
(Cont'd)

(Cont'd)
Caution! Make sure that the condensate drain pipe fits in the slot in the side
panel.
g) Fit the LH side panel (four screws).
2.2TB061093.en
h) Run the cables from the SA through the cable duct at the rear of the
electrical cabinet, and into the electrical cabinet.
Make all the necessary electrical connections at the SA terminal board.
See the EM for further details.
i) Connect up the pneumatic pipes (1051, 1051, 1060, 1061) at the front
LH panel of the SA.
1060 1050
1061 1051

6.9.4 Drying chamber

Caution! Make sure that the sterilisation bath is adequately supported from
beneath.
a) Remove the transport plate from the top of the column and sterilisation
bath.
Note! The transport plate is a machine accessory (TP No. 3-441725). Keep it safe.
b) Either:
Fit the special lifting tool which may be available from the local Service
Organisation (TP No. 76500-0101).
or:
Pass lifting ropes or slings through the top of the drying chamber on both
sides as shown in the figure below. Take care not to damage the
components inside the drying chamber.
2.2TB061093.en
c) Manoeuvre the drying chamber to just above the column.

(Cont'd)

(Cont'd)
d) Lift up the ends of the two chains from the sterilisation bath and pass
them over the sprockets (1) and rollers (2) in the drying chamber.
2 2
1 1
1 Sprocket
2 Roller
Caution! Tie the ends of the chains together to prevent them falling back into
the sterilisation bath.
e) Lower the drying chamber on to the top of the column.
f) Make sure that the four pins engage in the holes in the bottom of the
2.2TB061093.en
drying chamber (two at the top of the sterilisation bath, two at the top of
the column). Fit the pins if necessary.
(Cont'd)

(Cont'd)
Inside the drying chamber
a) Loosen the fixing screws of the chain steering blocks (1).
b) Fit the carrier (2) parallel with the rollers.
Note! The sharp edge of the carrier must face towards the rear of the machine, and
the carrier must be fitted outside the chain pins. See detail in figure below.
c) Remove any cord tying the chains.
Make sure that the chains rotate correctly.
Crank the carrier down into the bath.
1 2 1 Towards rear
1 Steering block
2 Carrier
2.2TB061093.en
(Cont'd)

(Cont'd)
d) Fit and tighten the drying chamber fixing screws (twelve screws).
e) Adjust the tension of the chains. Tighten the fixing screws of the chain
steering blocks (1).
2.2TB061093.en
f) Fit the two bottom drip plates (3) (four screws each).
g) Fit the two side drip plates (4) (two screws each).
.
1 Steering block
4 3 1 3 Bottom drip plate
4 Side drip plate
(Cont'd)

(Cont'd)
LH side of drying chamber
a) Fit the LH side cable duct with the two bottom screws only.
b) Fix the two cable tubes (two screws at the top of the cable duct; one
screw at the top of each cable tube).
2.2TB061093.en
(Cont'd)

(Cont'd)
c) Pass cable No. 418 through the cable tube to the rear door microswitch
(1). Connect the rear door microswitch.
Pass cable No. 416 through the cable tube to the front door microswitch
(2). Connect the front door microswitch.
1 2
1 Microswitch
2 Microswitch
d) Fit the calender roller position proximity switch (3), cable No. 422 (two
2.2TB061093.en
screws).
e) Fit the air knife position proximity switch (4), cable No. 423 (two
screws) and the cover plate (5) (two screws).
f) Connect up the bending roller motor cable (6), cable No. 404. See the
EM to avoid reversing the direction of motor rotation.
3 4 5 6
3 Proximity switch
4 Proximity switch
5 Cover plate
6 Motor cable
(Cont'd)

(Cont'd)
g) Arrange the cables tidily in the cable duct. Fit the cover of the cable duct
(two screws).
RH side of drying chamber

Fit the RH side cable duct (five screws) and run the cables from the RH side
of the column up through it.
Do not close the cable duct or make any electrical connections yet.
6.9.5 Hydrogen peroxide generator

2.2TB061093.en
Caution! Remove all sealing plugs before fitting components and pipes.
Fit the hydrogen peroxide generator (six screws on the bottom flange).

6.9.6 Large diameter pipes

a) Fit pipe (1) between the top of the hydrogen peroxide generator (2) and
the pre-sterilisation valve (3) (two flanges, four screws each).
3 1
2.2TB061093.en
1 Pipe
2 Hydrogen peroxide
generator
3 Pre-sterilisation valve
(Cont'd)

(Cont'd)
b) Fit pipe (4) between the suction valve (5) and the drying chamber (top
flange, four screws; bottom flange, only the two front screws).
Fit the adjuster bracket at the rear of the change-over valve and fix with
the remaining two screws.
5
2.2TB061093.en
4 Pipe
5 Suction valve
(Cont'd)

(Cont'd)
c) Fit pipe (6) between the pre-sterilisation valve (3) and the horizontal pipe
(7) near the platform (two flanges, four screws each).
2.2TB061093.en
3 Pre-sterilisation valve
7 6 Pipe
7 Pipe
(Cont'd)

(Cont'd)
d) Fit the sterile air pipe (8) between the air-knife connection (9) and the LS
nozzle (10) (top flange, three screws; bottom connection, one ring nut).
8 9
2.2TB061093.en
10 8 Pipe
9 Connection
10 LS nozzle
(Cont'd)

(Cont'd)
e) Fit the upper filling pipe inside the column.
f) Fix the connection plate (11) in place with the lock handle (12).
2.2TB061093.en
11
12
11 Connection plate
12 Lock handle
Note! Wait until test production is ready to start before fitting the lower filling pipe.
See the OM for further details.
(Cont'd)

(Cont'd)
g) Fit the CIP pipe (13) and secure it to bracket (14) under the platform
frame and to bracket (15) on the superstructure frame.
13
14
15
13 CIP pipe
14 Bracket
15 Bracket
h) Filling machines with HI only

2.2TB061093.en
Fit the extension (16) to the front connection on the CIP pipe.
Connect the small diameter pipe from the HI valve on the platform to the
connection (17) on the CIP pipe extension.
16
17
16 Extension
17 Connection

6.9.7 Aseptic product valve (APV) and remaining

large pipes
Make sure that the correct gaskets are fitted.
a) Fit the APV (1) to the bracket (2) on the top RH side of the column (four
screws).
1
C
2
A
B
1 APV
2.2TB061093.en
2 Bracket
b) Fit the product regulating valve (3) to the APV (one clamp). Make sure
that the regulating valve is supported by the two fingers of bracket (4).
Fit gasket TP No. 926822 between the regulating valve and the APV.
3 Regulating valve
TP No. 926822 4 Bracket
(Cont'd)

(Cont'd)
c) Fit the sterile air pipe with gaskets TP No. 342850-303 at both ends (two
clamps).
TP No. 342850-303
(Cont'd)
2.2TB061093.en

(Cont'd)
d) Filling machines without HI
Fit the product pipe with gasket TP No. 926822 at the regulating valve
and gasket TP No. 342850-303 at the upper filling pipe (two clamps).
Caution! When fitting the product pipe, make sure that the flanges of the pipe
and regulating valve are perfectly aligned and in close contact. If
necessary, slacken off the fixing screws of the APV and/or APV
bracket and adjust the position of the APV and regulating valve.
2.2TB061093.en
TP No. 926822
TP No. 342850-303
(Cont'd)

(Cont'd)
e) Filling machines with HI:
To prepare for production without HI:

– Fit the product pipe (5) with gasket TP No. 926822 at the regulating
valve and gasket TP No. 342850-303 at the upper filling pipe.
– Fit the cap on the HI stop valve pipe (6).
Caution! When fitting the product pipe, make sure that the flanges of the pipe
and regulating valve are perfectly aligned and in close contact. If
necessary, slacken off the fixing screws of the APV and/or APV
bracket and adjust the position of the APV and regulating valve.
6 5
TP No. 926822
TP No. 342850-303
2.2TB061093.en
5 Product pipe
6 Stop valve pipe
(Cont'd)

(Cont'd)
To prepare for production with HI:
– Fit the nozzle pipe (7) with gasket TP No. 342850-303 at the upper
filling pipe. Fit an O-ring TP No. 315204-0209 in the nozzle seat.
– Fit the extension pipe (8) with gasket TP No. 926822 at the regulating
valve.
– Fit the product pipe (9) with gasket TP No. 342850-304 at the
extension pipe and gasket TP No. 342850-303 at the nozzle pipe.
– Various injection nozzles (10) are supplied. Fit an intermediate size.
Fit the HI pipe (11) between the nozzle pipe and the HI stop valve
pipe (12), with an O-ring TP No. 315204-0209 at both ends. Make
sure that the O-rings are fitted correctly.
10 7 11 12 8 9
2.2TB061093.en
TP No. 342850-304
TP No. 926822
7 Nozzle pipe 10 Nozzle

TP No. 342850-303 8 Extension pipe 11 HI pipe
9 Product pipe 12 Stop valve pipe
(Cont'd)

(Cont'd)
f) Fit the product inlet pipe (13) and product outlet pipe (14) to the APV
with gasket TP No. 342850-305 between both pipes and the APV (two
pipes, one clamp each).
13 14 13 14
13 Product inlet pipe

14 Product outlet pipe
g) Fit the three sterile air L pipes (15) between the B-valve connection (16)
and the air knife connection (17) with gaskets TP No. 342850-304 at all
joints (top flange, four screws; other three flanges, one clamp each).
2.2TB061093.en
17
15
16
15 Pipe
16 Connection
17 Connection
(Cont'd)

(Cont'd)
h) Fit pipe (18) between the steam filter connection (19) and the lower
steam trap (20).
19 18
20
2.2TB061093.en
18 Pipe
19 Connection
20 Steam trap
(Cont'd)

(Cont'd)
i) Fit pipe (21) between the APV connection (22) and the upper steam trap
(23).
22
21
23
2.2TB061093.en
21 Pipe
22 Connection
23 Steam trap

6.9.8 Small diameter pipes

Make sure that you fit the air and hydrogen peroxide pipes to the
correct fittings on the hydrogen peroxide generator. Check the ‘AIR’
and ‘LIQUID markings on the valve on top of the generator.
a) Fit pipe (1) between the air side of connection valve (2) on the hydrogen
peroxide generator and the ‘T’ connection (3) on the pipe between
solenoid valve MY4 and spray tank MB43BA.
b) Fit pipe (4) between the liquid side of connection valve (2) on the
hydrogen peroxide generator and the bottom of solenoid valve MY35
(5).
1 3 5
2.2TB061093.en
2
1 Pipe
2 Connection valve
3 Connection
4 Pipe
5 Solenoid valve MY35
(Cont'd)

(Cont'd)
c) Fit pipe (6) between the bottom of solenoid valve MY4 (7) and the
connection (8) at the LH side of the air superheater.
8
2.2TB061093.en
6 Pipe
7 Solenoid valve
MY4
8 Connection
(Cont'd)

(Cont'd)
d) Fit pipe 70 (9) between the bottom of the C-valve and connection 70 at
the bottom of the drying chamber.
e) Fit pipe 71 (10) between the top of the C-valve and connection 71 at the
bottom of the drying chamber.
10
9 Pipe 70
10 Pipe 71
2.2TB061093.en
f) Fit pipe 90 (11) between the LH side of the A-valve and connection 90 at
g) Fit pipe 91 (12) between the RH side of the A-valve and connection 91 at
11 12
11 Pipe 90
12 Pipe 91
(Cont'd)

(Cont'd)
h) Connect pipe 80 (13) to the top of the B-valve.
i) Connect pipe 90 (14) to the bottom of the B-valve.
13
13 Pipe 80
14 14 Pipe 90
j) Fit pipe 1070 between the regulating valve and connection 1070 at the
2.2TB061093.en
bottom of the drying chamber.

without HI
(Cont'd)

(Cont'd)
k) Filling machines without HI
Fit pipe (15) between the connection at the front of solenoid valve MY34
and connection (16).
15
16
15 Pipe
2.2TB061093.en
16 Connection
(Cont'd)

(Cont'd)
l) Filling machines with HI
Fit pipe (15) from the bottom of the T connection at the front of solenoid
valve MY34 to connection (16).
Fit pipe (17) from the front of the T connector to the connection at the
LH side of the sterilisation bath.
15
16
17
2.2TB061093.en
LH side
15 Pipe
16 Connection
17 Pipe
(Cont'd)

(Cont'd)
Note! The following pipes are connected at the bottom of the drying chamber.
m) Fit pipe 40 (18) from solenoid valve MY4.
n) Fit pipe 190 (19) from the front of the pre-sterilisation air inlet valve.
o) Fit pipe 191 (20) from the rear of the pre-sterilisation air inlet valve.
18
19
20
18 Pipe 40
2.2TB061093.en
19 Pipe 190
20 Pipe 191
p) Fit pipes 210 (21) and 211 (22) from the calender roller and air knife
cylinders.
21 Pipe 210
22 Pipe 211
21 22

6.9.9 Electrical connections

Note! See the EM for further details on the following operations.
a) Connect the pre-sterilisation thermocouple, cable No. 407.
2.2TB061093.en
b) Connect the air-knife thermocouple (1), cable No. 411.

c) Connect the steam thermocouple (2), cable No. 412.
1 Thermocouple
2 Thermocouple
(Cont'd)

(Cont'd)
d) Connect solenoid valve MY34 (3), cable No. 430.
e) Connect solenoid valve MY35 (4), cable No. 431.
f) Connect solenoid valve MY4 (5), cable No. 432.
g) Connect the position switch (6) of valve B71, cable No. 454.
6
5
3
2.2TB061093.en
3 Solenoid valve
4 Solenoid valve
5 Solenoid valve
6 Position switch
(Cont'd)

(Cont'd)
Caution! Do not change the setting of the proximity switch.
h) Fit the regulating valve position proximity switch (7), cable No. 413 (one
screw).
i) Connect the regulating valve leakage detector cable No. 405 to the
regulating valve leakage detection terminals (8).
Note! Connect any one wire to the terminal on the metal section of the valve body
and the other wire to the terminal on the nylon section of the valve body.
j) Fit product pipe detection proximity switch (9), cable No. 421.
k) Filling machines with HI only
Fit the HI pipe detection switch (10), cable No. 709.
l) Fit B-valve position proximity switch (11), cable No. 424 (two screws).
m) Fit cleaning pipe detection proximity switch (12), cable No. 440 (two
screws)
n) Fit sterile air pipe detection proximity switch (13), cable No. 456 (two
screws).
7 8 9 10 12
2.2TB061093.en
7 Proximity switch
8 Terminals
9 Proximity switch
10 Proximity switch
13 11 11 Proximity switch
12 Proximity switch
13 Proximity switch
(Cont'd)

(Cont'd)
o) Connect level sensor cable No. 425 to spray tank MB43BA.
Note! Connect the three wires of the level sensor cable to the studs with the
corresponding numbers on the cover of the tank. Refer to the numbers on the
collars, not on the cables themselves.
Caution! Make sure that all cables and flexible hoses are kept clear of pipes
which may become hot.
2.2TB061093.en
p) Arrange the cables tidily in the cable duct and close the cable duct (four
screws).

6.9.10 Covers and guards

Packaging material covers
a) Fit the rear packaging material cover (1) between the SA infeed roller
and the opening in the platform.
b) Fit the front packaging material cover (2) between the SA outfeed roller
and the sterilisation bath.
1 2
2.2TB061093.en
1 Rear packaging
material cover
2 Front packaging
material cover
(Cont'd)

(Cont'd)
Protective guards
a) Fit the main RH top guard (1) (five screws).
b) Fit the front RH top guard (2) (four screws).
2 1
1 Main RH top guard

2 Front RH top guard
2.2TB061093.en
c) Fit the RH bottom guard (four screws).
(Cont'd)

(Cont'd)
d) Filling machines without HI only
Fit the LH guard (four screws).
2.2TB061093.en

6.10 Precision levelling

Caution! Do not raise the machine more than 170 mm from the floor when
levelling, or it may be impossible to connect the product supply pipes
later.
Note! If the slope of the floor makes longitudinal levelling difficult, a greater
tolerance can be accepted in longitudinal levelling.
a) Fit the spirit level to the outer LH guide of the jaw system again. See
section 6.8 Approximate levelling.
b) Adjust the front structural legs until the machine is level transversely and
longitudinally ± 0.2 mm/m.
150 ±20 mm
2.2TB061093.en
(Cont'd)

(Cont'd)
c) Fit the spirit level (TP No. 90243-163) across the bending roller at the
rear of the SA.
Rotate the roller to obtain the average spirit level value.
d) Adjust the two rear structural legs (if necessary) until the rear of the
machine is level transversely ±0.2 mm/m.
2.2TB061093.en
150 ±20 mm
e) Check that all the other legs are in firm contact with their feet. Screw
them down if necessary, taking care not to alter the levelling of the
machine.

6.11 Conveyor connections

a) Connect the package outfeed conveyor according to the plant installation
and connection drawings.
See the package outfeed conveyor’s own installation manual for
instructions.
Pass the outfeed conveyor’s electrical cables through the cable tube
under the LH side of the final folder.
Make all necessary electrical connections. See the EM for further details.
b) Set the conveyor speed to the recommended 25 m/min. See the

conveyor’s own documentation for further details.
c) Position the eject bin under the eject chute where it will catch all ejected
2.2TB061093.en
packages.

6.12 Utility, product, and drain

connections
Electrical power connections
a) Make sure that power is switched off upstream.
b) Pass the power cable through the cable guide.
DANGER! 0
1
Front view
Caution! Leave a length of slack cable inside the electrical cabinet to ensure
that there is no pull on the cable terminals if the cable is accidentally
pulled.
2.2TB061093.en
c) Connect the wires of the power cable to the power terminal board inside
the cabinet. See the EM for further details.
(Cont'd)

(Cont'd)
Utility connections
a) Connect the cold water hose to the cold water inlet (1), with the blue fish
symbol.
b) Connect the recirculated water inlet hose to the recirculated water inlet
(2) (if used).
c) Connect the recirculated water outlet hose to the recirculated water outlet
(3) (if used).
d) Connect the compressed air hose to compressed air inlet (4).
e) Connect the hot water supply hose to the hot water inlet (5), with the red
fish symbol.
f) Filling machines with HI only:
Connect the nitrogen supply line to the nitrogen inlet (6).
3 6
2.2TB061093.en
N2
4 5
1 Cold water inlet
2 Recirculation water inlet
3 Recirculation water outlet
4 Compressed air inlet
5 Hot water inlet
6 Nitrogen inlet
(Cont'd)

(Cont'd)
g) Connect the steam hose to the steam filter on the APV.
(Cont'd)
2.2TB061093.en

(Cont'd)
Product connections
Caution! Make sure that the product supply and forwarding lines are connected
to the correct connections.
Make sure that the correct gaskets are fitted.
a) Connect the product supply pipe to the inlet pipe (1), fitting gasket TP
No. 342850-305 in the joint.
b) Connect the product forwarding pipe to the product outlet pipe (2),
fitting gasket TP No. 342850-305 in the joint.
1 2
2.2TB061093.en
1 Inlet pipe
2 Outlet pipe
Drain connections
a) Connect the cleaning pump outlet to the waste water drain.
(Cont'd)

(Cont'd)
Caution! Check on the legal requirements applicable to the disposal of diluted
hydrogen peroxide. You may have to connect the dilution drain
connection to a separate drain.
b) Connect the water overflow (1) and the dilution tank drain connection (2)
to the waste water drain.
2 1
1 Water overflow
2 Dilution tank drain
connection
2.2TB061093.en

6.13 Other operations

a) Place spirit level TP No. 90243-165 (1) across the body of the regulating
valve as shown below and make sure that the metal body of the
regulating valve is level. The bubble must be within the two marks on the
transparent tube. If necessary, slacken off the clamps (2) at both sides of
the regulating valve and rotate the valve as required. Further adjustment
can be obtained by slackening the screws securing the positioning
bracket (3) and sliding the bracket up or down in its slots.
3 2
1
1 Spirit level
TP No. 90243-165
2.2TB061093.en
2 Clamp
3 Positioning bracket
b) Make sure that all ties have been removed from moving parts all around
the machine.
c) Fit the air and water guns to the corresponding connections above the
final folder.
(Cont'd)

(Cont'd)
d) Fill the detergent bottle with detergent of the correct pH. See section 3.8
Cleaning. Also see the OM for further details.
e) Fit the ink bottle in the dating unit. See the OM for further details.
f) Fit and connect up the hydrogen peroxide container. See the OM for
further details.
g) Thread the packaging material and strip and prepare the machine for
start-up. See the OM for further details.
2.2TB061093.en

2.2TB061093.en

2.2TB071093.en

7.1 Installation and connection checks

See section 6 Positioning, assembly, and connections for further details on
the following checks.
No. Check Done

1 The machine is level transversely and longitudinally,
±0.2 mm/m.
2 The outfeed conveyor is correctly connected.
The eject bin is correctly positioned.
3 The drain connections are secure:
– external cleaning pump
– water overflow
– dilution tank
4 The utility connections are secure:
– cold water inlet
– hot water inlet
– recirculated cooling water inlet (plugged if not used)
– recirculated cooling water outlet (plugged if not used)
– compressed air inlet
– steam inlet
– nitrogen inlet (filling machines with HI only)
5 The product inlet and outlet connections are secure.
6 The product regulating valve is level.
2.2TB071093.en
7 The electrical power cable is correctly connected:
– cable guide secure
– loop of cable inside cabinet
– terminals correct and secure
8 The hydrogen peroxide container is fitted.
9 The detergent bottle is installed and filled.
10 Upstream valves/switches are open/on:
– electrical power
– cold water
– hot water
– recirculated cooling water supply and return (if relevant)
– compressed air
– steam
– nitrogen (filling machines with HI only)
11 All ties have been removed.

7.2 Lubricant level checks

See the OM and MM for further details on the following checks.
No. Check Done

1 Drive unit worm gear
2 Central lubrication
3 Hydraulic system
4 Final folder indexing unit
5 Final folder worm gear
6 Outfeed unit
2.2TB071093.en

7.3 Valve checks

No. Check Done
1 The hydrogen peroxide tank drain

valve is closed.
2 The hydrogen peroxide sampling

valve is closed.
2.2TB071093.en
3 The dilution tank drain valve is
closed.
The air and water valves are set

correctly:
– air valve: open
4 – standard cooling water: all valves
open
– recirculated cooling water: A1, A3
open; A2, A4 closed

7.4 Safety checks

No. Check Done
1 All the doors open and close correctly.
2 All door microswitches are correctly operated by the blades on
the doors.
3 All removable hatches and covers are secure.
4 All the Emergency stop buttons engage and release correctly.
5 All protective guards are in place and secure.
2.2TB071093.en

2.2TB071093.en

8 Preparation for
commissioning
2.2TB081093.en

Perform the following checks even if an actual commissioning test is not

required.
Note! Commissioning covers only the functioning of the individual machine. A line
performance test is required to check the functioning of the machine as part
of a complete line. Check with the local Service Organisation what
arrangements have been made for a line performance test.
2.2TB081093.en

8.1 Presence and correctness checks

No. Check Done
1 The TP No. on the program diskette corresponds to the TP No.
in the EM.
2 The spare parts have been deposited in the spare parts stores.
3 The accessories are available to the operator:
– apron
– gloves
– goggles
4 All the documents correspond to the specific machine:
– OM
– EM
– MM
– SPC
– System drawings
– Machine Specification Document
– Final Inspection Report
– Machine Deviation Report (if relevant)
5 The tool locker is conveniently positioned and the tools are all in
place (if relevant).
6 The packaging material reel trolley is conveniently positioned
and functioning correctly.
7 The supply and quality of product is sufficient for the purposes
2.2TB081093.en
of commissioning.
8 Packaging material, LS strip, hydrogen peroxide, nitrogen
(filling machines with HI only), ink and detergent are all of the
correct type and are available in sufficient quantities for the
purpose of commissioning.
(Cont'd)

(Cont'd)
No. Check Done
9 The compressed air valve key is

present.
10 The electrical cabinet keys are

present.
2.2TB081093.en

8.2 Product and utility value checks

Make sure that the product and utility values are correct. Ask for the
assistance of the customer’s technical personnel if necessary. If values are
incorrect, inform the customer’s technical personnel and the local Service
Organisation. See section 3 Drawings and Technical Data.
No. Check Done

1 Product supply:
– pressure
– max pressure fluctuation
– inlet temperature
– max particle size
2 Electrical power supply:
– voltage
– max voltage fluctuation
– frequency
– fuse rating
3 Cold water supply:
– pressure
– max inlet temperature
– pH
4 Hot water supply:
– pressure
2.2TB081093.en
5 Detergent supply:
– pH
6 Compressed air supply:
– pressure
– max particle size
– max particle content
– dew point
– oil content
7 Steam supply:
– water quality
– pressure
– max pressure fluctuation
8 Hydrogen peroxide supply:
– aseptic (food) grade
– concentration (35%)
9 Nitrogen supply (filling machines with HI only):
– purity
– pressure

8.3 Function checks

8.3.1 Preparation
a) Make sure that the PLC program on the diskette corresponds with that in
the machine PLC. See the EM for further details.
b) If the product pipes have been welded:
Disconnect the product supply pipe from the inlet pipe (1). Disconnect
the product forwarding pipe from the product outlet pipe (2). Flush the
supply and forwarding pipes with clean water to remove any welding
residues. Connect the two pipes again.
1 2
2.2TB081093.en
1 Inlet pipe
2 Outlet pipe
Caution! Press the Inch button only very briefly to avoid damaging the
equipment if the direction of movement is incorrect.
c) Switch on mains power and step up to Preheating I. Very briefly press
the Inch button and check the direction of movement of the final folder
conveyor or jaw system.
Invert two phases in the mains power connections if necessary.
d) Perform CIP. See the OM for further details.
e) Connect a cold water supply to the product inlet connection.
f) Prepare the machine for production. See the OM for further details.
g) Make sure that start-up from cold takes less than 45 minutes at an
ambient temperature of no less than 20°C (68°F).
h) Start up the package outfeed conveyor.
i) Step up the machine to Production.

8.3.2 Normal operating checks

No. Check Done
1 The packaging material and LS strip move freely through the
machine and are correctly aligned.
2 The package outfeed conveyor removes the packages correctly.
3 Finished packages are correct in terms of:
– size and shape
– longitudinal and transversal sealing
– date code printing
– filled package weight/volume
See the OM for further details.
If necessary, change the PLC parameters. See section 8.3.3
Changing PLC parameters.
If necessary, change the HI nozzle (filling machines with HI
only). See section 6.9.7 Aseptic product valve (APV) and
remaining large pipes; see also Selecting injection nozzle size
(filling machines with HI only) below.
4 Production capacity is as specified (count the packages
produced in six minutes and multiply by ten.
5 All pressures remain within tolerance. See the OM.
6 There are no fluid leaks.
7 There are no unusual noises which could indicate loose or
misaligned parts.
2.2TB081093.en
8 There are no unusual smells which could indicate internal leaks

or burning of electrical circuits.
(Cont'd)

(Cont'd)
Selecting injection nozzle size (filling machines with HI only)
Apply the following criteria when selecting a new injection nozzle size.
Larger nozzles:
• increase the volume of injected gas
• increase the effect of pressure changes
• produce a coarser foam (with larger, short life bubbles - useful for
products which foam easily)
Smaller nozzles:
• reduce the volume of injected gas
• reduce the effect of pressure changes
• produce a finer foam (with finer, long life bubbles - useful for products
which do not foam easily)
2.2TB081093.en

8.3.3 Changing PLC parameters

Caution! Do not change the PLC parameters unless absolutely necessary.
Make a copy of the existing parameters before modifying them. Also
keep a copy of the new parameters for future reference.
GE Fanuc PLC
If package filling is incorrect, the filling sector parameters in the GE Fanuc
PLC must be changed. To do so, proceed as follows.
a) Connect the GE Fanuc serial cable (TP No. 90031-300) between the
portable PC running GE Fanuc LM 90 software (V 6.01 or later) and the
15 pin connector on the PLC.
LH side
View with temperature
setting panel open
2.2TB081093.en
b) Run the LM 90 program and display the filling sector settings.

c) Increase the values to increase package volume.
Decrease the values to decrease the package volume.
See the EM for further details on the program listing.
(Cont'd)

(Cont'd)
TMCC PLC
Note! TMCC parameters cannot be modified individually. The entire program must
be downloaded. This is only done if major changes are required.
a) Connect the TMCC PLC serial cable between the portable PC and the
RS232 9-pin serial connector on the TMCC.
TMCC
RS 232
RH side
b) Run the program on the TMCC program and communications diskette to

download the parameters.
2.2TB081093.en

8.4 Health and safety checks

No. Check Done
1 The door microswitches activate an alarm and stop the
machine.
2 The manual strip splice button is disabled when the SA doors
with microswitches are opened.
3 All the Emergency stop buttons stop the machine immediately
and activate the alarm.
4 Filled packages and outlet water samples have the correct
hydrogen peroxide residue/content as measured using:
– Test kit 90298-31 for packages
– Test kit 90298-30 for outlet water
2.2TB081093.en

8.5 Documentation
Note! No claims will be accepted for machines in commercial production if the
Startup Machine Quality Report has not been returned to the
manufacturer.
a) Compile the Transport Damage Report (a section of the Startup
Machine Quality report).
If no damage has occurred during transport, state “NO TRANSPORT
DAMAGE”.
b) Compile the Feedback from MC form only in case of claims on the
equipment.
For further information about claims see the Claim and Complaint
Handling procedure, available from the local Service Organisation.
c) Compile the Start-up Machine Quality Report.
List all work, besides the installation work, performed to ensure correct
functioning.
The installation work covered by this manual is now complete.
2.2TB081093.en

2.2TB091093.en

Important!
Caution! If the equipment is going to stand or travel in freezing conditions, the
water circuits must be drained to avoid freezing damage.
The equipment can be moved for short distances without being drained or
disassembled, but only if no freezing conditions will be encountered. The
equipment must be drained before long distance moves or long term storage.
If draining is necessary, perform the draining procedure before disconnecting
the equipment from the mains power supply.
Only skilled or instructed installation technicians are allowed to disassemble
the equipment for moving to other installation positions.
2.2TB091093.en

9.1 Draining
9.1.1 Draining methods
To drain certain circuits, the solenoid valves controlling them must be
energised. This can be done in two ways:
• electronically (using a PC)
• by manually bridging terminals in the electrical cabinet
The following is needed for the electronic procedure:

• Portable PC running GE Fanuc LM90 software, V 6.0 or later
• GE Fanuc PLC serial cable, TP No. 90031-300
• EM
The following is needed for the manual bridging procedure:

• EM
• Piece of cable, approx. 2 metres in length
2.2TB091093.en

9.1.2 Preparations
a) Disconnect the rapid coupling to the pressure accumulator, located above
the separator.
b) Leave the compressed air supply to the machine connected, and connect
2.2TB091093.en
a second compressed air supply line to the cold water inlet.
Note! If the compressed air circuit is de-pressurised, it will not be possible to

perform the following procedure.
(Cont'd)

(Cont'd)
Caution! If it is not possible to adjust the supply pressure of the second air
supply, open all the valves listed below very slowly to avoid pressure
surges.
c) Adjust the compressed air supply pressure to approx. 4 bar.
d) Make sure that no Emergency stops are engaged, all doors with
microswitches are closed, and no error conditions are present. Turn on
the main power switch and step up to step Preheating I.
e) Either:
On a machine with standard cooling system make sure that all the
water valves A1 (1), A2 (2), A3 (3), and A4 (4) are open;
or:
On a machine with recirculated cooling water, make sure that water
valves A1 (1) and A3 (3) are open and water valves A2 (2) and A4 (4) are
closed.
1 4 3
2.2TB091093.en
1 Valve A1
2 Valve A2
3 Valve A3
4 Valve A4
(Cont'd)

(Cont'd)
Risk of injury and damage!

Make sure that water expelled under pressure cannot cause damage
or injury.
WARNING! f) Position a splash guard and warning notices in front of the connection
panel if possible.
9.1.3 Draining procedure

If a portable PC running GE Fanuc LM90 software V 6.0 or later is available,
connect it to the PLC using the GE Fanuc PLC serial cable, TP No. 90031-
300. See the EM for further details.
Caution! When bridging two terminals, connect the cable to the control terminal
first and then to the power terminal. Take care not to cause short
circuits.
If the solenoids have to be energised manually, connect the piece of cable to
the +24 VDC power terminal XL.11.30 for all the bridging operations. See
the EM for further details.
The force symbol on the operator panel lights when an output is forced on,
and goes out when the output is forced off again.
2.2TB091093.en
The following instructions list the PLC outputs. The control terminals for the
manual procedure are shown in brackets.
Water gun circuit
Operate the water gun until only dry air comes out.
(Cont'd)

(Cont'd)
Compressor circuit (solenoid valve Y32)
a) Open (switch off) contact breaker Q006 to prevent the compressor motor
starting up.
b) Force PLC output Q19 on from the PC. (Control terminal X1.414.)
c) Wait for 5 - 10 seconds and force the output off again.
2.2TB091093.en
Final folder sprinkler circuit (solenoid valve Y31)

a) Force PLC output Q72 on from the PC. (Control terminal X1.412.)
b) Wait for 5 - 10 seconds and force the output off again.
Tube flusher circuit (solenoid valve Y39)

(Cont'd)

(Cont'd)
Cooling water circuit (solenoid valve Y33) (standard cooling
system)
For machines with recirculated cooling water, see below. For machines
with standard cooling system, proceed as follows.
b) Wait until all the water from the cooling circuit drains to the cleaning
tray under the final folder.
c) Close valve A4.
2.2TB091093.en
d) Remove the recirculated cooling water outlet plug.
(Cont'd)

(Cont'd)
e) Open valve A4 again.
f) Wait until only dry air comes out of the recirculated cooling water outlet.
g) Close valve A4 again.
h) Fit the recirculated cooling water outlet plug.
i) Remove the recirculated cooling water inlet plug.
2.2TB091093.en
j) Open valve A4 again.

k) Wait until only dry air comes out of the recirculated cooling water inlet.
Force output Q73 off again.
l) Fit the recirculated cooling water inlet plug.
m) Remove the compressed air connection from the cold water inlet. Fit the
cold water inlet plug.
(Cont'd)

(Cont'd)
Cooling water circuit (solenoid valve Y33) (recirculated cooling
water)
For machines with standard cooling system, see above. For machines with
recirculated cooling water, proceed as follows.
a) Remove the recirculated cooling water inlet and outlet connections (1)
and (2).
b) Remove the compressed air supply line from the cold water inlet (3) and
connect it to the recirculated cooling water inlet (1).
c) Fit the cold water inlet plug (3).
2.2TB091093.en
1 Recirculated cooling water inlet
2 Recirculated cooling water outlet
3 Cold water inlet
d) Force PLC output Q73 on from the PC. (Control terminal X1.372.)
e) Wait until only dry air comes out of the recirculated cooling water outlet.
Force output Q73 off again.
f) Remove the compressed air connection from the recirculated cooling
water inlet.
Fit the recirculated cooling water inlet plug.
g) Fit the recirculated cooling water outlet plug.
(Cont'd)

(Cont'd)
Sterilisation bath
a) Open the valve (1) on the pressure accumulator.
b) Wait until the pressure on the gauge (2) drops to zero.
2 1
1 Valve
2 Gauge
2.2TB091093.en
c) Open the air bleeder valve at the top of the sterilisation bath.
(Cont'd)

(Cont'd)
d) Wait for all the water to drain from the sterilisation bath.
Note! This may take a significant length of time since the water drains only under
the effect of gravity.
e) Close the bleeder valve at the top of the sterilisation bath.
f) Connect the rapid coupling (3).
g) Close the valve (1) on the pressure accumulator.
2.2TB091093.en
1 Valve
3 Rapid coupling
(Cont'd)

(Cont'd)
Sterilisation bath water pump (M17)
a) Remove the flange from the pump and dry inside the pump.
b) Fit the flange.
2.2TB091093.en
Hot water circuit (solenoid valve Y29)

a) Close valve A2 (machines with standard cooling system only).
(Cont'd)

(Cont'd)
b) Connect the compressed air supply line to the hot water inlet.
c) Force PLC output Q71 on from the PC. (Control terminal X1.410.)
d) Wait for 5 - 10 seconds and force the output off again.
e) Remove the compressed air supply line from the hot water inlet.
Fit the hot water inlet plug.
2.2TB091093.en
Cleaning system water circulation pump (M4)
a) Force PLC output Q16 on from the PC. (Close contactor K008.)
(Cont'd)

(Cont'd)
Compressor (M7)
a) Remove the drain plug from the bottom of the compressor flange.
2.2TB091093.en
b) Wait for all the water to drain out and securely fit the plug.
(Cont'd)

(Cont'd)
Separator
a) Unscrew the float chamber at the bottom of the separator.
b) Drain off all the water and fit the float chamber.
2.2TB091093.en
Peroxide tank
Hydrogen peroxide!
Follow the Safety Precautions.
a) Disconnect and remove the hydrogen peroxide container.

WARNING!
(Cont'd)

(Cont'd)
b) Open the drain valve under the hydrogen peroxide tank and wait for all
the hydrogen peroxide to drain into the dilution tank (15 minutes).
c) Force PLC output Q110 on from the PC. (Control terminal X1.246.)
2.2TB091093.en
d) Wait for 5 - 10 seconds and force the output off again.

e) Close the valve under the hydrogen peroxide tank.
f) Place a suitable container under the dilution tank drain outlet (1), open
the drain valve (2) and drain the tank into the container for disposal in
compliance with local regulations.
1 2
1 Drain outlet
2 Drain valve
(Cont'd)

(Cont'd)
Final checks
a) Make sure that all the connections on the connections panel are plugged.
b) Make sure that all cables used for the draining procedure (electronic
procedure or bridge procedure) are disconnected.
c) Make sure that all the valves on the valve panel, dilution tank, water and
hydrogen peroxide circuits are set to the correct operating position.
d) Make sure that the drain plug on the compressor is tight.
e) Make sure that the separator float chamber is fitted and tight.
f) Make sure that the flange of the sterilisation bath water pump is tight.
2.2TB091093.en

9.2 Moving and transporting the

equipment
9.2.1 Short moves and short term storage
the operations in this section.
To disassemble parts, follow the assembly instructions in the reverse order.
Note! The fully assembled equipment can be moved either on the wheeled
transporter (TP No. 271635, available from the local Service Organisation)
or by fork lift. Overhead gantries and mobile cranes cannot be used.
a) Turn off and padlock the mains power switch.
Turn off the power switch upstream from the machine.
b) Shut off all the utility and product supplies upstream from the machine:
– electrical power
– cold water
– hot water
– recirculated cooling water in and out (machines with recirculated
cooling water only)
2.2TB091093.en
– compressed air
– steam
– product
c) Release pressure from the water and air circuits by operating the water
and air guns.
Close all the utility and drain valves on the machine:
– compressed air valve (A2, compressed air system)
– water valve (A1, water system)
– steam valve (at APV)
– dilution tank drain valve
(Cont'd)

(Cont'd)
d) Disconnect the power, utility, drain, and product lines:
– electrical power (disconnect at power terminals and remove cable
from electrical cabinet)
– cold water
– hot water
– recirculated cooling water in and out (machines with recirculated
cooling water only)
– compressed air
– steam
– product
– water overflow
– dilution tank drain
– external cleaning pump outlet
e) Plug or protect all open connections.
f) Disconnect the package outfeed conveyor and remove the eject bin.
g) Remove the ladder and ladder handrails.
h) Move the filling machine to the new position.
2.2TB091093.en
i) Level the machine approximately.
j) Cover the equipment with a suitable protective covering.
k) Make sure that the storage conditions comply with specifications.
See section 5.4 Moving and storing the crate.

9.2.2 Long moves and long term storage

the operations in this section.
a) Drain the equipment. See section 9.1 Draining.
b) Lubricate all sliding components (rods, cams, etc.).
c) Drain the hydraulic system and refill with a suitable flushing fluid. See
the MM for further details.
d) Perform the operations listed in section 9.2.1 Short moves and short term
storage as far as step f).
e) Remove the protective guards and packaging material covers.
f) Disconnect the electrical connections on the RH side of the drying
chamber.
g) Remove all small diameter pipes.
h) Remove the regulating valve and APV.
i) Remove the large diameter pipes.
j) Remove the hydrogen peroxide generator.
k) Remove the cable duct on the RH side of the drying chamber.
l) Disconnect the electrical connections on the LH side of the drying
chamber and remove the cable duct.
2.2TB091093.en
m) Disconnect and secure the sterilisation bath chains, remove the drip
plates, and remove the drying chamber.
n) Fit the transport plate across the top of the column and sterilisation bath.
o) Remove the SA.
p) Remove the electrical cabinet cooler.
q) Remove the warning beacon.
r) Remove the handrail.
(Cont'd)

(Cont'd)
s) Remove the platform panels and side frame.
t) Remove the ladder and ladder handrails.
u) Support the filling machine on wooden blocks. Remove the feet and legs.
v) Wrap small components in bubble wrapping to prevent damage.
w) Pack the equipment in suitable crates. Use the original crates and
transport frame if available. Make sure that all groups and components
are adequately protected. Fix any loose sub-crates or boxes to the floors
or walls of the crates to prevent them moving during transport.
2.2TB091093.en

9.3 Return to the manufacturer

a) Prepare the equipment for transport. See section 9.2 Moving and
transporting the equipment.
b) Contact the local Service Organisation for further instructions and to
arrange shipment.
2.2TB091093.en

9.4 Disposal
If the equipment is to be permanently disposed of, perform the following
operations.
a) Drain the equipment. See section 9.1 Draining.
b) Drain the hydraulic tank and dispose of the hydraulic fluid in compliance
with local regulations. See the MM for further details.
c) Remove the packaging material and LS strip, and dispose of these in
d) Disassemble the machine as far as possible and separate the following
materials:
– stainless steel (panels and doors)
– cast iron (frames)
– glass (windows, etc.)
– rubber (seals, O-rings, etc.)
– nylon and other plastics
– electrical cables
– hydraulic and pneumatic hoses
– electrical components.
e) Recycle or dispose of all materials, groups, and components in
2.2TB091093.en

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IM

Tetra Brik Aseptic Tetra Bri

Series No/ Machine No Sign.

Tetra Brik Aseptic

Headspace by gas Injection

Tetra Brik Packaging Systems

General safety precautions . . . . . . . . . . . . . . . . . . . . . 17

Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . 19

Equipment for lifting and moving loads . . . . . . . . . . . 25

Tetra Pak Doc. No. IM-82109-0103 i

3 Drawings and Technical Data

3.2 Basic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3 Mass (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.5 Emissions and thermal load . . . . . . . . . . . . . . . . . . . . 38

3.9 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10 Outfeed conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.2 Lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.3 Unloading the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.4 Moving and storing the crate . . . . . . . . . . . . . . . . . . . 55

ii Doc. No. IM-82109-0103 Tetra Pak

6 Positioning, assembly, and connections

6.2 Opening the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6.3 Unpacking the crate . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.5 Disposal/return of packing . . . . . . . . . . . . . . . . . . . . . 71

6.6 Fitting the transporter . . . . . . . . . . . . . . . . . . . . . . . . . 72

6.8 Approximate levelling. . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.10 Precision levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.11 Conveyor connections . . . . . . . . . . . . . . . . . . . . . . . . 128

6.12 Utility, product, and drain connections. . . . . . . . . . . 129

6.13 Other operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Tetra Pak Doc. No. IM-82109-0103 iii

7 Final installation checks

7.2 Lubricant level checks . . . . . . . . . . . . . . . . . . . . . . . . 139

7.3 Valve checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7.4 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

8 Preparation for commissioning

8.2 Product and utility value checks. . . . . . . . . . . . . . . . 147

8.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

8.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

9 Disassembly and removal

9.2 Moving and transporting the equipment . . . . . . . . . 173

9.3 Return to the manufacturer . . . . . . . . . . . . . . . . . . . . 177

9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

iv Doc. No. IM-82109-0103 Tetra Pak

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View of filling machine

• Machine Specification Document

Tetra Pak Doc. No. IM-82109-0103 9

Standard International System abbreviations are used for all measurement

10 Doc. No. IM-82109-0103 Tetra Pak