IM

Installation Manual
Tetra Pak A1
632051-0900
Tetra Pak A1 for TFA

WARNING
Read and follow all safety precaution instructions throughout this
manual and on safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.

Doc. No. IM-80429-0107

Copyright © 2010 Tetra Pak Group
All rights reserved. No part of this document may be reproduced or copied in any form or by any means
without written permission from Tetra Pak Packaging Solutions AB.

and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
The content of this manual is in accordance with the design and construction of the machine or
equipment at the time of publishing. Tetra Pak reserves the right to introduce design modifications
without prior notice.
The English language version of this document contains the original instructions. All other language
versions are translations of the original instructions.
This document was produced by:
Tetra Pak Packaging Solutions AB
Ruben Rausings gata
SE-221 86 Lund
Sweden
Additional copies can be ordered from Tetra Pak. When ordering additional copies, always provide the
document number.
Doc. No. IM-80429-0107
Issue 2010-12
This manual is valid for: i Introduction

Series No./ Machine No. Sign.

ii Safety Precautions

1 Technical Specification

IM
Installation Manual
2 Preparatory
Requirements

3 Mechanical Completion

Tetra Pak A1 4 Commissioning

632051-0900
5 Performance Validation

6 Disassembly and
Removal

Machine or equipment configurations that

this manual is valid for are described on
the next page.

Doc. No. IM-80429-0107

Issue 2010-12

Tetra Pak Packaging Solutions AB

Valid for:
Name Drawing Specification Additional Information
and Development Step
Tetra Pak A1 for TFA 632051-0900 Volume and Package Shape:
-100
- 200B
- 250B
- 500S

Optional Equipment:
- 90067-0021 Paper reel trolley
- 3112819-0100 Ink Jet Printer
- 2842878-0100 Filter
- 3015755-0100 Bobbin Normal Reel
 Update Log for Doc. No. IM-80429-0107
This table shows all changes made to this manual, including installed
rebuilding kits, added or removed pages. Page numbering on added pages
begins with UP.

Date Installed Kit Added Pages Removed Pages Signature

(Doc. No.)
Date Installed Kit Added Pages Removed Pages Signature
(Doc. No.)
 i Introduction

Doc. No. IM-80429-0107 i - 1 (20)

 i Introduction

About the Introduction Chapter

This chapter contains basic information about this manual and the related
Tetra Pak equipment.

i - 2 (20) Doc. No. IM-80429-0107

i Introduction Table of Contents

Abbreviations and Terminology . . . . . . . . . . . . . . i - 5

Manual Information . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Typographical Conventions . . . . . . . . . . . . . . . . . . i - 8
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8

Machine Introduction . . . . . . . . . . . . . . . . . . . . . . i - 9
Intended Use of the Equipment . . . . . . . . . . . . . . . i - 9
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Support and Feedback . . . . . . . . . . . . . . . . . . . . . . i - 9
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . i - 9

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 17
CE Classification . . . . . . . . . . . . . . . . . . . . . . . . . . i - 17
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 17

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 18
Hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 19
Packaging Material. . . . . . . . . . . . . . . . . . . . . . . . . i - 19
Steam Barrier in the Product Valve . . . . . . . . . . . i - 19

How to Use This IM . . . . . . . . . . . . . . . . . . . . . . . i - 20

Purpose of the IM . . . . . . . . . . . . . . . . . . . . . . . . . . i - 20
Installation Workflow . . . . . . . . . . . . . . . . . . . . . . . i - 20

Doc. No. IM-80429-0107 i - 3 (20)

 i Introduction

This page intentionally left blank

i - 4 (20) Doc. No. IM-80429-0107

i Introduction Abbreviations and Terminology

Abbreviations and Terminology

Abbreviation/ Meaning Translation
Terminology
approx. approximately
ASU Automatic Splicing Unit
APV Aseptic Product Valve
DE Distribution Equipment
CIP Cleaning In Place
EM Electrical Manual
HMI Human Machine
interface
IH Induction Heating
IM Installation Manual
LS Longitudinal Seal(ing)
min Minimum
max Maximum
MM Maintenance Manual
OM Operation Manual
PC Personal Computer
PE Polyethylene
PLC Programmable Logic
Controller
PLMS Packaging Line
Monitoring System
SPC Spare Parts Catalogue
TFA Tetra Fino Aseptic
TP Tetra Pak
TPIH Tetra Pak Induction
Heating
UP Update Pages

Doc. No. IM-80429-0107 i - 5 (20)

Manual Information i Introduction

Manual Information
Tetra Pak recommends reading all delivered manuals carefully. Make sure
that the delivered manuals are available to personnel who operate or
maintain the equipment.
It is important to keep this manual for the lifetime of the equipment and to
pass the manual on to any subsequent holder or user.
Tetra Pak will not be held responsible for any damage to the equipment
caused by not following the instructions given in this manual.

Delivered Manuals
Manuals delivered with this equipment:
• EM
The Electrical Manual provides technicians with information about the
equipment’s electrical system.
• IM
The Installation Manual provides technicians with information required
to safely install the equipment.
• MM
The Maintenance Manual provides technicians with information on
maintaining the equipment.
• OM
The Operation Manual manual provides the operator with information
on handling and operating the equipment before, during, and after
production.
• SPC
The Spare Parts Catalogue provides the information necessary to order
spare parts from Tetra Pak

i - 6 (20) Doc. No. IM-80429-0107

i Introduction Manual Information

Page Layout
Every main page in a manual contains a header and a footer. The page header
contains the chapter name (1) and the section name (2). The page footer
contains the page number (3), and the document number (4). See also the
Page Numbering section.

1 2

9 General 9.2 Technical Data

Doc. No. MM-2730517-0103 9 - 41 (60)

4 3
1 Chapter name
2 Section name
3 Page number
4 Document number

Doc. No. IM-80429-0107 i - 7 (20)

Manual Information i Introduction

Page Numbering
A page number has three parts:
• chapter number (1)
• consecutive page number (2) within the chapter
• total number of pages (3) in the chapter.

4 - 11 (18)
1 Chapter number
2 Consecutive page number
1 2 3 3 Total number of pages

Typographical Conventions
Controls on the operator panel, emergency stop devices, and program steps
are printed in CAPITAL LETTERS.
Menu names, button names and other text displayed in software are printed
in Courier.
Cross-references are underlined.

Symbols
Symbols used in illustrations.
A pointer arrow indicates the position of an object.

A zoom arrow indicates that an object view is

enlarged. The arrow points towards the enlarged view
of the object.

A rotation movement arrow indicates rotational

movement of an object. The arrow points in the
direction of rotation.

A straight movement arrow indicates movement of an

object.
The arrow points in the direction of movement.

i - 8 (20) Doc. No. IM-80429-0107

i Introduction Machine Introduction

Machine Introduction
Intended Use of the Equipment
The intended use of this Tetra Pak equipment is to pack liquid food products.
All other use is prohibited. Tetra Pak will not be held responsible for injury
or damage if the equipment is used for any other purpose.

Manufacturer
This Tetra Pak equipment has been manufactured by
Tetra Pak Packaging Solutions AB
Ruben Rausings gata
SE-221 86 Lund
Sweden

Support and Feedback

If you encounter problems when operating this equipment or have other
inquiries, comments, or suggestions for improvement, contact Tetra Pak.

Declaration of Conformity
A copy of the Declaration of Conformity can be found below. The signed
Declaration of Conformity is delivered separately with the equipment.

Doc. No. IM-80429-0107 i - 9 (20)

Machine Introduction i Introduction

Tetra Pak
Declaration of Conformity
Tetra Pak Packaging Solutions AB
Ruben Rausing Gata
SE-221 86 Lund
Sweden
declare that this machine:

Tetra Pak A1 (632051-0900)

15029/XXXX
is in conformity with the following harmonized standards:
EN 415-3:1999+A1:2009
EN 61000-6-2:2005
EN 61000-6-4:2007

and is in conformity with the provisions of the Directive(s) -

including amendments:

X 2006/42/EC Machinery
X 2004/108/EC Electromagnetic compatibility (EMC)
2006/95/EC Low Voltage

The following person is authorised to compile the technical file:

Göran Berggren
Tetra Pak Packaging Solutions AB
Ruben Rausing Gata
SE-221 86 Lund
Sweden

Modena 01/01/2010

Marcello Poli
Director, Supply Chain-Capital Equipment-Carton Value & Economy
English
FORM 5293 version 2010-01-14

i - 10 (20) Doc. No. IM-80429-0107

i Introduction Machine Introduction

Tetra Pak Tetra Pak

Konformitätserklärung Konformitetserklæring
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
erklärt hiermit, dass diese Maschine / Anlage / erklærer at dette maskineri/dette udstyr/
komplexe Einrichtung: kompleks installation:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
konform ist mit den folgenden harmonisierten Standards: holder følgende harmoniserede standarder:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

und übereinstimmt mit den Vorschriften der Richtlinien samt bestemmelserne iht. direktivet/direktiverne,
einschließlich deren Ergänzungen: inkl. ændringer:

X 2006/42/EC Maschine X 2006/42/EC Maskineri

X 2004/108/EC Elektromagnetische Verträglichkeit (EMV) X 2004/108/EC Elektromagnetisk kompatibilitet
2006/95/EC Niederspannung 2006/95/EC Lav spænding

Folgender Person ist es gestattet, die technischen Unterlagen

zusammenzustellen: Følgende person er authoriseret til at udarbejde den tekniske fil:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Deutsch/German Dansk/Danish
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Tetra Pak Tetra Pak

Declaración de Conformidad Yhdenmukaistusvakuutus
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
declaramos que esta máquina/equipo/instalación compleja: vakuuttaa, että allamainittu kone/koneen osa/laitteisto/kompleksi
asennus:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
es conforme a los siguientes estándares armonizados: vastaa seuraavia harmonisoituja standardeja:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

y cumple con lo que dicta(n) la(s) Directiva(s) - y sekä seuraavia direktiivejä ja niihin liittyviä muutoksia:
sucesivas modificaciones:

X 2006/42/EC máquinas X 2006/42/EY Kone

X 2004/108/EC compatibilidad electromagnética X 2004/108/EY Sähkömagneettinen yhteensopivuus
2006/95/EC equipo eléctrico diseñado para el uso dentro 2006/95/EY Pienjännite
de ciertos límites de voltaje

La persona indicada a continuación está autorizada para compilar el

archivo técnico: Seuraava henkilö on valtuutettu täyttämään teknisen tiedoston:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Español/Spanish Suomi/Finnish
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Doc. No. IM-80429-0107 i - 11 (20)

Machine Introduction i Introduction

Tetra Pak Tetra Pak

Déclaration de Conformité  

 
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
déclare que la présente machine / l'équipement / %   " /   / ;* :
l'installation complexe :

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
est conforme aux normes harmonisées suivantes :    #   *  !  :
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

et est conforme aux dispositions des directives suivantes     #    () $(%) -
(amendements compris) :     %:

X 2006/42/EC Machine X 2006/42/ '"

X 2004/108/EC Compatibilité électromagnétique (EMC) X 2004/108/E
   (EMC)
2006/95/EC Basse tension 2006/95/E  

     !    "

La personne suivante est autorisée à élaborer le dossier technique : #:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Français / French /Greek
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Tetra Pak Tetra Pak

Verklaring van Overeenstemming Erklæring om samsvar
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
verklaart dat deze machine/uitrusting/ erklærer at denne maskinen / dette utstyret / denne komplekse
complexe installatie: installasjonen:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
overeenstemt met de volgende geharmoniseerde normen: er i samsvar med følgende harmoniserte standarder:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

en overeenstemt met de bepalingen van de Richtlijn(en) - og er i samsvar med bestemmelsene i følgende direktiver
inclusief amendementen: med endringer:

X 2006/42/EG Machine(s) X 2006/42/EF Maskiner

X 2004/108/ EG Elektromagnetische compatibiliteit (EMC) X 2004/108/EF Elektromagnetisk kompatibilitet (EMC)
2006/95/EG Laagspanning 2006/95/EF Lavspenning

De volgende persoon heeft toestemming om het technische dossier

samen te stellen: Følgende person er autorisert til å kompilere den tekniske filen:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Nederlands/Dutch Norsk/Norwegian
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

i - 12 (20) Doc. No. IM-80429-0107

i Introduction Machine Introduction

Tetra Pak Tetra Pak

Declaração de Conformidade Samræmisyfirlýsing
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
declaramos que a máquina/ equipamento/ instalação complexa lýsa hér með yfir að viðkomandi vélbúnaður/búnaður/
uppsetning samstæðu:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
está em conformidade com as seguintes normas harmonizadas: er í samræmi við eftirfarandi samræmda staðla:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

e está em conformidade com as disposições da(s) Directiva(s) - og í samræmi við ákvæði þessara tilskipana -
inclusive as sucessivas modificações: að meðtöldum breytingum:

X 2006/42/CE Máquinas X 2006/42/EB Vélbúnaður

X 2004/108/CE Compatibilidade electromagnética (CEM) X 2004/108/EB Rafsegulsviðssamhæfi (EMC)
2006/95/CE Baixa Tensão 2006/95/EB Lágspenna

A pessoa abaixo está autorizada a compilar o ficheiro técnico: Eftirfarandi einstaklingur hefur heimild til að taka saman tækniskjalið:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Português/Portuguese Íslenska/Icelandic
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Tetra Pak Tetra Pak

Dichiarazione di Conformità Försäkran om överensstämmelse
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
dichiara che questa macchina/ apparecchiatura/ försäkrar att denna maskin/utrustning/komplexa anläggning
installazione complessa:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
è conforme alle seguenti norme armonizzate: är i överensstämmelse med följande harmoniserade standarder:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

ed in conformità con quanto disposto nelle Direttive - och överensstämmer med bestämmelserna i följande direktiv
e relativi emendamenti: inklusive tillhörande ändringar:

X 2006/42/EC Macchinari X 2006/42/EG, maskiner

X 2004/108/EC Compatibilità elettromagnetica (EMC) X 2004/108/EG, elektromagnetisk kompatibilitet (EMC)
2006/95/EC Bassa tensione 2006/95/EG, lågspänning

La seguente persona è autorizzata a redigere il file tecnico: Följande person är behörig att ställa samman den tekniska dokumentationen:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Italiano/Italian Svenska/Swedish
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Doc. No. IM-80429-0107 i - 13 (20)

Machine Introduction i Introduction

Tetra Pak Tetra Pak

Prohlášení o shod Vastavuse Deklaratsioon
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
prohlašuje, že tento stroj/vybavení/komplexní instalace: deklareerib, et käesolev masin/seade/komplekspaigaldis

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
je v souladu s následujícími slad>nými normami: vastab järgmistele harmoniseeritud standardite nõuetele:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

a je v souladu s ustanoveními následujících sm>rnic ja on vastavuses direktiivide sätetega

v^etn> jejich dodatk=: kaasa arvatud muudatused:

X 2006/42/EC Strojní za]ízení X 2006/42/EC Masinad

X 2004/108/EC Elektromagnetická kompatibilita X 2004/108/EC Elektromagnetiline ühilduvus
2006/95/EC Nízké nap>tí 2006/95/EC Madalpinge

Ke zpracování technických soubor= je oprávn>na následující osoba: Tehnilise faili koostamiseks on luba järgmisel isikul:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
?eština/Czech Eesti/Estonian
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Tetra Pak Tetra Pak

Megfelelségi Nyilatkozat Atbilstbas deklarcija
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
nyilatkozom, hogy ez a gép/berendezés/komplex összeszerelés deklarXjam to, ka šJ mašJna/iekHrta/sarež[Jta instalHcija:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
megfelel a következ\ harmonizált szabványoknak atbilst šHdiem harmonizXtajiem standartiem:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

és megfelel a következ\, módosításokat is magukban foglaló un ir saskaWH ar direktJvas(u) prasJbHm,

Direktíváknak: ieskaitot direktJvas(u) labojumus:

X 2006/42/EC Gépek X 2006/42/EK MašJnas

X 2004/108/EC Elektromágneses összeférhet\ség (EMC) X 2004/108/EK ElektromagnXtiskH savietojamJba
2006/95/EC Alacsony feszültségi direktíva 2006/95/EK Zemspriegums

A m@szaki dokumentum összeállítására jogosult személy: SastHdJt tehnisko lietu ir pilnvarota šHda persona:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Magyar/Hungarian Latviski/Latvian
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

i - 14 (20) Doc. No. IM-80429-0107

i Introduction Machine Introduction

Tetra Pak Tetra Pak

Deklaracja Zgodno$ci Atitikties deklaracija
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
deklaruje, {e niniejsza maszyna/wyposa{enie/ pareiškia, kad šis mechanizmas/|renginys/kompleksin¦ |ranga
instalacja kompleksowa:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
jest zgodna z nast_puj`cymi normami zharmonizowanymi atitinka šiuos darniuosius standartus:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

oraz jest zgodna z postanowieniami nast_puj`cych Dyrektyw taip pat atitinka ši} direktyv} nuostatas,
wraz ze zmianami: |skaitant j} pataisas:

X 2006/42/WE Maszyny X 2006/42/EB mašin} direktyva

X 2004/108/WE Kompatybilno¨© elektromagnetyczna X 2004/108/EB direktyva d¦l elektromagnetinio suderinamumo
2006/95/WE Niskonapi_ciowy sprz_t elektryczny 2006/95/EB žem}j} |tamp} direktyva

Nast_puj`ca osoba jest upowa{niona do opracowania pliku technicznego: Technin| fail` sudaryti |galiotas šis asmuo:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
Polski/Polish Lietuvi} k./Lithuanian
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Tetra Pak Tetra Pak

  !"#""# Declaraie de conformitate
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
€‰‡…‡‰, € „‰ˆ…  ‰œ…‚‰/ ƒ¥ƒ‡£™‰‚€/ Žƒ¢‚‰ …‚Ž„‰‰†… declar“ c“ aceast“ ma—in“/ echipament/ instala˜ie complex“:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
€ ™ Ž‹ƒ„™€„Ž„™…€ Ž‹Ž Ž€‚…„€ Œ‰‡ ƒ‚…ˆ‰†…ƒ‚‚… Ž„‰‚‰‡„…: este în conformitate cu urm“toarele standarde armonizate
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

… € ™ Ž‹ƒ„™€Ž„™…€ Ž ‰£ˆ…„€ ‚‰ ¤…‡€„…‡…™‰„‰(…„€): - —i este în conformitate cu prevederile Directivelor -

™š…„€‚ƒ ŠƒŠ‡‰™…„€: inclusiv cu amendamentele:

X 2006/42/EC ›‰œ…‚… X 2006/42/EC Utilaje

X 2004/108/EC Ÿ€„‡ƒ ‰•‚…„‚‰ Ž‹™ €Ž„… ƒŽ„ (EMC) X 2004/108/EC Compatibilitate electromagnetic“ (EMC)
2006/95/EC ¡…Ž‹ ™ƒ„‰¢ 2006/95/EC Joas“ tensiune

~€‚ƒ„ƒ …†€ € ƒ„ƒ‡…ˆ…‡‰‚ƒ ‰ ŠƒŠ‹‚… „€Œ‚…€Ž… ‘‰’: Urm“toarea persoan“ este autorizat“ s“ redacteze dosarul tehnic:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy
”‹•‰‡Ž…/ Bulgarian Român“/Romanian
FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

Doc. No. IM-80429-0107 i - 15 (20)

Machine Introduction i Introduction

Tetra Pak Tetra Pak

Vyhlásenie o zhode Deklaracija o Skladnosti
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden
vyhlasuje, že tento stroj/zariadenie/komplexná inštalácia: izjavljam, da je ta stroj/oprema/kompleksna namestitev:

Tetra Pak A1 (632051-0900) Tetra Pak A1 (632051-0900)

15029/XXXX 15029/XXXX
zodpovedá požiadavkám nasledujúcich harmonizovaných noriem: izdelan v skladu z naslednjimi standardi:
EN 415-3:1999+A1:2009 EN 415-3:1999+A1:2009
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007

a je v zhode s ustanoveniami Smernice (Smerníc) - in v skladu z direktivo (direktivami) - vklju^no z dopolnili

vrátane ich zmien a doplnkov:

X 2006/42/ES Strojárska X 2006/42/EC Varnost strojev

X 2004/108/ES Elektromagnetická kompatibilita (EMC) X 2004/108/EC Elektromagnetna združljivost (EMC)
2006/95/ES Nízkonapäªové zariadenia 2006/95/EC Elektri^na oprema, namenjena za uporabo
v dolo^enih napetostnih obmo^jih

Nasledujúca osoba je oprávnená zostavovaª súbor technickej dokumentácie: Oseba, ki je pooblaš^ena za sestavljanje tehni^ne datoteke:
Göran Berggren Göran Berggren
Tetra Pak Packaging Solutions AB Tetra Pak Packaging Solutions AB
Ruben Rausing Gata Ruben Rausing Gata
SE-221 86 Lund SE-221 86 Lund
Sweden Sweden

Modena 01/01/2010 Modena 01/01/2010

Marcello Poli Marcello Poli

Director, Supply Chain-Capital Equipment-Carton Value & Economy Director, Supply Chain-Capital Equipment-Carton Value & Economy

Slovensky/Slovak Slovenš^ina/Slovenian

FORM 5293 version 2010-01-14 FORM 5293 version 2010-01-14

i - 16 (20) Doc. No. IM-80429-0107

i Introduction Identification

Identification
CE Classification
This equipment complies with the basic health and safety regulations of
the European Economic Area (EEA).

Machine Plate
The illustration below shows an example of the machine plate and its
location on the equipment. The machine plate carries data needed when
contacting Tetra Pak concerning this specific equipment.
Make sure that the equipment data in the front pages of this manual
corresponds to the machine plate data and the machine specification.

1 2
3
4
5
6

8 7
1 Machine type
2 Volume
3 Drawing specifications
4 Machine serial number
5 Designed by
6 Manufacturer
7 CE mark
8 Year of manufacture

Doc. No. IM-80429-0107 i - 17 (20)

Orientation i Introduction

Orientation
The illustration below shows the orientation of the equipment. This
orientation information will be used throughout this manual. The arrows
indicate the flow of material.

B C

A Front
B Right-hand side
C Left-hand side
D Back

i - 18 (20) Doc. No. IM-80429-0107

i Introduction Hygiene

Hygiene
Packaging Material
Avoid microbiological contamination of the packaging material:
• Always protect your packaging material against contamination.
• Always keep the doors to the filling room (area) closed. To prevent
contamination via air streams, never open a window when the machine is
in production.
• Never clean the floors or the machine in the filling room (area) when the
machine is in production.
• Compressed air used for cleaning purposes is to be used only for
cleaning filters and should only be used outside of the filling room (area)
or in the final folder compartment of the filling machine.
• Prepare the splicing of the packaging material as late as possible.
• Disinfect your hands before touching anything that may come into
contact with the product. Use code H disinfectant. See the Technical
Data chapter of the Maintenance Manual.
• Keep your hands clean.
• Always wear some type of hair protection (cap or hairnet) and clean
clothes (preferably white).
• Do not wear a watch, ring, necklace, earrings, or any other exposed
jewellery.

Steam Barrier in the Product Valve

The filling machine’s product valve employs a steam barrier to separate the
product supply line from the filling machine. The steam barrier allows the
machine and the product supply line to be independently sterilised to
commercial sterility conditions.
• Never disengage the steam barrier, and never interrupt the steam supply
when the filling machine or the product supply line is being brought to
the pre-sterilization phase, or when the machine is already in the
production phase.
• If any maintenance activity requires disengagement of the steam barrier
or the interruption of the steam supply to the machine, make sure that the
product supply line is idle and empty of product.

Doc. No. IM-80429-0107 i - 19 (20)

How to Use This IM i Introduction

How to Use This IM

Purpose of the IM
The IM provides technical specifications and preparatory information
needed during the quotation of the equipment and during the entire
installation process. The IM describes the equipment requirements in the
packaging line. It also provides instructions on how to mechanically install,
commission, and validate the performance of the equipment, and how to
disassemble and remove the equipment.
The intended users of the IM are project leaders, installation planners,
installation technicians, and other technicians involved in the equipment
installation project.

Installation Workflow
An installation of any Tetra Pak equipment follows the Installation to
Performance process. The process consists of five main activities and the IM
is structured to support the process. See the illustration and the table below.

Preparation Mechanical Commissioning Performance Hand Over

Completion Validation

1 2 3 4 5
Pos. Process Activity End State Related IM Intended User
Chapters
1 Preparation Equipment at prepared site Chapter 1 and 2 Installation
planner/
Project leader
2 Mechanical Completion Equipment mechanically installed Chapter 3 Installation
technician
3 Commissioning Equipment commissioned and Chapter 4 Installation
functionally validated technician
4 Performance Validation Equipment performance validated Chapter 5 Project leader
5 Hand Over Contract fulfilled - -

i - 20 (20) Doc. No. IM-80429-0107

ii Safety Precautions

Doc. No. IM-80429-0107 ii - 1 (36)

 ii Safety Precautions

Description
Safety Precaution Instructions

WARNING
Read and understand this manual before using the machine.
Failure to follow safety precautions and instructions can result in death or
serious injury.
Definition of Lockout Procedure
A lockout procedure is a procedure to put each necessary energy isolating
device in its safe position to prevent the energisation of the equipment, such
as when a maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an
energy isolating device cannot be operated.
An energy isolating device is a mechanical device that physically prevents
transmission or release of energy, such as a power supply disconnector.

ii - 2 (36) Doc. No. IM-80429-0107

ii Safety Precautions Table of Contents

Safety Messages Description. . . . . . . . . . . . . . . ii - 5

Personnel Requirements . . . . . . . . . . . . . . . . . . ii - 6
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Instructed Person. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6

Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Locations of Safety Signs . . . . . . . . . . . . . . . . . . ii - 10

Protective Devices. . . . . . . . . . . . . . . . . . . . . . . ii - 13
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 13
Emergency Stop buttons . . . . . . . . . . . . . . . . . . . ii - 14
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 15
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 18
Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 18

Safe Manual Handling . . . . . . . . . . . . . . . . . . . . ii - 19

Personal Protection. . . . . . . . . . . . . . . . . . . . . . ii - 20
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 20
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . ii - 20

Hazardous Substances . . . . . . . . . . . . . . . . . . . ii - 21
Disposal of Chemical Substances . . . . . . . . . . . ii - 22
Hydrogen Peroxide (H2O2) . . . . . . . . . . . . . . . . . ii - 23
Emergency Procedures. . . . . . . . . . . . . . . . . . . . . ii - 23
Personal Protective Equipment . . . . . . . . . . . . . . ii - 24
Handling of Hydrogen Peroxide . . . . . . . . . . . . . . ii - 25
Storage of Hydrogen Peroxide . . . . . . . . . . . . . . . ii - 26
Disposal of Hydrogen Peroxide . . . . . . . . . . . . . . ii - 27
Manual Emptying of the Peroxide Bath . . . . . . . . ii - 28

Supply Systems. . . . . . . . . . . . . . . . . . . . . . . . . ii - 29
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 29

Doc. No. IM-80429-0107 ii - 3 (36)

Table of Contents ii Safety Precautions

Residual Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 30
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 30
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 31
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 32
Steam Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 33
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 35

ii - 4 (36) Doc. No. IM-80429-0107

ii Safety Precautions Safety Messages Description

Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.
The safety alert symbol is used to alert about potential personal injury
hazards. To avoid hazards, obey all safety messages that follow this symbol.
The following safety alert symbols and signal words are used in this manual
to inform the user of hazards.

Danger indicates an imminently hazardous situation

DANGER which, if not avoided, will result in death or serious
injury.

Warning indicates a potentially hazardous situation

which, if not avoided, could result in death or serious
WARNING
injury.

Caution indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate
CAUTION injury. It may also be used to alert against unsafe
practices.

CAUTION Caution without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided,
may result in property damage.

Doc. No. IM-80429-0107 ii - 5 (36)

Personnel Requirements ii Safety Precautions

Personnel Requirements
Note! Personnel includes all persons working on or near this equipment.
Only skilled or instructed persons are allowed to work with this equipment.

Skilled Person
A skilled person must have relevant education and experience to enable him
or her to identify hazards, analyse risks, and avoid hazards which electricity,
machinery, chemicals, other energies, and supply systems on this equipment
can create.
Skilled persons must meet local regulations, such as certifications and
qualifications for working with these energies and systems.

Instructed Person
An instructed person must be adequately advised or supervised by a skilled
person. The skilled person enables the instructed person to identify hazards,
analyse risks, and avoid hazards which electricity, machinery, chemicals,
other energies, and supply systems on this equipment can create.

ii - 6 (36) Doc. No. IM-80429-0107

ii Safety Precautions Safety Signs

Safety Signs
WARNING
Damaged or missing safety signs.
Safety signs are used to indicate safety hazards.
If the signs are missing or damaged, they can not fulfil this function. Replace
all missing or damaged safety signs immediately.
Safety signs are attached to the equipment. The table below lists all the signs
that are used, and illustrations show their locations on the equipment. The
position numbers refers to the safety signs in the table.
• Make sure that each safety sign is legible and in its correct position after
installation and maintenance.
• Replace all missing or damaged safety signs immediately.

Pos. ISO sign

1

Hazardous voltage.
Can shock, burn, or cause death.
Read Maintenance Manual (MM) before using this socket outlet.
2

Moving part can crush and cut.

Do not operate with guard removed.
Follow lockout procedure before maintenance.
3

Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure before maintenance.
4

Chemical burn hazard.

Wear personal protective equipment.

Doc. No. IM-80429-0107 ii - 7 (36)

Safety Signs ii Safety Precautions

Pos. ISO sign

5
Hydrogen Peroxide H2O2
35% w/w UN No.2014
OM

Chemical hazard.
Corrosive and oxidising chemical. Could cause death or serious injury. Read
Safety Precautions in Operation Manual (OM) before handling hydrogen
peroxide.
6

Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
7

Inhalation hazard from chemicals and fumes.

Can cause irritation to mucous membranes and the respiratory tract. Follow
instructions for safe work practices.
8

Do not reach in.

Moving parts may cause injury
Follow instructions for safe work practice.
9

Max load.

ii - 8 (36) Doc. No. IM-80429-0107

ii Safety Precautions Safety Signs

Pos. ISO sign

10

To prevent serious injury:

Do not operate this machine unless all doors are closed and guards are in
place and operating. Read manual before first operating machine. If manual
is missing, contact Tetra Pak.

Doc. No. IM-80429-0107 ii - 9 (36)

Safety Signs ii Safety Precautions

Locations of Safety Signs

3
3

3
2

3
3
6 6

10

3
4

3
(Cont'd)

ii - 10 (36) Doc. No. IM-80429-0107

ii Safety Precautions Safety Signs

(Cont'd)

3
3 4, 6, 7
1

4, 7

8 8
4

3 3
5
5
5

(Cont'd)

Doc. No. IM-80429-0107 ii - 11 (36)

Safety Signs ii Safety Precautions

(Cont'd)

4, 6, 7

4, 6, 7

2
Illustration shows the splicing table opened

ii - 12 (36) Doc. No. IM-80429-0107

ii Safety Precautions Protective Devices

Protective Devices
There are different kinds of protective device designed to ensure safe use of
the equipment. See the sections below.

WARNING
Hazardous zones.
Hazardous zones are safeguarded and provided with protective devices. Do
not inch or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.

DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Hazardous voltage remains ON after activating an EMERGENCY STOP.

Emergency Stop
CAUTION
The hydrogen peroxide bath is not automatically emptied if an
EMERGENCY STOP button is pressed.
This has to be done manually.
Emergency stop devices are used to stop this equipment immediately in an
hazardous situation. Learn the positions of all emergency stop devices and
how to use them.
Instructions for a normal production stop are included in the Stop chapter of
the Operation Manual.

Doc. No. IM-80429-0107 ii - 13 (36)

Protective Devices ii Safety Precautions

Emergency Stop buttons

Push one of the EMERGENCY STOP buttons to stop this equipment
immediately.
Empty the peroxide bath. See Manually Emptying the Peroxide Bath on page
ii-28.
The location of each EMERGENCY STOP button is shown by an arrow.

This emergency stop button is placed

close to the manual hand packing station
(optional equipment).

ii - 14 (36) Doc. No. IM-80429-0107

ii Safety Precautions Protective Devices

Safeguards
WARNING
Moving machinery.
Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones,
are fitted with interlocking devices where required. These devices are usually
electric safety switches that are parts of the safety system and must never be
defeated, bypassed, or otherwise made inoperative.

CAUTION
Corners and edges.
Close the doors, guards, or parts of the equipment unless they must be
open during work.

CAUTION
Burn hazard.
Parts of the equipment protected by guards may be hot after operation.
Allow components to cool down or use personal protective equipment.
After installation and maintenance, and before this equipment is inched or
run, check that all safeguards are in place and that they operate correctly.
(Cont'd)

Doc. No. IM-80429-0107 ii - 15 (36)

Protective Devices ii Safety Precautions

(Cont'd)

CAUTION
Equipment damage.
The equipment can be damaged if it is not stopped in the correct way. Never
stop this equipment by opening a movable guard, for example, a door or
cover, equipped with an interlocking device.
The location of each interlocking guard is shown by an arrow.

(Cont'd)

ii - 16 (36) Doc. No. IM-80429-0107

ii Safety Precautions Protective Devices

(Cont'd)

Doc. No. IM-80429-0107 ii - 17 (36)

Protective Devices ii Safety Precautions

Warning Lamp
A warning lamp is a column of warning lights:
• A red light (2) indicates a hazardous condition. This is a situation that
requires immediate action.
• A yellow light (3) indicates an abnormal or impending critical condition.
This is a condition calling for action by the operator.
• A blue light (4) indicates that operator action is required.
• A green light (5) indicates a normal condition.

Audible Alarm
The audible alarm (1) produces a warning signal every time this equipment is
about to start. The warning signal sounds for approximately seven seconds
prior to starting to alert personnel.

1
2
3
4
5

1 Audible alarm
2 Red light
3 Yellow light
4 Blue light
5 Green light

ii - 18 (36) Doc. No. IM-80429-0107

ii Safety Precautions Safe Manual Handling

Safe Manual Handling

Use mechanical lifting aids whenever possible. If mechanical lifting aids are
not available, do not attempt to lift loads over 23 kg without the assistance of
a colleague. Avoid lifting below knee height and above shoulder height. If it
is necessary to lift from the floor, follow the instructions below to reduce the
risk of back and disc injuries.
• Use safety shoes and be sure that the surface of the floor is not slippery.
• Get close to the load.
• Take a wide stance and find the best positions for your feet.
• Bend your hips and knees, and use your leg muscles.
• Keep the load close to your body.
• Do not twist your body while moving the load.
• Take small steps when turning.

In order to reduce the risk of injury to discs and back muscles, be careful to
not bend or twist your back when lifting. Keep the load close to your body to
reduce the strain on your back.
To reduce the ergonomic risks to each individual operator, job rotation is
recommended, so that recovery and variety are provided.

Doc. No. IM-80429-0107 ii - 19 (36)

Personal Protection ii Safety Precautions

Personal Protection
This section applies to all personnel at all times when this equipment is in
operation. For special personal protective equipment required when handling
hazardous substances, see the Hazardous Substances section.

Noise Hazard
CAUTION
Hazardous noise.
May cause impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.

Entanglement Hazard
WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this
equipment. Restrain long hair with, for example, clips or rubber bands.

ii - 20 (36) Doc. No. IM-80429-0107

ii Safety Precautions Hazardous Substances

Hazardous Substances
WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by
the manufacturer or local supplier, when handling chemicals.
Make sure that:
• the safety data sheet is available
• the showers work
• an eyewash device, movable or wall-mounted, is available and
operational
• additional washing facilities are nearby

Note! Learn the locations of all washing facilities in order to act immediately
in case of an accident.

Doc. No. IM-80429-0107 ii - 21 (36)

Hazardous Substances ii Safety Precautions

Disposal of Chemical Substances

Always read and follow the disposal instructions in the safety data sheet
supplied by the manufacturer or local supplier.
It is strongly recommended that used chemical containers are
• disposed of according to the instructions immediately after use
• not used as disposal containers for other chemicals in order to avoid
uncontrolled chemical reactions within the container

ii - 22 (36) Doc. No. IM-80429-0107

ii Safety Precautions Hazardous Substances

Hydrogen Peroxide (H2O2)

WARNING
Corrosive chemical.
Wear personal protective equipment.
In both liquid and gas states, hydrogen peroxide may cause irritation or
damage if it comes into contact with skin, mucous membranes, eyes, or
clothes. Call for medical attention immediately if there is an accident.
Liquid hydrogen peroxide in concentrations of less than 1% is generally
considered harmless to humans.
Consult the instructions on the label of the tank or container.
Emergency Procedures
If there is an accident involving hydrogen peroxide, rinse the affected area as
soon as possible with large amounts of water.
Eyes
If splashes or vapour from hydrogen peroxide come in contact with the eyes
• wash the eyes thoroughly with lukewarm water for 15 minutes (keep
eyelids wide apart)
• call for medical attention immediately

Skin
If hydrogen peroxide comes into contact with skin or clothes
• rinse immediately with plenty of water
• call for medical attention immediately if skin burns appear
• thoroughly wash the clothes before wearing them again

Inhalation
If irritation or pain is experienced due to having inhaled hydrogen peroxide
vapour
• leave the affected area and get some fresh air
• call for medical attention if the symptoms get worse

Ingestion
If hydrogen peroxide is swallowed
• do not attempt to cause vomiting
• drink large amounts of lukewarm water to dilute the peroxide
• call for medical attention immediately

Doc. No. IM-80429-0107 ii - 23 (36)

Hazardous Substances ii Safety Precautions

Personal Protective Equipment

The personal protective equipment for hydrogen peroxide is
• protective goggles (for instance, TP No. 90303-11), tight fitting
If there is a risk of splashes, a visor is a suitable complement
• protective gloves made of neoprene (for instance, TP No. 90303-12),
nitrile, or butyl rubber
• protective apron (for instance, TP No. 90303-13), or protective suit when
handling larger amounts
• protective shoes or boots made of PVC, PE plastic, or rubber
• proper respiratory equipment, if ventilation is insufficient

ii - 24 (36) Doc. No. IM-80429-0107

ii Safety Precautions Hazardous Substances

Handling of Hydrogen Peroxide

WARNING
Sudden and violent chemical reaction.
Avoid any contamination of hydrogen peroxide.
Hydrogen peroxide can react very suddenly and violently in combination
with many compounds, or if it is contaminated. Never pour surplus hydrogen
peroxide back into the original container. There is a risk of a violent
decomposition liberating oxygen and heat, with a big increase in volume due
to the oxygen generated by the peroxide decomposition. This will cause a
large overpressure if the contaminated hydrogen peroxide is in a closed
container. If the integrity of the container fails, this could result in a
dangerous hazard.
Ensure that equipment used for handling and diluting hydrogen peroxide is
clean before it comes in contact with hydrogen peroxide. Pumps or other
equipment used for handling hydrogen peroxide must be used for this
purpose only and must be manufactured from appropriate materials, such as
stainless steel 316 L, glass, polyethylene, or teflon. After use, make sure that
all peroxide residue is rinsed away.
If hydrogen peroxide is spilled, dilute it with large amounts of water. Dispose
of the diluted hydrogen peroxide according to local regulations.

WARNING
Self-ignition.
Never wipe up hydrogen peroxide with materials such as rags or paper as
these may self-ignite several hours after contact.
If there is a fire, spray with large quantities of water.

Doc. No. IM-80429-0107 ii - 25 (36)

Hazardous Substances ii Safety Precautions

Storage of Hydrogen Peroxide

WARNING
Containers may become overpressurised if they are not properly
ventilated. If the integrity of a container fails, this could result in a
dangerous hazard.
Keep the container upright and fitted with its proper ventilation cap. If there
is a fire, cool all containers by spraying them with large quantities of water.
Hydrogen peroxide decomposes much faster with increasing temperature.
There is a risk of a container becoming overpressurised at high temperatures,
since the ventilation cap cannot release the gases produced quickly enough.
If the integrity of the container fails, this could result in a dangerous hazard.
Hydrogen peroxide must be stored in the original container delivered by
the supplier. Keep the container upright and fitted with its proper ventilation
cap, which allows oxygen to escape. Otherwise there is a risk of
overpressurisation of the container due to violent decomposition of the
peroxide. If the integrity of the container fails, this could result in a
dangerous hazard.

Make sure that the container is always properly closed.

(Cont'd)

ii - 26 (36) Doc. No. IM-80429-0107

ii Safety Precautions Hazardous Substances

(Cont'd)
Commercial food-grade hydrogen peroxide has been stabilized to inhibit the
catalytic decomposition effects of metals and other impurities, but it can
decompose into oxygen and water if it is exposed to heat or contaminated.
Make sure that the area used for storage of hydrogen peroxide is
• cool, clean, and well ventilated
• shielded from direct sunlight
• kept free from combustible materials

Disposal of Hydrogen Peroxide

Always read and follow the disposal instructions in the safety data sheet
supplied by the manufacturer or local supplier.

Doc. No. IM-80429-0107 ii - 27 (36)

Hazardous Substances ii Safety Precautions

Manual Emptying of the Peroxide Bath

If this equipment is stopped by an emergency stop device or by power
failure, the peroxide bath (1) must be manually emptied.

CAUTION
Hydrogen Peroxide.
Follow the instructions for Emergency Procedures, Personal Protective
Equipment, Handling of Hydrogen Peroxide, Storage of Hydrogen Peroxide,
and Disposal of Hydrogen Peroxide in this Hydrogen Peroxide (H2O2)
section.
a) Make sure that the waste peroxide container (3) is empty before
emptying the peroxide bath (1).
b) Open the drainage valve (2) (illustrated as open) to empty the peroxide
bath.
c) Make sure that the peroxide bath is completely empty before closing the
drainage valve.

Note! If there is peroxide spillage in the peroxide cabinet it has to be diluted

with water to a concentration of less than 1% before it is drained. Fill water in
to the peroxide cabinet and then open the drainage valve (4).

2 1 Peroxide bath
3 2 Drainage valve
3 Waste peroxide container
4 4 Drainage valve

ii - 28 (36) Doc. No. IM-80429-0107

ii Safety Precautions Supply Systems

Supply Systems
Power Supply
DANGER
Hazardous voltage and moving machinery.
The power supply disconnector must be turned off and secured with a lock
before any maintenance.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require power supply systems to be on.
These exceptions are clearly stated in the Maintenance Manual.
The illustrations show the power supply disconnector and its location.

Doc. No. IM-80429-0107 ii - 29 (36)

Supply Systems ii Safety Precautions

Residual Voltage

DANGER
Hazardous voltage.
Will shock, burn, or cause death.
After the power supply disconnector is turned off, residual voltage remains in
the capacitor circuits.
Wait five minutes before opening the enclosure containing these circuits.
Ensure that no residual voltage remains on the capacitors before touching
them.

Electrical Cabinet

DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Parts behind doors to electrical enclosures may be live. The power supply
disconnector must be turned off and secured with a lock before performing
maintenance inside the electrical cabinet.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
The use of a key or a tool is necessary to access to the electrical cabinet.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with locks must be locked.
The location of each electrical cabinet is shown by an arrow.

ii - 30 (36) Doc. No. IM-80429-0107

ii Safety Precautions Supply Systems

Socket Outlet

WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read the Maintenance Manual before using this socket outlet.
The socket outlet (1) is connected to a residual current device (2) to protect
users against electrical shock if there is an earth fault in the connected
equipment. The residual current device shall be tested each time before the
socket outlet is being used. See the MM for test procedure.
The illustrations show the socket outlet, the residual current device, and their
location.

1 Socket outlet
2 Residual current device 01F031

Doc. No. IM-80429-0107 ii - 31 (36)

Supply Systems ii Safety Precautions

Air Supply
WARNING
Compressed air and moving machinery.
Close the main air valve and lock it before any maintenance.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require air supply systems to be on.
These exceptions are clearly stated in the Maintenance Manual.
The illustrations show the shut off valve (1), the lock (2), and their location.

1 Shut off valve

2 Lock

ii - 32 (36) Doc. No. IM-80429-0107

ii Safety Precautions Supply Systems

Steam Supply
WARNING
Hot steam can cause scalds.
Pressurised steam can be discharged unexpectedly.
Close the steam supply valve and lock it, and safely vent all steam pressure
from the steam system before any maintenance on parts with steam, such
as pipes and valves.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require steam supply systems to be on.
These exceptions are clearly stated in the Maintenance Manual.
The illustrations show the steam supply valve (1), the lock (2) and their
locations.

1 Steam supply valve

2 Lock

(Cont'd)

Doc. No. IM-80429-0107 ii - 33 (36)

Supply Systems ii Safety Precautions

(Cont'd)

WARNING
Hot parts can cause severe burns.
Pipes, valves, and other parts containing steam can be extremely hot.
Do not touch hot parts.
The illustration shows hot parts of this equipment.

In this area all parts can be hot during

production and CIP.

ii - 34 (36) Doc. No. IM-80429-0107

ii Safety Precautions Supply Systems

Water Supply
CAUTION
Water under pressure.
Close the water supply valves before any maintenance.
Certain maintenance procedures may require water supply systems to be on.
These exceptions are clearly stated in the Maintenance Manual.
The illustrations show the water supply valve (1), and its location.

1 Water supply valve

Doc. No. IM-80429-0107 ii - 35 (36)

Supply Systems ii Safety Precautions

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ii - 36 (36) Doc. No. IM-80429-0107

1 Technical Specification

Doc. No. IM-80429-0107 1 - 1 (40)

 1 Technical Specification

Description
This chapter includes essential reference data and drawings used prior to and
during the equipment installation. Values are in millimetres unless otherwise
stated. All dimensions must be respected.

1 - 2 (40) Doc. No. IM-80429-0107

1 Technical Specification Table of Contents

1.1 Installation Drawings. . . . . . . . . . . . . . . . . . . . . . 1 - 7

1.1.1 Left Hand View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1.1.2 Front View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
1.1.3 Multi Installation (Optional) . . . . . . . . . . . . . . . . . . 1 - 9
1.1.4 Bottom View - Machine Feet Position . . . . . . . . 1 - 10
1.1.5 Module Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
1.1.5.1 Automatic Splicing Unit . . . . . . . . . . . . . . . . . . . . 1 - 11
1.1.5.2 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
1.1.5.3 Main Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
1.1.5.4 Electrical Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
1.1.6 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13

1.2 Equipment Specification. . . . . . . . . . . . . . . . . . 1 - 16

1.2.1 Mass (Weight). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
1.2.2 Static Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17

1.3 Lifting and Transportation Data . . . . . . . . . . . . 1 - 18

1.3.1 Crate and Equipment . . . . . . . . . . . . . . . . . . . . . . 1 - 18
1.3.1.1 Crate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
1.3.1.2 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
1.3.2 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . 1 - 19
1.3.2.1 Types of Lifting Equipment. . . . . . . . . . . . . . . . . . 1 - 19
1.3.2.2 Equipment Specifications . . . . . . . . . . . . . . . . . . . 1 - 20
1.3.2.3 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . 1 - 21
1.3.3 Space Requirements . . . . . . . . . . . . . . . . . . . . . . 1 - 22

1.4 Utility Connection Data . . . . . . . . . . . . . . . . . . . 1 - 23

1.4.1 Electrical Power Specifications . . . . . . . . . . . . . 1 - 23
1.4.1.1 Electrical Power Consumption. . . . . . . . . . . . . . . 1 - 23
1.4.2 Compressed Air Specifications . . . . . . . . . . . . . 1 - 24
1.4.2.1 Compressed Air Consumption - High Speed . . . 1 - 24
1.4.2.1 Compressed Air Consumption - Low Speed. . . . 1 - 24

Doc. No. IM-80429-0107 1 - 3 (40)

Table of Contents 1 Technical Specification

1.4.3 Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 25
1.4.4 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 25
1.4.5 Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
1.4.6 Wetting Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 27
1.4.7 Conveyor Speed . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 27
1.4.8 Cleaning in Place (CIP) . . . . . . . . . . . . . . . . . . . . 1 - 28
1.4.8.1 Recommended Cleaning Cycle. . . . . . . . . . . . . . . 1 - 28
1.4.9 Central Lubrication . . . . . . . . . . . . . . . . . . . . . . . 1 - 29

1.5 Product and Product Connection Data . . . . . . 1 - 30

1.6 Hygiene Function Connection Data . . . . . . . . . 1 - 31

1.7 Mechanical Line Integration and Connection . 1 - 32

1.7.1 Downstream Connection . . . . . . . . . . . . . . . . . . 1 - 32
1.7.1.1 Short Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 32
1.7.1.2 Hand Packing Line . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33

1.8 Communication . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 34

1.9 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 35

1.10 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 36

1.11 Site Environment Specification . . . . . . . . . . . . 1 - 37

1.11.1 Ambient Temperature . . . . . . . . . . . . . . . . . . . . . 1 - 37
1.11.2 Aseptic Packaging . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
1.11.2.1 Introduction of Aseptic Packaging . . . . . . . . . . . . 1 - 37
1.11.2.2 Aseptic Installation Policy. . . . . . . . . . . . . . . . . . . 1 - 37
1.11.2.3 Infection Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
1.11.2.4 Packaging Room Overpressure . . . . . . . . . . . . . . 1 - 38

1.12 Material Specification . . . . . . . . . . . . . . . . . . . . 1 - 39

1.12.1 Storing the Packaging Material . . . . . . . . . . . . . 1 - 39
1.12.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39
1.12.1.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39

1 - 4 (40) Doc. No. IM-80429-0107

1 Technical Specification Table of Contents

1.12.1.3 Storage of Material . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39

1.12.1.4 Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
1.12.1.5 Storage Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
1.12.1.6 Storage Conditions in Prior to Packing. . . . . . . . 1 - 40
1.12.1.7 Handling of Packaging Material . . . . . . . . . . . . . . 1 - 40
1.12.1.8 Storage of Jet Printer Ink (Optional Equipment) 1 - 40

Doc. No. IM-80429-0107 1 - 5 (40)

 1 Technical Specification

This page intentionally left blank

1 - 6 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.1 Installation Drawings

1.1 Installation Drawings

The following drawings provide the dimensions of the machine and the
dimensions for access around the machine. These dimensions must be
respected. All dimensions are in millimetres unless otherwise stated.

1.1.1 Left Hand View

7355**
4645

581
206

838
0

582*

0
2150**** 3658 800***
2897***
* Top surface conveyor, variation in height (± 15), due to adjustable legs on
the machine.
** Between walls
*** Minimum distance to wall
**** Tolerance ±100

Doc. No. IM-80429-0107 1 - 7 (40)

1.1 Installation Drawings 1 Technical Specification

1.1.2 Front View

4408**

1500*
1470*** 50***

6215*
4715*
1749

580

1139
0

* Variation in height (± 15), due to adjustable legs on the machine.

** Between walls
*** Minimum distance to wall

1 - 8 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.1 Installation Drawings

1.1.3 Multi Installation (Optional)

50* 5766 +25

0 1470*

7286**

*Minimum distance to walls.

** Between walls

Doc. No. IM-80429-0107 1 - 9 (40)

1.1 Installation Drawings 1 Technical Specification

1.1.4 Bottom View - Machine Feet Position

1690

1080
1103
1110
925
790
370
235

431
50
49
0
R1026
1051

0
50

321
R1026
R1026
1111

1946
R509
R766
R766 2793

3206

4568

* ASU door 1216* 1217*

** Main body door
1631** 1632**

1 - 10 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.1 Installation Drawings

1.1.5 Module Drawings

1.1.5.1 Automatic Splicing Unit

2200
901 1650
1.1.5.2 Superstructure

1366
1532
2410

2364

1407

Doc. No. IM-80429-0107 1 - 11 (40)

1.1 Installation Drawings 1 Technical Specification

1.1.5.3 Main Body

2047 2870
2386

1.1.5.4 Electrical Cabinet

650 1550
1975

1 - 12 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.1 Installation Drawings

1.1.6 Connections
The following table and drawings provide the dimensions and positions of
the connections to the machine.

Position Connection
1 CIP connection inlet 1 ½ ”
2 CIP connection outlet 1 ½ ”
3 Steam connection 12 mm
4 Product connection inlet 2 ”
5 Product connection outlet 2 ”
6 Air connection 20 mm
7 Water inlet 12 mm
8 Electrical connection M 50

(Cont'd)

Doc. No. IM-80429-0107 1 - 13 (40)

1.1 Installation Drawings 1 Technical Specification

(Cont'd)

2 5
3
8

4165* 4
7
1 3829*
3613*
3415*
3160*

2597*

0
103
178

162
303
24

57
133
0

*Variation in height (± 15), due to adjustable legs on the machine.

(Cont'd)

1 - 14 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.1 Installation Drawings

(Cont'd)

2969

298
172
189

20
63
0
8
4,5
3

6,7

Doc. No. IM-80429-0107 1 - 15 (40)

1.2 Equipment Specification 1 Technical Specification

1.2 Equipment Specification

1.2.1 Mass (Weight)
Equipment Mass (approx.) Notes
Tetra Pak A1 complete machine 4120 kg

Machine parts
Main body with platform 1730 kg
Superstructure 790 kg
Electrical cabinet 600 kg
Automatic splicing unit 780 kg
Pallets with plates 110 kg
Stairs, 2 legs, Domino 100 kg

1 - 16 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.2 Equipment Specification

1.2.2 Static Load

When installed and correctly levelled, the machine legs on the filling
machine have the following static load:

10
1
9

8 2

1 Leg 1
7 3 2 Leg 2
3 Leg 3
4 Leg 4
6
5 Leg 5
4
6 Leg 6
7 Leg 7
8 Leg 8
5 9 Leg 9
10 Leg 10

Leg Static Load on leg (kg) Notes

1 73-734 The total load of legs 1,2, 9 and 10 will never exceed
2 534-1595 2130 kg.
3 100
4 434
5 293
6 546
7 110
8 212
9 0-862
10 0-862

Doc. No. IM-80429-0107 1 - 17 (40)

1.3 Lifting and Transportation Data 1 Technical Specification

1.3 Lifting and Transportation Data

1.3.1 Crate and Equipment
The filling machine is delivered in two crates.
1.3.1.1 Crate Data
Machine type Gross Net Length Width Height
weight weight mm mm mm
kg (lbs) kg (lbs)
Tetra Pak A1 2950 2350 3600 2390 2520
Crate 1
Tetra Pak A1 3600 2900 4100 2300 2520
Crate 2

Note! Crate weight can increase significantly if the crate becomes wet.

Tetra Pak

1 - 18 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.3 Lifting and Transportation Data

1.3.1.2 Contents
Machine Type Contents
Tetra Pak A1 Machine
Crate 1 Electrical cabinet
Hand rail
Machine documents (box)
Declaration of conformity
Printer Domino
Regular accessories
TPIH
Platform
Plywood box (details)
Support leg (long)

Machine Type Contents

Tetra Pak A1 Superstructure
Crate 2 Packaging material reel
Lifting equipment
Trolley
Ladder
Automatic splicing unit
Decoration list
Cover

1.3.2 Auxiliary Equipment

1.3.2.1 Types of Lifting Equipment
The following types of equipment can be used to lift and move the crate:
• overhead gantry
• mobile crane
• fork-lift truck

Doc. No. IM-80429-0107 1 - 19 (40)

1.3 Lifting and Transportation Data 1 Technical Specification

1.3.2.2 Equipment Specifications

Make sure that the lifting equipment complies with the specifications given
in the following table.

Equipment or Tackle Lifting Capacity kg Notes

(lbs)
Overhead gantry 5 000 (11 100) 7 000 kg (15 500 lbs) required
if gantry does not have gradual
acceleration deceleration
ramps.
Mobile crane 5 000 (11 100) 7 000 kg (15 500 lbs) required
if crane does not have gradual
acceleration deceleration
ramps.
Fork-lift truck 6 000 (13 200) Higher capacity allows for
reach to centre of gravity of
1 000 - 1 500 mm (3’3” to
4’10”)
Lifting forks 6 000 (13 200) Min.length:
-2 000 mm (6’6”)
Recommended setting width:
-2 000 mm (6’6”)
Lifting chains, cables, ropes, tackle or hoist 5 000 (11 100)
slings

1 - 20 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.3 Lifting and Transportation Data

1.3.2.3 Auxiliary Equipment

Tools and auxiliary equipments are needed to unpack the crates. The
equipment used for lifting and moving the crate can also be used for
unpacking the crate.
Also use appropriate hand tools to open the crate, such as crow bar, hammer,
and socket wrench.

Figure Equipment Minimum Capacity Static test Dynamic Quantity

(Kg) coefficient test
coefficient
1 Fork-lift truck (crate lift) 6 000 - - 1
1 Fork-lift truck (superstructure, 3 000 - - 1
main body and automatic
splicing unit lift)
2 Pallet truck 2 000 -§ - 1
3 Elongated forks fitted to fork-lift 6 000 - - 1 set
truck
4 Lifting straps 5 000 - - 2
5 Lifting tool See machine sign 1.5 1.1 1 set
TP no: 2925908
6 Lifting arm See machine sign 1.5 1.1 1 set
TP no: 2925910
7 Lifting devices - - 2
Machine sign

1 2 3 5

6 7
4

8
9
10
11 12

8 Maximum work load

9 Material No.
10 Manufacture
11 Year of manufacturing
12 CE mark

Doc. No. IM-80429-0107 1 - 21 (40)

1.3 Lifting and Transportation Data 1 Technical Specification

1.3.3 Space Requirements

For information about recommended clearance around the assembled
equipment, see Section 1.1 Installation Drawings.
For information about the unpacking area, see Section 3.1.6 Unpacking the
Crate.

1 - 22 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.4 Utility Connection Data

1.4 Utility Connection Data

1.4.1 Electrical Power Specifications
Characteristic Value Notes
Supply voltage to machine 400/230 VAC, Other voltages available to
3 phase +N +earth order with transformer

Max voltage fluctuation ±10%

Frequency 50/60 ± 2% To be specified on order
Recommended main fuse 63 A Value for optimum
selectivity at 400/230 VAC

Control circuits voltage 24 VDC

1.4.1.1 Electrical Power Consumption

Consumption during: Value Notes
Preheating 1 9.3 kW
Tube sealing 19.9 kW
Preheating 2 7.9 kW
Spraying 6.2 kW
Drying 8.8 kW
Production 11.4 kW

Doc. No. IM-80429-0107 1 - 23 (40)

1.4 Utility Connection Data 1 Technical Specification

1.4.2 Compressed Air Specifications

Characteristic Value Notes
Supply Pressure 630 - 1000 kPa
(6.3 - 10 bar)
Max particle size 20 µm
Max particle content 25 mg/m³
Dew point 2 °C
(35.6 °F)
Oil content 0.01 mg/m³

1.4.2.1 Compressed Air Consumption - High Speed

Note! Commercial capacity; 500S 9800 p/h, 250B 12200 p/h,
200B 14000 p/h, 100 15000 p/h

Characteristic Value (Nl/min) Notes

Consumption approx. 975 (34.4 N cu ft/min)

1.4.2.1 Compressed Air Consumption - Low Speed

Note! Commercial Capacity; 500S 7300 p/h,
250B 9200 p/h, 200B 10500 p/h, 100 11300 p/h

Characteristic Value (Nl/min) Notes

Consumption approx. 870 (30.7 N cu ft/min)

1 - 24 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.4 Utility Connection Data

1.4.3 Water
Characteristic Value Notes
Water quality Council directive See M1282.812
98/83/EC The directive defines drinking
water quality.

Supply pressure 300 - 450 kPa

(3 - 4.5 bar)
Max inlet temperature +20 °C
pH 5-8
Consumption 0.3 l/min Cooling and tube flushing

1.4.4 Steam
Characteristic Value Notes
Water quality Council directive See M1282.812
98/83/EC
Min supply pressure 170 kPa
(1.7 bar)
Max supply pressure 270 kPa
(2.7 bar)
Max pressure fluctuation ± 30 kPa
(± 0.3 bar)
Manometer setting 170 kPa 130 ºC (Overpressure)
(1.7 bar)
Manometer setting 50 kPa 110 ºC (Overpressure)
(0.5 bar)
Steam temperature, Preheating 1 130 °C Measured after APV
Steam temperature, Tube sealing 130 °C Measured after APV
Steam temperature, Preheating 2 130 °C Measured after APV
Steam temperature, Spraying 130 °C Measured after APV
Steam temperature, Drying start 130 °C Measured after APV
Steam temperature, Drying finished 110 °C Measured after APV
Steam temperature, Production 110 °C Measured after APV
Consumption Ca 2.4 kg/h
(Ca 5.3 lbs/h)

Doc. No. IM-80429-0107 1 - 25 (40)

1.4 Utility Connection Data 1 Technical Specification

1.4.5 Hydrogen Peroxide

Characteristic Value Notes
Supply requirements According to TP standard M 1282.805,
M 1278.310

Characteristic Volume Speed kg/h 35% Notes

H2O2 consumption 500S Low 1.0 7300 p/h
High 1.3 9800 p/h
250B Low 0.9 9200 p/h
High 1.1 12200 p/h
200B Low 0.9 10500 p/h
High 1.1 14000 p/h
100 Low 0.6 11300 p/h
High 0.9 15000 p/h

1 - 26 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.4 Utility Connection Data

1.4.6 Wetting Agent

Characteristic Value Notes
Quality PSM, TP No. 90349-003
Concentration 0.3% This concentration is mixed by
the operator. See also OM-
80428-XXXX.

1.4.7 Conveyor Speed

The filling machine is prepared to be connected to conveyor UC 24.
The filling machine has a built in frequency converter controlling the outfeed
conveyor motor.
For conveyor parts order: Recommended outfeed conveyor motor is a fixed
speed 42 m/min version within the UC 24 Conveyor system.

Characteristic Volume Speed m/min

Filling Machine to Hand Packing All volumes All speeds 45 - 53
Filling Machine to Cardboard Packer

Doc. No. IM-80429-0107 1 - 27 (40)

1.4 Utility Connection Data 1 Technical Specification

1.4.8 Cleaning in Place (CIP)

Note! Soft start equipment is suggested

Characteristic Value Notes

Min. inlet pressure 160 kPa
(1.6 bar)
Max. inlet pressure 350 kPa
(3.5 bar)
Min. flow 8 m³/h

1.4.8.1 Recommended Cleaning Cycle

The following table reports the sequence of operations Tetra Pak
recommends for the cleaning in place. The values in the table are only valid
under special conditions. The cleaning cycle must be adjusted and verified
for each individual installation.

Step Phase Chemical Conc. Temperature1 Time2

1 Pre-rinse, cold, no re circulation Water Ambient 60 sec max
2 Pre-rinse, warm Water 60 ºC 10 min
WEEKLY CARE

3 Alkali Cleaning NaOH 1.5% 80 ºC 12 min

DAILY CARE

43 Rinse, cold, no re circulation Water Ambient 30 sec max

5 Rinse, cold, no re circulation Water Ambient 30 sec max
6 Rinse, cold, re circulation Water Ambient 1 min

7 Acid Cleaning HNO3 1% 60 ºC 10 min

8-103 As 4-6

(1) Measured on the return pipe

(2) Start counting time from when specified concentrations, temperatures and flows are achieved.
(3) Steps 6 and 10 may be repeated for up to 4 times, until the rinsing water has the same electrical
conductivity as the supply water

1 - 28 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.4 Utility Connection Data

1.4.9 Central Lubrication

Characteristic Value Notes
Supply requirements According to TP
standard K3446.10
Consumption (normal) 0.013 dl/h Low speed
0.017 dl/h High speed
Consumption (after cleaning) 0.026 dl/h

Doc. No. IM-80429-0107 1 - 29 (40)

1.5 Product and Product Connection
Data 1 Technical Specification

1.5 Product and Product Connection Data

Characteristic Value Notes
Supply pressure 50 - 250 kPa Range from minimum
(0.5 - 2.5 bar) permitted to maximum
permitted supply
pressure
Max pressure fluctuation 50 kPa Pressure may fluctuate by
(0.5 bar) max. 50 kPa within the range
50 - 250 kPa but never lower
than 50 kPa or higher than
250kPa
Product temperature 10 - 40 °C Varies from inlet temperature
(50 - 104 °F) by
1 - 2 °C
(2 - 4 °F)
Hard particles Absent Product must leave no hard
residue on a 600 µm mesh
Citrus fibres Absent Measured as fibre residue on a
600 µm mesh
pH 2.5 - 8

1 - 30 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.6 Hygiene Function Connection Data

1.6 Hygiene Function Connection Data

For information about Site Environment Specification, see Section 1.11 Site
Environment Specification.

Doc. No. IM-80429-0107 1 - 31 (40)

1.7 Mechanical Line Integration and
Connection 1 Technical Specification

1.7 Mechanical Line Integration and

Connection
1.7.1 Downstream Connection
Note! The layouts are only examples. Other setups may occur. It is required
to use line communications between the machines.
1.7.1.1 Short Interface

1 2 3 4 5 6 4

B C

Conveyor Length (m)

1 Filling machine
A 1 to 10 2 Conveyor powered by filling machine
B 1 to 10 3 Reject unit
C 1 to 10 4 Conveyor powered by distribution equipment 1
5 Package distance control unit, PDCU
6 Distribution equipment 1

(Cont'd)

1 - 32 (40) Doc. No. IM-80429-0107

 1.7 Mechanical Line Integration and
1 Technical Specification Connection

(Cont'd)
1.7.1.2 Hand Packing Line

1 2 3 4 5

Conveyor Length (m) 1 Filling machine

A 1 to 10 2 Conveyor powered by filling machine
3 Last point DE photocell
4 EMERGENCY STOP and STOP button (Optional
equipment)
5 External packaging solution

Doc. No. IM-80429-0107 1 - 33 (40)

1.8 Communication 1 Technical Specification

1.8 Communication
See Section 3.3.1 Signal Exchange for more information.

1 - 34 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.9 Noise

1.9 Noise
CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.
The following tables give the noise level measurements for Tetra Pak A1 for
TFA filling machine under the following conditions:
• machine on a concrete floor supported by standard feet
• production under normal operating conditions

Values declared in accordance with ISO 4871

Symbol Definition Declared Notes
value
LWA Measured A-weighted sound 89.5 dB(A) Values determined using the
power level basic standard ISO 3744
KWA Uncertainty factor 2.5 dB(A) (Engineering method)
LpA Emission sound pressure level, 73 dB(A) Values determined using the
operator position basic standard ISO 11204
KPA Uncertainty factor 2.5 dB(A) (Engineering method)

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1.10 Emissions 1 Technical Specification

1.10 Emissions
Characteristic Value Notes
Hydrogen peroxide 0.0 - 0.2 ppm Measured with Dräger Pac III
fumes in operator‘s environment during production
Hydrogen peroxide outlet to drain < 1% See the OM-80428-XXXX
Oil fumes in the operator‘s None
environment
Oil spillages (During production) 0.00100 l/h Low speed
0.00132 l/h High speed
Oil spillages (After cleaning) 0.00825
Detergent spillages None Except during external
cleaning
Water spillages 0.3 l/min Except during external
cleaning
Product spillages None

1 - 36 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.11 Site Environment Specification

1.11 Site Environment Specification

1.11.1 Ambient Temperature
Characteristic Value Notes
Recommended ambient temperature 15 °C - 30 °C
(59 °F - 86 °F)

1.11.2 Aseptic Packaging

1.11.2.1 Introduction of Aseptic Packaging
Aseptic packaging has a specified dimension in the sphere of food
processing and must be treated accordingly.
1.11.2.2 Aseptic Installation Policy
It is the policy of Tetra Pak Packaging Solutions AB that aseptic packaging
machines should be installed in a separate packaging room. Doing so
effectively reduces the quantity of airborne bacteria.
1.11.2.3 Infection Risks
Areas and activities where the infection risks are particularly
serious:
• Processing machine areas for certain products.
• Bottle, crate washer, and similar equipment areas.
• Rooms with strong air currents.
• Rooms with traffic to and from other plant areas.
• Rooms with high humidity, such as the room where the steriliser is
installed and where there are discharges of steam or hot water during
pre-sterilisation and/or production periods.
• All unnecessary activities, especially those producing or stirring up dust,
such as the erection of paper crates, wrapping, and so on.
• Under no circumstances should unsterile packages be handled in the
filling area.

Note! By complying with our installation policy, the risks for infection
mentioned above are minimized.

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1.11 Site Environment Specification 1 Technical Specification

1.11.2.4 Packaging Room Overpressure

In addition to siting the packaging machine in a separate packaging room,
overpressure by means of filtered air is to be maintained in the room in order
to prevent unfiltered air from entering the room. The reason for this is that
areas and spaces where food is produced or stored usually contain airborne
bacteria in quantities well above average.
• Overpressure is obtained by controlling the air intake and exhaust in the
packaging room through forced ventilation, including the incorporation
air-conditioning, if required.
• The exhaust system is basically under-dimensioned in comparison with
the air intake system, thus forcing exhaust air to seal off possible inlets,
such as doors and hatches.
• In designing the system for overpressure in the packaging room,
facilities to filter the incoming air must be included.
• As well as controlling the air flow in the packaging room, its temperature
and humidity should be controlled.

1 - 38 (40) Doc. No. IM-80429-0107

1 Technical Specification 1.12 Material Specification

1.12 Material Specification

1.12.1 Storing the Packaging Material
1.12.1.1 Introduction
To ensure that the properties of the material is not changed it is vital to
follow the storage and handling recommendation of packaging material and
additional material.
1.12.1.2 Delivery
The packaging material will be delivered in “small” or “jumbo” reels on one
way pallets. Normally the packaging material reel is wrapped in protective
shrink film. The individually wrapped reels are stacked on pallets. A hood of
shrink film or a stretch film is protecting the reel stack on a pallet against
moisture and dirt. In this way the reels are also secured to the pallet. With
customer agreements the reels can be delivered without the protective films.
Pallets can be stacked on top of each other, up to three pallets height.
A protection sheet must be used between the pallets. Be careful when lifting
the pallets and reels. Do not scratch the other reels.
The additional material is delivered in boxes.
1.12.1.3 Storage of Material
Recommendations:
• Use the material on first in - first out basis.
• Keep the storage premises clean.
• The material must be stored completely separate from other goods, such
as milk powder, essences, animal food, chemicals, detergents, etc. There
is a great risk that the packaging material is absorbing vapours which
could result in taste problems.
• Store the material on pallets only. The space to the nearest wall should be
min. 100 mm.
• The material must not be exposed to direct moisture, such as
condensation dripping from pipe etc., neither exposed in direct sunlight.
• If the material is stored longer than recommended, see specification,
reliable production check should be initiated.
• Partly used material shall be labelled with its identification and wrapped
with a protective film. The reels must be stored in accordance with this
recommendation.

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1.12 Material Specification 1 Technical Specification

1.12.1.4 Storage Conditions

Packaging material
• Temperature: Storage temperature between 0 ºC and +40 ºC.
• Humidity: Relative humidity (RH) of between 30% and 70%.

Additional material; LS-strips

• Temperature: Storage temperature between 0 ºC and +40 ºC.
• Humidity: Relative humidity (RH) of between 30% and 70%.

Variation from recommended humidity during short periods (4 to 5 days)

have no noteworthy effect on the humidity of the materials.
1.12.1.5 Storage Time
Storage time limit which guarantees the function of the material is specified
for each material and additional material types. The storage time is counted
from the manufacturing date of the material up until the time when it will be
applied in the filling machine. Packaging and additional material can be used
up to one year from P-order date.
1.12.1.6 Storage Conditions in Prior to Packing
The material must be allowed to reach the same temperature as the
temperature prevailing in the packing premises. If the packaging material is
protected with protective plastic film, this should be kept on until the reel
will be used.
1.12.1.7 Handling of Packaging Material
Use a special lifting/turning truck to handle the reels.
1.12.1.8 Storage of Jet Printer Ink (Optional Equipment)
The ink must be stored according to local safety regulations for chemicals,
see also the ink product specifications for further information. The ink must
be used within a year from manufacturing date.

1 - 40 (40) Doc. No. IM-80429-0107

2 Preparatory Requirements

Doc. No. IM-80429-0107 2 - 1 (12)

 2 Preparatory Requirements

Description
This chapter describes the requirements for the installation of the equipment.

2 - 2 (12) Doc. No. IM-80429-0107

2 Preparatory Requirements Table of Contents

2.1 Organization and Training . . . . . . . . . . . . . . . . . 2 - 5

2.2 Special Equipment . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

2.2.1 Equipment for PLC, HMI, PLMS, and TPOP. . . . . 2 - 6

2.3 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7

2.4 Maintenance Details . . . . . . . . . . . . . . . . . . . . . . 2 - 8

2.5 Spare Parts Supply . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

2.6 Quality Level and Procedures . . . . . . . . . . . . . 2 - 10

2.7 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11

2.7.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11

Doc. No. IM-80429-0107 2 - 3 (12)

 2 Preparatory Requirements

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2 - 4 (12) Doc. No. IM-80429-0107

2 Preparatory Requirements 2.1 Organization and Training

2.1 Organization and Training

Only skilled or instructed Tetra Pak installation personnel are allowed to
assemble the filling machine. See Section Personnel Requirements in
Chapter ii Safety Precautions.
Personnel must know how to use the PC programs for modifying PLC
program parameters and the Rockwell program.
Training of Service Engineers and Operators are available at the Technical
Training Center at Tetra Pak.

Doc. No. IM-80429-0107 2 - 5 (12)

2.2 Special Equipment 2 Preparatory Requirements

2.2 Special Equipment

For information about Special Equipment, see Section 1.3.2 Auxiliary
Equipment.

2.2.1 Equipment for PLC, HMI, PLMS, and TPOP

For information about Equipment for PLC, HMI, PLMS, and TPOP, see the
MM-80427-XXXX.

2 - 6 (12) Doc. No. IM-80429-0107

2 Preparatory Requirements 2.3 Consumables

2.3 Consumables
For information about recommended consumables to use, see the MM-
80427-XXXX, the SPC-80431-XXXX and the OM-80428-XXXX.
For information about the consumption of the consumables, see Section 1.4
Utility Connection Data in Chapter 1 Technical Specification.

Doc. No. IM-80429-0107 2 - 7 (12)

2.4 Maintenance Details 2 Preparatory Requirements

2.4 Maintenance Details

For information about how to perform the recommended maintenance, see
the MM-80427-XXXX.
For information about the recommended maintenance interval, see the TPMS
list for the current machine at the local Tetra Pak office.
For information about how to perform the daily- and weekly care, see the
OM-80428-XXXX.

2 - 8 (12) Doc. No. IM-80429-0107

2 Preparatory Requirements 2.5 Spare Parts Supply

2.5 Spare Parts Supply

For information about Spare Parts, see the SPC-80431-XXXX.

Doc. No. IM-80429-0107 2 - 9 (12)

2.6 Quality Level and Procedures 2 Preparatory Requirements

2.6 Quality Level and Procedures

See the Tetra Pak Quality Assurance Management guidelines.

2 - 10 (12) Doc. No. IM-80429-0107

2 Preparatory Requirements 2.7 Site Preparation

2.7 Site Preparation

The following guideline, containing requirements for the site working
environment, is available from Tetra Pak Quality Assurance Management:

Document Name Document No.

Guideline for the Hygienic Production of Liquid QAM-588013-xxxx
Food, Site & Building Recommendations

We recommend that you take advantage of Tetra Pak’s technical consulting

services during the planning stages.

2.7.1 Installation Area

a) Make sure that all customer preparation work has been completed to
prepare the site for the filling machine.
b) Make sure that necessary utility supplies are available. See Chapter
1 Technical Specification.
c) Clear all obstacles away from the installation site and, if necessary, clean
the floor of the site before starting to install the filling machine.
d) Make sure 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.
e) Valid for multi installation: Make sure there is sufficient space for all
the filling machines that is to be installed, and that item d) is valid during
the installation of all filling machines.
f) Leave the protective packing on parts until the parts are needed during
the filling machine assembly procedure.
g) Make sure that the lighting is adequate. Arrange additional portable
lights if necessary, making sure that cables are placed safely.
h) Take into account the extra space needed to lift the superstructure and the
electrical cabinet on to the machine. This space may vary due to different
lifting devices. Make sure there is enough space around and above the
filling machine.

Keep the packaging material and strip supplied with the machine in a dry
place.

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2.7 Site Preparation 2 Preparatory Requirements

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2 - 12 (12) Doc. No. IM-80429-0107

3 Mechanical Completion

Doc. No. IM-80429-0107 3 - 1 (68)

 3 Mechanical Completion

Description
This chapter describes the crates that the equipment is delivered in and how
to move and unpack the crates prior to the equipment installation. It also
includes how to assemble the equipment.

3 - 2 (68) Doc. No. IM-80429-0107

3 Mechanical Completion Table of Contents

3.1 Crate Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

3.1.1 Goods Reception and Storage . . . . . . . . . . . . . . . 3 - 5
3.1.1.1 Lifting and Unloading the Crated Equipment . . . . 3 - 5
3.1.2 Moving the Crated Equipment . . . . . . . . . . . . . . . 3 - 7
3.1.3 Storing the Crated Equipment . . . . . . . . . . . . . . . 3 - 7
3.1.4 Delivery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3.1.4-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3.1.4.1 Inspection Documentation . . . . . . . . . . . . . . . . . . . 3 - 8
3.1.5 Opening the Crate . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3.1.6 Unpacking the Crate . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.1.7 Disposal of Reusable Material and Waste . . . . . 3 - 10

3.2 Positioning and Assembly . . . . . . . . . . . . . . . . . 3 - 11

3.2-1 Moving the Uncrated Equipment . . . . . . . . . . . . 3 - 11
3.2.1 Assembly Standard Installation . . . . . . . . . . . . . 3 - 11
3.2.1.1 Main Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.2.1.1-1 Main Body - Lift . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.2.1.1-2 Main Body - Assemble . . . . . . . . . . . . . . . . . . . . 3 - 15
3.2.1.1-3 Main Body - Level . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
3.2.1.2 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
3.2.1.2-1 Superstructure - Lift . . . . . . . . . . . . . . . . . . . . . . 3 - 18
3.2.1.2-2 Superstructure - Assemble . . . . . . . . . . . . . . . . . 3 - 23
3.2.1.3 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 26
3.2.1.3-1 Platform - Assemble . . . . . . . . . . . . . . . . . . . . . . 3 - 26
3.2.1.3-2 Platform - Level . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27
3.2.1.4 Electrical Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
3.2.1.4-1 Electrical Cabinet - Lift . . . . . . . . . . . . . . . . . . . 3 - 28
3.2.1.4-2 Electrical Cabinet - Assemble . . . . . . . . . . . . . . 3 - 30
3.2.1.5 Automatic Splicing Unit . . . . . . . . . . . . . . . . . . . . 3 - 32
3.2.1.5-1 Automatic Splicing Unit - Lift . . . . . . . . . . . . . . 3 - 32
3.2.1.5-2 Automatic Splicing Unit - Assemble . . . . . . . . . 3 - 35
3.2.1.5-3 Automatic Splicing Unit - Level . . . . . . . . . . . . 3 - 36
3.2.1.6 Warning Beacon. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 38

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Table of Contents 3 Mechanical Completion

3.2.1.6-1 Warning Beacon - Assemble . . . . . . . . . . . . . . . 3 - 38

3.2.1.7 Ink Jet Printer (Optional) . . . . . . . . . . . . . . . . . . . . 3 - 39
3.2.1.7-1 Ink Jet Printer (Optional) - Install . . . . . . . . . . . 3 - 39
3.2.1.8 Cable Trays and Cables . . . . . . . . . . . . . . . . . . . . . 3 - 40
3.2.1.8-1 Cable Trays and Cables - Assemble . . . . . . . . . 3 - 41
3.2.1.9 Pipes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 49
3.2.1.9-1 Pipes and Hoses - Assemble . . . . . . . . . . . . . . . 3 - 49
3.2.1.10 Doors and Protections Plates . . . . . . . . . . . . . . . . 3 - 55
3.2.1.10-1 Doors and Protections Plates - Assemble . . . . . 3 - 55
3.2.1.11 External Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 55
3.2.1.11-1 External Conveyor - Assemble . . . . . . . . . . . . . 3 - 55
3.2.1.11-2 Outfeed Accessories - Assemble . . . . . . . . . . . . 3 - 56

3.3 Equipment Interfaces and Connections . . . . . 3 - 57

3.3-1 Electrical Connection . . . . . . . . . . . . . . . . . . . . 3 - 57
3.3-2 Utility Connections . . . . . . . . . . . . . . . . . . . . . . 3 - 59
3.3-3 Product Connections . . . . . . . . . . . . . . . . . . . . . 3 - 60
3.3.1 Signal Exchange . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61
3.3.1-1 CIP Unit Signal Exchange . . . . . . . . . . . . . . . . . 3 - 61
3.3.1-2 Process Unit Signal Exchange . . . . . . . . . . . . . . 3 - 61
3.3.1-3 Connection to PLMS Master PC . . . . . . . . . . . . 3 - 62
3.3.2 Ink Jet Printer (Optional) . . . . . . . . . . . . . . . . . . 3 - 63
3.3.3 External Emergency Stop (Optional) . . . . . . . . . 3 - 64

3.4 Restore Tools and Site . . . . . . . . . . . . . . . . . . . 3 - 65

3.5 Mechanical Completion Inspection . . . . . . . . . 3 - 66

3.5.1 Safety Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 66
3.5.2 Filling Machine Check. . . . . . . . . . . . . . . . . . . . . 3 - 66
3.5.3 Electrical Connections Checks . . . . . . . . . . . . . 3 - 67
3.5.4 Miscellaneous Checks . . . . . . . . . . . . . . . . . . . . 3 - 68
3.5.5 Lubricant Level Checks . . . . . . . . . . . . . . . . . . . 3 - 68

3 - 4 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.1 Crate Handling

3.1 Crate Handling

3.1.1 Goods Reception and Storage
3.1.1.1 Lifting and Unloading the Crated Equipment
Labels, symbols, and warning placards are located on the external surfaces of
the transit crate and outline the handling principles which must be observed.
• The crate should not be subjected to sudden shocks or movement.
• The crate is not load bearing and must not be stacked or have other items
placed on it.
• The transit crate should be kept in the indicated upright position.

Labels may be installed to indicate that the crate has been tipped over or
exposed to extremes of humidity.

Symbol Meaning
Centre of gravity

Lifting points for chains, cables, ropes or straps

This way up

Fragile

Keep dry

Top of crate

“Fragile” warning

“Handle with care” warning

“Not to be dropped” warning

“Gross weight” value

“Net weight” value

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3.1 Crate Handling 3 Mechanical Completion

Using an Overhead Gantry or Mobile Crane

The crate is marked with lifting tackle symbols (arrows).
The lifting tackle must be passed under and fixed at these points, as
illustrated below, when lifting the crate.
For capacity and length of the lifting tackle, see Section 1.3.2 Auxiliary
Equipment.
Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet.

Tetra Pak

Using a Fork-lift truck

The crate is marked with centre of gravity symbols.
The lifting forks must be positioned at equal distances from the symbol when
lifting the crate.
For the capacity, length, and setting width of the lifting forks, see Section
1.3.2 Auxiliary Equipment.

Tetra Pak

a b
a=b

3 - 6 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.1 Crate Handling

3.1.2 Moving the Crated Equipment

a) Lift the crate as instructed, see Section 3.1.1.1 Lifting and Unloading the
Crated Equipment. Lift only enough to clear the crate from the floor.
b) Make sure that the crate remains stable on the lifting equipment.

WARNING
Risk of minor personal injury.
Move the crate slowly and gently.
c) Move the crate to its destination.
d) Lower the crate gently to the floor, leaving enough room around it for
easy access to all sides.
e) Make sure that the crate is firmly supported. If necessary, place blocks or
plates under it.

3.1.3 Storing the Crated Equipment

Make sure that storage areas comply with specifications below.
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.

CAUTION
Risk of serious equipment damages.
Do not stack any item on top of the crate.

Characteristic Value Notes

Min and Max If the water system is drained,
°C -20 to +70 the equipment can withstand
(°F) (-4 to158) freezing conditions.
Max. relative humidity% 80 Non-condensing

ST00066

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3.1 Crate Handling 3 Mechanical Completion

3.1.4 Delivery Checks

3.1.4-1 Inspection
a) Examine the outside of the crate before start unloading, and record any
damage. This information must later be recorded on the Transport
Damage Report.
b) Record the readings of the humidity indicators and the tipping indicators
attached to the outside of the crate (if present). This information must
later be recorded on the Transport Damage Report.

3.1.4.1 Inspection Documentation

Carry out inspection by following the description in the Tetra Pak Quality
Assurance Management guidelines.

3.1.5 Opening the Crate

DANGER
Risk of serious personal injury.
Be sure to use the right equipment with the required capacity, during
uncrating and lifting. Follow local regulations regarding lifting.

CAUTION
Risk of machine damage.
Be sure to use the right equipment with the required capacity, during
uncrating and lifting. Follow local regulations regarding lifting.
For the minimum unpacking area, see Section 3.1.6 Unpacking the Crate.
a) Remove all the wood screws from the top/lid on the crate.

(Cont'd)

3 - 8 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.1 Crate Handling

(Cont'd)
b) Remove the top/lid from the crate with assistance of a fork-lift truck.

c) Determine which side is free of parts. This side must be removed first.

d) Remove all the wood screws from the side, except the two screws at the
top of the side.

(Cont'd)

Doc. No. IM-80429-0107 3 - 9 (68)

3.1 Crate Handling 3 Mechanical Completion

(Cont'd)
e) Hold the side against the crate with the assistance of a fork-lift truck and
remove the two wood screws on the top of the side. Remove the side
from the crate with the assistance of the fork-lift truck.

3.1.6 Unpacking the Crate

The minimum unpacking area must be at least twice the size of the crate.
Minimum area: 9000 x 5000 x 4000 mm high (30 x 17 x 14 ft high).
Check the two crates:
• for damage
• that all documentation is delivered
• that everything looks alright

3.1.7 Disposal of Reusable Material and Waste

Crates and wrapping material delivered with the filling machine are to be
recycled according to local regulations in the receiving country.

3 - 10 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

3.2 Positioning and Assembly

3.2-1 Moving the Uncrated Equipment
Make sure that the uncrated equipment safely can be transported to the
installation site. Take into account the extra space needed to lift and move the
equipment. See Section 1.1 Installation Drawings for measures.

3.2.1 Assembly Standard Installation

WARNING
Risk of falling off the platform.
If work is performed on the platform before the railings and the legs are
mounted, a shoulder harness must be used.
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 PLC program parameters and down loading the Rockwell
program.
The equipment used for lifting and moving the crates can also be used for
installing the equipment. See Section 1.3.2 Auxiliary Equipment for further
details.
Check that preparation of the site has been completed according to the
Section 2.7 Site Preparation. See also the measurements given in Section 1.1
Installation Drawings.

Doc. No. IM-80429-0107 3 - 11 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.1 Main Body

3.2.1.1-1 Main Body - Lift

WARNING
Risk of serious personal injury.
Do not lift the main body more than 20 mm above the floor while it is being
moved.

DANGER
Risk of serious personal injury or death.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.

CAUTION
Risk of machine damage.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.
Before moving the machine parts, see Section 1.2.1 Mass (Weight) regarding
weight, and see Section 1.3.2 Auxiliary Equipment for lifting equipment.
(Cont'd)

3 - 12 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Lifting With a Fork-lift Truck
To lift the main body from the side, place the forks of the fork-lift truck
under the main body (arrows).
To lift the main body from the back (ASU) side, place the forks of the fork-
lift truck under the main body (arrows).

WARNING
Risk of personal injury.
The main body can fall over. Check that the lifting protection are mounted
under the main body and that the forks of the fork-lift truck are inserted in the
lifting protection.
Lift and move the main body to its place of production and position it.

Lifting from the side Lifting from the back

(Cont'd)

Doc. No. IM-80429-0107 3 - 13 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)

Lifting With an Overhead Gantry or Mobile Crane

Mount the three lifting eye bolts (1) to the main body (3). Fix the lifting
straps (2) to the lifting eye bolts, lift the main body a few centimetres above
the floor with a crane, and move the main body to its place of production and
position it.

2
1

1 Lifting eye bolt

2 Lifting strap
3 Main body

3 - 14 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.1-2 Main Body - Assemble

WARNING
Risk of personal injury.
The main body can tip over. Make sure that it is sufficiently supported while
assembling the feet.
a) Attach and adjust the feet until the distance A between the main body
and the floor is approximately 170 mm.
Note! The distance between the main body and the floor can vary,
depending on where in the installation area the main body is assembled.
b) Remove the cover (1) from the main body.

1 Cover

A
A = 155 to 185 mm

(Cont'd)

Doc. No. IM-80429-0107 3 - 15 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)

WARNING
Risk of falling off the platform.
If work is performed on the platform before the railings and the legs are
mounted, a shoulder harness must be used.
c) Assemble the footplates (3), (4), and (9), and the corner strips (2) and (7)
to the part of the platform that is not folded.
Tip! Assemble the railings on the floor and lift them up to the platform as one
unit with an overhead gantry, a mobile crane or a fork-lift truck.
d) Assemble and attach the railings (5), (6), and (8) to the part of the
platform that is not folded.

6 7 8
5
9
4
3
2

2 Corner strip 5 Railing 8 Railing

3 Foot plate 6 Railing 9 Foot plate
4 Foot plate 7 Corner strip

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.1-3 Main Body - Level

Level the main body in the longitudinal and transversal direction by
adjusting the four adjustable feet (2). Check with a spirit level (4) on the
worked surface (3) on the main body frame (1) as illustrated below.
Note! Maximum divergence is 0.2 mm/m in each direction.

Longitudinal direction Transversal direction

1 1

4 4

3 3
2 2

1 Main body frame

2 Foot
3 Worked surface
4 Spirit level

Doc. No. IM-80429-0107 3 - 17 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.2 Superstructure
3.2.1.2-1 Superstructure - Lift

DANGER
Risk of serious personal injury or death.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.

CAUTION
Risk of machine damage.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.
Before moving the machine parts, see Section 1.2.1 Mass (Weight) regarding
weight, and see Section 1.3.2 Auxiliary Equipment for lifting equipment.
(Cont'd)

3 - 18 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Assemble the Lifting Tool

DANGER
Risk of death or serious personal injury.
The lifting tool is designed to lift the superstructure for the Tetra Pak A1
filling machine up on to the platform when assembling the machine. All other
usage is forbidden and could result in death or serious injury.
a) Make sure the lifting tool (1) TP no. 2925908 is attached to the flange on
the aseptic chamber with the screws (2).
b) Attach the lifting eye bolt (3).

DANGER
Risk of death or serious personal injury.
Make sure that the nut (4) for the lifting eye bolt is tightened. Minimum
temperature for use of this equipment is -20 °C.

1 Lifting tool 2
2 Screw
3 Lifting eye bolt
2
4 Nut

(Cont'd)

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3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
Lifting with an Overhead Gantry or Mobile Crane
a) Make sure that all parts on the superstructure are secured to each other.
b) Attach the lifting strap (1) to the lifting eye bolt (2) on the lifting tool and
to the overhead gantry (3) or mobile crane (3).
Note! Align the lifting eye bolt (2) to the direction of the lifting strap (1).
c) Lift the superstructure on to the platform slow and carefully without
large accelerations and make sure that the load is balanced.

1 Lifting strap
2 Lifting eye bolt
3 Overhead gantry or Mobile crane

(Cont'd)

3 - 20 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Lifting with a Fork-lift Truck

DANGER
Risk of death or serious personal injury.
The lifting arm is designed to lift the superstructure for the Tetra Pak A1
filling machine up on the platform when assembling the machine. All other
usage is forbidden and could result in death or serious injury.
a) Make sure that all parts on the superstructure are secured to each other.
b) Fit the lifting arm (1) TP no. 2925910 on to the forks (2).
c) Secure the lifting arm (1) to the fork lift truck with the snap hook (3).
Note! Keep the forks (2) horizontal and place the lifting arm (1) as close to
the truck as possible.

DANGER
Risk of death or serious personal injury.
Before using the lifting arm (1), make sure that the snap hook (3) is
connected to the fork lift truck. Check also that the lifting hook (4) is
undamaged and is safely attached to the lifting arm (1).
The use of this lifting equipment will change the features of the fork-lift
truck. The fork-lift truck to use must be able to handle weights for at least
3.000 kg.
Minimum temperature for use of this equipment is -20 °C.

1 4

3 2
1 Lifting arm
2 Fork
3 Snap hook
4 Lifting hook

(Cont'd)

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3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
d) Position the lifting arm (1) according to the illustration and connect the
lifting hook (4) with the lifting eye bolt (5).
e) Lift the superstructure on to the platform slow and carefully without
large accelerations and make sure that the load is balanced.

A = 900 mm
A
4
1

1 Lifting arm
4 Lifting hook
5 Lifting eye bolt

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.2-2 Superstructure - Assemble

WARNING
Risk of falling off the platform.
If work is performed on the platform before the railings and the legs are
mounted, a shoulder harness must be used.
a) Clean the contact surfaces (5) between the superstructure and the main
body.
b) Check that there is a spacer (3) over the holes in each corner of the
platforms contact surface.
c) Put the superstructure on the platform, with the two pins (2) on the main
body fitted into the holes (1) in the superstructure.
d) Use the four screws (4) to assemble the superstructure with the main
body.
Note! The screws (4) must be assembled into the superstructure from the
main body below.
e) Tighten the support to the platform (arrow). Check that there is no
tension when tightening the supports.

5 1 Hole
2 Pin
3 Spacer
4 Screw
1 2 3 4 5 Contact surface

(Cont'd)

Doc. No. IM-80429-0107 3 - 23 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
f) Disconnect the lifting eye bolt (6) from the lifting hook.
g) Loosen and remove the screws (7) and remove the lifting tool (8).

6 Lifting eye bolt

7 Screw
8 Lifting tool

(Cont'd)

3 - 24 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
h) Attach the cover (9) and tighten the screws (10).

10

10

9 Cover
10 Screw
10

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3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.3 Platform

WARNING
Risk of falling off the platform.
If work is performed on the platform before the railings and the legs are
mounted, a shoulder harness must be used.

WARNING
Risk of serious personal injury.
The folded part of the platform can easily fall if it is not completely
assembled. Mount the screws immediately and never put load on the
platform before it is completely assembled.

3.2.1.3-1 Platform - Assemble

a) Check that the main body still is in level. See Procedure 3.2.1.1-3 Main
Body - Level.
b) Lift the platform (2) into position with a truck or a crane.
c) Assemble the legs (3) to the platform while holding the platform with a
truck or a crane.
d) Attach the bolts (1) in the junction between the two platforms.

2
1

1 Bolt
2 Platform
3 Leg

3 - 26 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.3-2 Platform - Level

a) Check that the legs (3) are vertical.
b) Check that the two platform halves (1) and (2) are aligned. Adjust the
height of the feet (4), if necessary.
c) Attach the loose parts of the railings to the platform (2).
d) Attach the platform (2).

1
2

1 Platform
4 2 Platform
3 Leg
4 Foot

Doc. No. IM-80429-0107 3 - 27 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.4 Electrical Cabinet

3.2.1.4-1 Electrical Cabinet - Lift

DANGER
Risk of serious personal injury or death.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.

CAUTION
Risk of machine damage.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.
Before moving the machine parts, see Section 1.2.1 Mass (Weight) regarding
mass, and see Section 1.3.2 Auxiliary Equipment for lifting equipment.
Lifting with a Fork-lift Truck
Place the forks in the holes (arrows) under the electrical cabinet and lift it to
its installation site slow and carefully without large accelerations and make
sure that it is balanced.

(Cont'd)

3 - 28 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Lifting with a Overhead Gantry or Mobile Crane
a) Mount four lifting eye bolts (3) on the electrical cabinet (4). Fix the
lifting straps (2) in the lifting eye bolts and lift the cabinet. Make sure the
lifting point (1) is at least 1 m above the lifting eye bolts.
b) Lift the electrical cabinet to its installation site slow and carefully
without large accelerations and make sure that it is balanced.

1 A=1m

A
3

4
1 Lifting point
2 Lifting straps
3 Lifting eye bolt
4 Electrical cabinet

Doc. No. IM-80429-0107 3 - 29 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.4-2 Electrical Cabinet - Assemble

WARNING
Risk of falling off the platform.
If work is performed on the platform before the railings and the legs are
mounted, a shoulder harness must be used.
a) Attach the electrical cabinet (1) with three screws (2).

1 Electrical cabinet
2 Screw

(Cont'd)

3 - 30 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Platform
b) Assemble the ladder (9) to the back of the platform, and level the ladder
by adjusting the feet (10).
c) Attach the railings (4) and (5), the foot plates (3), (6) and (8), and the
corner strip (7).

4
5
6
7
8
3

10

3 Foot plate
4 Railing
5 Railing
6 Foot plate
7 Corner strip
8 Foot plate
9 Ladder
10 Foot

Doc. No. IM-80429-0107 3 - 31 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.5 Automatic Splicing Unit

3.2.1.5-1 Automatic Splicing Unit - Lift

DANGER
Risk of serious personal injury or death.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.

CAUTION
Risk of machine damage.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.
Before moving the machine parts, see Section 1.2.1 Mass (Weight) regarding
mass, and see Section 1.3.2 Auxiliary Equipment for lifting equipment.
(Cont'd)

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3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Lifting from the Side
a) Place the forks between the feet (arrows) and lift the automatic splicing
unit.
b) Attach the feet while lifted.
c) Move the automatic splicing unit into position.
d) Lower the automatic splicing unit to the floor.
e) Place four pipes (3) on the forks (2).
Note! The pipes will make it possible to push the automatic splicing unit
slightly towards the main body.
f) Place the forks between the feet (arrows) and lift the automatic splicing
unit.
g) Push the automatic splicing unit towards the main body and lower it to
the floor.

2 3

1 Foot
2 Fork
3 Pipe
1
(Cont'd)

Doc. No. IM-80429-0107 3 - 33 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
Lifting from the Back
a) Place the forks between the feet (arrows) and lift the automatic splicing
unit.
b) Attach the feet (1) while lifted.
c) Move the automatic splicing unit into position.
d) Lower the automatic splicing unit to the floor.

1 1 Foot

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.5-2 Automatic Splicing Unit - Assemble

Note! Lift the automatic splicing unit slightly to make the adjustment of the
feet smother.
a) Level the automatic splicing unit to fit the main body by adjusting the
four feet (3), so that the upper and the lower connection holes at the
cover (1) and the connection (4) is in level with the corresponding holes
in the main body.
CAUTION
Risk of internal stress between the main body and the automatic
splicing unit.
Make sure that the automatic splicing unit stands on the floor on all four feet.
Do not force the screws into place on the cover (1) and the connection (4).
b) Assemble the automatic splicing unit (2) with the main body at the
cover (1) and the connection (4).

1 2

1 Cover
4 3
2 Automatic splicing unit
3 Foot
4 Connection

Doc. No. IM-80429-0107 3 - 35 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.5-3 Automatic Splicing Unit - Level

Note! Lift the automatic splicing unit slightly to make the adjustment of the
feet smoother.
a) Check that the lower connection (1) between the automatic splicing unit
and the main body is horizontal. Check with a spirit level on the lower
connection and adjust by adjusting the right front foot (2).

1 Lower connection
2 Foot

(Cont'd)

3 - 36 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
b) Level the automatic splicing unit in the longitudal direction. Check with
a spirit level on the plate (4) and adjust by adjusting the three feet (3).
c) Level the automatic splicing unit in the transversal direction. Check with
a spirit level on the top of the bending roller (5) and adjust by adjusting
the three feet (3).
Note! The automatic splicing unit must be absolutely horizontal in the
transversal direction. Maximum divergence in the transversal direction is
0.1 mm/m.

3 3 Foot
4 Plate
5 Bending roller

Doc. No. IM-80429-0107 3 - 37 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.6 Warning Beacon

3.2.1.6-1 Warning Beacon - Assemble
Assemble the two warning beacons (arrow) to the platform.

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.7 Ink Jet Printer (Optional)

3.2.1.7-1 Ink Jet Printer (Optional) - Install
Position the ink jet printer according to the illustration below. For
information about connections to the filling machine, see Procedure 3.2.1.8-
1 Cable Trays and Cables - Assemble.

700 ±50 750 ±50

View from bottom of machine

750 ±50

Doc. No. IM-80429-0107 3 - 39 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.8 Cable Trays and Cables

Note! Make sure to separate the signal cables from the power cables.
The power cables have:
– a cable area (1) that is minimum 1.5 mm2
The signal cables have:
– a cable area (2) that is 0.75 mm2 or less
Signal cables Power cables
IH cable

12 G 0,75 (19AWG/12c) ROHS 7 G 2,5 (14AWG/7c) ROHS

2 1

3 G 0,75 (19AWG/3c) ROHS

1 Cable area
2 2 Cable area

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.8-1 Cable Trays and Cables - Assemble

Cable positions in cable tray
a) Make sure that the signal cables (1), the power cables (2) and the IH
cables (3) are correctly placed in the cable tray according to the table and
illustration below.
Cable Reference Designation Number
Signal cables 01W215
01W375
10W005
10W135
10W136
30W235
30W236
40W255
40W256
50W335
70W355
90W101
01W112
01W115
01W131
01W401
01W405
01W470
01W480
01W700
50W701
10W700
30W225
30W227
30W328
30W330
30W332
30W334
30W336
30W338
30W340
30W342
30W346
30W348
30W350
40W025

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3.2 Positioning and Assembly 3 Mechanical Completion

40W035
40W200
40W300
40W302
01W009
50W140
Power cables 10W101
30W231
30W232
30W233
40W251
50W331
10W010
10W155
40W040
50W050
52W145
70W070
10W100 (ground)
50W100 (ground)
IH cable 50W135

3
3
3

3
2

1 Signal cable area

2 Power cable area
3 Cable tie (IH cable position)

(Cont'd)

3 - 42 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
a) Tie the power cables (1) and the signal cables (2) to the brackets on the
inside of the superstructure.

1
2

1
2

1 Power cables
2 Signal cables

b) Pull the power cables (3) and the signal cables (4) from the main body to
the platform.
.

3
4

3 Power cables
4 Signal cables

(Cont'd)

Doc. No. IM-80429-0107 3 - 43 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
c) Pull the power cables (5) and the signal cables (6) from the automatic
splicing unit to the platform.

5 Power cables
6 Signal cables

(Cont'd)

3 - 44 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
d) Pull the signal cables (arrows) from the ink jet printer unit to the
platform.

(Cont'd)

Doc. No. IM-80429-0107 3 - 45 (68)

3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
e) Put the cables from the superstructure, automatic splicing unit, main
body, ink jet printer unit, and conveyor drive motor in the cable
tray (arrows) on the platform.

(Cont'd)

3 - 46 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
f) Pull the cables to the electrical cabinet and connect them according to
the EM.
g) Tie the cables to the brackets on the inside of the electrical cabinet
(arrow).

h) Attach the floor cover (arrow) over the cables.

(Cont'd)

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3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
i) Pull the ink jet printer head cable from the ink jet printer unit to the main
body. The cable are to be supported by the five hooks (arrows) on the
platform.
j) Connect the cable from the external stop to the superstructure connection
box 90X100. See EM-80430-XXXX, and 3.2.1.11-2 Outfeed
Accessories - Assemble.

View from bottom of machine

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.9 Pipes and Hoses

3.2.1.9-1 Pipes and Hoses - Assemble
a) Connect the pipe (1) to the spray system and the spreader nozzle
according to the illustration.

1 Pipe

(Cont'd)

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3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
b) Connect the peroxide hoses (1) and (2) from the spray pump to the spray
system.
c) Attach the hoses to the clamps (arrows) according to the illustration
below.
d) Connect the peroxide hoses (3) and (4) to the peroxide bath.

1 Hose - 3104639
2 Hose - 3104638
3 Hose, Pump - 3104641
4 Hose, Drainage - 3104640

(Cont'd)

3 - 50 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
e) Connect the tube (5) to the solenoid valve.
f) Connect the drain pipe (6) to the pipe from the steam trap.
g) Connect the air pipe to the inlet air valve (7), see 3.3-2 Utility
Connections.
h) Connect the water pipe from the main body to the inlet water valve (8)
on the superstructure.

8
7

6
5

5 Tube
6 Drain pipe
7 Air valve
8 Water valve

(Cont'd)

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3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
i) According to the pneumatic diagram, connect the air hoses from:
– superstructure (9), five hoses
– main body (11), two hoses
– automatic splicing unit (12), two hoses
Note! Connect the hoses to the back (arrow) of the panel (10) of the supply
unit. The air hose connected to the ink jet printer must be connected from an
external source.

10

11
12

9 Superstructure
10 Panel
11 Main body
12 Automatic splicing unit

(Cont'd)

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3 Mechanical Completion 3.2 Positioning and Assembly

(Cont'd)
Note! The filling pipe should only be mounted during production.
j) Attach the filling pipe (13) and the seal (14) to the fastening plate (15)
on the aseptic chamber.
k) Set the filling pipe according to the MM, Section Filling Pipe - set
position.

13
14
15

13 Filling pipe
14 Seal
15 Fastening plate

(Cont'd)

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3.2 Positioning and Assembly 3 Mechanical Completion

(Cont'd)
l) Assemble the cleaning pipe (16).
Note! It is very important that the cleaning pipe is correctly installed without
any tension in the system. See also 3.3-2 Utility Connections.

16

16 Cleaning pipe

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3 Mechanical Completion 3.2 Positioning and Assembly

3.2.1.10 Doors and Protections Plates

3.2.1.10-1 Doors and Protections Plates - Assemble
Assemble all the doors and protection plates to the filling machine.
3.2.1.11 External Conveyor
3.2.1.11-1 External Conveyor - Assemble
The external conveyor (1) must be ordered separately. The conveyor
body (2) is included in the standard machine.

DANGER
Hazardous voltage.
Will shock, burn, or cause death. Risk that the cable is powered. The power
supply disconnector must be turned off and secured with a lock before any
installation.
a) Assemble the external conveyor (1) to the conveyor body (2).
b) Assemble the cover (3) to the cover plate (4), over the external conveyor
(1).
c) Connect the power cable to the external conveyor drive motor. See the
EM-80430-XXXX for circuit diagram.
Note! For frequency converter settings, see Chapter 5 Electrical Cabinet in
the MM-80427-XXXX.

4
3

1 External conveyor
2 Conveyor body
3 Cover
4 Cover plate

2
1

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3.2 Positioning and Assembly 3 Mechanical Completion

3.2.1.11-2 Outfeed Accessories - Assemble

DANGER
Hazardous voltage.
Will shock, burn, or cause death. Risk that the cable is powered. The power
supply disconnector must be turned off and secured with a lock before any
installation.
a) Assemble the bracket with the emergency stop and the stop buttons (2)
and warning sign to the conveyor (1) close to the external packaging
unit (3) according to measure A.
b) Thread the cables through the cables channels in the machine.
c) Strap the cables to the conveyor, make sure that the cables are not
squeezed in the conveyor.
Connect the cables to the stop button according to the EM-80430-XXXX.

1 2 3

A = Min 3000 mm A
1 Conveyor powered by filling machine
2 EMERGENCY STOP and STOP button
3 External packaging unit

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 3.3 Equipment Interfaces and
3 Mechanical Completion Connections

3.3 Equipment Interfaces and Connections

For positions of all inlets and outlets, see Section 1.1.6 Connections.
For information on delivered connections, see the SPC-80431-XXXX,
Chapter Regular Accessories, Section Start-up kit.
3.3-1 Electrical Connection

DANGER
Hazardous voltage.
Will shock, burn, or cause death. Risk that the cable is powered. The power
supply disconnector must be turned off and secured with a lock before any
installation.
a) Make sure that the power supply disconnector (1) is switched OFF.
b) Pass the power cable through the cable gland (2).

2
1

1 Power supply disconnector

2 Cable gland

(Cont'd)

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3.3 Equipment Interfaces and
Connections 3 Mechanical Completion

(Cont'd)
c) Connect the wires of the power cable to the power terminal board (3)
inside the electrical cabinet, according to the EM-80430-XXXX.

Note! The power cable must be pulled straight up or straight out from the
filling machine. The power cable must not be pulled through the filling
machine.

3 Power terminal board

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 3.3 Equipment Interfaces and
3 Mechanical Completion Connections

3.3-2 Utility Connections

a) Connect the tap water pipe to the tap water inlet (1).
b) Connect the compressed air pipe to the compressed air inlet (2).
Note! Before the compressed air is connected, make sure that the pipes on
the filling machine are clean by gently blowing them with compressed air.
c) Connect the steam pipe to the steam inlet (3).
d) Connect pneumatic connections according to the pneumatic diagram.
e) Prepare the pipes in the main body for CIP, according to the OM.
f) Adjust the CIP pipes in the main body. Make sure that there are no
tensions in the pipes.
g) Connect the CIP inlet pipe to the CIP inlet (4).
h) Connect the CIP outlet pipe to the CIP outlet (5).

5 2

1 Water inlet
2 Air inlet
3 Steam inlet
4 CIP inlet
5 CIP outlet

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3.3 Equipment Interfaces and
Connections 3 Mechanical Completion

3.3-3 Product Connections

CAUTION
Risk of damage to machine.
Do not weld the inlet/outlet product pipe and the inlet/outlet CIP pipe before
checking that it is possible to connect them to the machine (arrows). Make
sure that there are no tensions in the pipes.
a) Connect the product supply pipe to the product inlet (1).
b) Connect the product outlet pipe to the product outlet (2).

2 1

1 Product inlet
2 Product outlet

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 3.3 Equipment Interfaces and
3 Mechanical Completion Connections

3.3.1 Signal Exchange

3.3.1-1 CIP Unit Signal Exchange
Two signals are needed:
• Tetra Pak A1 ready for CIP (from Tetra Pak A1 to CIP unit):
This signal allows the CIP unit to start the CIP (to be connected to
connector 90X100).
• CIP done (from CIP unit to Tetra Pak A1):
This signal must be high (24 V) when the CIP is finished (to be
connected to connector 90X100).

Connect the cables according to the circuit diagram. See the EM-80430-
XXXX.
3.3.1-2 Process Unit Signal Exchange
Three signals are needed:
• External product signal, PROCESS to Tetra Pak A1 (to be connected to
connector 90X100).
• Ready for production, Tetra Pak A1 to PROCESS (to be connected to
connector 90X100).
• Machine in PRODUCTION, Tetra Pak A1 to PROCESS (to be
connected to connector 90X100).

Connect the cables according to the circuit diagram.

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3.3 Equipment Interfaces and
Connections 3 Mechanical Completion

3.3.1-3 Connection to PLMS Master PC

a) See 3.2.1.8 Cable Trays and Cables for the cable path.
b) Connect the ethernet cable (1) to the ethernet switch (2).
c) Connect the master PC (4) to the ethernet switch (2) using the ethernet
cable (3).
d) Connect the ethernet cable (1) to the IPC level 5 connector marked ETH.

2 4

1 3

1 Ethernet cable
2 Ethernet switch
3 Ethernet cable
4 PC

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 3.3 Equipment Interfaces and
3 Mechanical Completion Connections

3.3.2 Ink Jet Printer (Optional)

Note! The Ink Jet Printer main power supply and compressed air supply
must be separated from the filling machine. For more details see the Ink Jet
Printer manuals/documents.
For installation area, see 3.2.1.7 Ink Jet Printer (Optional).
For cable connection and path, see 3.2.1.8-1 Cable Trays and Cables -
Assemble.

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3.3 Equipment Interfaces and
Connections 3 Mechanical Completion

3.3.3 External Emergency Stop (Optional)

For line solutions the emergency stop push-button must be placed close to
the manual hand packing station. This to be compliant to EN 619
(Continuous handling equipment and systems).
For fully automatic lines, the use of the emergency stop push button is
optional, depending on the risk assessment for the line.

1
2

4 1 Emergency stop button 01F490

2 Push button 90S121
3 Connection box 90X120
4 Cable 90W120

3 - 64 (68) Doc. No. IM-80429-0107

3 Mechanical Completion 3.4 Restore Tools and Site

3.4 Restore Tools and Site

For information, see Section 2.7 Site Preparation.

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3.5 Mechanical Completion Inspection 3 Mechanical Completion

3.5 Mechanical Completion Inspection

Note! This is the first time the filling machine is being run since its final
testing at the factory.
It is recommended that water is packaged instead of the actual product
during final installation checks.
Verify the installation work by following the checklist below.
For further details, see Chapter 3.2 Positioning and Assembly.

3.5.1 Safety Checks

No Check Done
1 All doors open and close correctly.
2 All hatches and safety covers are secured.
3 All the Emergency stop buttons.
See the Safety Precautions chapter for further details.
Press each emergency stop button and make sure that the
machine steps down to OFF.
4 All the doors, covers and guards.
See the Safety Precautions chapter for further details.
Open each door, cover or guard and make sure that the
controlpanel displays the correct message.
5 The filling machine and the area around the machine are
free from remaining installation packing and wrapping.

3.5.2 Filling Machine Check

No Check Done
1 Crank the machine by hand in order to check that
everything moves easily and freely. Observe the
direction of rotation for the drive motor.
2 Inch the filling machine by means of the inching
button at it lowest speed and check that the direction
of rotation for the drive motor is correct.

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3 Mechanical Completion 3.5 Mechanical Completion Inspection

3.5.3 Electrical Connections Checks

DANGER
Hazardous voltage.
Will shock, burn, or cause death. Risk that the cable is powered. The power
supply disconnector must be turned off and secured with a lock before any
installation.

No Check Done
1 The electrical power cables are correctly connected
- in the main switch cabinet
- between the main switch and the electrical cabinet
- in the electrical cabinet
2 The protective earthing (grounding)
- in the electrical cabinet
- on the filling machine
- in the customer´s terminal box
3 The 3 phase sequence monitoring relay (30B144) in
the electrical cabinet.

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3.5 Mechanical Completion Inspection 3 Mechanical Completion

3.5.4 Miscellaneous Checks

No. Check Done
1 The machine is levelled transversally and
longitudinally.
2 All railings have been attached.
3 The utility connections work is done.
4 The conveyor equipment is connected.
5 The connection work to the service unit is finished.
6 The connection work to the superstructure is finished.
7 All covers are attached.
8 The filling pipe and the seal ring are attached.
9 The protective cover for the outfeed is attached.
10 The peroxide container is in place.
11 The detergent container/containers are installed and
filled with the correct detergent, see the OM-80428-
XXXX.
12 The transport securing devices are removed.
13 The eject conveyor/bin is connected/positioned.
14 Upstream valves/switches are open/on:
- electrical power
- compressed air
- steam
15 There are no leakages from the utility connections.
16 The production line is flushed with water to eliminate
welding residues, and to detect any leakages.
17 The machine crates and other packaging materials
have been taken care of as agreed with the
customer.
18 The air valve

3.5.5 Lubricant Level Checks

See the MM-80427-XXXX for further details on the following level checks.

No. Check Done

1 Machine body - Lubrication system

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 4 Commissioning

Doc. No. IM-80429-0107 4 - 1 (12)

 4 Commissioning

Description
This chapter consists of the following parts:
• Verification instructions of the equipment to verify that it is ready for
start of commercial production.
• The signing of the commissioning certificate when the commissioning is
finalized.
• Procedures related to the functional validation of the equipment, and
verification of the site conditions.

4 - 2 (12) Doc. No. IM-80429-0107

4 Commissioning Table of Contents

4.1 Functional Validation . . . . . . . . . . . . . . . . . . . . . 4 - 5

4.1.1 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
4.1.1.1 Presence and Correctness Checks . . . . . . . . . . . . 4 - 5
4.1.1.2 Product and Utility Value Checks. . . . . . . . . . . . . . 4 - 6
4.1.2 Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
4.1.2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
4.1.2.2 Changing PLC Parameters . . . . . . . . . . . . . . . . . . . 4 - 8
4.1.2.3 Health and Safety Checks. . . . . . . . . . . . . . . . . . . . 4 - 9

4.2 Commissioning Validation . . . . . . . . . . . . . . . . 4 - 10

4.3 Commissioning Inspection. . . . . . . . . . . . . . . . . 4 - 11

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 4 Commissioning

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4 - 4 (12) Doc. No. IM-80429-0107

4 Commissioning 4.1 Functional Validation

4.1 Functional Validation

4.1.1 Start Up
4.1.1.1 Presence and Correctness Checks
No Check Done
1 The TP No. on the program CD corresponds to the No. in
the SPC-80431-XXXX.
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:
- EM-80430-XXXX
- IM-80429-XXXX
- OM-80428-XXXX
- MM-80427-XXXX
- SPC-80431-XXXX
- system drawings
- Machine Specification Document
- Final Inspection Report
- Machine Deviation Report (if relevant)
5 A packaging material trolley must be available.
6 The supply and quality of product is sufficient for the
purpose of the commissioning.
7 All supplies are of the correct type and are available in
sufficient quantities for the purpose of the commissioning:
- packaging material
- LS strip
- hydrogen peroxide
- detergent

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4.1 Functional Validation 4 Commissioning

4.1.1.2 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.
See Chapter 1 Technical Specification.

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 Compressed air supply
- pressure
- max. particle size
- max. particle content
- dew point
- oil content
4 Steam supply
- water quality
- pressure
- max. pressure fluctuation
- inlet temperature
5 Detergent
- correct type (specifications)
- ph
6 Hydrogen peroxide supply
- aseptic (food) grade
- concentration (35%)

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4 Commissioning 4.1 Functional Validation

4.1.2 Test Run

4.1.2.1 Preparation
No. Check Done
1 Make sure that the PLC program on the CD corresponds
with the one in the machine PLC. See the SPC-80431-
XXXX for further details.
2 Connect a cold water supply to the product inlet
connection. (If the product pipes have been welded have
them flushed thoroughly before using).
3 Switch on the mains power switch. (Make absolutely sure
that the rotation directions of the electrical motors are
correct. See the EM-80430-XXXX for further details).
4 Perform CIP. See the OM-80428-XXXX for further details.
5 Prepare the machine for production. See the OM-80428-
XXXX for further details.
6 Make sure that the starting up from cold takes less than
35 minutes at an ambient temperature of no less than
20 °C (68 °F).
7 Start up the package outfeed conveyor.
8 Put the machine into PRODUCTION according to the
OM-80428-XXXX.
9 Finished packages are correct in terms of
- size and shape
- longitudinal and transversal sealing
- date code printing
- filled package weight/volume
See the OM-80428-XXXX for further details.
10 Production capacity is as specified (count the packages
produced in ten minutes and multiply by six).
11 All pressures remain within tolerance. See the MM-
80427-XXXX for further details.
12 Steam temperature and that there are no steam leakage.
13 Peroxide function.
14 There are no fluid leaks.
15 There are no unusual noises which could indicate loose
or misaligned parts.
16 There are no unusual smells which could indicate internal
leaks or burning of electrical circuits.
17 The peroxide concentration continuously to detect any
sign of degradation.
18 Defective packages are ejected (start up, short stop,
material splice, strip splice, production stop).
19 Perform strip splice to verify the function. See the OM-
80428-XXXX for further details. Three packages shall be
discarded, the package before the splice, the package
with the splice, and the following package.
20 Packaging material trolley function.

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4.1 Functional Validation 4 Commissioning

21 Perform package material splice to verify the function.

See the OM-80428-XXXX for further details. Three
packages must be discarded, the package before the
splice, the package with the splice, and the following
package.
22 Stop methods. Stop the machine according to the OM-
80428-XXXX to verify the different stop functions.
23 Perform external cleaning.

4.1.2.2 Changing PLC Parameters

CAUTION
Risk of damage to equipment.
Only skilled or instructed persons are allowed to make changes to the PLC
parameters.
Do not change the PLC parameters unless it is absolutely necessary. Make
a copy of the existing parameters before modifying them. Also keep a copy
of the new parameters for future reference.
(Cont'd)

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4 Commissioning 4.1 Functional Validation

(Cont'd)
4.1.2.3 Health and Safety Checks
No. Check Done
1 All the emergency stop buttons.
See the ii Safety Precautions for further details.
Press each emergency stop button and make sure
that the machine steps down to OFF.
2 All the doors, covers and guards.
See the ii Safety Precautions for further details.
Open each door, cover or guard and make sure that
there is a signal on the Control Panel.
3 Outfeed accessories external stop (optional
equipment).
The machine stop is placed close to the manual
hand packing station.
Press the machine stop button and make sure that
the machine stops producing packages.
External audible alarm produces a warning signal
when this machine is about to start.
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

Doc. No. IM-80429-0107 4 - 9 (12)

4.2 Commissioning Validation 4 Commissioning

4.2 Commissioning Validation

See the Tetra Pak Quality Assurance Management guidelines.

4 - 10 (12) Doc. No. IM-80429-0107

4 Commissioning 4.3 Commissioning Inspection

4.3 Commissioning Inspection

See the Tetra Pak Quality Assurance Management guidelines.
For further information about claims see the Global Procedure for Claims
and Technical Issue Management, available from the local Service
Organisation.

Doc. No. IM-80429-0107 4 - 11 (12)

4.3 Commissioning Inspection 4 Commissioning

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4 - 12 (12) Doc. No. IM-80429-0107

5 Performance Validation

Doc. No. IM-80429-0107 5 - 1 (12)

 5 Performance Validation

Description
This chapter describes the performance validation of the equipment. The
performance validation covers the activities from when the equipment is
ready for commercial production until the equipment is handed over to the
final user.
The chapter includes information on how to verify that the equipment
achieves the performance targets during commercial production.

5 - 2 (12) Doc. No. IM-80429-0107

5 Performance Validation Table of Contents

5.1 Performance Preconditions . . . . . . . . . . . . . . . . 5 - 5

5.2 Commercial Production . . . . . . . . . . . . . . . . . . . 5 - 6

5.3 Monitor and Improve Performance . . . . . . . . . . 5 - 7

5.4 Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8

5.5 Performance Validation Inspection . . . . . . . . . . 5 - 9

5.5.1 Performance Validation Checklist . . . . . . . . . . . 5 - 10
5.5.2 Performance Validation Criteria . . . . . . . . . . . . . 5 - 11
5.5.3 Performance Validation Completed . . . . . . . . . . 5 - 12

Doc. No. IM-80429-0107 5 - 3 (12)

 5 Performance Validation

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5 - 4 (12) Doc. No. IM-80429-0107

5 Performance Validation 5.1 Performance Preconditions

5.1 Performance Preconditions

To ensure an effective and successful performance validation, the following
has to be in place prior to the execution of the performance validation:
• Commercial production: commercial production must have started.
• Attendance: both Tetra Pak and the final user must have appointed
representatives to participate in the performance validation.
• Operation: the equipment must be operated according to the Operation
Manual for each component in the line.
Qualified personnel from the final user should operate the equipment
during the performance validation procedures.
• Production plan: a production plan covering the duration of the
performance validation must be available and agreed between Tetra Pak
and the final user of the equipment before the start of performance
validation.
The production plan should reflect the normal constant running
conditions, including the range of products and packaging material that
the final user intends to use with the equipment, as well as any expected
product changes.
The production plan should include, in particular
– preparation/sterilisation schedule
– production schedule and resources
– CIP schedule
– volume to be produced
– number of product changes and product availability
– number of design changes and packaging/additional material
availability
• Packaging material: all packaging materials and secondary packaging
material must be available (including strips, tabs, and so on).
• Consumables: all relevant consumables (hydrogen peroxide, lubricants,
ink, and so on) have to be available.
Parts: an adequate supply of spare parts must be maintained on site according
to Tetra Pak recommendations.

Doc. No. IM-80429-0107 5 - 5 (12)

5.2 Commercial Production 5 Performance Validation

5.2 Commercial Production

The performance validation is performed when the equipment runs in
commercial production. See the sales agreement for more information.

5 - 6 (12) Doc. No. IM-80429-0107

5 Performance Validation 5.3 Monitor and Improve Performance

5.3 Monitor and Improve Performance

During the performance monitoring period the actual performance of the
equipment is measured and any non-performance issues are solved. See the
sales agreement for more information.

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5.4 Performance Test 5 Performance Validation

5.4 Performance Test

During the performance test the actual performance of the equipment during
a pre-defined period is measured. The result of the performance test is
recorded as the certified performance in the performance certificate. See the
sales agreement for more information.

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5 Performance Validation 5.5 Performance Validation Inspection

5.5 Performance Validation Inspection

The purpose of the performance validation inspection is to verify that the
equipment in question fulfils the performance agreed upon. This inspection
must be carried out in conjunction with all involved parties, prior to final
hand over of the equipment.
Defects or faults together with necessary actions and time to correct the
deviations must be recorded in the checklist. See Section 5.5.1 Performance
Validation Checklist.
Use the checklist as follows:
• Under Note, document any deviations, incorrect values, or comments.
• Under Value, document the actual value.
• Under Signature, sign that the check is performed.

Doc. No. IM-80429-0107 5 - 9 (12)

5 - 10 (12) 5.5.1 Performance Validation Checklist
Machine Country Final User Site
No.

Checklist completed by Checklist completion date

Doc. No. IM-80429-0107

5 Performance Validation
 5 Performance Validation
5.5.2 Performance Validation Criteria
Check Reference document IM unless other Note Value Signature
document specified
1 Commercial production started.

2 The General Performance Preconditions Sales agreement with schedules

are fulfilled.

3 The Special Performance Preconditions Sales agreement with schedules

are fulfilled (if applicable).
Doc. No. IM-80429-0107

4 A production plan for the performance Sales agreement with schedules

validation period is established and
communicated.

5 The Machine Mechanical Efficiency

(MME) and Line Machine Mechanical
Efficiency (LMME) has been monitored
and optimized.
6 Performance Test has been carried out PLMS,
(if applicable; sales agreement). Performance specification

7 PLMS data (bin files) has been PLMS

downloaded for Performance Monitoring
Period and Line Performance.
5 - 11 (12)
5 - 12 (12)
5.5.3 Performance Validation Completed
Check Reference document IM unless other Note Value Signature
document specified
1 Performance certificate issued.
Doc. No. IM-80429-0107

5 Performance Validation
6 Disassembly and Removal

Doc. No. IM-80429-0107 6 - 1 (10)

 6 Disassembly and Removal

Description
This chapter describes what must be done if the equipment is placed in long
term or short term storage and how to permanently dispose of this
equipment.

CAUTION
Risk of damage to equipment.
If the equipment is going to stand or travel in freezing conditions, the product
circuits, the peroxide spray tank and circuits and the peroxide bath tank and
circuits must be drained to avoid damage from freezing.
Sterilization peroxide bath pump:
Remove the connections and run the pump to drain the water. Assembly the
connections. Open the pump house to drain the water. Close the pump
house.
The equipment can be moved for short distances without being drained, 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.

6 - 2 (10) Doc. No. IM-80429-0107

6 Disassembly and Removal Table of Contents

6.1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5

6.2 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
6.2-1 Disconnect Utilities . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
6.2-2 Disassemble Machine . . . . . . . . . . . . . . . . . . . . . . 6 - 7
6.2-3 Re-Crating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7

6.3 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . 6 - 8

6.4 Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9

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 6 Disassembly and Removal

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6 - 4 (10) Doc. No. IM-80429-0107

6 Disassembly and Removal 6.1 Preparation

6.1 Preparation
DANGER
Risk of serious personal injury or death.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.

CAUTION
Risk of machine damage.
Make sure to use the right equipment with the required capacity during
uncrating and lifting. Follow local regulations regarding lifting. Lift slow and
carefully and make sure that the load is balanced.
Do not lift the filling machine more than 20 mm off the floor while it is being
moved.

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6.2 Disassembly 6 Disassembly and Removal

6.2 Disassembly
6.2-1 Disconnect Utilities
a) Turn off and padlock the mains power switch.
b) Shut off all the utility and product supplies upstream:
– electrical power
– cold water
– compressed air
– product
– steam
– CIP
– communication cables (when used)
c) Release pressure from the water and air circuits by operating the water
and air guns. Close the following valves:
– compressed air valve
– cold water valve
– steam valve
d) Disconnect the power, utility, drain, and product lines:
– electrical power (disconnect at power terminal and remove the cable)
– communication cables (when used)
– cold water
– compressed air
– product
– steam
– CIP lines
– drainage
e) Plug or protect all open connections.
f) Make sure that cables are put away safely.

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6 Disassembly and Removal 6.2 Disassembly

6.2-2 Disassemble Machine

WARNING
Risk of burn injuries to skin and eyes.
Make sure to carefully drain pipes containing chemicals.
Disassemble the machine in reverse order to the assembly instructions in
Chapter 3.2 Positioning and Assembly.
6.2-3 Re-Crating
a) Install transport devices in the same locations from which they were
removed from when the machine was assembled. The purpose is to
prevent movement during transport.
b) Lubricate all sliding components such as rods, cams, etc.
c) Wrap small components in bubble wrapping or similar to prevent
damage.
d) The equipment must be packed in suitable crates to ensure safe transport
and to achieve the correct storage conditions. Use the original crate and
packing if available. Make sure that the parts are adequately protected
from transport damage. All parts must be fixed to the crate with proper
bolts or similar equipment. Fix any loose sub-crates or boxes to the floor
or walls of the crate to prevent them from moving during transport. The
crate must also be protected from a weather point of view to prevent rain,
snow, sand, etc. from entering the crate.

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6.3 Storage Preparation 6 Disassembly and Removal

6.3 Storage Preparation

Make sure that the storage environment respects the following conditions:

Characteristic Value Notes

Min and Max If the water system is drained,
°C 5 - 40 the equipment can withstand
(°F) (40 - 105) freezing conditions.
Max. relative humidity% 80 Non-condensing.

ST00066

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6 Disassembly and Removal 6.4 Moving

6.4 Moving
See Section 1.3.2 Auxiliary Equipment.

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6.4 Moving 6 Disassembly and Removal

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