TBA 19 Production Checklists

Operator’s Name Production Date Product Brand/Flavour

Product Volume Product 1(P1): Product 2(P2): Product 3(P3):
Start Time
End Time

Items Instructions Remarks Items Instructions Remarks

Pre – Operation Checks
P1 P2 P3 P1 P2 P3
1.Pressure Gauges 2.Air and Water Valves

Close the TS cooling

water valve (2).
Make sure all
Open the input air valve
pressure gauges
(3).
show zero.
Close the cooling water
valve (4).

3.Steam Valve
4. Temperature Controlled
Steam Barrier
Make sure that the
steam valve is open
If not adjust it. This
Corresponds
Temp range of 109 to
111°C.
5.Hydrogen peroxide HIGH Position
Conc (sterilisation):steam
pressure should be
between 1.7 and 1.8 bar.
Corresponds to 130 to
Check the hydrogen 131°C.
peroxide LINE Position: corresponds to Turn the selector to the
concentration the steam pressure in the line. OFF position.
LOW position(production):
the steam pressure should be
between 0.4 and 0.5 bar.

6.Water Pressure 7. Lamp test

Press the LAMP TEST
button (arrow) on
the TPOP and check
that:
Water Pressure
- Audible alarms
should be 1.5 bar
- Warning Lamps
flashing
- Buttons on TPOP
Flashing
8.Reset Package Counter 9. Preheating I

Reset the package Turn selector switch on

counter in TPOP to the left
manoeuvre systems Press program up button
on TPOP. Preheating I lights

10. Product Pipe after CIP

Lift the sensor (1) and open the valve (2) to drain the
cleaning pipe. Close the valve (2) completely. Remove
the product pipe (3).Visually inspect the product pipe
for residue. Clean product line with P3-mip FPC alkali
and dry cloth if necessary. Fit the cap

11.Remove the cleaning 12.Remove the cleaning pipe

attachment
Loosen the nut (1) Release the nuts (1) and
and remove the remove the
cleaning attachment Cleaning pipe (2).
(2) Remove the cap (3).

13.Gaskets Remove gaskets 14.Fit the sterile air pipe Fit the sterile air pipe as
 from pipe fittings shown in the diagram
using the slot
indicated
Change gaskets if it
has worn out or too
dirty.
Disinfect gaskets
with
spitaderm(alcohol),
Alcodes(alcohol) or
Oxonia active(acid)
Replace in pipe
without rinsing
15.Fit the product Pipe 16.Inspect the cleaning Pipe
Inspect the cleaning pipe
Fit the product pipe and clean the flexible
as shown in the part.
diagram Store the cleaning pipe
in a clean place.

17.Aseptic Chamber Thread the 18. Lower aseptic chamber

door packaging material door
slowly
over the roller (1),
under the bending
roller (2), over the
roller (3), and down Open the lower aseptic
through the aseptic chamber door and open
chamber. the divided forming ring
Make sure that the by lifting the handle (1).
packaging material
is
aligned with the
pointer (4) in the
aseptic
Chamber.
19.LS Strip pressure 20.Pull Packaging material
roller through DFR an d LFR Pull the packaging
Make sure that the
material down
LS strip pressure
through the divided
roller
forming ring and
• is correctly
lower forming ring.
attached
DFR- Divided forming
• is clean
rings
• has no surface
LFR-Lower forming
defects
rings
21. Close the divided 22.Close aseptic chamber door
forming ring.

Make sure that the Close all covers and

guide roller is doors on the machine
lowered and press the flashing
and the packaging ACKNOWLEDGE
material passes on button to Acknowledge
each side of it. the alarm.

23. Filling Pipe with 24.Tetra pak multipurpose

Locking Fork compact controller
Make sure that the
O-ring (1) is in the
On the FCS TMCC2
correct position on
card (A310) make
the upper filling
sure that the LED S8 on
pipe
the front panel is
and not worn or
OFF.
damaged, replace if
Required.

25. Pull the packaging 26. Slow inching.

material down to the
jaws.
Before touching the
packaging material,
disinfect your hands
or gloves. Press the INCHING
Pull the packaging button until the jaws
material down to the grip the packaging
jaws. material and pull it
Swing the dow n
photocells back into
their
production position
27.P.M position in 28.Overlapping of PM
guides

Make sure that the LH

edge of the
Make sure that the packaging material
packaging material overlaps the RH
is correctly edge.
positioned in the
guides

29.Preheating II Press the 30.Transducer pressure

PROGRAM UP
button until the Check the I/P transducer
PREHEATING II pressure is
symbol stops 2.0 bar
flashing
but remains lit.
31. Strip Supply 32.Tube Sealing

When the TUBE

SEALING symbol and
Thread the LS strip the PROGRAM UP
button start to flash,
press PROGRAM UP.

33.Package Checks Pick out the last 34.Preheating III

package discarded
When the packaging
from
material tube is sealed,
the machine.
the PREHEATING III
Check the LS strip
symbol stops flashing
is correctly
but remains lit.
positioned
and properly sealed,
35.Spraying Symbol 36.Drying Symbol
When the pre-
sterilisation
temperature is After spraying, the
reached, the DRYING symbol
SPRAYING symbol Lights.
and the The drying time is 20
PROGRAM UP minutes.
button begin to
flash.

37. Reset the TMCC2 38.Signal to steriliser and from

parameter This instruction is steriliser
valid when changing When the SIGNAL TO
from a high STERILISER
viscosity product Symbol and the
(i.e. tomato paste) to PROGRAM UP button
a low viscosity start to flash, press the
product (i.e. tea) and PROGRAM UP button.
vice versa. Reset the The SIGNAL TO
TMCC2 parameter STERILISER symbol
by pressing stops flashing but
the filling mode remains lit.
RESET button
39. Check Machine On the process 40.Signal from steriliser
sterility The SIGNAL FROM
recorder air knife
STERILISER symbol
channel, at least two
stops flashing but
items which
remains lit when
represent
steriliser is ready
60 seconds should
Proceed Production
be over 200 °C.
41.Ready for Production 42.Motor start
When READY FOR
PRODUCTION Keep the PROGRAM
symbol and the UP button pressed until
PROGRAM UP the drive motor starts
button start to flash, and the MOTOR
press the START symbol stops
PROGRAM UP flashing remains lit.
button

Operating Checklist
43.Filling Mode When the FILLING 44. Production When the packages start
symbol lights, the to be produced
level start to increase correctly, the
and is indicated PRODUCTION symbol
from LED S8 to LED Stops flashing but
S5 on TMCC2; the remains lit.
level indicator should The packages are
stabilise within seven directed to the final
 or Eight packages. folder.
45.Package checks 46.Setting Values Pressure(Bars)
Check that all pressure gauges Cutting Pressure(8-9)
show the Jaw Pressure(9-9.6)
Correct settings during Cold water (0.30-0.45)
production. Hot water(0.3-0.45)
Sterile Air(0.30-0.35)
Air (6.5-7)
Air peroxide(3)
Calender Rollers(2.4)
Flap Sealing(1.5-2)
Temperatures(ºC)
Pick out the first two
Hot air element(165)
consecutive packages
Pre-sterilisation(270)
discharged from the
Water Bath (74)
final folder and
Water Bath (Pre-ste)(80)
perform package
LS sealed Tube(280)
checks on them.
LS sealing(380)
Air Superheat Pre(400)
Air Superheater(360)
Air Knife(125)
Steam(130)
Sterilising peroxide(70)
Flap sealing:
Top LH(420)
Top RH(420)
Bottom LH(400)
Bottom RH(400)

Post – Ops Checklist

47. Production Finished Stop
A. When PRODUCTION B. Venting After two minutes the
is finished, press the VENTING symbol
PROGRAM UP becomes fixed. Venting
button. of the aseptic chamber
starts

After five minutes, the

VENTING
FINISHED symbol
starts to flash.

C. Cut the P.Material Open the aseptic D. Preparation for CIP Press program down
chamber door. Turn switch right
Cut the packaging Press program up
material. Close the Preparation for CIP
aseptic chamber door. symbol becomes fixed.
The VENTING
FINISHED symbol
remains lit.

E. Remove packaging Press the INCHING

button to remove all
the packaging material
from the lower part
of the aseptic chamber
and jaw system.
48.If Machine not stepped to production after
20 mins If the machine cannot 40 minutes If the machine cannot be
be stepped to stepped to
PRODUCTION within PRODUCTION within
20 minutes, press 40 minutes, the
the INCHING button packaging material may
to renew the length tear.
of packaging material If the machine cannot be
between the stepped to
Pull Tab unit and the PRODUCTION within
jaws 40 minutes, press
PROGRAM DOWN
twice. The program
steps to VENTING.