Tetra Pak A3/Speed Introduction PDF
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This document is a training guide for a Tetra Pak A3/Speed machine. It includes important information for course participants, such as course schedules, lunch procedures, safety regulations, and locations within the building. The document primarily focuses on the introduction to Tetra Pak A3/Speed machines and is likely part of a wider training program related to food processing and packaging.
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Course Introduction 1 Tetra Pak A3/Speed Introduction 2 Tetra Pak...
Course Introduction 1 Tetra Pak A3/Speed Introduction 2 Tetra Pak Tube Forming 3 A3/Speed Drive and Jaw System 4 Functions and Settings Design Control System 5 Training Document This Training Document is intended for Training purposes only, and must not be used for any other purpose. Filling System 6 The Training Document does not replace any instructions or procedures (e.g. OM, MM, TeM, IM, SPC) intended for specific Final Folder 7 equipment, and must not be used as such. Note! For safe and proper procedures, refer to ASU 8 the equipment specific documentation. Sterile System 9 Name: Head Space by Injection 10................................................................................................................ 11 12 13 14 15 16 17 18 Technical Training Centre 19 Lund, Sweden WB-277-01 Issue /15 20 1 Course Introduction Technical Training Centre Information to Course Participants at the Technical Training Centre in Lund Welcome to Technical Training Centre! Here is some information which might be helpful to you as a course participant. If you need additional information or help, feel free to ask your instructor. Start of course Normally, the first day of your course begins at 08.30. Your instructor will meet and welcome you in the coffee room. Daily time schedule Classes 08.00 - 09.30 Breakfast 09.30 - 10.00 Classes 10.00 - 12.00 Lunch 12.00 - 13.00 Classes 13.00 - 16.00 Your instructor will tell you if there are any changes in the schedule. Breakfast Breakfast is free of charge and served in the restaurant, where a special area has been reserved for Technical Training Centre course participants. Breakfast consists of coffee or tea and bread rolls. If you want anything in addition, for instance from the serving counters of the restaurant or cafeteria, you have to pay for it yourself. Your instructor will help you with the procedure. Lunch Lunch is served in the restaurant. You can choose among several dishes; men- us are posted in the restaurant. If you are a customer course participant, your instructor will give you a cash card. For participants other than customers, cash cards are for sale in the caf- eteria. Your instructor will help you with the procedure. Coffee room You are invited to use the coffee room and the vending machine during all breaks in classes. Smoking The entire Tetra Pak plant, outdoors as well as indoors, is a no smoking area. Smoking is allowed though in special smoking areas. Telephones If you need to call long-distance within Sweden or abroad, please use the phone in the telephone room. When using the phone, please be brief, as there may be others who wish to make calls. Technical Training Centre 6/1106 TM-00010 1 Computers There are a number of computers for the use of course participants. The computers access the Tetra Pak Intranet and the World Wide Web. ID card On your first day you will receive an ID card. This card must be returned at the Tetra Pak Main reception at the end of the course. Anyone not handing the card back will be charged SEK 400. Safety regulations At the start of the course, your instructor will go through the Safety Regula- tions (TM-00001). These regulations must be strictly observed. In case you are uncertain about anything in the regulations, you must have it clarified with your instructor. Course evaluation You are requested to write down your comments on the Course Evaluation form. At the end of the course your instructor will collect all the forms. Working clothes It is necessary to wear safety shoes in the Technical Training Centre, while working at the machines. If you didn’t bring your own, safety shoes are for sale in the Support Centre. Your instructor will take you there. For your use during the course, you may borrow a set of coveralls. Each participant is given a locker in the changing-room. The instructor will hand you the locker key. You may then select a set of coveralls from the cab- inet in the changing-room. Your instructor will help you if needed. You may exchange your coveralls for clean ones every Monday morning. Tell your instructor if you need to change at any other time. Used and soiled cov- eralls are to be placed in the laundry basket in the changing-room. At the end of the course you have to empty and lock your locker and return the key to the instructor. If you wish to retain your locker for a subsequent training course, tell your instructor. Valuables You are responsible for your own valuables. Transport Certain hotels provide free of charge transport to and from Tetra Pak. Ask the hotel receptionist about this. If you wish to use this service, you must tell the receptionist the day before. Medical care For medical care, unless it is an emergency situation, go to Carema Specialist- vård Lund (Carema healthcare Lund), located in the centre of Lund. Sport Centre Bookings for the Tetra Pak Sport Centre are free of charge and can be made at the Main Guard, located next to the Main Reception. If you visit the Sport Cen- tre, you must enter and leave via the Main Guard. Technical Training Centre 6/1106 TM-00010 2 Tetra Pak 1 Main Reception Part of the plant at 2 Main Guard Ruben Rausings gata Lund 3 Technical Training Centre 4 Restaurant 5 Support Centre 6 Sport Centre 1 2 315 305 4 306 313 310 3 101 5 309 311 N 106 6 107 111 Technical Training Centre 6/1106 TM-00010 3 2 Tetra Pak A3/Speed Introduction Technical Training Centre Tetra Pak A3/Speed 0300 Main groups Technical Training Centre Superstructure Lund, Sweden Electrical cabinet Machine type TP A3/Speed 0300 Service unit Issue 2/1010 OH 2199 Automatic splicing unit Drive Final folder Jaw system Machine body Reference designation Main groups Technical Training Centre Lund, Sweden A02 A01 Machine type U70 Tetra Pak A3 K80 A02 − Electrical cabinet pre−applicator T10 A01 − FM general purpose Issue G20 4/1103 U70 − Superstructure K80 − Service unit U30 T40 T10 − ASU T50 P60 OH 2200:1 G20 − G29 − Pre−applicator U30 − Rear Module T40 − Jaw system T50 − Final folder P60 − TPOP Tetra Pak® A3/Speed 0400 iLine ine ™ Tetra Pak® A3/Speed Tetra Pak® A3/Speed iLine™: the fastest line from Tetra Pak for Tetra Brik Aseptic portion or family packages. The Tetra Pak® A3/Speed iLine™ is the ideal line for customers producing from 35/40 million packages upwards. It offers fast and efficient production at the lowest possible operating costs and full line integration makes for smooth, low-waste operations. It’s cheaper to operate, faster and more reliable than any previous Tetra Pak packaging line. So if your production needs are relatively simple – i.e. seldom requiring package volume/format changes – the Tetra Pak® A3/Speed iLine™ is the best choice for your business. Commercially released for 11 volumes ranging between 100 to 1000 ml, Tetra Pak® A3/Speed runs at 15,000 packages per hour for family packages and at 24,000 packages per hour for portion packages. CAPACITY FILLING MACHINE NOISE Tetra Pak A3/Speed Tetra Pak A3/Speed Tetra Pak A3/Speed Portion Family Family PT Packages per hour (selectable capacity): Operator position, LpA* 78 dB(A) 79.5 dB(A) 79.5 dB(A) TBA 100 B 20.000-24.000 p/h Measured A-weighted TBA 300 S 16.000-20.000-24.000 p/h Sound Power Level (Lwa)** 96 dB(A) 98 dB(A) 99 dB(A) TBA 125 S 16.000-20.000-24.000 p/h *Determined according to ISO 11204 TBA 200 B 16.000-20.000-24.000 p/h **Determined according to ISO 3744 TBA 200 M 16.000-20.000-24.000 p/h TBA 200 S 16.000-20.000-24.000 p/h TBA 250 B 16.000-20.000-24.000 p/h UTILITIES TBA 250 S 16.000-20.000-24.000 p/h Electrical power TBA 1000 Sq PT / PLH 9.000-12.000-15.000 p/h Voltage, V: 400/230 ± 10% TBA 1000 S PT / PLH 9.000-12.000-15.000 p/h Frequency, Hz: 50/60 ± 2% TBA 1000 B 9.000-12.000-15.000 p/h Recommended main fuse, A 160 A Note: No viscous and semi-viscous product can be packed. Consumption Tetra Pak A3/Speed Tetra Pak A3/Speed Tetra Pak A3/Speed Portion Family Family PT Tube sealing (kW) 6,2 6,6 6,9 Preheating (kW) 32,9 34,7 35,9 PRODUCT SUPPLY Spraying (kW) 28,2 30,5 28,8 Product pipe size (portion packs) 2”- 3” Drying (kW) 25,8 26,3 27,6 Product pipe size (family packs) 3” Production start (kW) 58,5 66,3 70,5 Product temperature range C° (F°) 10-30 (50-86) Production stable (kW) 35,9 50,1 51,0 Note 1: higher product temperatures are possible with reduced capacity. Note 2: processing capacity +20%. Compressed air Tetra Pak A3/Speed Tetra Pak A3/Speed Tetra Pak A3/Speed Portion Family Family PT Min. supply pressure, kPA (bar) 6,0 6,0 6,5 Characteristic Value Notes Consumption during production (Nl/min) 835 ± 17 1010 ± 20 2020 ± 41 150 - 250 kPa Supply pressure Measured near the Peak consumption (Nl/min) 990 ± 20 1900 ± 38 2120 ± 43 (1.5 - 2.5 bar) accepted range product valve. [21.7 - 36.2 psi] Water supply, cold ±50 kPa Variation within the Connection pressure, kPa (bar) 300-450 (3-4,5) Max. pressure (±0.5 bar) supply pressure Max inlet temperature, °C (°F) 14-20 (57-68) variation [±7.25 psi] accepted range. Water during production: Tetra Pak A3/Speed Tetra Pak A3/Speed Tetra Pak A3/Speed Portion Family Family PT The pressure shock Consumption (l/min) 15,6 ± 0,7 22,7 ± 1,0 24,3 ± 1,0 100 kPa duration is a Max. pressure Steam (1 bar) maximum of shock Min. connection pressure, kPA (bar) 200 (2) [14.5 psi] 1 second (within the pressure range). Temperature °C (°F) >130 (>266) Consumption (kg/h) 2,4 during production Maximum fluctuation Filling 10 - 30°C during production Hydrogen peroxide (H2O2) temperature (50 to 86°F) ±5°C. Concentration 35% Feed capacity at the Consumption, I/h 3,0 to 5,0 first start and for Grease Overcapacity 20% bucket refilling, Consumption, I/h FP 240 cc/1.000.000 packs see note below. PP 160 cc/1.200.000 packs Product must leave Particles Absent no hard residue on a 600 μm mesh. Measured as fibre Citrus fibres Tube is emptied > Stop > Alarm >98% Production continues for 30s > Stop > Alarm 90% Technical Training Centre Lund, Sweden 60% (setpoint) Filling ok window Machine type TP A3/Speed 020V 30% Production continues for 30s > Stop > Alarm Issue 3/1004 Tube is emptied > Stop > Alarm 0% OH 1971 Product Level Detection Level Sensor Product Level Detection Possible faults Technical Training Centre Lund, Sweden 100% 100% 1 Bad centering 2 Bad vertical alignment 3 Missing magnet 7% 0% 7% 0% 4 Faulty switch Level indication Level indication (TMCC input) (TMCC input) Machine type 5 Moisture in sensor Tetra Pak A3 6 Product in float (leakage) 2 4 Hall effect switches Product Moisture Issue 1/0710 100% OH 1973 7% 0% Level indication (TMCC input) kg 1 3 5 6 Start with empty tube Technical Training Centre / 120 100 Flow (%) TM-01390 80 Level (%) Training Document. For training purpose only. 60 40 20 0 0 Start 10 Filling sector At level >20% TMCC switches from Start flow Time (s) sequence + register mark to Product flow regulation. Start with prefilled tube Tetra Pak A3/Speed 0300 Technical Training Centre 3/1009 120 100 Flow (%) TM-01363 80 Training Document. For training purpose only. 60 Level (%) 40 * 20 0 0 10 20 Time (s) * If the level reaches 20%, the A-valve and Regulating valve close. The level continues to increase somewhat due to the response time. Final Folder Unit Technical Training Centre Final folder Package Air for heating Pressure Movement Technical Training Centre Machine type Issue Lund, Sweden TBA/22 1/9903 OH 806:1 Final Folder Overview Technical Training Centre Machine type Issue Lund, Sweden TP A3/Speed 020V 1/0805 OH 1968 Final folder Infeed Technical Training Centre Machine type Issue Lund, Sweden Tetra Pak A3/Speed 1/0402 OH 1504 Heading 1 Frametext - PosNo Frametext - Normal Heading 2 Text Technical Training Centre 1/01110 TM-02147 Training Document. For training purpose only. Flap sealing element Final folder TP A3/Flex & Speed TP A3/CompactFlex Technical Training Centre Machine type Issue Lund, Sweden TP A3 Platform 4/1102 OH 2203 Squeezer Technical Training Centre Machine type Issue Lund, Sweden TP A3/Speed 020V 1/0910 OH 2201 Discharge Device Final Folder Technical Training Centre Machine type Issue Lund, Sweden TP A3/Speed 020V 1/0805 OH 1969 Final Folder Discharge Device Technical Training Centre 1/ TM-02497 Training Document. For training purpose only. Automatic Splicing Unit Technical Training Centre Automatic Splicing Unit Splicing device Electrical cabinet Technical Training Centre Lund, Sweden Strip magazine Material holder Machine type TP A3/Speed 0300 Strip applicator Pneumatic panel Issue 1/1209 Paper reel holder (web magazine) OH 2655 Bobbin brake ASU Motor Control T10T0160 A01K5200 T10T9020 T10T0170 PLC Technical Training Centre 1/1502 TM−02689 Training Document. For training purpose only. ASU Splice Sequence Denominations 1 2 3 1 ASU Loop encoder 2 Driven bending roller 3 Photocell (reading register mark) 4 Web tension cylinder 4 5 6 5 Rubber dolly 6 Pressure rail 7 Knife 8 Cutting cylinder 9 Locking cylinder 10 Heating unit 11 Pneumatic hose 12 Sealing plate 19 13 Heating bar 14 Photocell (packaging material reel empty) 15 Braked roller 16 Bobbin brake cylinder 17 Packaging material reel 10 18 Reflector 19 Web stop 11 7 8 12 13 9 14 15 17 16 18 Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986:1 ASU Splice Sequence Finding stop position Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 2 ASU loop encoder 0 2000 100 s tep s Technical Training Centre Lund, Sweden 439 mm 2000 steps (bending roller circumference) repeat length Machine type 0 A3 one package one revolution packaging material splice initiated Issue motor speed 3/1007 Finding stop position OH 1992 6 Hz 0 virtual register mark position stop position final adjustment (adjustable on TPOP) ASU Splice Sequence Stop position found Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 3 ASU Splice Sequence Cutting packaging material Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986:4 ASU Splice Sequence Cylinder retraction Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 5 ASU Splice Sequence Sideways movement Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 6 ASU Splice Sequence Sealing Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 7 ASU Splice Sequence Splice completed Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 8 ASU Splice Sequence Web stop Technical Training Centre Machine type Issue Lund, Sweden TP A3/Flex 5 Speed 0300 3/1009 OH 1986: 9 ASU Splice sequence diagram 0 1000 2000 3000 4000 5000 6000 7000 8000 Time (mS) 9000 0 TMR_SplicePart1 Technical Training Centre Lund, Sweden Packaging material end or manual splice T10B1240, T10B1250 T10S1100 2800 Web tension T10K1641:12 ASU register mark signal A01K5200:27 Loop motor speed packaging material unsticking Machine type T10T0160 TP A3/Speed 020V 3200 Splice stop position (by angle encoder) T10B9023 50 600 0 2500 Pressure rail splice (constant heat sealing) T10K1621:14 Issue 200 600 3/1408 Material cutting ASU T10K1631:14 max 1500 ms ASU Splice head servo T50M9020 0 4200 TMR_SplicePart2 OH 2010 Finding stop position Stop position found Cutting packaging material Cylinder retraction Sideways movement Sealing Splice completed ASU Virtual Register Mark Technical Training Centre Lund, Sweden Example 1: Blue/Yellow alarm (Photocell) virtual register mark readings actual register mark readings Machine type accumulated faults 0 1 2 3 4 5 6 Blue alarm Yellow alarm A3 interval of 50 readings 50 number of consequtive correct readings Issue 2/1011 Example 2: Blue/Yellow alarm (Encoder) virtual register mark readings OH 1993:1 actual register mark readings accumulated faults 0 1 2 3 4 5 6 Blue alarm Yellow alarm ASU Virtual Register Mark Example 3: Blue/Yellow alarm (Photocell/Encoder) Technical Training Centre Lund, Sweden virtual register mark readings actual register mark readings accumulated faults 0 1 2 3 4 5 6 Blue alarm Yellow alarm Machine type interval of 50 readings 50 number of consequtive correct readings A3 If the difference between the 2 signals is more than +/− 3mm Example 4: Reducing number of accumulated faults Issue 3/1105 virtual register mark readings actual register mark readings OH 1993:2 accumulated faults 0 1 2 3 0 Blue alarm interval of 50 readings 50 number of consequtive correct readings 50 Strip applicator Encoder Pressure roller Strip guide Inductor Matching transformer Splice detector Technical Training Centre Machine type TP A3 Issue Lund, Sweden Speed/020V, Flex/020V 2/0910 OH 1990 ASSU Overview Technical Training Centre Machine type Issue Lund, Sweden Tetra Pak A3 Speed 2/1007 OH 2017 Splice Sequence Strip splice prepared ASSU Technical Training Centre Machine type Issue Lund, Sweden ASSU 1/0410 OH 1608:1 Splice Sequence ASSU Splicing Technical Training Centre Machine type Issue Lund, Sweden ASSU 1/0410 OH 1608:2 Splice Sequence Cooling and unlocking ASSU Technical Training Centre Machine type Issue Lund, Sweden ASSU 1/0410 OH 1608:3 Splice Sequence Splice sequence completed ASSU Technical Training Centre Machine type Issue Lund, Sweden ASSU 1/0410 OH 1608:4 Strip Splice Sequence Diagram PAR_BobinMotorStopDlyTime Technical Training Centre Lund, Sweden Manual start ASSU, strip end T10S1110, T10B1330, T10B1340 PAR_BobinMotorUnstickPulse Reverse motor old bobin 300 900 Machine type TP A3/Flex 020V Reverse motor PAR_BobinMotorUnstickPulse new bobin 1700 2300 VAR_StripSealingCoolingTime Cooling T10K1780:14 2000 PAR_SealingHeadCylCloseDly Issue 1/0806 Heating HMI_StripSealingTime_Set T10K0020 1500 PAR_SealingHeadCylOpenDly OH 2039 Splice head VAR_StripSealingTimeOff movement T10K1770:14 200 1600 TMR_StripSplice.ACC Sterile System Technical Training Centre Sterile system overview Technical Training Centre Lund, Sweden Air Aseptic chamber Peroxide Product Water Machine type Tetra Pak A3/Flex Packaging material Issue 1/0306 Peroxide bath OH 1410 Compressor Tight tube Air superheater Peroxide tank 78 77 Sterile system 66 Tetra Pak A3/Speed 0400 25 56 26 28 27 Technical Training Centre Lund, Sweden 68 58 55 73 29 57 67 12 13 69 34 53 74 76 52 65 33 75 31 31 54 59 15 16 30 24 35 Machine type 64 Tetra Pak A3/Speed 0400 10 32 40 A 14 63 11 36 9 6 7 37 8 38 70 22 23 20 62 41 Issue 39 17 42 18 1/1211 5 71 72 21 44 19 43 2 45 49 47 OH 2666:1 4 1 48 60 46 50 51 3 61 Sterile system Tetra Pak A3/Speed 0400 Technical Training Centre Lund, Sweden Denomination 1 Compressor 29 Reference point valve 59 Suction air flow meter 2 Water separator 30 Sterilisation bath 60 Level sensor, water seperator 3 Air superheater 31 Heating carpet 61 Air superheater temp. 4 Heat exchanger 32 Air knife heater 62 Sealing water flow meter 5 Heat exchanger valve 33 Water heaters 63 Presterilisation temp. 6 Spray nozzle 34 Air bleeder 64 Temp. sensor (PT100) Machine type 7 Preheating valve 35 Heat exchanger 65 Steam temp. Tetra Pak A3/Speed 0400 8 Silencer 36 Safety valve 66 Air knife temp. 9 Regulating valve 37 Automatic filling valve 67 Aseptic chamber temp. 10 Product valve (A) 38 Expansion tank 68 Pressure switch in AC 11 Sterile air valve (B) 39 Peroxide concentration detector 69 Level sensor, peroxide bath 12 Steam barrier valve (C) 40 Circulation pump, hot water 70 Peroxide bath temp 13 Steam pressure 41 Valve, filling peroxide bath 71 Level sensor, peroxid tank regulator, TCSB 42 Valve, draining peroxide bath 72 Peroxide tank temp. 14 Product flow meter 43 Filter 73 Level sensors, spray tank 15 Steam trap 44 Peroxide pump 74 Suction air temp. 16 Steam flushing valve 45 Peroxide tank 75 Heat exchanger temp. Issue 17 Sealing water valve 46 Cooling valve 76 Flow switch 1/1211 18 Sealing water 47 Valve, refilling peroxide 77 UV lamp pressure regulator 48 Peroxide container 78 Radiometer 19 Scrubber 49 Peroxide diluting valve 20 Float 50 Safety cap 21 Filling pipe 51 Diluting tank OH 2666:2 22 Level detector 52 Spray valve 23 Change over valve 53 Filling spray tank valve 24 Aseptic chamber 54 Filter 25 Pendulum roller 55 Spray tank 26 Air knife 56 Compress air filter 27 Squee−gee rollers 57 Safety exhaust valve 28 Suction valve 58 Spray valve Sterile System Option PullTab 1 2 1. Change over valve 2. Sterile air blower DIMC 4 B 3 A A 1. Blowing device 2. Nozzles for blowing device 3. Nozzle for blowing device 4. Suction / sterile air inlet for blowing device 2 B 1 Technical Training Centre Machine type Issue Lund, Sweden TP A3/Speed 0300 1/1206 OH 2592 Scrubber Water Air Tetra Pak Processing & Packaging Systems AB Machine type Issue Technical Training Centre, Lund, Sweden Tetra Pak A3 2/0510 OH 1460 Water separator Water Air Technical Training Centre Machine type Issue Lund, Sweden 1/0709 OH 1960 3TERILE 3YSTEM 7ATER RING COMPRESSOR 4ECHNICAL 4RAINING #ENTRE ,UND 3WEDEN -ACHINE TYPE )SSUE /( 2OTATING WATER RING !IR MIXED WITH WATER Sterile air flow meter Working principle - vortex meters Technical Training Centre 2/1009 TM-01413 v Sensor Training Document. For training purpose only. Sensor Vortex meters work on the principle of the Karman vortex street. When fluid pass a bluff body, vortices are alternately formed on both sides with opposite directions of rotation. These vortices generate a local low pressure. The pressure fluctuations are recorded by a sensor and converted to electrical pulses. The vortices develop very regularly within the application limits of the device. Therefore, the frequency of vortex shedding is proportional to the volume flow. Compressor unit Technical Training Centre Lund, Sweden Overview APC TPOP Air Pre−heated air alt. cooled air Sterile air Flow PLC Water Sealing water Flow Machine type Tetra Pak A3/Flex 0300 Issue 2/1009 Variable Frequency Drive OH 2250 Insulating material Pre−heated air Hot air Air Air superheater Technical Training Centre Machine type Issue Lund, Sweden TBA/19 TBA/21 TBA/22 3/9508 OH 107 Heat Exchanger Valve Heat exchanger valve Remote I/O DO_U70M2450_Fwd Motor DO_U70M2450_Bwd connection Sensor Heat exchanger AI_U70B2490 connection Air superheater DeviceNet PLC Shaft 0% - Maximum cooling Shaft 100% - Maximum heating (by-pass mode) Technical Training Centre 1/0803 TM-01306 Training Document. For training purpose only. 1 Compressed air Peroxide Spray nozzle Technical Training Centre Machine type Issue Lund, Sweden Tetra Pak A3 3/1005 OH 1300 U70M2360 - U70M2350 + U70K2360 OFF U70K2350 ON Technical Training Centre Sensor Lund, Sweden Cylinder U70M2360 U70B3220 Valve U70K2360 PLC address U70K2070_OUT3 Sensor U70B3020 Sensor U70M2360 - U70M2350 - U70B3230 U70K2360 OFF U70K2350 OFF Cylinder U70M2350 Machine type Valve U70K2350 PLC address U70K2070_OUT2 Tetra Pak A3 To air knife Air inlet Sensor U70B3030 Issue 5/1110 U70M2360 + U70M2350 + Butterfly valve U70K2360 ON U70K2350 ON OH 1935 Air knife valve To aseptic chamber Change over valve C A B AP−Valve 440630−020V (Aseptic Product Valve) Technical Training Centre Machine type Issue TETRA PAK Lund, Sweden 1/9208 OH 453:1 Aseptic Product Valve 440630-101/102 (The function is identical with valve 90 207-40/41) Technical Training Centre Lund, Sweden Machine type Issue 2/0601 OH 1:7 Working principles of refractometers Optimal image Process medium Technical Training Centre Machine type Issue Lund, Sweden Processing 1/9610 OH 642:1 Peroxide system Peroxide level monitoring Tetra Pak A3 level level sensor analogue signal input: U30K1140_IN-0 magnetic float 100% 10000 mV 9900 Level in Preparation if pump is OFF 9000 Level in Preparation if pump is ON 8400 Safety level: Low level in Stop 2500 Safety level: High level in Production 375 High level in Production 219 Low level in Production 30 Minimum level (Pump stop) 0% 0 mV Level measuring Transducer: 0-10000mV The level in the peroxide tank is measured by means of the level probe, a transducer and an analogue signal input. Analogue signal input: U30K1140_IN-0 The level is measured every 0,1 sec and an average (new filtered value) is calculated by the following formula: new filtered value = 10% of measured value + 90% of previous filtered value There is no calibration in the sensor. The new filtered value is used for all the level monitoring functions. When the magnetic float is in the highest possible position the analogue signal input = 10000 mV (100%) When it is in the lowest possible position the analogue signal input = 0 mV (0%). Safety levels The safety levels are checked: If the level is lower than 8400 during a stop it is not possible to start the machine. There is not enough peroxide in the tank to fill the bath. If the level is above 2500 during Production the machine stops. Technical Training Centre 2/1007 TM-01298 Training Document. For training purpose only. 1 1. A1 2. A1 Level relay Technical Training Centre Lund, Sweden 230V 230V Latch function A2 A2 B1 B3 B2 15 16 18 B1 B3 B2 15 16 18 To PLC INPUT To PLC INPUT Machine type L 11 (24 VDC) L 11 (24 VDC) 3. A1 4. A1 Issue 230V 230V 2/0405 A2 A2 B1 B3 B2 15 16 18 B1 B3 B2 15 16 18 OH 1223 To PLC INPUT To PLC INPUT L 11 (24 VDC) L 11 (24 VDC) 1 5 6 7 8 UV Lamp 3 4 Technical Training Centre Lund, Sweden Components 2 TP A3/Speed 0200/0300 Machine type Issue 2/1009 13 12 11 10 9 OH 1945:1 1 Generator (power supply) 9 Deioniser 2 Thermocouple 10 Thermocouple Tap water 3 UV lamp 11 Pump 14 UV lamp cooling water 4 UV radiometer 12 Tank 15 5 Flow switch 13 Conductivity transmitter 6 Filter 14 Peroxide diluting valve 7 Heat exchanger 15 Peroxide tank 8 Water purification unit 2 3 UV Lamp Technical Training Centre Lund, Sweden 4 Cooling System Overview 1 TP A3/Speed 0200/0300 Machine type 5 8 6 10 13 9 7 Issue 2/1009 12 11 OH 1945:2 1 Generator (power supply) 9 Deioniser 2 Thermocouple 10 Thermocouple 14 3 UV lamp 11 Pump Cooling media 4 UV radiometer 12 Tank Tap water 5 Flow switch 13 Conductivity transmitter 6 Filter 14 Peroxide diluting valve UV lamp cooling water 15 7 Heat exchanger 15 Peroxide tank 8 Water purification unit UV lamp Technical Training Centre Lund, Sweden Quartz cladding tube Excimer lamp Machine type Tetra Pak A3/Speed Issue 1/0311 OH 1472 High voltage electrode Discharge gap Ground electrode Sterile system to B−valve OH 1970:2 Technical Training Centre Machine type Issue Lund, Sweden Tetra Pak A3 4/1206 OH 1970:1 Sterile system OH 1970:1 Technical Training Centre Lund, Sweden 1 Compressor 24 Valve − filling peroxide bath 2 Water separator 25 Valve − draining peroxide bath 3 Air superheater 26 Peroxide strainer 4 Heat exchanger − sterile air 27 Peroxide pump 5 Heat exchanger valve 28 Peroxide tank 6 Spray nozzle 29 Peroxide concentration meter Machine type 7 Spray generator 30 Valve − refilling peroxide Tetra Pak A3 8 Preheating valve 31 Peroxide container 9 Sealing water valve 32 Safety cap 10 Sealing water pressure regulator 33 Diluting tank 11 Scrubber 34 Filter − spray tank, peroxide 12 Change over valve 35 Filter − spray tank air 13 Sterilisation bath 36 Spray tank 14 Heating Carpets 37 Suction air temp. 15 Air knife heater 38 Temp. sensor − air superheater 16 Water heaters 39 Suction air flow meter Issue 17 Heat exchanger − hot water 40 Temp. sensor − pre−sterilisation 6/1206 18 Circulation pump − hot water 41 Temp. sensor − air knife 19 Automatic filling valve 42 Level sensor − peroxide bath 20 Pressure expansion tank 43 Temp. sensor − peroxide bath 21 Flow switch H2O2 heating system water 44 Level sensor − peroxide tank 22 Safety valve OH 1970:2 45 Temp. sensor − peroxide tank 46 Temp. sensor − heat exchanger hot water 47 Safety exhaust valve, air 48 Safety spray valve, air 49 Flow meter − sealing water 50 Peroxide diluting valve 51 Peroxide cooling valve 52 Pressure gauge Sterile system Tetra Pak A3/Speed 0400 Preparation Technical Training Centre Lund, Sweden Air Hot air Pre−heated air alt. cooled air Steam Product Water Machine type Tetra Pak A3/Speed 0400 Peroxide Compressed air Cleaning liquid Issue 1/1211 OH 2666: 3 Ladder diagram TP A3/Speed 0300, TP A3/Flex 0300 Signal to sterilizer............................................ Dairy Ready for production. Various module function OK. Sterilization done............................................. Various module sterilization function OK. DE ready. Drying...................................................... Sterile function OK, no sterilization alarm, 15 min drying Spraying.................................................... 3 sec