Pre - Operation Checks P1 P2 P3 P1 P2 P3: Product 1 (P1) : Product 2 (P2) : Product 3 (P3) [PDF]

Zitiervorschau

TBA 19 Production Checklists Operator’s Name Product Volume

Production Date

Product Brand/Flavour Product 1(P1):

Product 2(P2):

Product 3(P3):

Items

Instructions

Remarks

Start Time End Time Items

Instructions

Remarks

P1 1.Pressure Gauges

Pre – Operation Checks P2 P3

P1

2.Air and Water Valves

Close the TS cooling water valve (2). Open the input air valve (3). Close the cooling water valve (4).

Make sure all pressure gauges show zero.

3.Steam Valve 4. Temperature Controlled Steam Barrier Make sure that the steam valve is open

5.Hydrogen peroxide Conc

Check the hydrogen peroxide concentration

6.Water Pressure

LINE Position: corresponds to the steam pressure in the line. LOW position(production): the steam pressure should be between 0.4 and 0.5 bar. 7. Lamp test

Water Pressure should be 1.5 bar

8.Reset Package Counter

If not adjust it. This Corresponds Temp range of 109 to 111°C. HIGH Position (sterilisation):steam pressure should be between 1.7 and 1.8 bar. Corresponds to 130 to 131°C. Turn the selector to the OFF position.

Press the LAMP TEST button (arrow) on the TPOP and check that: Audible alarms Warning Lamps flashing Buttons on TPOP Flashing

9. Preheating I

Reset the package counter in manoeuvre systems on TPOP.

Turn selector switch on TPOP to the left Press program up button 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 attachment

12.Remove the cleaning pipe Loosen the nut (1) and remove the cleaning attachment (2)

13.Gaskets

Remove gaskets

Release the nuts (1) and remove the Cleaning pipe (2). Remove the cap (3).

14.Fit the sterile air pipe

Fit the sterile air pipe as

P2

P3

from pipe fittings 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

shown in the diagram

16.Inspect the cleaning Pipe Inspect the cleaning pipe and clean the flexible part. Store the cleaning pipe in a clean place.

Fit the product pipe as shown in the diagram

17.Aseptic Chamber door

19.LS Strip pressure roller

Thread the packaging material slowly over the roller (1), under the bending roller (2), over the roller (3), and down through the aseptic chamber. Make sure that the packaging material is aligned with the pointer (4) in the aseptic Chamber. Make sure that the LS strip pressure roller • is correctly attached • is clean • has no surface defects

21. Close the divided forming ring.

18. Lower aseptic chamber door

Open the lower aseptic chamber door and open the divided forming ring by lifting the handle (1).

20.Pull Packaging material through DFR an d LFR

22.Close aseptic chamber door Make sure that the guide roller is lowered and the packaging material passes on each side of it.

23. Filling Pipe with Locking Fork

25. Pull the packaging material down to the jaws.

Pull the packaging material down through the divided forming ring and lower forming ring. DFR- Divided forming rings LFR-Lower forming rings

Make sure that the O-ring (1) is in the correct position on the upper filling pipe and not worn or damaged, replace if Required.

Close all covers and doors on the machine and press the flashing ACKNOWLEDGE button to Acknowledge the alarm.

24.Tetra pak multipurpose compact controller On the FCS TMCC2 card (A310) make sure that the LED S8 on the front panel is OFF.

26. Slow inching. Before touching the packaging material, disinfect your hands or gloves. Pull the packaging material down to the jaws. Swing the photocells back into their production position

Press the INCHING button until the jaws grip the packaging material and pull it dow n

27.P.M position in guides

28.Overlapping of PM

Make sure that the LH edge of the packaging material overlaps the RH edge.

Make sure that the packaging material is correctly positioned in the guides 29.Preheating II

Press the PROGRAM UP button until the PREHEATING II symbol stops flashing but remains lit.

31. Strip Supply

30.Transducer pressure Check the I/P transducer pressure is 2.0 bar

32.Tube Sealing When the TUBE SEALING symbol and the PROGRAM UP button start to flash, press PROGRAM UP.

Thread the LS strip

33.Package Checks

Pick out the last package discarded from the machine. Check the LS strip is correctly positioned and properly sealed,

35.Spraying Symbol

34.Preheating III When the packaging material tube is sealed, the PREHEATING III symbol stops flashing but remains lit. 36.Drying Symbol

When the presterilisation temperature is reached, the SPRAYING symbol and the PROGRAM UP button begin to flash. 37. Reset the TMCC2 parameter

39. Check Machine sterility

This instruction is valid when changing from a high viscosity product (i.e. tomato paste) to a low viscosity product (i.e. tea) and vice versa. Reset the TMCC2 parameter by pressing the filling mode RESET button On the process recorder air knife channel, at least two items which represent 60 seconds should be over 200 °C.

41.Ready for Production

After spraying, the DRYING symbol Lights. The drying time is 20 minutes.

38.Signal to steriliser and from steriliser

40.Signal from steriliser

When the SIGNAL TO STERILISER Symbol and the PROGRAM UP button start to flash, press the PROGRAM UP button. The SIGNAL TO STERILISER symbol stops flashing but remains lit.

The SIGNAL FROM STERILISER symbol stops flashing but remains lit when steriliser is ready Proceed Production

42.Motor start When READY FOR PRODUCTION symbol and the PROGRAM UP button start to flash, press the PROGRAM UP button

Keep the PROGRAM UP button pressed until the drive motor starts and the MOTOR START symbol stops flashing remains lit.

Operating Checklist 43.Filling Mode

When the FILLING symbol lights, the level start to increase and is indicated from LED S8 to LED S5 on TMCC2; the level indicator should stabilise within seven

44. Production

When the packages start to be produced correctly, the PRODUCTION symbol Stops flashing but remains lit. The packages are directed to the final

or Eight packages. 45.Package checks

46.Setting Values Check that all pressure gauges show the Correct settings during production.

Pick out the first two consecutive packages discharged from the final folder and perform package checks on them.

folder. Pressure(Bars) Cutting Pressure(8-9) Jaw Pressure(9-9.6) Cold water (0.30-0.45) 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) Hot air element(165) Pre-sterilisation(270) Water Bath (74) Water Bath (Pre-ste)(80) LS sealed Tube(280) 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 When PRODUCTION A. is finished, press the PROGRAM UP button.

B.

Venting

After two minutes the VENTING symbol becomes fixed. Venting of the aseptic chamber starts After five minutes, the VENTING FINISHED symbol starts to flash.

C. Cut the P.Material

Open the aseptic chamber door. Cut the packaging material. Close the aseptic chamber door. The VENTING FINISHED symbol remains lit.

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 If the machine cannot 20 mins be stepped to PRODUCTION within 20 minutes, press the INCHING button to renew the length of packaging material between the Pull Tab unit and the jaws

D. Preparation for CIP

Press program down Turn switch right Press program up Preparation for CIP symbol becomes fixed.

40 minutes

If the machine cannot be stepped to PRODUCTION within 40 minutes, the packaging material may tear. If the machine cannot be stepped to PRODUCTION within 40 minutes, press PROGRAM DOWN twice. The program steps to VENTING.

E. Remove packaging