Aseptic food processing

Aseptic food processing
Sterilized
packaging
material
Sterile
surrounding
Commercially
sterile food
Aseptic
transfer
Aseptic packages
Water ring compressor
Rubber roller
Peroxide bath
Water separator
Product
Peroxide can
Air
superheater
Cooler
Tube heater
Tight tube
Air
Sterile area
Peroxide
Product
Water
Packaging
material
TBA/3_600V Step up conditions
10. Cleaning
9. End of Production
8. Filling / Production
7. Start sequense
6. Tube Heater -high temp.
5. Sterilizersignal:
TO / FROM
4. Sterilizing / Cooling
3. Tube sealing / St.Air temp.
2. Preheating / Preh. finished
TBA/3_FINO Step up conditions
.
Cleaning
push
End of Production
push
within 90 Sec.
A-valve close,Dropchute back in , After 7 Sec. C-valve slowly
close (4-12s),After 10-12Sec. main motor stop,LS,SA nozzles back .
. ..
.
Tube heat temp .back to 240 c/235 c , Splash valve(Y31) open,
Boosted cooling valve(Y33) open ;Jet diverter valve(Y41) close,
countdown 3 mins ;Jet diverter valve reopen after 3 mins.
In production
Production
7 Sec.countdown OK
Drop chut out;Package counter on .
29s/26s countdown OK
C-valve open ,then after 1-2Sec. A-valve open ,Jet diverter valve open,
countdown 7 Sec.
Filling
Push within 20Sec. after
tuber heater w2 ok
Start Sequense
Flash
Main motor On;SA,LS nozzles in position;Driven bending roller run;
Tube sprinkler valve (Y31) close;
Boosted cooling valve (Y33)off;Heat exchange valve(Y44) on.
Hour meter run;Countdown 29s/26s.
Tuber heater w2 ok
.
Tube Heater -high temp.
Push
.
.
Tuber Heater(w2)on(470 c/500ml,480 c/250ml), LS temp. to w1(210 c)
countdown 20s after Tuber heater w2 temp .reached.
Signal OK
No action after countdown 20s
Countdown 3 mins.Inch
Signal from Sterilizer
A104 B4 light .
Signal to Sterilizer
Push
K103 act;B-Valve close.
10 mins. reached
Cooling
30 mins. countdown
reached
Sterilizing
Push
.
280 C reached
St.Air temp.
29s or 26s count down
arrived
Tube Sealing
Push
Boosted cooling valve (Y33) open; Jet diverter valve(Y41) close;
Countdown 10 mins.
.
. c/500ml,240 c/250ml);
Tube Heat on (235
Countdown 30 mins.
Main motor stop ;SA,LS nozzle back;Tube sprinkler valve(Y31)
open ;B-valve(Y8,Y67) open;B-valve temp. monitor start to
.
read temp . value(280 c);Hour meter stop.
Flash
SA,LS nozzle in position ;Main motor run ;Driven berding roller turn;
countdown 29s (250)/26s(500); Cutting valve(Y60,Y61) on ;IH on;
Hour meter run.
5 mins.countdown OK
Ready for tube sealing.
Preh. Finished
Keep pushing till
compressor arrive 0.45bar
Preheating
Flash
Power,Cooling water, Air
.
Compressor run;Supper heater on (360 c);LS (W2) SA heating;H2O2
` supper heater
pump run;Lub.pump run;Coneyor run ;After temp. of
`
LS and SA arrived ,Start countdown 5 mins.
Water to compressor valve(Y32)open;Tube sprinkler valve(Y31)close;
Jet diverter valve(Y41)open;Paper spliceing element on.
Sterile air system
Checking, tightness
Check that the pipe connections and unions are
tight.
1
2
3
4
5
6
7
8
9
10
11
Compressor
Water separator
Valve, drainage
Valve, boosted cooling
Valve, sealing water
for compressor
Valve, boosted cooling
Diversion valve
Ejector
Overflow valve
Pressure guard
Air superheater
12 Air superheater
temperature
13 SA heater
14 SA heater
temperature
15 LS heater
16 LS heater
temperature
17 Sterile air cooler
18 Sterile air temperature
19 Jet diverter valve
20 Suction filter
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Product valve “A”
Sterile air valve “B”
Sterile air temperature
Proximity switch
sterile air valve (B)
Steam barrier valve
(C)
Steam temerature
Proximity switch
steam barrier valve
(C)
Air knife
Edge dryer
28
27
Peroxide bath
Peroxide bath cooling
Tube heater
Float
Valve, sprinkler
Steam trap
29
30
26
25
31
21
13
35
23
14
22
24
20
15
16
1
11
32
5
18
19
2
33
3
4
34
10
17
7
9
12
8
6
GBAABB77
89
Doc No MM-80269-0102
TBA/3 Tetra Fino
Issue
9510
MM 175-12 1(1)
Compressor of water ring type
Overhaul
1
2
3
4
Shaft
Motor
Pump housing
rotor
68
MM 160-32 4(5)
Issue
9508
Doc No MM-80269-0102
TBA/3 Tetra Fino
Principle of constant flow valve
Rubber ring
Constant
flow rate
of water
Water with
fluctuating
pressure
Water at low
pressure
Constant
flow rate
Water at high
pressure
Technical Training Centre
Lund, Sweden
Constant
flow rate
Machine type
Issue
1/9904
OH 819
Water separator
Dismantling, Cleaning, Checking float
a) Detach the entire water separator from the
machine.
b) Remove the flanges (2) and (3).
c) Check that float mechanism (4), the container
and the piping. If necessary use a deliming
agent.
Fitting
a) Check the O-ring (5,6) of the flanges and the
pipe-union seals.
b) Fit the water separator.
c) After starting the compressor, check that no
water comes of the overflow pipe (7). If so, the
water separator must be removed again and the
function of the float checked.
Note!
Water may also come out of the overflow pipe if the
sterile air cooler is blocked, see page 165-13 3(3)
1
2
3
4
Pressure gauge
Upper flange
Lower flange
Float mechanism
5 O-ring
6 O-ring flow
7 Overflow pipe
73
Doc No MM-80269-0102
TBA/3 Tetra Fino
Issue
9508
MM 162-21 1(1)
Air
superheater
Air
Hot air
Technical Training Centre
Lund, Sweden
Machine type
Issue
Tetra Brik Aseptic
1/9504
OH 537
Sterile air cooler
Checking tightness
Loosen the connections (1) and (2) on the cooler
and the connections (3) and (4) on the cylinder.
Connect a pipe (nipple TP No 90030-115) (5) to a
hose (9) put into a tank of water (6).
Plug the upper connection with a nipple
(TP No 90030-115) and a plugged pipe (7). Plug
the lower pipe (1) with a welded-up coupling
(TP No 90330-064). Plug the lower connection of
the cylinder with a welded-up plug (TP No 90224097) (8).
Remove the fuses to the air superheater and step up
the machine to Preheating. Check that
there is no bubbling in the tank (6). Replace the
fuses and once again check that there is no
bubbling.
When the machine has reached the Ready for
sterilization state, disconnect the
sterile air going to the tube by removing the quick
coupling on the B-valve.
Turn the jet deflector valve by pushing the cylinder
to the outer position. Once again check that there is
no bubbling. Step down the machine to
Cooling and check that water is sucked up
into the hose (9).
1
2
3
4
5
6
7
8
9
Connection
Connection
Connection
Connection
Pipe
Tank of water
Plugged pipe
Welded-up plug
Hose
79
Doc No MM-80269-0102
TBA/3 Tetra Fino
Issue
9508
MM 165-11 1(3)
Sterilization liquid
This section contains information on how to proceed
when handling the hydrogen peroxide used as
sterilisation liquid
• Concentration
!
WARNING!
Risk of personal injury! Hydrogen
peroxide. Follow the Safety precautions.
Concentration
1
The following equipment is required:
• aerometer with termometer
• graduated cylinder of plastic with an
inside diameter of 35 - 50 mm
CAUTION!
The equipment must be thoroughly
cleaned.
Open the valve (arrow) and draw approx
250 ml of hydrogen peroxide from the
machine into a clean vessel.
Pour a small amount of hydrogen peroxide
into the graduated cylinder. Lower the
areometer into the cylinder making sure
that there is enough to float the areometer.
If there are air bubbles on the areometer,
stir gently until the bubbles disappear.
Read the density at the liquid level on the
areometer and at the same time read the
temperature.
Doc No OM-80268-0101
TBA/3 Fino
113
Sterilization liquid
2
The hydrogen peroxide concentration in
terms of per cent by weight can now be
read from the nomogram.
Temperature
80
70
60
Density g/cm3
1.200
50
By means of a ruler, join the density value
of the sample (on the density scale) with
the temperature value on the temperature
scale.
If the hydrogen peroxide
concentration is incorrect
If the concentration is below 30% or
above 50%, replace the hydrogen
peroxide.
Hydrogen peroxide
%/weight
1.190
1.180
50%
40
1.170
45%
1.160
1.150
30
40%
1.140
20
35%
1.130
1.120
10
30%
1.110
1.100
25%
0
1.090
20%
1.080
1.070
15%
1.060
1.050
10%
1.040
1.030
5%
1.020
1.010
0%
1.000
114
Doc No OM-80268-0101
TBA/3 Fino
RUN
Temperature regulating principle
PLC
0
Technical Training Centre
Lund, Sweden
240
Machine type
Issue
1/9601
OH 574
Principle of tube heater TBA/3
Temperature on
inside of packaging
material
Peroxide
on packaging
material
Product
Peroxide
Cooled air
Technical Training Centre
Lund, Sweden
Machine type
TBA/3
Issue
1/9107
OH 414
L1
L2
L3
Tube heater TBA/3_600V, TBA/3 Fino
N
F003A
F003B
A307
K10
9
10
27
K307
26
18+
23
17
24
19
M.B44
M.R34
Yellow
1
Red
2
20
SP1
SP1
Production
Disconnected
0-3 min
SP1
Product(AP) Valve
Graph for the cylinders and the drive motor
The synchronization of the cylinders must follow
the graph.
Sterilization off
Preheating off
Sprinkler on
Production off
Production on
Tube sealing
Sterilization on
Cooling on
Sprinkler on
Sprinkler off
Preheating on
The closing time of the C valve varies (4-12sec), depending
on product viscosity. The higher the viscosity, the
longer time. Adjust vith the throttle (25).
Open
Closed
A
Tight tube feed 26 - 46 sec
B
Open
Closed
C
Open
Closed
5 sec 4 - 12 sec
Open
Closed
Drive
Motor
13 sec
4 sec
Tight tube feed 26 - 46 sec
A) Product
B) Hot air or cleaning
C) Steam
21
22
23
24
25
Open position
Close position
Exhaust
Air in
Throttle
25
All valves are shown in closed
position. the cylinders are vented
and springs are closing them.
44
Doc No MM-80269-xxxx
TBA/3 Tetra Fino
Issue
9912
MM 127-XX x(x)