EA-4000/8000/12000/16000

Quick Guide (Chapter 6 in Instruction manual)

1. Pre-sterilization
Before starting the pre-sterilization, perform the following preparations:
1. The machine is set to No Mode.
2. The electric supply has been turned on from the main switch on the rear
control panel.
3. The compressed air supply is at 6 bar or more.
4. The control voltage is enabled.
5. Turn on the heating of the sealing devices from the touch screen.
6. Ensure that all the UV lights are on.
7. Wipe the film widening wire, the filling nozzle, the screen plate and the
pre-sterilization plug with sterilising agent.
8. Check that the filling tube is clean and has no milk spills. If necessary,
clean it with a washing detergent and a brush.
9. Install the screen plate and the filling nozzle.
10. Close the filling tube with the pre-sterilization plug. See Figure 100
Inserting the Pre-sterilization Plug (Instruction manual).
11. Fill up the hydrogen peroxide baths.
12. Make sure the date-stamping unit is ready.
13. Thread the pre-sterilization film around the filling tube. For detailed
instructions, see section 6.5.1 (Instruction manual)
14. Spray sterilising agent to UV-cabin.

To start the pre-sterilization:

1. Open the Mode of Operation page from the touch screen and select Pre-
sterilization in the Cycle Selection field. The message PRE-STERILIZATION
RUNNING is shown on the display.
2. When the dosage starts, check the pressure indicator to make sure the
circulation of hot water starts.
3. Start the SIP for the Elecster Sterile Air Unit (ESA).
4. When the message ADD HYDROGEN PEROXIDE is shown on the display, fill
the hydrogen peroxide cups.

To start Sterile Cooling:

1. Open the Mode of Operation page and select Sterile Cooling in the Cycle
Selection field. The message STERILE COOLING RUNNING is shown on the
display.
2. When the set point (SP) value for the cooling phase has been reached,
remove the pre-sterilization plug so that it falls inside the first empty

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 EA-4000/8000/12000/16000
Quick Guide (Chapter 6 in Instruction manual)

pouch. Note: Secure Filling nozzle and Film widening wire correct
fastening.
3. Draw the pre-sterilization film down by turning the Forward/Reverse and
jog switches until the pre-sterilization film has been removed and only the
normal packaging film again is drawn around the filling tube or draw the
pre-sterilization using semi-automatic pre-sterilization film threading. Be
careful not to damage the film or contaminate the aseptic conditions inside
the sealing cabinet.
4. Using function switch in pos. 3, press the Start button and make pouches
filled with sterile water until the normal packaging film reaches around the
filling tube. Check thoroughly that the film overlaps evenly and that the
print registration system functions correctly.

2. Production
To start the production:
5. Open the Mode of Operation page and select Production in the Cycle
Selection field. The message PRODUCTION RUNNING is shown on the
display.
6. When the message START FILLING is shown on the display or some other
indication from process is shown for example green light, press the Start
button on the front control panel to activate the sealing unit.

3. Performing Aseptic Intermediate Cleaning (AIC)

To start the AIC:

7. Open the Mode of Operation page from the GUI and select AIC in the
Cycle Selection field. The message AIC RUNNING is shown on the display.
8. When the message AIC END is shown on the display, restart the
production. See instructions in section 0.
9.
4. Preparing for Cleaning in Place (CIP)
1. TPC and Yeast/mould testing for UV-, hydrogen peroxide and sealing cabinets
2. Hydrogen peroxide concentration checking

5. Performing Cleaning in Place (CIP)

Preparations for the CIP:

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 EA-4000/8000/12000/16000
Quick Guide (Chapter 6 in Instruction manual)

1. Cut the packaging film below the UV cabinet and remove the film from
around the filling tube.
2. Secure the end of the packaging film to the roof of the film cabinet.
3. Remove the filling nozzle and the screen plate, wash and store in sterilising
solution until the next production run.
4. Remove the film widening bar, wash it, and store it in sterilising solution
until the next production run.
5. Clean the outer surfaces and the filling tube with warm water and a brush.
6. Empty the hydrogen peroxide cups.
7. Close off the filling head with the CIP plug.
8. Uninstall extension spindles and make CIP cleaning with max filling
volume.

To start the CIP:

9. Open the Mode of Operation page from the GUI and select CIP in the
Cycle Selection field. The message CIP RUNNING is shown on the display.
10. When the message START DOSAGE is shown on the display, press the
Dosing button.
11. Monitor the flow through all filling heads

After the CIP:

1. disassemble the filling cylinder and wash the piston and packings with a
detergent
2. disassemble the filling cylinder adjustment end and wash the piston and
packings with a detergent
3. Wash hydrogen peroxide baths
4. Wash hydrogen peroxide drying rubbers
5. Make other daily cleaning and service tasks for sealing devices, cabinet and
outer cleanings
6. In addition, disassemble at least once a week the control cylinder of the
filling machine to clean the O-rings and packings and check their condition.
7. NOTE: Leave UV-light on overnight.
8. Housekeeping: Machine outside, conveyors, walls, floor

6. Performing Cleaning result evalution

1. CCP checkings
Note: Leave UV-light on overnight

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Quick Guide (Chapter 6 in Instruction manual)

7. Record collection
1. Running hour recording
2. Collect records from production/operation (logbooks)
3. Collect records from service (service tables)
4. Collect records from operator panel (alarm lists)
5. Collect records from sterilizer recorder (temperature/pressure/conductivity
graphs)
6. Collect record from laboratory

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