Contents

Aseptic food processing .

Sterile system overview

Creating and maintaining a sterile surrounding

Components in the sterile system

Scrubber

Water ring compressor

Water separator
Heat exchanger
Air superheater
Peroxide evaporator
Suctionvalve ‎‫ا‬

The function of the sterile system ‎‫ب‬... ‫تت‬ ‫ ااا‬81

Starting the filling machine . .. ........ ... .. ... ... . ... ... ... 18
Preheating I . .
Preheating 11
Tube sealing
Preheating I11
The spray sequence
Filling spray tank
Spraying

Drying
Signal exchange with the processing equipment . .
Production .......... ... ... .. ..
Top filling the peroxidebath . ...........................
Stopping the filling machine . .. ............... ... ... ... ...
Normal stop
Short stop ...
Security stop
Emergency stop
End of production . .
Venting
Venting; Ready for dooropening . ........................
 Sterile system
TBA/19 020V
This description of the sterile system of a TBA/19 machine includes the
following topics:
٠ A brief explanation of the concept “Aseptic 1000 processing”.
TBA ٠ An overview of the sterile system in a TBA machine.
Tetra Brik Aseptic
٠ Descriptions of ‎‫ عط‬components in the sterile system.
٠ An overview of the aseptic production cycle.
٠ Description of ‎‫ عط‬function of the sterile system ‎‫ م ص‬TBA/19 machine.

Aseptic food processing

The sterile system

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Aseptic packages
Aseptic food processing

Sterile Before arriving at the filling machine, the product is treated so that it is free
Free from micro-organisms. from all micro-organisms able of multiplying, which means that it is
commerecially sterile.D
Commercially sterile
Free from micro-organisms The piping is sterilised before conveying any product, which means that ‎‫عدا‬
able of multiplying. transfer to the filling machine takes place under aseptic conditions.@
Aseptic The packaging material is sterilised by the sterile system of the machine.®
Prevents reinfection
The sterile system also creates a sterile surrounding © in which aseptic
packages are produced.®

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5161116 system overview

000 ‎‫“ند‬
8 Peroxide
Aseptic chamber [0 Product
O water

Peroxide bath

Compressor Peroxide tank

Air superheater

Sterile system overview

Before production can take place, the packaging material must be sterilised
and a sterile surrounding must be created in the aseptic chamber. This is the
task of the sterile system.
The aseptic chamber is sterilised by a small amount of peroxide, sprayed into
the aseptic chamber during start.
To maintain ‎‫ عط‬sterile surrounding in the aseptic chamber, micro-
organisms must ‎‫ عط‬prevented from entering during production. This is done by
creating an overpressure with heat-sterilised air in the aseptic chamber.
The packaging material is sterilised by warm peroxide in the peroxide bath,
before entering the aseptic chamber.

4 Training Document. For training purpose only. L ‎‫ دمع‬Training Centre 1/0303


Creating and maintaining
a sterile surrounding
in the aseptic chamber
g ‎‫ ميت‬Training Centre 1/0303
The peroxide is
condensed and then
dried with hot sterile air.
Aseptic machine sterilisation
Sterilisation is part of the start procedure, and is performed in several steps.
First the sterile air system has to be isolated from the surrounding environ-
ment. This is done by forming the packaging material into a tube and seal it.
Then a sterile surrounding in the aseptic chamber is created by spraying
peroxide into the heated air in the sterile air system. The peroxide will
evaporate in the hot air.
When ‎‫ عط‬peroxide vapour reaches the aseptic chamber, it will condense on the
cold surfaces.
The peroxide will ‎‫ عط‬dried up by means of heat-sterilised air, circulating
through the aseptic chamber.
During production, the sterile system will create an overpressure with heat-
sterilised air in the aseptic chamber. Thus the sterile surrounding is
maintained.
Training Document. For training purpose only. 5
Components in the sterile system

1. Water ring compressor 11.Air 10161 valve 19. Bending roller 30. Peroxide tank
2. Scrubber 12. Product valve, 20. Driven bending roller 31. Peroxide pump
3. Constant flow valve (A-valve) 21. Suction valve 32. Spray tank
4. Water separator 13. Sterile air valve, 22. Chamber pressure valve 33. Spray tank level sensor
5. Venting valve (B-valve) 23. Water circulation pump 34. Spraying peroxide valve
6. Heat exchanger 14. Steam barrier valve, 24. Water bath heater 35. Air valve, spraying
7. Heat exchanger valve (C-valve) 25. Water bath
8. Air superheater 15.LS-element 26. Peroxide bath
9. Peroxide evaporator 16.LS short stop-element 27.Membrane valve
10. Presterilisation 17.Filling pipe 28. Peroxide container
temperature sensor 18. Air knife 29. Filling peroxide pump
Sterile system TBA/19, Denominations

Training Document. For training purpose only. 72 ‫ مامه‬Traring‫‏‬ ‫ ماه‬10303

Scrubber The purpose of the scrubber 15 to remove the peroxide from the air exhausted
by suction from the peroxide bath and the aseptic chamber.
This is done by cooling the warm air with water. The peroxide, which is in
state of vapour, will then condense and mix with the water. For maximum
cooling effect, a nozzle will sprinkle the water finely into a mesh, which will
increase the contact area between the water and the air.
The scrubber will also remove paper dust from the air coming from the aseptic
chamber. The paper dust will stick ‎‫ ما‬the water and follow it further ‎‫ ما‬the
water separator.

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 Rubber ring Constant
flow rate
of water

Water with
fluctuating
pressure

Water at low
pressure

Water at high
pressure

Constant flow valve

There is a constant flow valve fitted just before the scrubber. Its purpose is to Constant flow valve
see to that the water flow coming to the scrubber is constant no matter what
the incoming water pressure is.
The working part of the valve is a thick rubber ring.
When the incoming water pressure is low, the opening of the ring will remain
unaffected. But, when the incoming water pressure is high, the ring will be
deformed and its opening will become narrower. Thus the water flow rate after
the ring will be the same, no matter what the water pressure is.

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 ‫ل‬8 Ar inlet‫‏‬
[ Rotating water‫وما ‏‬
B Airand water outlet‫‏‬
Water ring compressor
‘Water ring compressor
g ‎‫ ميت‬Training Centre 1/0303
The purpose of the water ring compressor 15 to pump the air around in the
sterile air system.
When the compressor is running, a ring of water rotates against the inside of
the compressor housing.
The rotor is fitted assymmetrically in the lower part of the compressor
housing. When the rotor chambers are in the lower position they will ‎‫ عط‬almost
filled with water, whereas in the upper position they will be almost empty.
This alternately filling and emptying, causes the pumping action. One could
say that the water works as pump pistons.
Some water will follow the air out of the compressor and continue to the water
separator, and new water is continously fed from the scrubber.
Training Document. For training purpose only. 9
 O water
‎‫تدم‬

Water separator

The purpose of the water separator is ‎‫ ما‬remove the water from the air that ‘Water separator
comes from the water ring compressor.
The separator is so designed that a whirl will arise when the air enters it. The
air is forced uppwards, through a filter, where the water will gather into bigger
drops and fall down.
On the bottom of the separator there is a float which will open and let the water
out when the level is rising, and then close again when the level is sinking. The
water that remains on the bottom of the separator works as a waterseal,
preventing air leakage during operation.

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 @ Air
M Hot air
[0 Pre-heated air alt. cooled air
Heat exchanger

Heat exchanger The purpose of the heat exchanger is to cool as well as to warm up the air.
The cold air coming 7o the air superheater @ is used to cool the air coming
from the air superheater @), so that it doesn’t heat up the packaging material
nor the aseptic chamber ©
In its turn, the cold air is warmed up by the hot air before entering the air
superheater @, which reduces energy consumption.

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 O ‎‫عتم‬
][ Preheated air
. Hot air
. Insulating material

Air superheater

The purpose of the air superheater is to heat-sterilise the air in the sterile air Air superheater
system. All micro-organisms will be killed in the hot air.

12 Training Document. For training purpose only. ‎‫ ككل‬Technical Teining Gentre 110303
 Spray nozzle

Peroxide evaporator [ Peroxide

[ compressed air
[ Hot air

Peroxide evaporator The purpose of the peroxide evaporator is to evaporate the peroxide.
Compressed air and peroxide is forced through the spray nozzle and into the
evaporator. The peroxide will evaporate in the hot air, that comes from the air
superheater. A spiral inside the evaporator helps the hot air and the peroxide
mix.

72 ‫ مامه‬Traiing‫ مومه ‏‬110303 Training Document. For training purpose only. 13

 Suction valve, position during Production Suction valve, position during Normal stop and Short stop

The purpose of the suction valve is ‎‫ ما‬control the exhaustion of air mixed with Suction valve
peroxide vapour from the peroxide bath and the aseptic chamber.
The suction valve has got two positions. During production it is open to let
warm air from the air knife pass. This air contains peroxide vapour coming
from the packaging material When the machine stops it changes position and
opens for peroxide vapour remains to be exhausted from the peroxide bath,
when this is emptied.
On the suction valve is fitted a connection to the LS element as well. If the
machine makes a stop during production, warm air from the LS element will
be exhausted in order to reduce the flow of warm air in the aseptic chamber.
This is done to spare the packaging material.

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 (|9 0

Aseptic product valve

Aseptic product valve The AP valve is in fact ‎‫ د‬combination of three valves; the A-, B- and C-valves.
(AP valve) ٠ The A-valve controls the product flow. It opens ‎‫ ما‬let product in ‎‫ ما‬the
filling machine.

W Hot air [ Cleaning liquid

8 Steam 8 Cleaning liquid
[ Product AP valve, Position during production

L ‎‫ دهز‬Training Centre 1/0303 Training Document. For training purpose only. 15

 « The B-valve controls part of the sterile air flow. It opens to let sterile
air in to the filling pipe during sterilisation.

AP valve, Position during sterilisation

« The C-valve opens and closes the part of the AP valve that is used to
create a steam barrier between the filling machine and the product
piping. At the same time the steam will sterilise this space.

AP valve, Steam barrier

The AP valve can take a number of positions. In addition to above shown,

there is for example the position it takes during final cleaning:

[l Hot air [l Cleaning liquid

8 Steam 8 Cleaning liquid
O Product
AP valve, Position during final cleaning

16 Training Document. For training purpose only. ‎‫ ككل‬Technical Teining Gentre 110303
 The aseptic production cycle
The aseptic production cycle describes what phases the Tetra Brik Aseptic
filling machine goes through. The sterile system is in operation only during a
part of the cycle.

Preparation of filling machine

Sterilsation of filling machine

No production planned time

Production

External cleaning

sterile system in

Aseptic production cycle

g ‎‫ ميت‬Training Centre 1/0303 Training Document. For training purpose only. 17

The function of the sterile system
This section describes how the sterile system works. Below you can see which
machine modes, and sequences, are described:
Preheating 1
Start Preheating 1T
Tight tube
Spray Preheating 1
Sterilisation
sequence Filling spray tank
Spraying
Pause
Drying
Signal exchange
Production
Top filling during production
Normal stop
Short stop Stops
Security stop
Emergency stop
End of production
Venting
Venting; Ready for door opening

Starting the filling machine

The start of the filling machine is performed by the control system of the ma-
chine, with assistance from the operator.
The start is performed in several steps, beginning with Preheating I and ending
with Production. Before stepping up the machine, it must be provided with
* cooling water
* compressed air and
* power supply.
Below is described what happens in each step.

18 Training Document. For training purpose only. 72 ‫ مامه‬Traring‫ ماه ‏‬10303

 516116 system TBA/19 ‎‫م‬.
Preheating |

O ar
M Hot arr
[] Pre heatedair
alt.cooled alr
[ steam
[ Product
[0 water
(I Peroxide
[ compressedair

Sterile system TBA/19, Preheating |

Preheating 1 In this mode the water bath is ‎‫ عط ما‬warmed up and the peroxide tank ‎‫عط ما‬
filled up.
‘When the machine ‎‫ قا‬stepped up ‎‫ ما‬Preheating I, ‎‫ عط‬heating of the water in the
water bath starts and the circulation pump starts circulating the water.
The peroxide tank is filled with peroxide from the peroxide container. The
filling peroxide pump will stop when the correct level is reached, and the ma-
chine can be stepped up to Preheating II.

L Techrica Treining Centre 110303 Training Document. For training purpose only. 19
Sterile system TBA/19 o
Preheating 1 «‫برج‬

O ‎‫علم‬
8 Hot arr
[ Pre heatedair
alt.cooled alr
[ steam
[ Product
@ water
[ Peroxide
[ compressedair

Sterile system TBA/19, Preheating Il

In this mode the LS-element is to be heated, as well as the piping between the Preheating 1
air superheater and the air inlet valve.
The peroxide starts circulating to be warmed up in the peroxide bath.
When ‎‫ عط‬machine is stepped up ‎‫ ما‬Preheating II, the water ring compressor
will start. Once the pressure is correct, the compressor will continue running Ls
Longitudinal seal
by itself. As soon as the compressor has started, the LS-element will be acti-
vated as well.
The compressor circulates the air in the sterile air system. The heat exchanger
will be bypassed and the cold air will continue directly to the air superheater,
where it is heated, and then further on to the aseptic chamber and the LS-
nozzle. This way the LS-nozzle will reach its correct temperature faster.
When the LS-nozzle has reached the correct temperature, the machine 15 ready
to create a tight tube.

20 Training Document. For training purpose only. 72 ‫ مامه‬Traring‫ ماه ‏‬10303

 516116 system TBA/19 v
Tube sealing

O ‎‫علم‬
M Hot arr
[ Pre heated air
alt.cooledalr
[ steam
[ Product
8 water
[ Peroxide
[ compressed air

= =)

Sterile system TBA/19, Tube sealing

Tube sealing In this mode ‎‫ عط‬packaging material, which is formed into a tube, is sealed.
This will isolate the aseptic chamber from the surrounding environment.
The machine will feed the packaging material and LS-strip will be applied by
the strip applicator. To make sure that the whole length of packaging material
is fitted with strip, the feeding will continue until the packaging material from
the strip applicator has reached the jaw system.
The machine will also check that there is neither strip splices nor packaging
material splices inside the aseptic chamber. Should that be the case, Tube seal-
ing will proceed until any splice has left the aseptic chamber.
The machine will finish Tube sealing by performing a transversal sealing on
the last package in the machine; and the tube is sealed.
Now, sterilisation can take place. The machine will automatically change ‎‫ما‬
Jast packagein Preheating I11.
the machine

transversal seal

Packaging material tube

L Techrica Treining Centre 110303 Training Document. For training purpose only. 21
Sterile system TBA/19 o ‎‫كا‬ =
Preheating Il QL

[ ‫علم‬
‫كنا‬
][ Pre heatedair
alt.cooled alr
[ steam
[ Product
[0 water
[ Peroxide
[ compressedair

Sterile system TBA/19, Preheating ‎‫ا‬

In this mode the piping between the air superheater and the air inlet valve is to Preheating 1
be sterilised.
The air inlet valve changes position ‎‫ ما‬prevent the air from passing through the
aseptic chamber, ‎‫ ما‬prevent unwanted heating. Instead it will ‎‫ عط‬led back to the
scrubber.
Asno airis let into the aseptic chamber, the suction valve changes position and
air is exhausted via the peroxide bath instead. On the bath is 111160 a membrane
valve, letting in air.
The pressure chamber valve too, will change position ‎‫ ما‬increase the amount
of air let in.
When pre-sterilisation air temperature is reached at the air inlet valve, the
spray sequence can be started.

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 The spray sequence
The spray sequence is a sequence of four modes:
« Filling spray tank
* Spraying
* Pause
٠ Drying

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516116 system TBA/19 ‎‫م‬.
Filling spray tank

2 O ‎‫علم‬
8 Hot arr
[ Pre heatedair
= alt.cooled alr
[ steam
[ Product
@ water
[ Peroxide
[ compressedair

Sterile system 18/8/19, Filling spray tank

In this mode the spray tank is to be filled up with peroxide. Filling spray tank
When ‎‫ عط‬machine is not in production, the peroxide is kept in the peroxide
tank. From there it is pumped ‎‫ ما‬the spray tank. In the spray tank are 11160 two
level sensors. The short one indicates when the correct level is reached.
The peroxide surplus will ‎‫ عط‬led back ‎‫ ما‬the peroxide tank.
If the spray container level is correct within a certain time limit, the machine
will automatically change to Spraying.

Spray tank

24 Training Document. For training purpose only. L ‎‫ دمع‬Training Centre 1/0303

 Sterile system TBA/19 ..
Spraying

O ‎‫علم‬
8 Hot arr
[ Pre heated air
alt.cooledalr
[ steam
[ Product
8 water
[ Peroxide
[ compressed air

Sterile system TBA/19, Spraying

Spraying In this mode the aseptic chamber is sprayed with peroxide.

The spraying peroxide valve opens at the same time as the air valve opens for
the compressed air. The compressed air is led into the spray tank and will press
the peroxide through a pipe to the spray nozzle on the peroxide evaporator.
From the air valve, there is also a pipe leading compressed air directly to the
spray nozzle.
The compressed air and ‎‫ عط‬peroxide is forced through the spray nozzle and
into ‎‫ عط‬peroxide evaporator.The peroxide will evaporate in the hot air, coming
from the air superheater. It will follow the air flow, via the air knife into the
aseptic chamber, and through the B-valve via the filling pipe, the LS-element
and the LS short stop-element into the aseptic chamber.
10 make the peroxide vapour reach also the part of the bending roller covered
by packaging material, the roller rotates during spraying.
To make sure that the peroxide vapour reaches the peroxide bath, and to pre-
vent that the peroxide vapour is exhausted out of the aseptic chamber immedi-
ately, the suction valve is in position to allow exhaustion from the peroxide
bath.

L Techrica Treining Centre 110303 Training Document. For training purpose only. 25
Sterile system TBA/19 v

‫علم ل‬
‫كنا‬
][ Pre heated air
alt.cooled alr
[ steam
[ Product
[0 water
[ Peroxide
[ compressedair

Sterile system TBA/19, Pause

In this mode the peroxide vapour will condense on the cold surfaces in the Pause
aseptic chamber.
To make this possible, the air inlet valve will change position to by-pass the
aseptic chamber and lead the air directly to the compressor.
The heat exchanger valve changes position to let the cold air flow via the heat
exchanger to cool the heated air from the air superheater.
During Pause the bending roller continues to rotate.
The machine will automatically change ‎‫ ما‬drying.

26 Training Document. For training purpose only. 72 ‫ مامه‬Traring‫ ماه ‏‬10303

 Sterile system TBA/19 ‎‫م‬.
Drying

O ‎‫علم‬
8 Hot arr
[ Pre heated air
alt.cooledalr
[ steam
[ Product
8 water
[ Peroxide
[ compressed air

= =

Sterile system TBA/19, Drying

Drying In this mode the peroxide in the aseptic chamber will be dried up.
The air inlet valve will change position and let the warm air circulate via the
aseptic chamber. The peroxide will evaporate and follow the air flow, out of
the aseptic chamber.
The bending roller rotates during the end of this mode, to allow the peroxide
on all of its surface to dry up.
The B-valve will close at the end of this mode, to stabilise the air flow to the
LS-element, and to increase the air flow through the jet diverter pipe, making
drying-up more efficient.
Now, the filling machine is sterilised and ready to produce packages.

L Techrica Treining Centre 110303 Training Document. For training purpose only. 27
A signal is sent from the filling machine to the processing equipment.(?) Signal exchange with the
If ‎‫ عط‬processing equipment is ready for production and there is product in the processing equipment
product pipe, a signal is sent from the processing equipment to the filling ma-
chine.® "’
During this signal exchange, nothing changes in the sterile system of the filling
machine. -

&)
[0 Product

Signal exchange

28 Training Document. For training purpose only. L ‎‫ دمع‬Training Centre 1/0303

 Sterile system TBA/19 ‎‫هه‬...) ‫= اح‬
Production

[ Ar
M Hotarr
[ Pre heated air
alt. cooled alr
[ steam
O Product
8 water
[ Peroxide
[l compressed air

= =)

Sterile system TBA/19, Production

Production Before production can start, the jaw system and the final folder are synchro-
nised, the peroxide bath is 11160 with peroxide and the LS short stop-element
is activated for a short while before the counter roller and the LS-element are
activated.
Then the drive motor will feed the packaging material that has been standing
still in the peroxide bath and the aseptic chamber.
When the correct filling position is found, the A-valve opens and the packag-
ing material tube is filled with product.
When the design correction system has located the correct position of the
packaging material, the packages will drop into the final folder unit, and pro-
duction has started.

L Techrica Treining Centre 110303 Training Document. For training purpose only. 29
Sterile system TBA/19 ‎‫ىه‬.
Top filling during production

[ ‎‫علم‬
[l Hotar
[] Pre heatedair
alt.cooled alr
[ steam
< |

[ Product
[0 water
[ Peroxide
[ compressedair

= =)

Sterile system TBA/19, Top filling the peroxide bath

Some of the warm peroxide will evaporate and ‎‫ عط‬exhausted from the peroxide ~ Top filling ‎‫ عط‬peroxide
bath. To compensate for this 1055, and ‎‫ ما‬renew the peroxide in the bath, more bath
peroxide will be added at regular intervals.
The amount of peroxide being pumped from the peroxide tank to the bath is
bigger than the amount lost. The peroxide surplus will flow back to the perox-
ide tank. This is called top filling.
At top filling the temperature and concentration of the peroxide is levelled out
between the bath and the tank.

30 Training Document. For training purpose only. L ‎‫ دمع‬Training Centre 1/0303

 Stopping the filling machine
The filling machine can be stopped in several ways:
٠ Normal stop is used when the length of the stop is estimated ‎‫مت ما‬
more than 40 minutes.
* Short stop and Security stop is used when the length of the stop is
estimated to no more then 5 minutes. Should the length of the stop
exceed 5 minutes, the machine will automatically change to Normal
stop.
* End of production ‎‫ قا‬used when production is finished.
« Emergency stop ‎‫ قا‬used in case of danger ‎‫ ما‬person or machine.
The machine, and the sterile system, will respond differently depending on
which way the machine is stopped.
The machine can also be stopped by its control system, for example; in case of
an alarm.

L Techrica Treining Centre 110303 Training Document. For training purpose only. 31
516116 system TBA/19 v
Normal stop

O ar
M Hot arr
[ Pre heatedair
alt.cooled alr
[ steam
[ Product
@ water
[ Peroxide
[ compressedair

Sterile system TBA/19, Normal stop

Normal stop is used when the time of the stop is estimated ‎‫ ما‬04-5 minutes. Normal stop
The A-valve is closed to stop the inflow of product but the machine will
continue in order to empty the tube of product.
When ‎‫ عط‬machine has stopped, the peroxide bath will ‎‫ عط‬emptied and the
suction valve will change position.
When ‎‫ عط‬stop has lasted for 20 minutes, the machine must ‎‫ عط‬inched as the
packaging material might have been affected by peroxide vapour from the
peroxide bath, and the heat in the aseptic chamber.
‫ تعلط‬a Normal stop,‫ عط ‏‬machine is still sterile and production‫‏‬ ‫ صق‬be restarted‫‏‬
if the maximum time of 40 minutes has not been exceeded.‫‏‬

32 Training Document. For training purpose only. L ‎‫ دمع‬Training Centre 1/0303