Package Interiry

BoC
Book of Competence
TechPub_2614345_0103 - BoC_2712261_0101_fro.fm
This is an uncontrolled print out of the document
Package Integrity
WARNING
This document may not be copied, transferred, or modified
without the prior written consent of Tetra Pak Carton
Ambient S.p.A.
Doc. No. BoC-2712261-0101
and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
This document was produced by:
Sara Davolio and Monica Malagoli
Tetra Pak Carton Ambient
Via Delfini 1
41100 MODENA
Italy
Additional copies can be requested to the authors or downloaded from the TPCA Package Integrity
webpage. When ordering additional copies, always provide the document number. It is printed on the
front cover and in the footer on each page of the manual.
Doc. No. BoC-2712261-0101
Issue 2004-11
All rights reserved. No part of this document may be reproduced or copied in any form or by any means
without written permission from Tetra Pak Carton Ambient
Copyright 2004 Tetra Pak Group
i Introduction
ii Safety Precautions
BoC
iii Getting to know the

Package
Book of Competence
1 Transversal Seal
(TS)
Package Integrity
2 Longitudinal Seal
(LS/SA)
4 Package Integrity
5 Package Forming
Appendix A:
Flowcharts and
Troubleshooting
Appendix B:
Tools and Chemicals
Appendix C:
Data Record
Doc. No. BoC-2712261-0101

Issue 2004-11
3 Opening Devices
Major inputs have been received from FiSQA and System Specialists.
Among the contributions, a special thanks goes to Kevin, Reinhard
Shigeru Okada and Hitoshi Matsumoto for constant inputs and
support.
Sara Davolio
Monica Malagoli
November 2004
This Book of Competence - Package Integrity is based on the state of

the art spread in the Company on Package Integrity Competence.
Foreword
TechPub_2614345_0103 - BoC_2712261_0101_intro.fm
i Introduction
Doc. No. BoC-2712261-0101
i - 1 (14)
i Introduction
i - 2 (14)
Doc. No. BoC-2712261-0101
This chapter contains basic information about this manual.
Table of Contents
i Introduction
Personnel Requirements . . . . . . . . . . . . . . . . . . . i - 5
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Specialized Personnel . . . . . . . . . . . . . . . . . . . . . . . i - 5
How to use this book . . . . . . . . . . . . . . . . . . . . . . i - 6

Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
A: General Information. . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
B: Procedures, Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Abbreviations and Terminology . . . . . . . . . . . . . . i - 9

Reference documents . . . . . . . . . . . . . . . . . . . . . i - 11
Manual Information . . . . . . . . . . . . . . . . . . . . . . . i - 12
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 12
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13
Typographical Conventions . . . . . . . . . . . . . . . . . i - 13
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13
Doc. No. BoC-2712261-0101
i - 3 (14)
C: Appendix, additional material. . . . . . . . . . . . . . . . . . i - 8
This page intentionally left blank
i - 4 (14)
Doc. No. BoC-2712261-0101

i Introduction
i Introduction
Personnel Requirements
Personnel Requirements
Note!
Personnel includes all persons working with Package Integrity
methods and Equipment.
The methods described in this Book of Competence must be performed by
qualified or specialised personnel. The level of expertise required is
mentioned at the beginning of each method. Training is available at TTC.
Qualified Personnel
Qualified means that personnel have received specific training on Package
Integrity QC Methods. This level of education is required in most of the
methods.
Specialized personnel are chemists, laboratory technicians which have a

professional knowledge of reagents and laboratory techniques. This level of
education is required for methods which imply the use of chemicals and
solvents.
FiSQA officers and Technical Service Specialists are considered specialized
personnel once specific training has been taken.
CAUTION
Always handle the chemicals carefully and wear protective
goggles and gloves. Dispose of chemicals in the manner
prescribed by current regulations.
Doc. No. BoC-2712261-0101
i - 5 (14)
Specialized Personnel
i Introduction
How to use this book

Purpose
This book is mainly addressed to:
FiSQA Officers
Technical Instructors
System Specialists
Senior Tetra Pak Field Service Engineers

Senior Technical Support Staff.
The aim is to give clear instructions on how to evaluate the integrity of the
TPCA packages.
Package Integrity Methods must be performed on regular basis during and

after Production, to monitor the quality of the packages and the
performance of the filling machines. Specific checks must be carried out for
special products (e.g. products with fibres) and opening devices (PullTab,
FlexiCap).
A defect in the package microbiological barrier does not necessarily imply a
microbiological problem, since the following conditions must take place in
addition:
presence of microorganisms in the package surrounding;

favourable environmental conditions;
period of time in which they grow and spoil the product.
On the other hand, when visible integrity problems such as leakage during
transportation or package blowing occur, we are sure that the package is
defective, and that the packages close to it might be affected by the same
defect. In this case, a troubleshooting procedure is needed to investigate the
causes of the proven unsterility.
Package Integrity Methods can be grouped into a limited number of
procedures as follows, according to the kind of investigation needed.
The Appendix A: Flowcharts and Troubleshooting section includes a step by
step description of each procedure.
(Cont'd)
i - 6 (14)
Doc. No. BoC-2712261-0101
A package showing product spills is easy to detect. Less visible defects that
jeopardise the protective function of the package can be detected following
the correct procedures described in this manual. Package Integrity Quality
Methods are systematic, precise and destructive. Samples are no longer
available after evaluation, hence the importance of performing them
correctly.
TPCA packages contain and protect the packed product from filling to
recommended consumption, at ambient temperature.
i Introduction
(Cont'd)
QC checks during Production
These are checks carried out by the operator during production. They are
aimed at evaluating the appearance of the package (shape and design, flap
sealing, surfaces), the fulfilment of legal requirements (date printing, weight)
and the quality of the package sealing (Tranversal Sealing and Longitudinal
Sealing tear down). The machine settings (temperatures, pressures, weight
and design control settings) can be corrected accordingly, in order to ensure a
good production.
Laboratory QC checks after Production

These checks must be carried out on a regular basis by qualified personnel, in
an area appropriately equipped. They are destructive, and imply the use of
chemicals or specific laboratory tools. The data are analyzed statistically, in
order to evaluate the incidence of defective packages in a population.
Testing products with fibres
Products containing more than 5% of citrus fibres can compromise the
integrity of the TS as fibres can be trapped in the sealing creating channels to
the outside of the package. A specific procedure must be followed to
investigate the performance of the product.
Troubleshooting
When a production proves defective due to leakages or package blowing, the
causes of the unsterility must be investigated. In this case, the analysis is not
statistical, but aims at identifying the origin of specific defects. The samples
must be prepared so that the package is not cut apart but analyzed as a whole
to be able to see if package integrity is the reason for the unsterility.
It is advisable to test a tray of packages where one or more samples are
suspected to be defective, so that the overall behaviour of the Production can
be assessed.
The test methods are applied in a defined sequence aiming to get an
unequivocal answer if package integrity is the main cause for the unsterility
in terms of:
Loss of microbiological barrier (corners, K-cracks, fin tears)

PullTab
Longitudinal Sealing
Trasversal Sealing
Doc. No. BoC-2712261-0101
i - 7 (14)
Note!
This book does not include instructions reported on OM, MM manuals
and TTC brochures, such as machine setting procedures or volume
dependent values. Refer to these manuals to integrate this kind of
information.
i Introduction
Structure
The content of this book is divided into three main groups. They are
described below.
A: General Information
ii Safety
Precautions
iii Getting to
know the
package
1 Transversal Seal (TS) tests

(MTD 1201 - 1208 - 1211)
2 Longitudinal Seal (LS/SA) test

(MTD 1202)
3 Opening Devices test

(MTD 1211)
4 Package Integrity tests
(MTD 1203 - 1204 - 1207)
5 Package Forming tests

(OM as a reference)
These chapters provide general

information, important safety
information, and overview of packaging
material, strips and package terminology.
These chapters include:
Introduction
Safety Precautions
Getting to know the package.
B: Procedures, Tests
These chapters provide a sequence of
instructions for the tests to be performed
on the package.
Transversal Seal
Longitudinal Seal
Opening Devices
Package Integrity
Package Forming.
C: Appendix, additional
material
C
Flowcharts and
troubleshooting
Tools and
Chemicals
Data recording
sheets
These chapters provide information

about additional material used to carry
out the tests and record the results.
Flowcharts and troubleshooting
i - 8 (14)
Tools and Chemicals

Data recording sheets.
Doc. No. BoC-2712261-0101
i Introduction
i Introduction
Abbreviations and Terminology
Abbreviation
Meaning/Definition
Al-foil
Aluminium foil
Ammeter
Instrument measuring electric

current in amperes
ASU
Automatic Splicing Unit
Base (package shape)
Blocked Seal
Cold Seal
DE
Distribution Equipment
DIMC
Direct Injection Moulding Cap
FiSQA
Field Service Quality Assurance
FlexiCap
Flexible Cap
HDPE
High Density Polyethylene
IH
Induction Heating
LLDPE
Linear Low Density Polyethylene
LH
Left Hand
LS
Longitudinal Sealing
max
Maximum
min
Minimum
MM
Maintenance Manual
mPE
LLDPE syntetized by metallocene

catalyst process
MTD
Method
OK
Optional Kit
OE
Optional Equipment
OM
Operation Manual
PE
Polyethylene
Plastic Lumps
Hard residue of plastic that

hardens out of the TS sealing
area. They might be referred as
walling (USA terminology)
PLH
Pre Laminated Hole
PM
Packaging Material
PT
PullTab
QA
Quality Assurance
QC
Quality Control
RH
Right Hand
Slim (package shape)
SA
Strip Applicator
Notes
Technique used in FlexiCap

application
It uses DIMC technology
(Cont'd)
Doc. No. BoC-2712261-0101
i - 9 (14)
i Introduction
Sealing Monitoring
Sq
Square (package shape)
TBA
Tetra Brik Aseptic
TCA
Tetra Classic Aseptic
TFA
Tetra Fino Aseptic
TPA
Tetra Prisma Aseptic
TPCA
TPCC
Tetra Pak Carton Chilled
TPIH
Tetra Pak Induction Heating
TS
Transversal Sealing
TTC
Technical Training Centre
TWA
Tetra Wedge Aseptic
SM
i - 10 (14)
Doc. No. BoC-2712261-0101
(Cont'd)
i Introduction
Reference documents
Reference documents
Refer to the following other documents:
OM pecularities of the filling machine
TTC Package Integrity Compact Disk
CD-00002-01
TTC TS evaluation brochure 1991
Doc. No. BoC-2712261-0101
i - 11 (14)
i Introduction
Manual Information
Manual Information
Page Layout
Every main page in this manual contains a header and a footer. The page
header contains the section name (1) and the chapter name (2). The page
footer contains the manuals document number (3), and the page number (4).
See also the section Page Numbering.
1.2 Transversal Seal - Evaluation by

tearing (P 1201)
1 Transversal Seal (TS)

Prepare samples for TS
accurate check
1
Cut off the top and bottom of the
packages at a distance of about 25-30
mm from the top and bottom creases.
1 - 10 (36)
Doc. No. BoC-81865-0102
3
1
2
3
4
i - 12 (14)
Doc. No. BoC-2712261-0101
Section name
Chapter name
Document number
Page number
Issue 1
Cut off 1 mm maximum from the edges.
TechPub_2614345_0103 - 01_81865_02_en.fm
Rinse the samples and dry them with

compressed air.
i Introduction
Manual Information
Page Numbering
A page number has three parts:
chapter number (1)

consecutive page number (2) within the chapter
total number of pages (3) in the chapter.
4 - 11 (18)
1
1 Chapter number
2 Consecutive page number
3 Total number of pages
Typographical Conventions
Symbols
The following symbols are used in illustrations:
A pointer arrow (1) indicates the position of an object
A zoom arrow (2) indicates that an object view is enlarged. The arrow
points towards the enlarged view of the object
A rotation movement arrow (3) indicates rotational movement of an
object. The arrow points in the direction of rotation
A straight movement arrow (4) indicates movement of an object.
The arrow points in the direction of movement
Doc. No. BoC-2712261-0101
3
1
2
3
4
Pointer arrow
Zoom arrow
Rotation movement arrow
Straight movement arrow
i - 13 (14)
Cross-references are underlined.
i - 14 (14)
Doc. No. BoC-2712261-0101
i Introduction
Manual Information
TechPub_2614345_0103 - BoC_2712261_0101_sp.fm
Doc. No. BoC-2712261-0101
ii - 1 (2)
Safety Messages Description
Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.
This is the safety alert symbol. It is used to alert about potential personal
injury hazards. To avoid hazards, obey all safety messages that follow this
symbol.
The following safety alert symbols and signal words are used in this manual
to inform the user of hazards.
ii - 2 (2)
Doc. No. BoC-2712261-0101
CAUTION
Caution indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be
used to alert against unsafe practices.
CAUTION
Caution without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property
damage.
TechPub_2614345_0103 - BoC_2712261_0101_sp.fm
WARNING
Warning indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
TechPub_2614345_0103 - BoC_2712261_0101_gtk.fm
iii Getting to know the

Package
Doc. No. BoC-2712261-0101
iii - 1 (16)
iii Getting to know the Package
iii - 2 (16)
Doc. No. BoC-2712261-0101
This chapter contains basic information on how a TPCA

package is sealed and formed; which are the major
differences on packaging materials, and where the defects
are located.
Table of Contents
Aseptic Packaging. . . . . . . . . . . . . . . . . . . . . . . . iii - 5

Packaging Material . . . . . . . . . . . . . . . . . . . . . . . iii - 6
Packaging Material Layers . . . . . . . . . . . . . . . . . . iii - 7
Guidelines for the choice of Packaging
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii - 9
Packaging Material Reel . . . . . . . . . . . . . . . . . . . iii - 10
Pre-Laminated Hole . . . . . . . . . . . . . . . . . . . . . . . iii - 11
Package Terminology . . . . . . . . . . . . . . . . . . . . iii - 12
LS Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii - 14
PT Strips (Tab, Patch, Outer Patch) . . . . . . . . . . iii - 15
Identification of package defects . . . . . . . . . . . iii - 16
Doc. No. BoC-2712261-0101
iii - 3 (16)
Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii - 14
iii - 4 (16)
Doc. No. BoC-2712261-0101
Aseptic Packaging
Aseptic Packaging
Aseptic packaging prevents microbes and bacteria from getting in once the
package is closed. Obviously, this is a great advantage for foods and drinks.
For packaged foods and drinks to be completely free from infection, the
product itself must also be sterile. In other words the following conditions
must be achieved:
Sterile product: The product itself must be sterile.
Sterile product supply: The equipment delivering the product to the
filling machine must be sterile.
Sterile packaging material: The packaging material must be sterile
when it comes in contact with the product.
Sterile filling environment: The part of the filling machine where
package filling actually takes place must be sterile.
Aseptic packages: Packages must be tight, so that microbes and bacteria

cannot get in from the outside.
The diagram below illustrates the aseptic packaging process.

This is taken care of by

the filling machine.
Sterile
packaging
material
Sterile
filling
environment
Sterile
product
Sterile product
supply
Aseptic package
This is taken care of by

the processing equipment
in the factory.
Doc. No. BoC-2712261-0101
iii - 5 (16)
Packaging Material
Packaging Material
The packaging material protects the product inside the package from the
environment outside.
It also needs to be firm enough to give the package a good shape.This is
essential for transport and handling. The packaging material is also printed
with information about the contents of the package.
The packaging material used in the filling machines is a very special
laminate material. Laminate means that the material is made up of several
different layers. Though different products may require slightly different
packaging materials, all TPCA Packaging Materials are laminate.
TBA package is shown
iii - 6 (16)
Doc. No. BoC-2712261-0101
When the packaging material is shaped into packages it is folded along preformed creases. The heavy gray lines in the drawing to the right show the
crease pattern for one package.
Packaging Material
Packaging Material Layers

The packaging material used is multilayer. The different combination of
layers determines the type of material.
All of the packaging materials contain a paperboard layer (2), an Al-foil
layer (4) and a variable number of plastic based (usually LDPE or me-PE)
layers.
The paperboard gives stability to the package and allows printing of the
design and data.
The Al-foil acts as a barrier against aroma, oxygen and light. It also protects
the flavour of the product and it is used to seal, by induction heating,
layers (3), (1).
The polyethylene (LDPE, m PE) allows the adhesion of the different
materials, seals in the liquid and protects the package from external moisture.
1. Outside plastic layer/Decor layer

Protects the package against external
humidity. Also allows sealing of the
package (Flaps and Overlap).
4. Al-foil
Protects the product against
oxygen and light.
2. Paperboard and printing

Strengthens the package and
offers a good printing surface.
3. Lamination
A plastic layer which allows the
paperboard to stick to the al-foil.
5. Internal coating
A coating that offers adhesion
between the al-foil and the
inside plastic layer.
6. Inside plastic layer

Prevents the liquid contents
from soaking into the material.
Also allows sealing of the
package (SA, LS, TS).
(Cont'd)
Doc. No. BoC-2712261-0101
iii - 7 (16)
The package microbiological barrier is composed by layers (6), (5), (4), (3).
Packaging Material
(Cont'd)
The picture below describes what type of effects the different layers in the
Packaging material protect against.
Light,
Aroma,
Oxygen
Inner
Sealing
External
moisture
2
1
3
Package
Stability
7
Microbiological
barrier
1
2
3
4
5
6
7
iii - 8 (16)
Doc. No. BoC-2712261-0101
Outer coating
Paperboard
Lamination
Al-foil
Internal Coating 1
Internal Coating 2
Product
Packaging Material
Guidelines for the choice of Packaging Material

This is an extract from the Carton Ambient Product Portfolio booklet
(FDM 11th edition).
Please refer to it for any official info about Filling and Distribution
Machines, Packaging Material and Strips.
--/m
Plain milk, sweetened

milk
--/j
--/aqk
--/ok
--/olk
UHT Cream and nondairy milk

Coconut drinks, soy bean
drinks, rice drinks
LS strips
PPP (or MPM (2))
Flavoured milk
Recombined milk
PPP (or MPM (2))
PPP (or MPM (2))
PPP (or MPM (2))
Formulated tomato
--/lk(1)
PPP (or MPM (2))
Fruit and vegetable

juices and drinks
PPP (or MPM (2))
Teas and coffees
PPP (or MPM (2))
Wine
x(4)
Wine
Alcohol drinks <20 %
x(4)
Wine
Dressing
x
x
Soups and Sauces
Alcohol drinks >20 %
Oil
Vinegar products
max.1.0% acetic acid
Special dietetic products
x
x
Flavoured water
PPP (or MPM (2))/

LSE (or MSE)
PPP (or MPM (2))
x(3)
Water
PPP (or MPM (2))
PPP (or MPM (2))
Products for hot-vending

machines
Nutritional products
Wine
PPP (or MPM (2))/

LSE (or MSE)
x(3)
PPP (or MPM (2))/

LSE (or MSE)
PPP (or MPM (2))

PPP (or MPM (2))
PPP (or MPM (2))
(1)
The use of --/lk materials is equivalent to --/jk, --/tk and --/wk materials.
MPM and MSE to improve the strip sealability. MPM strip does not
impart higher barrier properties than PPP, such as MSE has the same barrier
properties as LSE.
(3)
According to the specific formulation per each different product.
(4)
The use of --/j material for packing wine and alcoholic drinks <20% is
approved. The --/w material production will be discontinued.
(2)
Doc. No. BoC-2712261-0101
iii - 9 (16)
Product type
Packaging Material
Packaging Material Reel

A label indicating packaging material type (i.d. TBA/m, TBA/j, TBA/jl,
TBA/lk) and Production Order is attached to each reel. Always keep the label
and quote the data when performing package integrity tests.
Tetra Pak
TP ORDER
TP PRODUCT
P202-0123456 D00-0000-01
CUST No
ID No
Tetra Pak Carton Ambient S.p.A

Via Delphini 1
MODENA
123456789
Photocell TBA/J FCD
123-4567
TYPE
TBA/J
VOLUME
REEL No
QUANTITY
PROD DATE
01-0001
7500
25-MAY-2008
12345678910 11121314151617181920
10
11
1
2
3
4
5
6
7
8
9
10
11
iii - 10 (16)
Customer address
Tetra Pak product code
Tetra Pak Production Order number
Customer code
Identification number
Type of Packaging Material
Volume of package
Quantity of packages on the reel
Reel number
Date of Production
Bar code containing parts of the above
information
Doc. No. BoC-2712261-0101
1000 ml
3
4
5
6
7
8
Packaging Material
Pre-Laminated Hole
The Pre-Laminated Hole is presently used for packages with Post-applied
Caps. The hole is punched and laminated during converting. The cap is
applied after product filling and package leaving the Filling Machine.
Note!
The PLH does not require dedicated package evaluation procedures
for Package Integrity tests (as for PullTab and FlexiCap).
Pre-Laminated Hole
Post-applied cap
outside of package
inside of package
6 5
1
2
3
4
5
6
Outside plastic layer (decor layer)

Paperboard
Laminate layer
Alu-foil
Inner layer 1
Inner layer 2
Doc. No. BoC-2712261-0101
iii - 11 (16)
Package Terminology
Package Terminology
Longitudinal creases, top creases and bottom creases: These are the
pre-formed folds in the packaging material. They give the package its
final squared form.
Top fin and bottom fin.: These are the top and bottom areas of the
package where it is sealed and cut.
Transversal seal (TS): Seals the package at the top and bottom.
Top longitudinal
creases
Top fin
Transversal seal (TS)
Bottom fin
Longitudinal
sealing
Transversal seal (TS)
(Cont'd)
iii - 12 (16)
Doc. No. BoC-2712261-0101
Top longitudinal
creases
Package Terminology
(Cont'd)
Longitudinal seal (LS): Seals the package along the long side.
LS strip: A strip of laminated plastic applied on the inside of the
longitudinal seal. Prevents the product from soaking into the edge of the
packaging material.
LS overlap: The area over which the two edges of packaging material
overlap down the long side of the package. Ensures that the longitudinal
seal is rigid and does not leak.
Top and bottom flaps: The corners of the package that are folded and
sealed to the package body.
Top flap
Top flap
inside of package
Longitudinal seal
(LS)
LS strip
Bottom flap
LS overlap
outside of package
Bottom flap
Bottom crease
LS strip
Doc. No. BoC-2712261-0101
iii - 13 (16)
Top creases
Strips
Strips
LS Strip
The LS strip has the following tasks:
it prevents liquid from being absorbed by the packaging material edge;
it prevents micro-organisms which could be present on the packaging
material edge from contaminating the product;
it creates a gas barrier in the longitudinal seal which prevents both
aromatic substances from escaping through the seal and air (oxygen)
from penetrating and affecting the product;
it reinforces the longitudinal seal.
LHL
PPP/PPPw
Primer
PET
HDPE
Milk
LDPE
Juice / Wine
LDPE
MPM
LSE
mLLDPE
LDPE
LDPE
Primer
Primer
PET
EVOH
TBA/jl
(TBA Wide)
Primer
Primer
LDPE
Primer
Special
products
LDPE
mLLDPE
(Cont'd)
iii - 14 (16)
Doc. No. BoC-2712261-0101
LDPE
LDPE
LS strips are formed by different layers and have different utilisation

depending of the product and package type. Here below some examples:
Strips
(Cont'd)
PPP-STRIPS
7,5/0,075
449732:16:3
lot number
PT Strips (Tab, Patch, Outer Patch)

A label identifying strip type and lot number is attached to every strip box.
Take note of these data and quote them when performing package integrity
tests.
UNIFIED TAB STRIP

1234-123
PEP-STRIP
29/0,050
ART. NO
LOT NO.
1234-123 123456
12341212
REELS
10
USE BEFORE DATE
12345678910 11121314151617181920
NET WEIGHT KG
123456
123456
PALLET - BOX NO.
Quantity
Lot. No.
Prod. date
1234 m
123345678
1234-12-12
Use before: 1234-12-12
12345678910 11121314151617181920
Doc. No. BoC-2712261-0101
iii - 15 (16)
A label identifying strip type (i.d. PPP, MPM) and lot number is attached to
every strip reel. Take note of these data and quote them when performing
package integrity tests.
Identification of package defects
Identification of package defects

Defect location
Defect name
MTD
LS
- not sealed
- blisters
- channels
1202
Corners
- red ink leakage
1203 - 1204
TS
- channel / blocking
- plastic lumps
- overheating
- Af-foil TS crack
- fibres trapped in TS
1201 (Production)
1208 (QC,
Troubleshooting)
1210
TS/LS cross
- channels
- plastic lumps
1208 (QC)
1201 (Production)
PullTab / Opening
- red ink leakage
1211
Fin
- top fin tearing

- bottom fin tear (TWA only)
1204
Bottom flap
- k-cracks leakage
1203 - 1204
3
4
2
iii - 16 (16)
Doc. No. BoC-2712261-0101
inside of package
Pos
The following table summarizes the defect location on the package and
which MTD has to be followed to identify them:
TechPub_2614345_0103 - 01_2712261_01_en.fm
Doc. No. BoC-2712261-0101
1 - 1 (42)
Methods:
Methods:
MTD 1201 - Transversal Seal Tearing
Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD 1201, issued by Sara Davolio, 1996/02/27.
TTC TS evaluation brochure 1991.
Personnel
This method must be performed by Specialized personnel. Refer to section
Tools and Chemicals
the tools used.
Reference Documents
Previous version, MTD 1208 issued by Sara Davolio, 1996/11/19.
MTD 1210 - Transversal Seal Al-foil cracks

Personnel
Tools
the tools used.
Reference Documents
Previous version, MTD 1210, issued by Sara Davolio, date 1996/02/29.
1 - 2 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
MTD 1208 - Transversal Seal Dissolving and Red Ink
Table of Contents
1.1 Transversal Seal - General information. . . . . . . 1 - 5

1.2 Transversal Seal - Tearing (MTD 1201) . . . . . . . 1 - 7
1.2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1.2.2
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
1.2.3
Preparation of the Samples. . . . . . . . . . . . . . . . . . 1 - 9
1.2.4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
1.2.5
Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 13
1.3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
1.3.2
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
1.3.3
Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 19
1.3.4
1.3.3-1
Cut packages . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
1.3.3-2
Dissolving of packages . . . . . . . . . . . . . . . . . . . 1 - 22
1.3.3-3
Drying the samples . . . . . . . . . . . . . . . . . . . . . . 1 - 29
1.3.3-4
Red Ink Tightness . . . . . . . . . . . . . . . . . . . . . . . . 1 - 30
1.4 Transversal Seal - Al-Foil Cracks

(MTD 1210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
1.4.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 37
1.4.2
1.4.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39
1.4.4
Doc. No. BoC-2712261-0101
1 - 3 (42)
TechPub_2614345_0103 - 01_2712261_01_en.fm
1.3 Transversal Seal - Dissolving and Red Ink

(MTD 1208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
1 - 4 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Table of Contents
1.1 Transversal Seal - General information

The Transversal Seal is formed in the jaw system by two jaws working in
pairs (e.g. Tetra Pak A3/Flex and TBA/21) or in 10 jaws linked in chain
working in pairs (e.g. Tetra Pak A3/Speed and TBA/22).
the sealing jaw (A) contains the inductor

the pressure jaw (B) contains the pressure rubber dollies and the cutting
knife plus the cutting rail.
Note!
In some filling machine applications the names of Sealing Jaw and
Pressure Jaw can be different (Cutting Jaw is also used).
2 Jaws working in pair
10 Jaws linked as chain
TechPub_2614345_0103 - 01_2712261_01_en.fm
5
2
6
1
7
10
8
7
10
A Sealing Jaw
B Pressure Jaw
C Volume Flap
(Cont'd)
Doc. No. BoC-2712261-0101
1 - 5 (42)
(Cont'd)
The inductor on the sealing jaw induces eddy currents into the Al-foil of the
packaging material, producing a heat that melts the plastic layers in the area
where the sealing is needed.
The rubber dollies on the pressure jaw exert pressure, allowing the plastic
layers to be sealed together. The pressure is produced hydraulically or
mechanically depending on the machine type. The knife cuts the packaging
material tube separating the packages.
Each pair of jaws makes two seals, i.e. the bottom seal of one package and
the top seal of the next one.
Most applications use Ridge inductor, but in most of TCA, TFA and some
TWA applications inductors with lower ridge might be used.
4
5
2
4
10
10
10
6
11
11
10
1 - 6 (42)
1
1
2
3
4
5
6
Dolly
Cutting rail
Knife
Upper package
Heat pattern
Inductor coil
Doc. No. BoC-2712261-0101
7
8
9
10
11
Inductor body
Cutting groove
PM cutting line
Ridge
Lower package
TechPub_2614345_0103 - 01_2712261_01_en.fm
10
1.2 Transversal Seal - Tearing (MTD 1201)
1.2 Transversal Seal - Tearing

(MTD 1201)
1.2.1 Introduction
The method consists in pulling the transversal sealing apart using the stretch
pliers and examining how the seal separates.
By visually checking the seal, it is possible to notice the presence of plastic
ridges or lumps along it. These ridges could punch the packaging material
layers, compromising the integrity of the package.
The seal must be mechanically stronger than the packaging material. If the
sealing is good, the packaging material layers (plastic film, Al-foil or
paperboard) break while the seal does not separate.
Upper Package
10
Upper
Package
4
TOP TS
5
BOTTOM TS
9
Lower Package
TechPub_2614345_0103 - 01_2712261_01_en.fm
Lower
Package
Doc. No. BoC-2712261-0101
1
2
3
4
5
6
7
8
9
10
Filling product
Al-foil
Paperboard
Cutting line
Plastic film,
double layers
Blocked area
Sealed area
Ridge
Outer coating
Stretch pliers
1 - 7 (42)
1.2.2 Definitions
Blocked seal
Blocked seals are often called cold sealings. Since the reason for a blocked
sealing might be either low setting or low pressure the term cold sealing
refers mainly to energy.
Note!
The only way to detect a blocked seal it is the manual Tear Down
during Production. Conductivity test and Red ink test would not detect
a blocked seal.
1
2
3
4
5
6
7
8
9
Filling product
Al-foil
Paperboard
Cutting line
Plastic film, double layers
Blocked area
Sealed area
Ridge impression
Outer coating
3
5
1 - 8 (42)
Doc. No. BoC-2712261-0101
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The TS with a good heat pattern will progressively tend to appear as blocked,
when torn by means of the stretch pliers or by hand. This effect, called decay,
typical of wet sealings, depends on the filling product (water included),
sealing settings, packaging material and storage time.
For this reason during troubleshooting and after production (1 week is the
reference interval considered), dissolving and heat pattern analysis is the
only reliable method to access the TS quality.
Decay
1.2.3 Preparation of the Samples

Note!
The test must be performed during Production. If special activities
are planned on the samples (i.e. sealing window), the test can be
carried out within 1 week from production.
Prepare samples for TS rough

check
Unfold the top and bottom flaps of the
package.
If there is product leakage, the TS has a

gross defect (most likely a dolly is
missing).
TechPub_2614345_0103 - 01_2712261_01_en.fm
If any product leakage is found stop the

machine and call a technician.
Note! If there is any leak from
between the PLH and the package, it
is not due to the TS sealing. Call a
service technician.
Doc. No. BoC-2712261-0101
1 - 9 (42)
Check if the package has product

leakages from the TS by gently
squeezing the package with the fingers.
Prepare samples for TS

accurate check
1
Cut off the top and bottom of the
packages at a distance of about 25-30
mm from the top and bottom fin creases.
Rinse the samples and dry them with
compressed air.
Cut off 1 mm maximum from the edges.
1 - 10 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Note! Use compressed air with care

since it might damage the sample.
1.2.4 Procedure
TS rough TS check
Check the integrity of the TS by gently
squeezing the package with the fingers.
If there is product leakage, the TS has a
gross defect (most likely a dolly is
missing).
TS accurate check
TechPub_2614345_0103 - 01_2712261_01_en.fm
Run you finger over the TS and check if

there are plastic lumps or ridges.
Plastic lumps and ridges show that the
sealing is not correct. See section 1.2.5
Evaluation of the Samples for further
details.
2
Place the sample in the stretch pliers and
gently stretch the TS.
Doc. No. BoC-2712261-0101
1 - 11 (42)
3
Stretch by pressing the plier handles
along the whole length of the sample
Stretch a little bit at a time, from both
ends (1) towards the LS/TS cross (3).
Stretch the LS/TS cross last.
CAUTION
Risk of sample damage.
Take a lot of care in the point where
the TS and LS cross and on the
edges, since the magnetic field and
heat pattern is weaker in these areas.
The cross might be the last part
stretched to enable a better
evaluation.
WRONG
1 - 12 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
CORRECT
1.2.5 Evaluation of the Samples

The seal can be either good or defective. A seal is good when it is
mechanically more resistant than the packaging material. If a seal is
defective, it could easily cause unsterility.
The first sign of a good seal is stretched plastic film. Breakage in the Al-foil
and paperboard layers also shows that the seal is stronger than the packaging
material.
The rules apply also in the TS/LS cross where the strip is part of the seal.
Here you have some representative examples of good and defective seals.
TechPub_2614345_0103 - 01_2712261_01_en.fm
Plastic lumps are a potential

danger in the aseptic
package. The hard residue
might punch the PM layers
during distribution of the
package compromising the
package integrity.
Defective seal
Plastic lumps are the signal
of a too high or uneven
sealing temperature, too high
pressure or wrong jaw
system alignment.
2
The seal does not come
apart; the plastic film
stretches and breaks, leaving
the paperboard uncovered.
Good seal
Typical behaviour of TBA/lk and TBA/jl
Doc. No. BoC-2712261-0101
1 - 13 (42)
Before pulling the seal apart,

it is easier to notice the
presence of plastic ridges or
lumps along it.
3
The case described above
applies also to the cross,
where TS and LS meet. The
LS must be considered and
additional plastic multilayer.
The picture shows the LS
which stretches and
delaminates.
Good seal
Good seal
Typical behaviour of TBA/j

(that has high adesion to Al-foil)
5
The plastic film layers
separate from the Al-foil,
leaving it uncovered and
shiny.
Good seal
Typical behaviour of TBA/jm

(that has low adesion to Al-foil)
1 - 14 (42)
Doc. No. BoC-2712261-0101
The seal does not come

apart; the plastic film breaks
leaving the paperboard fibres
and the Al-foil uncovered.
TechPub_2614345_0103 - 01_2712261_01_en.fm
6
The seal separates; no
rupture occurs in the
packaging material layers.
The seal appears mattish or
greyish. This is a so called
blocked seal.
Blocked seals are often due

to too low sealing
temperature or too low
pressure during sealing.
Energy settings must be
adjusted, inductors and
dollies checked and jaw
pressure verified.
7
TechPub_2614345_0103 - 01_2712261_01_en.fm
The seal is overheated; the

two PE layers are burnt and
the Al-foil shows microcracks and cuts.
Defective seal
Overheated seals are often
due to too high sealing
temperature or by excessive
pressure. Sealing settings,
cooling water temperature or
jaw pressure must be
adjusted.
8
The Al-foil is cracked in the
ridge area.
Defective seal
Further investigate the
packages to detect Al-foil
cracks along the TS, see 1.4
Transversal Seal - Al-Foil
Cracks (MTD 1210).
Doc. No. BoC-2712261-0101
1 - 15 (42)
Defective seal
1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208)
1.3 Transversal Seal - Dissolving and Red Ink

(MTD 1208)
1.3.1 Introduction
This section describes the method to evaluate the Transversal Seal (TS) by
dissolving the Al-foil (2) with chemical agents and separating the inner
plastic layers (5) from the other package layers, obtaining a inner plastic bag.
The inner plastic bag (see picture below) is then analysed to check the heat
distribution along the TS (heat pattern).
The TS tightness is tested using the leakage detection fluid (red ink).
TOP TS
TOP TS
BOTTOM TS
5
Lower Package
Upper
Package
Lower
Package
BOTTOM TS
1
2
3
4
5
Filling product
Al-foil
Paperboard
Cutting line
Plastic film, double
layers
6
7
8
9
Blocked area
Sealed area
Ridge impression
Outer coating
(Cont'd)
1 - 16 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Upper Package
1.3.2 Definitions
Heat pattern
The heat pattern is the mark left by the inductor on the packaging material
during sealing. The pictures below shows the Heat pattern areas.
Heat pattern
= heat pattern
Ridge impression
Lower Blocked area
LS
LS / TS cross
Air channel
Upper Blocked area
Bending Off
(Cont'd)
Doc. No. BoC-2712261-0101
1 - 17 (42)
TechPub_2614345_0103 - 01_2712261_01_en.fm
Ridge impression
(Cont'd)
The heat pattern can be analysed with the use of a zonoscope and a
magnifier.
The heat pattern must be symmetrical with respect to the LS and the cutting
line and fulfil the geometrical measurements shown below.
The causes of uneven distribution are mostly unparallel pressure distribution,
banana shaped inductors or dollies status.
Dimension
Acceptable (mm)
NOT Acceptable (mm)
>0
0.2
1
1
< 0.2
<1
<1
1 - 18 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Note!
These dimensions are in general not influenced by the filling machine
(e.g. the heat pattern of a TBA/21 is similar to the heat pattern of a
TBA/22 given the package size).
D, usually, is wider than C.

1.3.3-1
Cut packages
1
CAUTION
Risk of sample damage!
Always handle the samples with care.
Mechanical stress due to improper
handling can compromise the results
of the test.
TechPub_2614345_0103 - 01_2712261_01_en.fm
The along the TS should be about 50 mm

wide with the LS at its central axis.
Cut out the front panel of the package at
approximately 25 mm from the top and
bottom TS.
2
Mark each sample in order to distinguish
the Top and Bottom seal after dissolution.
For example, write T (for Top) and B (for
Bottom) on the inside of the package
with a permanent marker.
Mark the samples with progressive
numbers.
Note! If packages was containing
high fat products it might be difficult to
use the permanent marker.
Doc. No. BoC-2712261-0101
1 - 19 (42)
Unfold all the flaps and flatten the

package. Cut the package in a I shape, as
shown in the picture.
3
If possible, cut the top of the package
using the pinking scissors for an easy
identification of the top.
The scheme below shows the PM layers
before starting the procedure:
3
4
5
6
1 - 20 (42)
Doc. No. BoC-2712261-0101
1
2
Outer coating
Paperboard
Lamination
Al-foil
Inner coating 1
Inner coating 2
TechPub_2614345_0103 - 01_2712261_01_en.fm
1
2
3
4
5
6
4
Carefully peel off the external packaging
material layers (starting from the LS
overlapping), as shown in the top picture.
The outer polyethylene layer and part of
the paperboard layer will come off.
The sample in the bottom picture will be
obtained.
Note! TFA packages do not need this
step since the paperboard is too thin
to peel apart.
2
3
4
5
6
TechPub_2614345_0103 - 01_2712261_01_en.fm
The PM layers left, at this stage, on the

sample are the following:
Paperboard
Lamination
Al-foil
Inner coating 1
Inner coating 2
2
3
4
5
6
TCA packages
Prepare the packages as shown in the
picture.
Doc. No. BoC-2712261-0101
1 - 21 (42)
1.3.3-2
Dissolving of packages
Packages can be dissolved either using an acid or an alkaline solution. See
chapter 1.6 Preparation of Chemicals for details on the composition and
preparation of the solutions.
There are three methods that can be followed according to the urgency of
results:
The alkaline agent (slow method) acts more slowly; the samples must
stay immersed in the solution for at least 6 hours. This method is
advisable when there are many samples to evaluate (e.g. during
troubleshooting).
Dissolving of
packages methods
Solutions
used
Acid agent method 1

(very fast)
Acid agent method 2

(fast) *
- HCl 1:1 solution

- HCl 1:3 solution
- Neutralizing solution
- HCl 30% solution

Alkaline agent
(slow)
- Alkaline solution
Advantages
very fast (sample ready

in 15 min)
fast (sample ready in

less than one hour)
safer (no acid solutions

involved)
Disadvantages
risk of spoiling of the

sample with too long
immersion in solution
not very fast as Acid

agent method 1
slow (sample ready in 6

hours)
go to page 1-23
go to page 1-26
go to page 1-28
* used in Tetra Recart

applications
(Cont'd)
1 - 22 (42)
Doc. No. BoC-2712261-0101
The acid agent (very fast method) acts fast, therefore it is advisable
when the results of the test are urgent (e.g. during Production). A fume
extractor and a water bath are needed for preparation and usage.
The acid agent (fast method) acts slower that the above solution, but is
faster than the alkaline solution. With this method is possible to obtain
the samples in less than one hour. Fume extractor is highly
recommended.
TechPub_2614345_0103 - 01_2712261_01_en.fm
(Cont'd)
Acid agent method 1 (very fast)
WARNING
Risk of personal injury!
Observe safety regulations when working with acids. Preparation and
handling of HCl solutions must be carried out in a well-ventilated
environment, as fumes may be given off. Always wear protective
goggles and gloves. Use heat resistant beakers for preparation and
storage. Exhausted chemicals must be disposed of in accordance
with current regulations.
Immerse the samples in HCl 1:1 solution

one at a time for approximately 4 minutes
at temperature between 55 C and 60 C.
Use a water bath.
Note! Temperature settings might
need adjustments given the
equipment used.
2
Remove the samples from HCl 1:1
solution and immerse them in the
Neutralizing Solution to neutralize the
acid.
Neutralizing Solution solution should
bubble as soon as the samples are
immersed; if not, prepare a new solution.
Doc. No. BoC-2712261-0101
1 - 23 (42)
TechPub_2614345_0103 - 01_2712261_01_en.fm
Note! Always use the tongs to

immerse and remove the sample
from the solutions, avoiding the
contact with the hands.
3
The external lamination layer should
easily separate from the Al-foil by
mechanical hand action.
The inner plastic layers and the Al-foil
are left. The Al-foil will be dissolved in
the next step.
The PM layers left, at this stage, on the
sample are the following:
4
Note! This step is the most sensitive.
The temperature of HCl 1:3 solution
increases when samples are immersed
into it, therefore there is a high risk of
burning the packages.
CAUTION
Bath 2 must be at room temperature.
Immerse the samples into HCl 1:3
solution, no more than two at a time,
until Al-foil is dissolved. Keep the
samples in motion to reduce the
temperature.
1 - 24 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
4
5
4 Al-foil
5 Inner coating 1
6 Inner coating 2
5
The Al-foil comes off. The inner plastic
bag, eventually isolated, must be first
neutralized in the Neutralizing solution,
then rinsed carefully under tap water.
The PM layers left at the end of the
dissolving are the following:
TechPub_2614345_0103 - 01_2712261_01_en.fm
5
6
6
Dry the samples, see 1.3.3-3 Drying the
samples.
Doc. No. BoC-2712261-0101
1 - 25 (42)
5 Inner coating 1
6 Inner coating 2
Acid agent method 2 (fast)

WARNING
2
Remove the samples fromthe HCl 30%
solution and immerse them in
Neutralizing solution to balance acidity.
1 - 26 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Immerse the samples in the HCl 30%

solution one at a time for approximately
1 hour.
Note! Always use the tongs to

immerse and remove the sample
from the solutions, avoiding the
contact with the hands.
3
Rinse the samples under tap water. The
external lamination layer and the Al-foil
should easily separate from the inner
plastic layer.
TechPub_2614345_0103 - 01_2712261_01_en.fm
5 Inner coating 1
6 Inner coating 2
5
6
4
samples.
Doc. No. BoC-2712261-0101
1 - 27 (42)
Alkaline agent (slow)
1
Carefully immerse all the samples in the
dissolving solution. Leave the beaker
uncovered to allow hydrogen fumes to be
ventilated.
If fresh, the solution should immediately
start to bubble. If not, prepare a new
solution.
Make sure the Al-foil has dissolved

completely; if not leave the samples in
the solution a little longer or prepare a
fresh one.
15% of citric acid solution might be used
to neutralize the samples.
Rinse the samples under tap water and
carefully separate the inner plastic bag.
5 Inner coating 1
6 Inner coating 2
5
6
3
samples.
1 - 28 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Leave the samples in the dissolving

solution for at least 6 hours, or until no
Al-foil is visible on the upper samples.

1.3.3-3
Drying the samples
1
CORRECT
Carefully dry the inside of the samples

with paper tissue (1) and dry thoroughly
on filter paper, in a well ventilated area.
The presence of water may interfere with
the results of the test.
WRONG
2
Spoiled samples must be discarded.
The picture shows a sample that has been
heated too much during the chemical
exposure, becoming unreliable.
Doc. No. BoC-2712261-0101
1 - 29 (42)
TechPub_2614345_0103 - 01_2712261_01_en.fm
CAUTION
Do not reverse the bags while drying
them, or they could be spoilt.
1.3.3-4
Red Ink Tightness
1
CAUTION
Handle the samples with care.
Mechanical stress due to improper
handling can compromise the results
of the test.
Take one sample at a time, make sure that
it is completely dry.
Let the red ink spread along the TS.

Hold the sample with both hands and
visually check it.
If the TS is not tight and there are
channels in it, the red ink will pass to the
outside of the bag.
If the result is doubtful, let the samples
dry and repeat the red ink test, at room
temperature.
Filter paper can be used to see spots of
red ink passing through the sealing.
1 - 30 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Put some red ink with a plastic pipette

inside the plastic bag along the TS.

Irregularities of the TS which are easy to notice at this point are the
following:
plastic lumps;
Al-foil TS cracks;
product residue;
overheated seal;
channels (unsealed spots)
cuts in the ridge area.
bending off
sealing simmetry
TechPub_2614345_0103 - 01_2712261_01_en.fm
The sealing is even, the heat pattern is

regular, no cracks are visible.
The sample shows bubbles that might
appear after the dissolving due to the
chemical exposure. Those bubbles are
not evidence of anomalies in the sample.
Good seal
2
The sealing is smooth, the heat pattern is
Good seal
Doc. No. BoC-2712261-0101
1 - 31 (42)
Here you have some representative examples of TS.
3
The sealing is smooth, the heat pattern is
Good seal
Good seal
5
The sealing shows cuts in the ridge area
that might be due to dissolving procedure
or high pressure.
Good seal
6
The sealing shows tiny bubbles toward
the product side that do not reach the
ridge (very typical for TBA/22 040).
Good seal
1 - 32 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
The heat pattern is not regular towards

the cutting side suggesting jaw pressure
or knife problems, however, this sealing
is still acceptable for package integrity
but defect might arise.
7
Solid LDPE can be found at the fin, at the
cutting side. Pressure and cutting might
need verification.
Good seal
Trapped product might be spotted in the

sealing. Further analysis could be
needed. If the red ink does not pass
through, the sealing is good.
TechPub_2614345_0103 - 01_2712261_01_en.fm
Good seal
9
Al-foil TS cracks
The TS shows lack of PE along the ridge.
This rupture corresponds to a crack
occurred in the Al-foil during the sealing
pulse, which caused and interrupted the
resulting heat pattern. Refer to
MTD 1210 for details.
Defective seal
Doc. No. BoC-2712261-0101
1 - 33 (42)
10
Plastic lumps
The TS shows plastic lumps.
Defective seal
11
Defective seal
12
Overheating
The seal shows bubbles and melted spots.
This indicates that the sealing
temperature setting was too high or
unparallel jaw pressure.
Defective seal
1 - 34 (42)
Doc. No. BoC-2712261-0101
Product resides (e.g. fruit juice fibres) are

trapped into the TS and pass the ridge.
Fibres can create channels inside it or
perforate the TS up to the paperboard.
TechPub_2614345_0103 - 01_2712261_01_en.fm
Product residue
13
Cutting knife and pressure
problems
The seal shows channels from the cutting
area towards the product side.
Defective seal
Cutting knife and pressure

problems
TechPub_2614345_0103 - 01_2712261_01_en.fm
The seal shows channels from the cutting

area towards the product side.
Defective seal
Doc. No. BoC-2712261-0101
1 - 35 (42)
14
Here you have some examples of good and defective heat patterns.
Good seal
Defective seal
Defective seal
Good seal
Defective seal
Good seal
1 - 36 (42)
Doc. No. BoC-2712261-0101
Defective seal
Good seal
TechPub_2614345_0103 - 01_2712261_01_en.fm
1.4 Transversal Seal - Al-Foil Cracks (MTD 1210)
1.4 Transversal Seal - Al-Foil Cracks

(MTD 1210)
Note!
This procedure is very uselful as troubleshooting procedure.
1.4.1 Introduction
The purpose of this method is to detect cracks which can occur in the Al-foil
along the ridge, especially in the fin corners. This method has been
developed for filled packages produced in filling machines with ridge
inductor.
Package integrity can be compromised if the crack arises at the ends of the
seal, before or during the pulse. The current circulation in the Al-foil is
interrupted by the crack and the sealing is not performed correctly. As a
result, the heat pattern (distance A) does not comply with the minimum
required values.
packaging material;
status of the sealing components;

TS configuration;
tolerances of the machine settings (i.e. design correction and folding
flaps);
TS power setting;
jaw pressure.
Good
Defective
Defective
Doc. No. BoC-2712261-0101
1 - 37 (42)
TechPub_2614345_0103 - 01_2712261_01_en.fm
At the present level of knowledge, the occurrence of cracks depends on:

1
Unfold all the flaps of the package
samples.
TechPub_2614345_0103 - 01_2712261_01_en.fm
Make a cut, either with scissors or a

cutter, 5 cm long, on one side of the
package to empty it from its content.
3
Starting from the LS overlap, tear away
the outer layers of packaging material
over the top and bottom TS.
Mark top and bottom of the package to
identify them.
1 - 38 (42)
Doc. No. BoC-2712261-0101
1.4.3 Procedure
1
TechPub_2614345_0103 - 01_2712261_01_en.fm
2
If the light source at your disposal is not
powerful enough, dip the packages in
warm water and carefully remove the
paperboard layers covering the Al-foil in
the TS area with an abrasive sponge.
3
Put the samples against the light source
and look for cracks in the Al-foil along
the ridge.
Doc. No. BoC-2712261-0101
1 - 39 (42)
If a very bright lamp is available, put the

edge of the sample against the light
source. The area in which the light passes
through the packaging material
corresponds to a crack in the Al-foil.

1
A crack is defined as any spot through
which the light, from a source placed
below the sample, can be seen, as shown
in the picture.
machine settings (design correction

and folding flaps);
TS power setting;
status of the sealing components

TS configuration
2
Defects are visible also with the aid of a
magnifying lens or microscope.
This seal shows a crack due to excessive
pressure of the dollies or knife return
problems, which does not cause a
magnetic field interruption. The heat
pattern is regular.
This is NOT a TS Al-foil crack (cracks
out of the ridge area).
Good seal
3
This crack compromises the distribution
of heat along the TS; the heat pattern will
consequently be irregular.
This is a TS Al-foil crack in the ridge
area.
Defective seal
1 - 40 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
Defective seal
Cracks are due to problems connected

with:
packaging material;
TechPub_2614345_0103 - 01_2712261_01_en.fm
For further investigation dissolve the

packages, see 1.3 Transversal Seal Dissolving and Red Ink (MTD 1208) and
analyse the heat pattern, to confirm its
irregularity.
Doc. No. BoC-2712261-0101
1 - 41 (42)
1 - 42 (42)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 01_2712261_01_en.fm
TechPub_2614345_0103 - 02_2712261_01_en.fm
2 Longitudinal Seal (LS/SA)
Doc. No. BoC-2712261-0101
2 - 1 (24)
Methods:
Methods:
MTD 1202 - Longitudinal Seal Tearing
Personnel
Tools and Chemicals
the tools used.
Reference Documents
Tools and Chemicals

the tools used.
Reference Documents
2 - 2 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Personnel
MTD 1202 - Longitudinal Seal by Red Ink
Table of Contents
2.1 Longitudinal Seal - General information . . . . . . 2 - 5

2.2 Longitudinal Seal (LS/SA) - Tearing
(MTD 1202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
2.2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
2.2.2
2.2.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
2.2.3-2
Mechanical test . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12

2.2.4-1
Rolling ball point pen test

(after mechanical tear down) . . . . . . . . . . . . . . . 2 - 17
TechPub_2614345_0103 - 02_2712261_01_en.fm
2.3 Longitudinal Seal - Red Ink Injection. . . . . . . . 2 - 18

2.3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
2.3.2
Preparation of the Sample. . . . . . . . . . . . . . . . . . 2 - 19
2.3.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
2.3.4
Doc. No. BoC-2712261-0101
2 - 3 (24)
2.2.4
2.2.3-1
2 - 4 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Methods:
2.1 Longitudinal Seal - General information

This seal creates the tight tube of packaging material just before product
filling. A strip of PE (LS strip) is attached to one edge of the packaging
material before sterilization by the Strip Applicator (SA) (Figure 1) by hot
air or induction heating depending on the machine type.
Figure 1
Figure 2
The Strip Applicator side (SA side) (4) of the seal is where the strip was
attached to the packaging material by the Strip Applicator; the packaging
material edges overlap in this area.
The LS side (1) is where the strip was attached to the packaging material
during tight tube forming; the packaging material is single.
An air gap (3) is present in the middle of the seal.
outside package
inside package
TBA package is shown
(Cont'd)
Doc. No. BoC-2712261-0101
2 - 5 (24)
TechPub_2614345_0103 - 02_2712261_01_en.fm
During tight tube forming, the edge of packaging material without the strip is
heated by induction or hot air depending on the machine type; the two edges
are then overlapped and pressed together to create the sealing (Figure 2).
(Cont'd)
SA
LS
TBA/3
hot air
hot air
TFA/3
hot air
hot air
TBA/9 - TWA
hot air
hot air
TBA/8
hot air
hot air
TBA/19
induction
heating
hot air
TBA/21
induction
heating
induction
heating
TBA/22
induction
heating
induction
heating
hot air
hot air
Tetra Pak A3/Flex
induction
heating
induction
heating
Tetra Pak A3/Speed
induction
heating
induction
heating
Tetra Pak A1
Note!
Induction heating and hot air give different results in terms of visual
appearance, therefore it is important to bear in mind which kind of
sealing system is used in the packages under investigation.
IH Sealing produces wrinkles on the Alu-foil. Higher sealing settings
would not eliminate, but increase them. Hot air, on the contrary, does
not usually creates wrinkles in the Alu-foil unless excessively high
settings are used.
2 - 6 (24)
Doc. No. BoC-2712261-0101
Filling Machine
TechPub_2614345_0103 - 02_2712261_01_en.fm
The following table shows the type of sealing (hot air or induction heating)
used in TBA machines for the sealing of SA and LS.
2.2 Longitudinal Seal (LS/SA) - Tearing (MTD 1202)
2.2 Longitudinal Seal (LS/SA) - Tearing

(MTD 1202)
Note!
This test can be carried out during or after Production.
2.2.1 Introduction
The quality of the seal is tested by tearing the LS strip manually. The seal
must be mechanically stronger than the packaging material. If the sealing is
good, the packaging material layers (plastic film, Al-foil or paperboard)
come apart together with the strip.
TechPub_2614345_0103 - 02_2712261_01_en.fm
The heat distribution along the seal can be examined with the use of a
zonoscope to detect possible asymmetry.
Doc. No. BoC-2712261-0101
2 - 7 (24)

1
CAUTION
Do not stress or flatten the samples
since channel leaks might be
induced.
Unfold the flaps of the package samples.
3
Open up the sample, rinse it with water
and dry it.
2 - 8 (24)
Doc. No. BoC-2712261-0101
Cut two opposite corners (top right,

bottom left), empty the package content,
and cut the sample corner to corner in a
diagonal, across the front panel of the
package, leaving the LS intact.
TechPub_2614345_0103 - 02_2712261_01_en.fm
2.2.3 Procedure
2.2.3-1
Visual checks
1
Strip position
LS
SA
Note!
The LS side (2) of the seal is where the
packaging material (1) is single. The SA
side (4) is where the packaging material
is double.
TBA, TPA, TWA, TFA

packages
Check that the strip is centred in the seal.
TBA,TPA,TWA,TFA
TechPub_2614345_0103 - 02_2712261_01_en.fm
An air gap (3) must be present in the

centre of the seal.
4
TCA packages
In TCA packages, the strip is off-centred
with respect to the seal; 2/3 of the strip
cover the SA side.
TCA
1/3
2/3
LS
SA
Note! When the risk of strip folding is

reported the strip (2) can be more on
the SA side (naturally 2/3) than on
the LS (the remaining 1/3). This is
recommended for MPM type strip.
Doc. No. BoC-2712261-0101
2 - 9 (24)
2
Blistering
Check for any blister or bubble along the
heated zone of strip.
The presence of blisters in the LS side of
the strip indicates too high sealing
setting.
The presence of blisters in the SA side of
the strip indicates too high sealing setting
of the Strip Applicator.
PE residue
LDPE residue are trapped below the strip
affecting the sealing.
Defective seal
2 - 10 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Defective seal
4
Overheated LS
Excessive settings or uneven pressure
(LS roller not in control) result in risk of
affecting the performance.
5
Heat distribution
Use the zonoscope to examine the heat
distribution along the LS/SA. The heat
pattern must be present even on the
packaging material beyond the edge of
the strip.
Refer to Use of the Zonoscope, page
Appendix-11, when using the Zonoscope.
Defective seal
Doc. No. BoC-2712261-0101
2 - 11 (24)
TechPub_2614345_0103 - 02_2712261_01_en.fm
Defective seal
2.2.3-2
Mechanical test
1
3
TechPub_2614345_0103 - 02_2712261_01_en.fm
Cutting line is (3).
2
Pull off the outer layer of packaging
material where it is double, to check the
overlap.
2 - 12 (24)
Doc. No. BoC-2712261-0101
Cut the package sample along the middle

of the LS (1) and LS air channel (2).
3
Pull the strip slowly, at an angle of 90,
20 mm at the time.
TechPub_2614345_0103 - 02_2712261_01_en.fm
Note! Best results are achieved if the

sample is pulled on a flat surface
(table).
Doc. No. BoC-2712261-0101
2 - 13 (24)

Note!
Evaluate the samples soon after preparation as the sealing could be
affected by the environment conditions.
When pulling the LS strip (1), it must be mechanically stronger than the
packaging material (2). If the sealing is good, the packaging material layers
(plastic film, Al-foil or paperboard) come apart together with the strip.
Delamination of the strip up to PET layer, or delamination of material up to
Al-foil, are easy to see due to the shining surfaces of PET and Al-foil.
Delamination of the strip layers and the internal of the PM layer is more
difficult to notice.
3
3
1
2
1 LS Strip
2 Packaging Material
3 Cutting line
2 - 14 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Note!
In the drawing below, the LS strip is shown in three layers for easier
reading.
Separation between the two

inner coatings
When the strip is pulled off and
one of the inner coatings comes
off with the strip (1) leaving a
rupture edge (2) along the seal:
Good seal
TechPub_2614345_0103 - 02_2712261_01_en.fm
Separation between the Alfoil and the inside coatings

When the strip (1) is pulled off
and the two inner coatings come
off leaving the Al-foil bare
Good seal
TBA/j packaging material with PPP strip
Rupture in the paperboard

When the strip is pulled outwards
and all inner layers including the
Al-foil come off with the
strip (1),possibly leaving
paperboard fibres (3).
TBA/jl packaging material with MPM strip
Good seal
4
Rupture in the paperboard

Stretch of the Polymer and
rupture to the paperboard
Good seal
TBA/jl packaging material with MPM strip
Doc. No. BoC-2712261-0101
2 - 15 (24)
5
Separation in the LS
strip

and one of the strip layers is left
on the packaging material (i.e.
strip de-lamination). This can
happen also in the cross, where
LS and TS meet.
Good seal
6
Good seal
7
Cold or blocked seal

and it comes off leaving the inner
coatings unaffected or with a
greyish surface
Defective seal
2 - 16 (24)
Doc. No. BoC-2712261-0101
When all inner layers including

the Al-foil come off with the strip
(1) possibly leaving part of the
inner LDPE layer (lamination
layer) (4) on the paperboard.
TechPub_2614345_0103 - 02_2712261_01_en.fm
Separation of inner PE

2.2.4-1
Rolling ball point pen test (after mechanical tear down)
1
Edge
Note! After the strip has been

pulled away, take care not to
touch the spot with fingers.
Press a rolling ball point pen (see
1.5 Tools and Equipment for
details) on a point of the LS edge
after pulling it.
Pulled
strip
Red colour pens are the best

performing.
If the sealing is good, the ink

moves along the sealing fracture
point by capillary action.
TechPub_2614345_0103 - 02_2712261_01_en.fm
Good seal
3
If the sealing is defective, the ink
does not move. This means that
the seal is blocked (cold).
Defective seal
(blocked)
Doc. No. BoC-2712261-0101
2 - 17 (24)
2.3 Longitudinal Seal - Red Ink Injection

2.3.1 Introduction
The quality of the LS is tested by injecting Red Ink into the air channel in the
middle of the seal. The Red Ink must run along the entire channel without
interruption. Any transversal channels of ink would indicate a defective seal
(see section 2.3.4 Evaluation of the Samples).
2 - 18 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
LS Ink Injection and Mechanical Tear Down are pointing at different

properties. The Red Ink Injection does not substitute the Mechanical Tear
Down.
2.3.2 Preparation of the Sample

1
CAUTION
Do not stress or flatten the samples.
TechPub_2614345_0103 - 02_2712261_01_en.fm
2
Cut two opposite corners (top right,
bottom left), empty the package content,
and cut the sample corner to corner in a
diagonal, across the front panel of the
package, leaving the LS intact.
3
Open up the sample, rinse it with water
and dry it.
Doc. No. BoC-2712261-0101
2 - 19 (24)
Unfold the flaps of the package samples.
2 - 20 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Make an oblique cut across the LS as

shown.
2.3.3 Procedure
By red ink injection
CAUTION
Do not stress or flatten the samples.
By red ink contact
TechPub_2614345_0103 - 02_2712261_01_en.fm
Evaluation can be done also by applying

the red ink on the inside of the package,
outside of the LS strip, by means of a
pipette.
2
Leave the sample to dry or wipe the
excess of red ink before looking for
leakages.
Doc. No. BoC-2712261-0101
2 - 21 (24)
Inject 1 ml of red ink into the air channel

of the LS with a 1 ml syringe. The needle
should be around 0.4-0.5 mm to get
into the air channel.

1
Check that the strip is tight and no
transversal air channels are present
This picture shows a good seal, in which

the LS induction heating setting is at
acceptable values.
Good seal
3
This picture shows a good seal, in which
the LS induction heating setting is at
acceptable values.
Good seal
2 - 22 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Critical points are where the LS and the

TS meet, and on the top and bottom
creases.
4
The Red ink flows straight in the air
channel and there are no deviations.
Good seal
TechPub_2614345_0103 - 02_2712261_01_en.fm
This picture shows a seal in which the ink

flows in the air channel showing
deviations that are not compromising
package integrity yet.
Good seal
6
This picture shows a seal in which the
deviations of the ink in the air channel
are worsened making a leaking channel.
Defective seal
Doc. No. BoC-2712261-0101
2 - 23 (24)
7
This picture shows wrinkles and
transversal air channels running across
the LS.
This is typical of the LS made by
Induction Heating when the settings of
the inductors are too high.
2 - 24 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 02_2712261_01_en.fm
Defective seal
TechPub_2614345_0103 - 03_2712261_01_en.fm
3 Opening Devices
Doc. No. BoC-2712261-0101
3 - 1 (24)
3 Opening Devices
Methods:
Methods:
MTD 1211 - Opening Device PullTab and FlexiCap
Personnel
Tools
the tools used.
3 - 2 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 03_2712261_01_en.fm
Reference Documents
Table of Contents
3 Opening Devices
3.1 Opening Devices - General Information . . . . . . 3 - 5

3.2 Opening Devices - PullTab (MTD 1211) . . . . . . . 3 - 6
3.2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
3.2.2
3.2.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3.2.4
Evaluation of the Samples . . . . . . . . . . . . . . . . . . 3 - 9
3.3 Opening Devices - FlexiCap (MTD 1211) . . . . . . 3 - 11

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.3.1.1
FlexiCap top crease faults . . . . . . . . . . . . . . . . . . 3 - 13
3.3.1.2
FlexiCap longitudinal crease faults . . . . . . . . . . . 3 - 15
3.3.1.3
FlexiCap injection faults . . . . . . . . . . . . . . . . . . . . 3 - 17
3.3.1.4
Underfilled FlexiCap . . . . . . . . . . . . . . . . . . . . . . . 3 - 19
3.3.2
3.3.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
3.3.4
Doc. No. BoC-2712261-0101
3 - 3 (24)
TechPub_2614345_0103 - 03_2712261_01_en.fm
3.3.1
3 - 4 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 03_2712261_01_en.fm
3 Opening Devices
Methods:
3 Opening Devices
3.1 Opening Devices - General Information
3.1 Opening Devices - General Information

The methods reported in this section are aimed at assessing the integrity of
TPCA opening devices.
PullTab and FlexiCap are two opening devices made in the filling machine.
To allow these applications, the packaging material is punched and sealed
again to restore integrity during the production cycle.
The integrity of the PT application is ensured by the PEP strip (Inner Patch)
sealed in the inside of the package, which isolates the product from
paperboard fibres around the punched hole.
For the FlexiCap, the PE and the MasterBatch granulate of the cap is melted
and injected so that it is sealed to the inner PE layer of the packaging
material, restoring the microbiological barrier.
TechPub_2614345_0103 - 03_2712261_01_en.fm
Opening such as StreamCap and SpinCap are applied over a PLH (Pre
Laminated Hole) after the package leaving the Filling Machine and not
treated in the manual. Check also section Pre-Laminated Hole at page iii-11.
PullTab
FlexiCap
Doc. No. BoC-2712261-0101
3 - 5 (24)
3 Opening Devices
3.2 Opening Devices - PullTab (MTD 1211)

3.2.1 Introduction
This document describes a method to evaluate the integrity of the PullTab
(PT) opening by means of the leakage detection fluid (Red Ink).
A PT opening consists in a hole punched in the packaging material (3).
The hole is then closed on the outside by an aluminium Tab (1) and on the
inside by a multi-layer plastic strip (Inner Patch, IP) (4).
Tab and Inner Patch are sealed together before forming the package.
The overall PT quality is also given by PullTab position, Tab folding and
Sealing/Heat pattern.
1
3
4
5
TBA, TCA and TPA Family packages
2
3
4
5
TPA Portion packages
1
2
3
4
5
Tab
Outer patch
Packaging material
Inner patch
Air gap
(Cont'd)
3 - 6 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 03_2712261_01_en.fm
An air gap (5) is present around the entire perimeter of the hole. This free
space prevents packaging material fibres from coming into contact with the
inner patch (4) since it could eventually damage or perforate it. The Inner
Patch seals the punched hole, isolating the product from the rest of the
packaging material layers. This restores the microbiological barrier and
ensures package integrity.
In TPA portion packages, a plastic unilateral strip (Outer Patch, OP) (2) is
applied onto the external surface of the packaging material before punching
the hole, to cover the paperboard fibres when the PT is opened for
consumption.
3 Opening Devices

1
Select a suitable number of packages
according to the level of accuracy
needed.
Cut the packages into two halves with a
cutter; only the top parts will be used for
the test.
TechPub_2614345_0103 - 03_2712261_01_en.fm
Rinse the package samples and let them

dry in a well ventilated area or using
compressed air.
Doc. No. BoC-2712261-0101
3 - 7 (24)
3 Opening Devices
3.2.3 Procedure
1
Apply red ink over the inner surface of
the PT hole with a plastic pipette,
covering the inner patch completely.
Leave the red ink inside the package for
at approximately 5 minutes.
Remove the excess of red ink with the
pipette.
Clean the inside of the package with a

dry paper towel or let it dry thoroughly in
a well ventilated area.
Note! Flushing with water might give
problems if water is not carefully
dried before unfolding the flaps and
splitting the packaging material.
3
Flatten the package by opening the flaps.
Carefully, starting from the LS overlap,
split the paperboard and remove the outer
layer.
Continue peeling the package. Some
paperboard will come off together with
the outer layer of PE and the PT will open
up.
3 - 8 (24)
Doc. No. BoC-2712261-0101
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Note! Do not pour red ink out of the

package as this could lead to false
positive reading.
3 Opening Devices
4
Continue peeling the package.
Some paperboard will come off together
with the outer layer of PE and the PT will
open up.
Note! If the ink is still in the package
before performing this operation,
artifact defects might be created.
TechPub_2614345_0103 - 03_2712261_01_en.fm
The PullTab sealing is good if there are

no red ink spots on the paperboard layer
around the PullTab hole.
Good application
2
The PullTab sealing is defective if there
are red ink spots on the paperboard layer
around the PullTab hole.
Defective application
Doc. No. BoC-2712261-0101
3 - 9 (24)
3 Opening Devices
3
This is typical problem due to confetti
removal failure. The confetti waste box
and waste tube are filled up and their
presence in the system create this defect
in the application.
If the PE residue is completely missing,

the pressure or heat, during application,
was too high and Package Integrity can
be affected.
A
TBA
If the PE residue is too wide, pressure or

heat, during application, was too low and
pouring performances can be affected.
Note! TPA packages, having a wider
hole might show more residue than
TBA packages. If ReCap is present
the cap helps in getting improved
pourability.
Note! Refer to the Filling Machine
Operation Manuals for related
measures A.
A
A
TPA
3 - 10 (24)
Doc. No. BoC-2712261-0101
Check if there is a residue of PE all

around the PT hole, measure A (see table
below). This residue corresponds to the
unsealed area of the strip, it is to say the
air gap.
TechPub_2614345_0103 - 03_2712261_01_en.fm
3 Opening Devices
3.3 Opening Devices - FlexiCap (MTD 1211)

3.3.1 Introduction
This chapter describes how to evaluate the quality of the FlexiCap openings.
FlexiCap Opening, like PT Opening, consists in a hole which is punched in
the packaging material; the hole is then hermetically closed on the outside by
a cap which is injection-moulded directly on to the packaging material
before forming the packages.
The FlexiCap integrity is tested by the leakage detection fluid (red ink), by
visually checking the cap and testing the FlexiCap opening force.
TechPub_2614345_0103 - 03_2712261_01_en.fm
faults which are a result of the positioning of the punched hole,

faults which are a result of the positioning of the FlexiCap,
faults which are a result of a combination of the positioning of both the
punched hole and the FlexiCap,
faults which are a result of the setting of the moulding tools and/or
injection system.
In general, FlexiCap faults are:

result of the hole and FlexiCap positioning,
combination being correctly aligned to each other but incorrectly

positioned on the packaging material,
inaccurately set moulding tools and/or injection system.
Doc. No. BoC-2712261-0101
3 - 11 (24)
FlexiCap faults can be categorized into four distinct groups:
3 Opening Devices
1
2
3
4
5
6
7
8
3 - 12 (24)
Lid
Membrane
Hinge
Dog bone
Injection Point
PullTab
Tamper evidence
Punched hole edge
9
10
11
12
13
14
15
16
Spider leg
Leg
Membrane support
Pouring lid
Inside sealing area
Knife
Stepped membrane
Membrane support rib
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FlexiCap Terms
3 Opening Devices
FlexiCap top crease faults
TechPub_2614345_0103 - 03_2712261_01_en.fm
Delamination
If the FlexiCap is positioned too close to the top crease there is an increased
risk of delamination of the packaging material at the edge of the punched
hole, see Figure 1. This will occur when the packaging material is being
folded into the package shape in the filling machines final folder.
figure 1
Doc. No. BoC-2712261-0101
3 - 13 (24)
3.3.1.1
3 Opening Devices
Transportation damage - cracks in the rear

If the FlexiCap is positioned too close to the top fin crease then there is a
higher risk of FlexiCap damage during transportation.
Typically the packages are stacked on top of each other and then distributed
on pallets. If the FlexiCap is too close to the top fin crease, there is an
increased load applied to the FlexiCap from the packages stacked above and
this combined with the vibration and motion of the truck during
transportation creates a fault in the FlexiCap.
figure 2
Cap in the Jaws

Although this is a very uncommon problem, if the FlexiCap is positioned
extremely close to the top fin crease there is a risk of the FlexiCap being
trapped between the inductors of the filling machines jaw system.
3 - 14 (24)
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Generally this appears as a crack at the rear of the FlexiCap, see figure 2.
3.3.1.2
FlexiCap longitudinal crease faults
TechPub_2614345_0103 - 03_2712261_01_en.fm
Broken membrane
If the FlexiCap is positioned too far over the longitudinal crease there is an
increased risk of the membrane being broken at the front of the FlexiCap, see
figure 3. This happens when the folding flaps of the jaw system grip the
packaging material to keep the tube within design.
It is acceptable for the folding flaps to pinch the end of the FlexiCap tab, but
if the FlexiCap is positioned too far over the longitudinal crease the folding
flaps will pinch too much of the FlexiCap and as a result the membrane can
be broken.
figure 3
Doc. No. BoC-2712261-0101
3 - 15 (24)
3 Opening Devices
3 Opening Devices
Positioning impact
If the FlexiCap is positioned too far from the longitudinal crease both
pouring performance and closure after opening performance are affected and
tamper evidence might get broken during package forming in the line.
This is because the edge of the package side panel (longitudinal crease)
supports the FlexiCap, but if the FlexiCap is positioned too far from this
extra support, cracks in the front of the FlexiCap can form under the pouring
lip, see figure 4.
figure 4
3 - 16 (24)
Doc. No. BoC-2712261-0101
Transportation damage - crack in the front

If the FlexiCap is positioned too far in from the longitudinal crease,
occasionally cracks are formed in the front of the FlexiCap, normally the
cracks appear after and as a result of transportation and distribution of the
packages.
TechPub_2614345_0103 - 03_2712261_01_en.fm
The FlexiCap has been designed to be moulded over the edge (longitudinal
crease). Pouring performance is also affected by FlexiCap positioned far
from the side panel. The longitudinal crease gives the proper support to allow
reclosability.
3 Opening Devices
3.3.1.3
FlexiCap injection faults

Overfilled FlexiCap
The amount of plastic used in each FlexiCap is regulated by adjusting the
stroke of the injection cylinder, see the DIMC Multi maintenance manual
Injection system - set cylinder for more details.
TechPub_2614345_0103 - 03_2712261_01_en.fm
If too much plastic is injected, splashes of plastic will be visible around the
inside of the FlexiCap, see figure 5.
figure 5
(Cont'd)
Doc. No. BoC-2712261-0101
3 - 17 (24)
3 Opening Devices
(Cont'd)
The first FlexiCaps produced can be overfilled. This is due to a change in the
characteristics of the plastic left in the injection system from the previous
production, which allows more plastic to be injected. This is normal and no
corrective action is required.
TechPub_2614345_0103 - 03_2712261_01_en.fm
figure 6
figure 7
3 - 18 (24)
Doc. No. BoC-2712261-0101
If the FlexiCaps have a fin along the top of the lid, this too could be the result
of too much plastic being injected. But it is more likely to be a small amount
of cured plastic trapped between the two halves of the lower tools stopping
the two halves of the lower tools from closing completely. See figure 6 and 7.
3 Opening Devices
3.3.1.4
Underfilled FlexiCap
TechPub_2614345_0103 - 03_2712261_01_en.fm
Underfilled FlexiCaps are a direct result of an incorrectly set injection

system, see figure 8.
figure 8
Doc. No. BoC-2712261-0101
3 - 19 (24)
3 Opening Devices

1
Select a suitable number of packages
according to the level of accuracy
needed.
Note! At least 1 package produced
by each moulding station must be
sampled and checked.
Cut the packages into two halves with the

scissors. Only the top parts will be used
for the test.
Rinse the package samples and let them
dry in a well ventilated area or using
compressed air.
3 - 20 (24)
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If the test is applied during

troubleshooting take a tray of packages in
which at least 1 appears defective.
3 Opening Devices
3.3.3 Procedure
FlexiCap Integrity Check
1
Note! If the check is being carried out
after a packaging material splice
check the FlexiCap forming as
described in the FlexiCap forming
Apply red ink to the inside of the package
in the area indicated in the illustration
with a plastic pipette, covering the
FlexiCap completely.
at approximately 5 minutes. Remove the
excess of red ink with the pipette.

positive reading.
2
Break the tamper evidence of the
FlexiCap and lift it just enough to see
inside. Check that the red ink has not
passed through the membrane (in the area
indicated on the illustration).
If the red ink has passed through the
membrane, corrective action shall take
place.
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3 - 21 (24)
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Wait for the ink to completely dry.
3 Opening Devices
3 - 22 (24)
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Carefully peel off the outer layer of PE

starting from the LS overlap. Some
PE.
3 Opening Devices

1
Check for any red spots around the
application. Absence of red spots
indicates that the FlexiCap application is
good.
2
Red spots indicate that the FlexiCap
application is defective.
Note! Problems with FlexiCap
sealing may result in unsterile
packages and corrective action shall
take place.
Doc. No. BoC-2712261-0101
3 - 23 (24)
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Good application
3 - 24 (24)
Doc. No. BoC-2712261-0101
3 Opening Devices
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4 Package Integrity
Doc. No. BoC-2712261-0101
4 - 1 (20)
4 Package Integrity
Methods:
MTD 1203 - Package Integrity - Conductivity test
Personnel
Tools and Chemicals
the tools used.
Reference Documents
Tools and Chemicals

the tools used.
Reference Documents
Previous version, MTD1207, issued by Sara Davolio, date 2002/03/05.
MTD 1204 - Package Integrity - Red Ink test

Personnel
Tools and Chemicals
the tools used.
Reference Documents
Previous version, MTD1204, issued by Sara Davolio, date 1996/04/20.
4 - 2 (20)
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Personnel
MTD 1207 - Package Integrity - Copper test
Table of Contents
4 Package Integrity
4.1 Package Integrity - General Information . . . . . . 4 - 5

4.2 Package Integrity - Conductivity Test
(MTD 1203) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
4.2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
4.2.2
4.2.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
4.2.4
Evaluation of the Samples . . . . . . . . . . . . . . . . . . 4 - 9
4.3.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
4.3.2
4.3.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
4.3.4
4.4 Package Integrity - Red Ink Test (MTD 1204) . 4 - 15

4.4.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
4.4.2
4.4.3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
4.4.4
Doc. No. BoC-2712261-0101
4 - 3 (20)
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4.3 Package Integrity - Copper Test (MTD 1207). . 4 - 10
4 - 4 (20)
Doc. No. BoC-2712261-0101

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4 Package Integrity
4 Package Integrity
4.1 Package Integrity - General Information
4.1 Package Integrity - General Information

The present chapter reports test methods aimed at the microbiological barrier
of a TPCA package.
The microbiological barrier consists of the inner plastic layer, the Al- foil
and the lamination layer between the Al- foil and the paper board.
All three layers have to be broken before the microbiological barrier is lost.
By definition, aseptic package integrity requires, beside sealing quality as
described in the dedicated chapters, an intact microbiological barrier.
The tests are:
Conductivity Test (MTD 1203)
Copper Test (MTD 1207)

Red Ink Test (MTD 1204)
TechPub_2614345_0103 - 04_2712261_01_en.fm
Depth of
defect
Conductivity
Test
Red Ink
Test
Copper
Test
Tight
Package
Corrective
actions
needed
NO
YES
YES
YES
YES
YES
YES
NO
B
A
1
2
3
4
5
6
D
1
Inner layer (PE, m-PE)

Adhesion layer
Al-foil
PE Lamination
Paperboard
Outer layer
Doc. No. BoC-2712261-0101
4 - 5 (20)
Defects are detected according to the table below.
4.2 Package Integrity - Conductivity Test (MTD 1203)
4 Package Integrity
4.2 Package Integrity - Conductivity Test

(MTD 1203)
4.2.1 Introduction
This chapter describes how to detect ruptures of the inner PE layer, which
leave the Al-foil uncoated.
The package is immersed in an electrolytic solution (salt solution). If there is
a crack in the PE layers, an electrical contact is established between the
electrolytic solution outside the package and the package content, which is
measured by an ammeter (electrolytic tester).
Note!
The only way to detect a blocked seal it is the manual Tear Down
during Production. Conductivity test and Red ink test would not detect
a blocked seal.
To detect where the rupture is located, the test must be followed by the 4.3
Package Integrity - Copper Test (MTD 1207) or by the 4.4 Package Integrity
- Red Ink Test (MTD 1204).
4 - 6 (20)
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Packages filled with fat products should not be checked with this method
after storage, as the greasy components could create an insulating layer on
the inside of the package, preventing current from circulating. Adopt the Red
Ink Integrity test, instead.
This method can be used for packages containing liquid products such as
water, wine or fruit juice.
4 Package Integrity

1
Cut all the selected packages in two
halves with a sharp cutter or scissors.
2
Rinse the packages and wipe the cut
edges thoroughly with a paper tissue or
let them dry before testing; a wet edge
might cause a false current deflection.
Doc. No. BoC-2712261-0101
4 - 7 (20)
TechPub_2614345_0103 - 04_2712261_01_en.fm
Note! The best procedure is anyway

to keep the package in one sample
only.
4 Package Integrity
4.2.3 Procedure
1
Put table salt (10 g per litre of water) into
a plastic water basin.
Fill a third of each package sample with
the NaCl solution. Make sure the solution
reaches the weak areas of the package,
such as corners and creases.
Put the sample carefully into the bowl, so
that the outside corners are fully covered.
CAUTION
Risk of false readings!
Keep the package cut edges dry to
prevent them from acting as a bridge
and giving false deflections.
Be careful not to scratch the inside of
the packages with the electrodes.
Note! The electrodes can be
connected to the ammeter by wires,
in order to facilitate the work.
4 - 8 (20)
Doc. No. BoC-2712261-0101
Dip the positive probe (Red) of the

ammeter inside the package and the
negative one (Black) outside of it, into
the NaCl solution.
TechPub_2614345_0103 - 04_2712261_01_en.fm
Note! The black probe (negative) has

to be placed in the water, the red
probe (positive) in the package
sample.
4 Package Integrity
TechPub_2614345_0103 - 04_2712261_01_en.fm
Read the deflection of the ammeter:

If the reading is 0 A, the sample has
no ruptures in the internal PE
coating; (negative samples).
If the ammeter reading is unsteady
and greater than 0 A, wipe the edge
once more and make a new reading;
if still unsteady, let the sample dry.
If the deflection is quick and steady
and the reading is greater than 0 A,
it means that there is contact to the
Al-foil (i.e. a hole on the inner PE
layers). Those samples shall be
submitted to further investigations,
(positive samples).
Note! A reading below half scale is
almost always a wet paper edge.
Doc. No. BoC-2712261-0101
4 - 9 (20)
4.3 Package Integrity - Copper Test (MTD 1207)
4 Package Integrity
4.3 Package Integrity - Copper Test

(MTD 1207)
4.3.1 Introduction
This document describes a method to locate ruptures in the inner layers of
the Tetra Pak Carton Ambient packages.
Ruptures in the inner PE layers can be detected by the conductivity test
(MTD 1203). The package is immersed in an electrolytic solution (i.e. salt
solution). In case of a crack in the PE layers, which leave the Al-foil
uncovered, an electrical contact is established between the electrolytic
solution outside the package and the package content.
4 - 10 (20)
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If some copper solution is poured into the package, the copper oxide
solidifies in the area of the cracks when a copper tester is used, allowing to
locate the fault.
4 Package Integrity

1
Cut all the selected packages in two
halves with a sharp cutter or scissors.
2
Rinse the packages and wipe the cut
edges thoroughly with a paper tissue or
let them dry before testing; a wet edge
might cause a false current deflection.
Doc. No. BoC-2712261-0101
4 - 11 (20)
TechPub_2614345_0103 - 04_2712261_01_en.fm

only.
4 Package Integrity
4.3.3 Procedure
Note!
If the Red ink test (MTD 1204) is going to be performed on the
packages, do it before the copper test. The copper test can cause an
enlargement of the cracks in the packaging material, compromising
the results of the ink penetration.
1
Put some NaCl solution (approx. 10%)
into a plastic water basin.
Refer to Use of the Electrolyte Copper

Tester, page Appendix-12, when using
the Tester.
2
Press the Push button for approximately
four seconds to turn on the tester.
If the ammeter shows a current deflection
over 50 A, there might be the presence
of a crack in the inner layer up to the
Al-foil.
4 - 12 (20)
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Put the red electrode into the sample

package and the black one in contact with
the salt solution.
Put some copper solution into the sample

package, to cover corners and creases,
and dip it carefully into the basin, so that
it is steady.
4 Package Integrity
TechPub_2614345_0103 - 04_2712261_01_en.fm
4
Move the red electrode around the inner
corners of the packages for
approximately 3 minutes; the copper will
deposit on the cracks, making them
visible.
Mark the areas of deposition with a
permanent marker.
Repeat the test with all the packages, on
both halves.
Doc. No. BoC-2712261-0101
4 - 13 (20)
Press the button Push once again.

Electrolysis starts. The red LED lights
up.
4 Package Integrity

1
After the copper test has been performed,
rinse the sample packages with water.
Let them dry thoroughly; use compressed
air to speed the process.
Unfold the flaps and peel off the outer
layers.
If no red ink is found on the packaging

material, the contact was due to a rupture
of the plastic layers up to the Al-foil (3)
(cases B, C or D).
D
7
1
2
3
4
5
6
7
4 - 14 (20)
1
Inner layer (PE, m-PE)
Adhesion layer
Al-foil
PE Lamination
Paperboard
Outer layer
Copper deposition
If red ink spots are visible, in

correspondence of a copper deposition
area (7), a rupture of the plastic layers
and Al-foil occurred, causing a defect
(case A).
Count the number of packages with
exposed Al-foil, packages with red ink
failures that compromise the package
integrity and the total number of tested
packages. Record the data.
Doc. No. BoC-2712261-0101
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Look for red ink spots on the paperboard.
4 Package Integrity
4.4 Package Integrity - Red Ink Test (MTD 1204)
4.4 Package Integrity - Red Ink Test

(MTD 1204)
4.4.1 Introduction
TechPub_2614345_0103 - 04_2712261_01_en.fm
An aseptic package is conventionally defined as leaking when Red Ink

penetrates the coating layers and stains the paperboard. According to this
definition, a package is defective when it is positive to the Red Ink Test,
since all the microbiological barriers performed by the Al-foil and inner PE
layers are broken: integrity is therefore not guaranteed.
Doc. No. BoC-2712261-0101
4 - 15 (20)
4 Package Integrity

1
During troubleshooting
Cut out a hole in the front panel of the
package.
This allows to investigate the package as
a whole, identifying the defective areas
in an accurate way.
During Production or After

Production Laboratory
checks
Cut the packages in two halves using a
cutter.
only.
4 - 16 (20)
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Note! TFA packages should be cut

into halves, making sure not to cut on
damaged spots.
4 Package Integrity
4.4.3 Procedure
1
Apply red ink over the critical points of
the package, such as corners, TS, crosses.
approximately 5 minutes.
Remove the excess of red ink with the
pipette.
TechPub_2614345_0103 - 04_2712261_01_en.fm
2
Clean the inside of the package with a
dry paper towel or let it dry thoroughly
in a well ventilated area.
3
Once samples are dry, unfold the flaps
and carefully peel off the outer layer of
PE starting from the LS overlap. Some
the PE.
Note! If ink is still present in the
package, leakage can be caused by
opening the flaps and breaking the
inner PE layer.
Doc. No. BoC-2712261-0101
4 - 17 (20)

positive reading.
4 Package Integrity

1
Check for any red ink spots on
the paperboard layer on the
corners, TS, and crosses areas.
Any red ink leakage corresponds
to a defect in the package.
Defective
TBA and TPA packages can be

affected by fin tears in the top
due to interactions between the
PM and folding flaps.
TWA packages are affected by
fin tears in the bottom (since the
folding flaps act on the bottom).
Check for any red ink spots on
the fins.
Any red ink leakage corresponds
to a defect in the package.
TWA package shown
4 - 18 (20)
Doc. No. BoC-2712261-0101
Defective
TechPub_2614345_0103 - 04_2712261_01_en.fm
Fin tear can develop into integrity

defects.
Fin tearing
4 Package Integrity
2
If the red ink spot is larger on the
peeled external layer than on the
package side, it means that the
ink has leaked from the
OUTSIDE of the package to the
INSIDE.
TechPub_2614345_0103 - 04_2712261_01_en.fm
1
2
3
4
5
Larger red ink spot

PM external layer
Split paperboard
Smaller red ink spot
PM internal layers
4
5
Doc. No. BoC-2712261-0101
4 - 19 (20)
This is NOT an integrity defect

but simply and artifact by
applying the procedure.
See diagram.
4 - 20 (20)
Doc. No. BoC-2712261-0101
4 Package Integrity
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5 Package Forming
Doc. No. BoC-2712261-0101
5 - 1 (8)
5 Package Forming
5 - 2 (8)
Doc. No. BoC-2712261-0101
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The methods reported in this section are additional checks

which are not aimed at assessing package integrity, but
other important aspects of the packages such as flap
sealing, data printing, weight. They are included here to
give a complete picture of what is a good package, also
from appearances point of view.
Table of Contents
5 Package Forming
5.1 Package Forming. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Date Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Flap Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Crease lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
LS Overlap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
TechPub_2614345_0103 - 05_2712261_01_en.fm
Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Doc. No. BoC-2712261-0101
5 - 3 (8)
5 - 4 (8)
Doc. No. BoC-2712261-0101

TechPub_2614345_0103 - 05_2712261_01_en.fm
5 Package Forming
5 Package Forming
5.1 Package Forming
5.1 Package Forming

Note!
The machine OMs always report an updated and exhaustive version
of package appearance and forming checks.
Date Printing
Check the date and code printing.
Weight
TechPub_2614345_0103 - 05_2712261_01_en.fm
Weigh the packages.

Record their weight and weight
deviations.
After setting, pick out new packages and
check them.
Flap Sealing
Unfold the flaps and check that they are
properly sealed.
On the bottom flaps the heat should not
be directed on the TS.
Burnt marks might impact on package
integrity.
Doc. No. BoC-2712261-0101
5 - 5 (8)
If necessary, stop the filling machine and

adjust the date printing according to the
instructions supplied with the printer.
5 Package Forming
5.1 Package Forming
Crease lines
Lift the package top or bottom fin (1).
fig.1
Bottom view of package
Note! To correct check crease lines

alignment it is important to lift the
flaps, since closed flaps might give
indication of wrong set of creases
lines, but due to package folding.
Check the position of the preformed
crease lines (2).
fig.1
The position is acceptable if
fig.2
the creases are opposite one another

(fig.1) either parallel (fig.2) or at an
angle (fig.3).
the preformed crease lines are not

opposite one another (fig.5 and 6).
If there are any defects, corrective

actions should be taken.
fig.3
fig.4
2
fig.5
After adjustment, pick out new packages

and check them.
Note! To correct assess crease lines
alignment it is important to lift the
flaps, since closed flaps might give
indications of wrong set of creases
lines, but they are due to package
folding in the Final Folder Unit, as
shown the picture below.
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 05_2712261_01_en.fm
The position is not acceptable if
5 - 6 (8)
5 Package Forming
5.1 Package Forming
LS Overlap
With the aid of a vernier calliper check
the width of the packaging material
overlap, distance B.
If the overlap is out of the range

indicated, corrective actions should be
taken.
Surfaces
fig.1
Cut two opposite corners (fig.1) and

empty the content of the package (fig.2)
fig.2
Cut transversally the front panel of the

package, from the lower cut corner to the
opposite one (fig.2 and 3).
Split the TS apart and open the package
(fig.4).
Rinse and dry the package with
compressed air from the filling machine.
Check the outside and inside surfaces of
the package for scratches.
fig.3
Inside deep scratches might cause

package integrity problems.
If there are any defects, corrective
actions should be taken.
fig.4
Doc. No. BoC-2712261-0101
5 - 7 (8)
TechPub_2614345_0103 - 05_2712261_01_en.fm
Note! Refer to the Filling Machine

Operation Manuals for related
measures B.
5 - 8 (8)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - 05_2712261_01_en.fm
5 Package Forming
5.1 Package Forming
TechPub_2614345_0103 - A1_2712261_01_en.fm
Appendix A:
Flowcharts and
Troubleshooting
Doc. No. BoC-2712261-0101
Appendix - 1 (14)
Appendix - 2
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A1_2712261_01_en.fm
Appendix A:Flowcharts and

Troubleshooting

Troubleshooting
Table of Contents
A.1 Operator Checks . . . . . . . . . . . . . . . . . . Appendix - 5

A.1.1
Checking scheme. . . . . . . . . . . . . . . . . . . Appendix - 5
A.1.2
Flowchart of the Production Quality

Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 7
A.2 Laboratory QC Checks . . . . . . . . . . . . . Appendix - 9

A.3 Products with Fibres Checks . . . . . . . Appendix - 10
A.4 Troubleshooting . . . . . . . . . . . . . . . . . Appendix - 12
Homogeneous (Water-based)
Products . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 13
A.4.2
Viscous and Fatty Products . . . . . . . . . Appendix - 14
TechPub_2614345_0103 - A1_2712261_01_en.fm
A.4.1
Doc. No. BoC-2712261-0101
Appendix - 3 (14)
Appendix - 4
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A1_2712261_01_en.fm

Troubleshooting

Troubleshooting
A.1 Operator Checks
A.1 Operator Checks

A.1.1 Checking scheme
The Checking Scheme, present in the OM of the filling machine, describes
the recommended sequence of checks to be done on the packages.
The Checking Scheme table explains:
TechPub_2614345_0103 - A1_2712261_01_en.fm
the event which it is recommended that the package checks are

performed immediately after, e.g. Production Start (1).
the number of packages needed for checks according to which event has
prompted the package checks (2).
the number of packages on which to perform the individual checks (3).

the check to be performed (4).
the page number of the check instructions (5).
to mark the check box when the check has been completed (6)
Note!
For some checks, the number of packages checked depends on the
number of jaws of the filling machine. This variable is identified as X.
X is equal to the number of jaws of the FM (e.g. 2 jaws in TBA/19 and
TBA/21, and 10 jaws in Tetra Pak A3/Speed and TBA/22).
X+1 means that the number of packages to be checked are equal to
the number of jaws plus one package.
Refer to the specific machine OM for instructions on how to select and
mark the packages for quality checks.
Extract from the Checking Scheme schedule
2
3
Date Print
Production
Start
page
123
(Cont'd)
Doc. No. BoC-2712261-0101
Appendix - 5 (14)

Troubleshooting
A.1 Operator Checks
(Cont'd)
Here below an example of Checking Scheme as you can find it in the OM.
These checks can be carried out by the operator in the machine area, during
Production. These checks are Filling Machine and PullTab unit dependent
due to number of jaws (X variant) of the FM or/and PullTab unit with single
or double index (Y variant). Please refer to the machine OM as detailed
reference.
Date print
Weight
TS
X
After a raw
material splice
After a LS
strip splice
After a patch or
tab strip splice
Date print
Weight
TS
TS
(Accurate)
X (Accurate)
Shape &
design
Shape &
design
Tab
position
Tab
position*
Flap
sealing
Flap
sealing
TS
Crease
lines
Overlap
Surfaces
Tab
position
Crease
lines
Overlap
Surfaces
Hole
position
Hole
position
Hole
position
Patch &
tab sealing
Patch &
tab sealing
Patch &
tab sealing
LS/SA
Appendix - 6
LS/SA
LS/SA
Doc. No. BoC-2712261-0101
Production
start
TechPub_2614345_0103 - A1_2712261_01_en.fm
X+1

Troubleshooting
A.1 Operator Checks
A.1.2 Flowchart of the Production Quality Checks

The Flowchart of Production Quality Checks displays:
the checks to be performed in the sequence described in the checking

scheme table (1)
the type of check (2)
the necessary actions (if any) to be taken depending on the result of the
completed check (3).
Note!
For some checks, the number of packages checked depends on the
number of jaws of the filling machine. This variable is identified as X.
X is equal to the number of jaws of the FM (e.g. 2 jaws in TBA/19 and
TBA/21, and 10 jaws in Tetra Pak A3/Speed and TBA/22).
X+1 means that the number of packages to be checked are equal to
the number of jaws plus one package.
Refer to the specific machine OM for instructions on how to select and
mark the packages for quality checks.
TechPub_2614345_0103 - A1_2712261_01_en.fm
Extract from Flowchart of operator quality checks
2
1
Flap
Sealing
No
OK?
TPOP
Setting
Yes
TS
Rough
2
No
OK?
Call a
Technician
Stop
Production
Yes
= Legal requirement related check

= Package integrity related check
= Package appearance and line efficiency related check
(Cont'd)
Doc. No. BoC-2712261-0101
Appendix - 7 (14)

Troubleshooting
A.1 Operator Checks
(Cont'd)
Here below an example of Production Quality Check Flowchart as you can
find it in the OM. These checks can be carried out by the operator in the
machine area, during Production. These checks are Filling Machine and
PullTab unit dependent due to number of jaws (X variant) of the FM or/and
PullTab unit with single or double index (Y variant). Please refer to the
machine OM as detailed reference.
Date print
1
no
Ok?
Stop
Production
call a
technician
Crease
lines
yes
Weight
no
Machine
setting
Ok?
TS
(rough)
Ok?
Stop
Production
call a
technician
no
Stop
Production
call a
technician
Stop
Production
call a
technician
Surfaces
yes
Ok?
TS
(accurate)
no
Ok?
yes
Stop
Production
Machine
setting
LS/SA
no
yes
Ok?
Shape and
design
no
Ok?
yes
Machine
setting
continue
Production
additional
X+1 packages to
yes
1
call a
technician
yes
no
Stop
Production
Overlap
yes
no
yes
Laboratory
QA checks
Flap
sealing
Ok?
no
Machine
setting
yes
Appendix - 8
Doc. No. BoC-2712261-0101
Ok?
Machine
setting
TechPub_2614345_0103 - A1_2712261_01_en.fm
no
Ok?

Troubleshooting
A.2 Laboratory QC Checks
A.2 Laboratory QC Checks

These checks must be carried out on regular basis by qualified personnel, in
an area appropriately equipped. This allows to constantly monitor the quality
of the packages.
Conductivity
X test
MTD
1203
LS by red ink
injection
MTD
1202
yes
test ok?
record
results
no
test ok?
no
defect
found
corrective
actions
yes
test ok?
record
results
Alu-foil TS
cracks
MTD
1210
Dissolve
packages
MTD
1208
yes
urgent
check?
Leakages
? by red ink
MTD
1204
no
defect found
corrective actions
no
method 2:
dissolving in
alkaline solution
method 1:
dissolving in
acid solution
record results
obtain
samples
MTD
1208
Heat pattern
yes
MTD
1208
TS integrity
by red ink
yes
test ok?
record
results
no
defect
found
corrective
actions
Doc. No. BoC-2712261-0101
Appendix - 9 (14)
TechPub_2614345_0103 - A1_2712261_01_en.fm
yes

Troubleshooting
A.3 Products with Fibres Checks

These checks can be of help to investigate the behaviour of products
containing fibres. Due to the fact that the Transversal Sealing takes place in
the product flow, fibres can be trapped in the TS (usually bottom seal for
TPA, TBA, TCA and TFA packages, top seal for TWA packages), causing
unsterility during storage and transportation.
By definition, the filled product should be homogenous, i.e. no particles must
be retained on a sieve 0.6 span.The only non-homogeneous products
accepted by TPCA are citrus juices with a maximum fibre content of 5%.
Fibres hardness is a parameter that can highly influence performance even
though it is not measurable and specified.
Description
Packaging Lines
HVA (High Viscosity

Aseptic) kit
Helps the product run

through the filling
system avoiding valve
clogging
TBA/8
TBA/19
Special packaging
material
TBA/lk-25 and
TBA/lk-36
The LLDPE film

improves packing of
hard particles
All except TBA/3
Modified counter
pressure rubber
dollies in combination
with modified jaw
system settings
Help to free the sealing

area from particles
TBA/3
TBA/8
TBA/9
TBA/19
TBA/21
Non-trapped fibre
Upper
package
Top seal
Lower
package
Bottom seal
Trapped fibre
(Cont'd)
Appendix - 10
Doc. No. BoC-2712261-0101
Item
TechPub_2614345_0103 - A1_2712261_01_en.fm
Special equipment and packaging material have been designed to reduce the
risks of defective seals when packing fibrous products, see table below. For
further information, refer to the TPCA Sealing Technology and Food
Technology Departments.

Troubleshooting
(Cont'd)
The following flowchart represent part of a test procedure which should be
carried out on a representative batch of at least 6000 packages to get reliable
results. The procedure should be performed before and after full distribution
(i.e. transportation).
Conductivity MTD
1203
test.
300
no
defective
packages
test ok?
TechPub_2614345_0103 - A1_2712261_01_en.fm
Dissolve
100 packages
no
fibres are
not a
problem
fibres
in TS?
TS integrity
by red ink
no
test ok?
fibres are a
problem
yes
yes
Dissolve
packages
fibres may
be a
problem
fibres in
TS?
no
fibres are
not a
problem
yes
fibres may
become
problem
Doc. No. BoC-2712261-0101
Appendix - 11
yes

Troubleshooting
A.4 Troubleshooting
A.4 Troubleshooting
These checks take place during troubleshooting to investigate if the
unsterility is due to package integrity. Care in every step of the evaluation is
important since the methods are destructive and packages will not be
available for further checks afterwards.
Package forming and data printing should be analysed and recorded since
they may add relevant information to find the cause of unsterility.
The procedure is slightly different for homogeneous (water-based) products
(e.g. water, fruit juice) and viscous or fatty products (e.g. cream, tomato
sauce).
The overall troubleshooting procedure should be performed by:

FiSQA Officers
System Specialists
Appendix - 12
Senior Tetra Pak Field Service Engineers

Senior Technical Support Staff.
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A1_2712261_01_en.fm
The optimal population to investigate consists of the blown package (which

most likely will show also burst spots on the TS) and the packages produced
close to it (most likely belonging to the same tray).
The Conductivity Test is not effective with packages filled with fat products,
as fat can create a layer which covers the defects and does not allow the flow
of current. The Red Ink Test is performed instead.
Products like cream might interact with packaging material causing a
phenomenon called Environmental Stress Cracking.

Troubleshooting
A.4 Troubleshooting
A.4.1 Homogeneous (Water-based) Products

X
Weight,
date print
perform A.1
Operator Checks
Conductivity
test
MTD
1203
no
test ok?
yes
corrective
actions
MTD
1210
no
defect
found
test
ok?
yes
Leakages
by red ink
MTD
1204
yes
test ok?
MTD
1208
Dissolve
packages
no
yes
defect
found
record
results and
corrective
actions
no
urgent
check?
* method 2:
dissolving in
alkaline solution
method 1:
dissolving in
acid solution
get
samples
Heat pattern
MTD
1208
TS integrity
by red ink
MTD
1208
yes
no
(*) Recommended
corrective
actions
defect
found
Doc. No. BoC-2712261-0101
test ok?
packages
are integer
Appendix - 13
TechPub_2614345_0103 - A1_2712261_01_en.fm
Alu-foil TS
cracks

Troubleshooting
A.4 Troubleshooting
A.4.2 Viscous and Fatty Products

Wash the inside of the packages with warm water and alcohol before
performing the test, to take away as much product residue as possible, at
ambient temperature.
X
Date, Printing,
Forming
Leakages by
red ink
perform A.1
Operator Checks
MTD
1204
Crease, Flap
alignment
no
defect
found
test ok?
corrective
actions
MTD
1210
Alu-foil TS cracks
no
defect
found
test ok?
corrective
actions
yes
method 1:
dissolving in
acid solution
MTD
1208
Dissolve
packages
yes
* method 2:
dissolving in
alkaline solution
no
urgent
check?
obtain samples
packages
are integer
(*) Recommended
Appendix - 14
Heat pattern
MTD
1208
TS integrity
by red ink
MTD
1208
no
yes
test ok?
defect
found
Doc. No. BoC-2712261-0101
corrective
actions
TechPub_2614345_0103 - A1_2712261_01_en.fm
yes
TechPub_2614345_0103 - A2_2712261_01_en.fm
Appendix B:
Tools and Chemicals
Doc. No. BoC-2712261-0101
Appendix - 1 (24)
Appendix B:Tools and Chemicals
Appendix - 2 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A2_2712261_01_en.fm
This chapter contains description and materials used in

Package Integrity test methods.
Table of Contents
B.1 Area Requirement . . . . . . . . . . . . . . . . . Appendix - 5

B.2 Tools and Equipment . . . . . . . . . . . . . . Appendix - 6
B.3.1
Copper Solution . . . . . . . . . . . . . . . . . . . Appendix - 14
B.3.2
Dissolving Solutions . . . . . . . . . . . . . . . Appendix - 16
TechPub_2614345_0103 - A2_2712261_01_en.fm
B.3.3
B.3.2.1
Acid Dissolving Solution

(very fast method) . . . . . . . . . . . . . . . . . . Appendix - 17
B.3.2.2
Acid Dissolving Solution

(fast method) . . . . . . . . . . . . . . . . . . . . . . Appendix - 19
B.3.2.3
Alkaline Dissolving Solution

(slow method) . . . . . . . . . . . . . . . . . . . . . Appendix - 20
Leakage Detection Fluid . . . . . . . . . . . . Appendix - 21

B.3.3.1
Red Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 21
B.3.3.2
Blue Ink. . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 23
Doc. No. BoC-2712261-0101
Appendix - 3 (24)
B.3 Preparation of Chemicals . . . . . . . . . . Appendix - 13
Appendix - 4 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A2_2712261_01_en.fm
B.1 Area Requirement
B.1 Area Requirement

An adequately equipped area must be available to carry out integrity tests.
The area must be ventilated and with good illumination.
3
2
TechPub_2614345_0103 - A2_2712261_01_en.fm
A fume extractor is needed for the preparation of the dissolving solutions.

Running water is needed. Compressed air can be useful.
4
5
1
2
3
4
5
6
Conductivity
Water
Magnifying lenses
Compressed air
Microscope
Dissolving station
Doc. No. BoC-2712261-0101
Appendix - 5 (24)
B.2 Tools and Equipment
Picture
Supplier and code
Used in
Rolling ball
point pen (felt
tip pen (red)
Any
2.2.4-1 Rolling ball

point pen test (after
mechanical tear
down)
Permanent pen
Any
All
Scissors
Fiskars
All
No. 9451-7097
Pinking
scissors
Fiskars
No. 9445-7097
1.3 Transversal Seal

- Dissolving and Red
Ink (MTD 1208)
- Al-Foil Cracks (MTD
1210)
Cutter
Any
All
Note! Snap off

blades are not used
in many food
industries. Refer to
local regulation.
Paper towels
Appendix - 6 (24)
Any
Doc. No. BoC-2712261-0101
All
Name
TechPub_2614345_0103 - A2_2712261_01_en.fm
Here you have a list of tools and equipment used in Package Integrity
Methods, with reference to the specific method in which they are needed and
item code.

Picture
Supplier and code
Used in
Light source
Any

1210)
Beakers
Any
B.3 Preparation of
Chemicals
Pipettes
Any
B.3 Preparation of
Chemicals
Water tray
Any
4.2 Package Integrity

- Conductivity Test
(MTD 1203)
Note! Cat litter tray

(HDPE) can work
very well.
Doc. No. BoC-2712261-0101

- Copper Test (MTD
1207)
Appendix - 7 (24)
TechPub_2614345_0103 - A2_2712261_01_en.fm
Name
Picture
Supplier and code
Used in
Disposable
syringe
needle 0.4-0.5 mm 2.3 Longitudinal Seal

- Red Ink Injection
Gloves
Any
All
Safety goggles
Any

Ink (MTD 1208)
B.3.1 Copper
Solution
Tongs
Any
(wooden material is
preferable)

Ink (MTD 1208)
Appendix - 8 (24)
Doc. No. BoC-2712261-0101
Name
TechPub_2614345_0103 - A2_2712261_01_en.fm

Picture
Supplier and code
Used in
Abrasive
sponges
Any

1210)
Magnifying
lamp with
in-built light
Any
(this model is PEAK)

- Tearing (MTD 1201)
Magnifying
lenses
Peak

Scale Lupe 10X

No.2028 (78073-101) 1.3 Transversal Seal
Ink (MTD 1208)
Zoom Lupe 816
No.2044
Scale Lupe 10X
No.1983
Light Lupe 15X
TP No. 1326015
Stretch pliers
Tetra Pak

No.78073-0101
Spare parts:
Small spring
No.566772
Big Spring
No.566773
Doc. No. BoC-2712261-0101
Appendix - 9 (24)
TechPub_2614345_0103 - A2_2712261_01_en.fm
Name
Name
Picture
Zonoscope

Supplier and code
Used in
Tetra Pak

Ink (MTD 1208)
No.90243-0203
2.2 Longitudinal Seal

(LS/SA) - Tearing
(MTD 1202)
PullTab positioning
(OM)
No.90243-0110
Copper tester
Tetra Pak
No.90459-0095
Water bath
(bain-marie)
Dinkelberg
No.ATH232319
Appendix - 10 (24)
Doc. No. BoC-2712261-0101

- Conductivity Test
(MTD 1203)

- Copper Test (MTD
1207)

Ink (MTD 1208)
Tetra Pak
TechPub_2614345_0103 - A2_2712261_01_en.fm
Ammeter
Use of the Zonoscope

The zonoscope is a polarizer which allows to better enhance and analyse the
heat pattern of the LS. It does not give any indication on the quality of the
sealing as far as distribution of pressure is concerned.
When analysing the LS through the zonoscope, a different range of colours
appear (dark blue and brown); this is due to the fact that the multilayer
plastic of which it is made filters the light reflected from the Al-foil
differently from the PE of the LS.
The zonoscope has two sides. The one marked with a double circle is
designed for TBA/K packaging material; turn this side facing upwards when
analysing TBA/K. The other, marked with two lines, is intended for all the
other packaging materials.
TechPub_2614345_0103 - A2_2712261_01_en.fm
The zonoscope is also widely used in PT applications to locate heat

distribution.
TBA/lk
TBA/j
(Cont'd)
Doc. No. BoC-2712261-0101
Appendix - 11 (24)
Either way, turning the zonoscope only changes the range of visible colours
as light is filtered differently; therefore choose the side which better
enhances the heat pattern under investigation.
(Cont'd)
Use of the Electrolyte Copper Tester
CAUTION
Risk of instrument damage.
Never switch On the tester when the electrodes are in short circuit.
Press the Push button for approximately four seconds to turn on the tester.
The green LED 100A lights up; the tester acts as voltage generator and
detects the current loss between two liquids by the two electrodes. The
display shows the value of the current deflection.
Press the Push button once again to make the tester produce electrolysis
acting as current generator. The red LED 100mA lights up. The display
shows the value of the current circulating between the two liquids.
TechPub_2614345_0103 - A2_2712261_01_en.fm
To switch off the instrument manually, press the button Push for five
seconds.
Appendix - 12 (24)
Doc. No. BoC-2712261-0101
The tester switches off automatically if there is no current circulating for 5

minutes.
B.3 Preparation of Chemicals
TechPub_2614345_0103 - A2_2712261_01_en.fm
Name
Picture
Supplier and code
Used in
Copper solution
Preparation is required,
see B.3.1 Copper
Solution
4.3 Package Integrity Copper Test (MTD 1207)
Dissolving
solutions
(alkaline or acid)
see B.3.2 Dissolving
Solutions
1.3 Transversal Seal Dissolving and Red Ink

(MTD 1208)
Leak detection
fluid
(red ink)
Can be ordered from

Tetra Pak on TP
No.90298-26 or prepared
according to section
B.3.3 Leakage Detection
Fluid
1.3 Transversal Seal Dissolving and Red Ink

(MTD 1208)
2.3 Longitudinal Seal Red Ink Injection
3.2 Opening Devices PullTab (MTD 1211)
4.4 Package Integrity Red Ink Test (MTD 1204)
Leak detection
fluid
(blue ink)
see B.3.3.2 Blue Ink
Doc. No. BoC-2712261-0101
Not used in TPCA

Package Integrity
Methods
Appendix - 13 (24)
Here you have a list of the chemicals used in Package Integrity Methods.
Specific information about each chemical preparation and usage follow.
B.3.1 Copper Solution

Ruptures in the inner PE layers can be detected by the conductivity test
(MTD 1203). The package is immersed in an electrolytic solution (i.e. salt
solution). In case of a crack in the PE layers, which leave the Al-foil
uncovered, an electrical contact is established between the electrolytic
solution outside the package and the package content. If some copper
solution is poured into the package, the copper concentrates in the area of the
cracks when a copper tester is used, allowing to locate the fault.
Ingredients
Cu2SO4.5H2O
Emulsifying agent
Distilled water
HNO3 (concentrated 65%)
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Weight 100 g of Cu2SO4.5H2O in a

plastic beaker.
2
Put a 1 l flask on the scale. Reset and add
0.5-1.0 g of any emulsifying agent using
a pipette.
Add 200 cm3 distilled water.
Appendix - 14 (24)
Doc. No. BoC-2712261-0101
3
Mix the solution well with a magnetic
agitator. Add the Cu2SO4.5H2O.
4
CAUTION
Use protective goggles and gloves
when handling HNO3; put the acid
into the solution, never the other way
round
Add 2.6 g of concentrated (65%) HNO3
with a syringe and mix for additional 5
minutes.
The copper solution is ready.
Store the solution in a glass bottle, filter
or decant it after usage.
Doc. No. BoC-2712261-0101
Appendix - 15 (24)
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Add 800 cm3 of distilled water while

mixing. Make sure that the
Cu2SO4.5H2O is completely dissolved.
B.3.2 Dissolving Solutions

These solutions can be used to dissolve the Al-foil and separate the internal
polyethylene bag from the remainder of packaging material layers, when the
Transversal Seal is under investigation.
1) Acid solution (very fast method), follow B.3.2.1 Acid Dissolving
Solution (very fast method).
2) Acid solution (fast method), follow B.3.2.2 Acid Dissolving Solution
(fast method).
3) Alkali solution (slow method), follow B.3.2.3 Alkaline Dissolving
Solution (slow method).
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Note!
Hydrofluoric Acid is used in local applications but fumes that give off
are of health concern.
(Cont'd)
Appendix - 16 (24)
Doc. No. BoC-2712261-0101
Refer to the 1.3.3-2 Dissolving of packages chart at page 1-22 for determine
which type of solution is more suitable:
(Cont'd)
B.3.2.1
Acid Dissolving Solution (very fast method)
Three different solutions are used, which we will call:

1) HCl 1:1 Solution,
2) HCl 1:3 Solution,
3) Neutralizing Solution.
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This method is very fast, therefore it is advisable when the results of the test
are urgent. A fume extractor and a water bath are needed.
Ingredients:
HCl (37% - starting solution as commercially available),
Distilled water (1:1),

CuCl2,
Na2CO3 in cristals.
(Cont'd)
Doc. No. BoC-2712261-0101
Appendix - 17 (24)
WARNING
Never poor water into the acid but always acid in water.
(Cont'd)
1) HCl 1:1 Solution (Hydrochloric acid at 60 C)
Note!
The solution is prepared at room temperature but must be heated
using a water bath at 60 C when in use.
a) Dilute the concentrated HCl in distilled water (1:1) at room temperature.
b) Add 1wgt % CuCl2 (e.g. 1 l. HCl, 1 l. distilled water, 20 g. CuCl2) at
room temperature.
c) Store the solution in a glass container with a glass lid when not in use.
The bath can be filtered at room temperature and reused.
3) Neutralizing Solution (Sodium Carbonate at room

temperature)
Note!
Bath 3 spoils very quickly. If the solution does not start to bubble as
soon as the samples are immersed into it, prepare a new one.
a) Prepare 10 wgt % solution of Na2CO3 in distilled water (e.g. 100 g.
Na2CO3, 1 l. distilled water) at room temperature.
b) Store the chemical in a glass container with a glass lid. The bath can be
filtered at room temperature and reused.
Appendix - 18 (24)
Doc. No. BoC-2712261-0101
a) Dilute the concentrated HCl in distilled water (1:3).

b) Add 0.5 wgt % CuCl2 (e.g. 250 cm3 HCl, 750 cm3 distilled water,
5 g.CuCl2);
c) Store the chemical in a glass container with a glass lid. The bath can be
filtered at room temperature and reused for several TS examinations.
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2) HCl 1:3 Solution (Hydrochloric acid at room temperature)

B.3.2.2
Acid Dissolving Solution (fast method)

WARNING
Never poor water into the acid but always acid in water.
2) Neutralizing Solution.
This method is fast, but slower than the method at B.3.2.1 Acid Dissolving
Solution (very fast method). A fume extractor is needed.
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Ingredients:
HCl (37% - starting solution as commercially available),

Distilled water (1:1),
Na2CO3 in cristals.
1) Acid Solution (Hydrochloric acid)

Prepare an acid solution of HCl 30% (e.g. for 3 litres solution put 600 ml of
water in a beaker and add carefully 2400 ml of HCl 37%).
2) Neutralizing solution
Prepare 10 wgt% Na2Co3 in distilled water (e.g. 100 g Na2Co3 and add water
until the solution is 1 litre.
Doc. No. BoC-2712261-0101
Appendix - 19 (24)
Two different solutions are used:

1) Acid Solution,
B.3.2.3
Alkaline Dissolving Solution (slow method)

Ingredients:
Distilled water,
NaOH
Prepare a 15% NaOH solution with distilled water. Stir the solution while
adding water to the NaOH pellets. The solution warms up while adding
water. Do not wait too long before using the solution or it may lose its
efficiency.
Appendix - 20 (24)
Doc. No. BoC-2712261-0101
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Note!
CIP solution (normally 30% with no added cleaning agents) can be
used after dilution 1:1
B.3.3 Leakage Detection Fluid

B.3.3.1
Red Ink
Red ink is pure isopropanol based solution (99.5%), which has the
characteristic of penetrating the small cracks and pinholes which can be
present inside the package. The red colour is due to the addition of
erithrosine, and it allows to visually detect the ink leakage, which simulates
the penetration of microorganisms across the packaging material layer.
Isopropanol has a high capillary action but does not interact, at room
temperature, with the internal plastic layers of the package.
Other solvents, like turpentine, would damage PE and therefore give false
results, whereas Ethylic Alcohol (Ethanol) cannot be used worldwide due to
special local regulations.
TechPub_2614345_0103 - A2_2712261_01_en.fm
1
Weight approximately 1.5 g of powder
Erythrosin .
Doc. No. BoC-2712261-0101
Appendix - 21 (24)
Ingredients
Erythrosin , sodium salt
Isopropyl alcohol (99.5 %, commercial purity)
2
Mix the Erythrosin with 1 l. of
Isopropyl alcohol.
Filter the solution with a funnel covered

with a paper towel, into a spare container.
The red ink is ready to be used.
Store the red ink in a convenient cabinet
at room temperature, in a closed
container to reduce evaporation.
Appendix - 22 (24)
Doc. No. BoC-2712261-0101
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Shake well and leave to decant overnight.

B.3.3.2
Blue Ink
Blue ink is a water based solution which is used to test the tightness of the
external layer of the package (decor layer) to the penetration of water and
humidity. Its characteristic colour is due to the addition of methylene blue.
Blue ink cannot be used to assess microbiological tightness of the package at
any level. It is not used for TPCA applications, but only for TPCC. The
recipe is included here in case of interest.
Ingredients
Methylene blue
Emulsifying agent
Ethanol (95%, commercial purity).

Distilled water
1
TechPub_2614345_0103 - A2_2712261_01_en.fm
Weight 5 g of Methylene blue.
2
Warm up 1 l. distilled water in a heat
resistant flask at about 45 C.
Dilute the Methylene blue into the
distilled water.
Mix the solution using a magnetic
agitator.
Doc. No. BoC-2712261-0101
Appendix - 23 (24)
Remove the flask from the agitator and

add 200 cm3 Ethanol.
Close tight and shake the solution well.
Blue ink is ready.
Store it at room temperature in a closed
container to reduce evaporation.
Appendix - 24 (24)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A2_2712261_01_en.fm
Add 5 cm3 of emulsifying agent

(Polyoxyethylene (20) Sorbitan
Mono-oleate) using a pipette and mix
well with the magnetic agitator.
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Appendix C:
Data Record
Doc. No. BoC-2712261-0101
Appendix - 1 (8)
Appendix C:Data Record

Documenting and recording any changes related to
package integrity tests are of the utmost importance at any
stage of the product cycle, i.e. during Production and during
laboratory checks.
If unsterility problems occur and a troubleshooting
procedure is needed, it is vital to trace back past production
parameters and events to have a complete picture of the
situation.
In some countries, such as USA, Regulatory Agencies
require the documentation of the defects detected and of all
the related corrective actions.
Appendix - 2 (8)
Doc. No. BoC-2712261-0101
TechPub_2614345_0103 - A3_2712261_01_en.fm
This section includes examples of forms which can be used

as reference.
Table of Contents
C.1 Production Package Recording

Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 5
C.2 Laboratory Package Recording
Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 6
C.3 Sample Collection Form . . . . . . . . . . . . Appendix - 7
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C.4 Troubleshooting General Data

Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 8
Doc. No. BoC-2712261-0101
Appendix - 3 (8)
Appendix - 4 (8)
Doc. No. BoC-2712261-0101
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ID
Doc. No. BoC-2712261-0101
event
LabCheckForm1.xls
last update 13/09/2004
time
n.packs
taken
EXAMPLE
Operator signature
Machine number
Machine type
Date
check box
Date print
check box
Weight
ID event
Production Package Recording Sheet
check
box
setting
TS rough
Packages
codes
PM
P.O.
type
LS
check box
check box
check box
Shape and
Flap sealing Crease lines
design
Checks
type
setting
TS accurate
Product
temperature
check box
type
TechPub_2614345_0103 - A3_2712261_01_en.fm
check box
Overlap
P.O.
EX
X = not performed
PL
check box
setting
LS/SA
yes
Sara Davolio
Monica Malagoli
no
lab. checks?
Note: packages tested as from event scheme

on OM package checks
AM
check box
Surfaces
V = passed
KO = not passed
legend

C.1 Production Package Recording Sheet
C.1 Production Package Recording Sheet
Appendix - 5 (8)
Appendix - 6 (8)
Doc. No. BoC-2712261-0101
10
09
08
07
06
05
04
03
02
01
10
09
08
07
06
05
04
03
02
01
link n.
LabCheckForm1.xls
last update 13/09/2004
ID
event
date
Sample ID
machine
PM
P.O.
Red ink
Heat pattern
Red Ink
TS quality by dissolving
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Top
Bottom
Top
Bottom
Top
Bottom
Top
Bottom
check box check box check box check box check box check box check box check box
Conductivity
Package integrity
Checks
Type
LS
P.O.
check box
LS (by red ink

injection)
Type
Check box legend
EX
Sara Davolio
Monica Malagoli
PL
AM
X = not performed
KO = NOT passed
Temper.
Product
Type
Operator signature
Pack
Codes
V = passed
ID event
Machine number
Machine type
Date
Laboratory Package Recording Sheet
C.2 Laboratory Package Recording Sheet
C.2 Laboratory Package Recording Sheet
C.3 Sample Collection Form
C.3 Sample Collection Form

Sample Collection Sheet
Machine Type
Machine Number
Operator Name
Date
Time
Batch No.
Link No.
TechPub_2614345_0103 - A3_2712261_01_en.fm
EX
AM
PL
TOP
BOTTOM
Comments:
monica malagoli
sara davolio
updated 13/09/2004
Doc. No. BoC-2712261-0101
Appendix - 7 (8)
C.4 Troubleshooting General Data Form
C.4 Troubleshooting General Data Form

Troubleshooting Sheet - General Data
Test Code (if more than one)
Date
Report Reference
Package
Volume
Family
Opening
Filling Machine
Cutting Rail
End Pieces
Inductors
Dollies
Pulse Time
TS Setting
Jaw pressure (bar)
Jaw Gap (mm) if not standard
TS working window performed?
TS working window settings and location
Purpose of the Test

Package Integrity
Short description
Amount of Samples
Unsterility Rate
Red Ink
TS Cracks
Inner bags
heat Pattern
Numbering Progressive
Project number
Notes
Appendix - 8 (8)
Doc. No. BoC-2712261-0101
Sealing Configuration
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PL
AM
Filling product
Production Date
Exp.Date
Product temperature (C)
Packaging Material Design
Packaging Material
Converting factory
P.Order
LS Strip
Al-Foil
Thickness()
EX
Customer
Type
Development Step
Serial number

Package Interiry

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BoC

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Copyright 2004 Tetra Pak Group

iii Getting to know the

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Tetra Pak Carton Ambient

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This Book of Competence - Package Integrity is based on the state of

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This chapter contains basic information about this manual.

How to use this book . . . . . . . . . . . . . . . . . . . . . . i - 6

Abbreviations and Terminology . . . . . . . . . . . . . . i - 9

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C: Appendix, additional material. . . . . . . . . . . . . . . . . . i - 8

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Specialized personnel are chemists, laboratory technicians which have a

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How to use this book

How to use this book

Senior Tetra Pak Field Service Engineers

Package Integrity Methods must be performed on regular basis during and

presence of microorganisms in the package surrounding;

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How to use this book

Laboratory QC checks after Production

Loss of microbiological barrier (corners, K-cracks, fin tears)

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How to use this book

1 Transversal Seal (TS) tests

2 Longitudinal Seal (LS/SA) test

3 Opening Devices test

5 Package Forming tests

These chapters provide general

These chapters provide information

Tools and Chemicals

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Abbreviations and Terminology

Instrument measuring electric

Automatic Splicing Unit

Base (package shape)

Direct Injection Moulding Cap

Field Service Quality Assurance

High Density Polyethylene

Linear Low Density Polyethylene

LLDPE syntetized by metallocene

Hard residue of plastic that

Pre Laminated Hole

Slim (package shape)

Technique used in FlexiCap

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Abbreviations and Terminology

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