Im823640102 2017111682953 577664 40 2

IM
Installation Manual
TBA/21 040V
IM1.182364012.fro
Tetra Pak
Doc No. IM-82364-0102
This document is valid for:
Series No/ Machine No Sign.
Tetra Brik Aseptic

TBA/21
648570-040V
Equipment included:
PullTab unit PT21

1095933-020V
Cooling system ice water

1260547-010V
Headspace by Injection HI21

1296061-010V
3” Product valve
IM1.182364012.fro
576434-010V
TPOP Serial communication

1254443-010V
Upgraded cleaning
Issue 9711
Doc No. IM-82364-0102
Tetra Brik Packaging Systems

Table of contents
Introduction
Equipment information . . . . . . . . . . . . . . . . . . . . . . . . . 2
Document information . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions
Hazard information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mandatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General safety precautions . . . . . . . . . . . . . . . . . . . . . 13

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Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . 15

Emergency stop buttons . . . . . . . . . . . . . . . . . . . . 15
Doors, covers and guards . . . . . . . . . . . . . . . . . . . 16
Chemical products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Personal protective equipment . . . . . . . . . . . . . . . 17
General emergency procedures . . . . . . . . . . . . . . . 17
Hydrogen peroxide . . . . . . . . . . . . . . . . . . . . . . . . 18
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Equipment for lifting and moving loads . . . . . . . . . . . 22
Tetra Pak Doc No. IM-82364-0102 i

Table of contents
3 Drawings and Technical data

3.1 Installation drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Basic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Mass (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 Emissions and thermal load . . . . . . . . . . . . . . . . . . . . 34
3.6 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.7 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.9 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.10 Outfeed conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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4 Site preparation
4.1 Specific construction details . . . . . . . . . . . . . . . . . . . 44
5 Crate handling
5.1 Crate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1.1 Main crate (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1.2 Second crate (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.3 Third crate (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3.2 Using an overhead gantry or mobile crane . . . . . . 50
5.3.3 Using a fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Table of contents
5.4 Moving and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.4.1 Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 4.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Positioning, assembly and connections

6.1 General requirements. . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Opening the crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3 Unpacking the main crate (1). . . . . . . . . . . . . . . . . . . . 58

6.3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.3.2 Removing the machine body with an
overhead gantry or mobile crane . . . . . . . . . . . . . . 59
6.3.3 Removing the machine body with a fork lift. . . . . 60
6.3.4 Transport of the machine body . . . . . . . . . . . . . . . 61
6.3.5 Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.4 Unpacking the third crate (3) (only PT machines) . . . 64

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6.4.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4.2 Removing the ASU/PullTab with an
6.4.3 Removing the ASU/PullTab with a fork lift . . . . . 66
6.4.4 Transport of the ASU/PullTab unit . . . . . . . . . . . . 67
6.4.5 Docking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.5 Other operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.5.1 Levelling TBA/21 Std . . . . . . . . . . . . . . . . . . . . . . 69
6.5.2 Levelling TBA/21 PT . . . . . . . . . . . . . . . . . . . . . . 70
6.5.3 Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.6 Unpacking the second crate . . . . . . . . . . . . . . . . . . . . 72

6.6.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.6.2 Removing the machine parts with an
6.6.3 Removing the machine parts with fork lift . . . . . . 74
6.6.4 Transport of the machine parts . . . . . . . . . . . . . . . 74
Tetra Pak Doc No. IM-82364-0102 iii

Table of contents
6.7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.7.1 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.7.2 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.7.3 Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.7.4 Stair and railings . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.8 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.8.1 Utility connections . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.8.2 Conveyor equipment . . . . . . . . . . . . . . . . . . . . . . . 82
6.8.3 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.8.4 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.8.5 Electrical cabinet and other electrical supplies . . . 85
6.9 Final assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

6.9.1 Automatic splicing unit . . . . . . . . . . . . . . . . . . . . . 88
6.9.2 Machine body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.9.3 Drive and Jaw system. . . . . . . . . . . . . . . . . . . . . . . 89
6.9.4 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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6.9.5 Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.9.6 Date unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.9.7 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.10 Disposal/return of packing . . . . . . . . . . . . . . . . . . . . . 94
7 Final installation checks

7.1 Installation and connection checks . . . . . . . . . . . . . . 96
7.2 Lubricant level checks . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.3 Valve checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.4 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
iv Doc No. IM-82364-0102 Tetra Pak

Table of contents
8 Preparation for commissioning

8.1 Presence and correctness checks . . . . . . . . . . . . . . 103
8.2 Product and utility value checks . . . . . . . . . . . . . . . . 105
8.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.3.2 Normal operating checks. . . . . . . . . . . . . . . . . . . 106
8.3.3 Changing PLC parameters . . . . . . . . . . . . . . . . . 108
8.4 Health and safety checks . . . . . . . . . . . . . . . . . . . . . . 109
8.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9 Disassembly and removal

9.1 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.1.1 Draining methods . . . . . . . . . . . . . . . . . . . . . . . . 113
2.282364012TOC
9.1.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

9.1.3 Draining procedure . . . . . . . . . . . . . . . . . . . . . . . 114
9.2 Moving and transporting the equipment . . . . . . . . . 124

9.2.1 Short moves and short-term storage . . . . . . . . . . 124
9.2.2 Long moves and long-term storage . . . . . . . . . . . 126
9.3 Return to the manufacturer . . . . . . . . . . . . . . . . . . . . 128
9.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Tetra Pak Doc No. IM-82364-0102 v

Table of contents
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2.282364012TOC
vi Doc No. IM-82364-0102 Tetra Pak

Introduction
To ensure maximum safety, always read the Safety Precautions section
before doing any work on the equipment or making any adjustments.
2.282364012.int
Tetra Pak Doc No. IM-82364-0102 1

Introduction
Equipment information
Intended use
This Tetra Pak equipment is designed to package liquid food products.
Manufacturer
This Tetra Pak equipment has been manufactured by:
Tetra Brik Packaging Systems AB
Ruben Rausings gata
221 86 LUND
Sweden
or by:
Tetra Brik Packaging Systems S.p.A.
Via Delfini 1
411 00 MODENA
Italy
Service
Contact the nearest Tetra Pak service station.
(Cont'd)
2.282364012.int
2 Doc No. IM-82364-0102 Tetra Pak

Introduction
(Cont'd)
Identification
The figure below shows an example of the equipment data plate. The plate
carries data needed when contacting Tetra Pak concerning this specific
equipment.
CE marking
This equipment complies with the basic health and safety regulations of the
European Economic Area (EEA).
1 2
Machine type 3
Drawing Spec.
Machine No.
Manufacturer
4
5
Year of manufacture
6
8 7
2.282364012.int
1 Machine type
2 Volume
3 Drawing specifications
4 Machine serial number
5 Manufacturer
6 (Designed by)
7 CE mark
8 Year of manufacture

Introduction
Document information
Purpose of Installation Manual (IM)
The purpose of this Installation Manual is to provide service technicians with
information on how to safely install this Tetra Pak equipment
It is important to:
• keep the manual for the life of the equipment
• pass the manual on to any subsequent holder or user of the equipment.
Design modifications
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Tetra Pak
production plant.
Number of pages
This document contains a total of 132 pages.
Copyright  1997
Tetra Brik Packaging Systems
All rights reserved. No part of this document may be reproduced or copied in
any form or by any means without the written permission of Tetra Brik
Packaging Systems.
Technical publications
2.282364012.int
The technical publications for this equipment are:
• Electrical Manual (EM)
• Installation Manual (IM)
• Maintenance Manual (MM)
• Operation Manual (OM)
• Spare Parts Catalogue (SPC)
Additional copies can be ordered from the nearest Tetra Pak service station.
When ordering technical publications, always quote the document number
that can be found in the machine specification document.

Introduction
Other documents
The following document are attached to the crate:
• Packing list
• Declaration of EC conformity (for equipment delivered in EEA only)
• Installation manual (this manual)
The following document are located on the equipment itself, behind the
marked LH door of the machine body:
• Machine Specification Document
• Final Inspection Report
• Machine Deviation Report (if relevant)
• Start Up Machine Quality Report (including Transport Damage Report)
• Feedback from MC
• System drawings.
2.282364012.int

Introduction
Abbreviations
The following abbreviations are used in this Installation Manual.
Abbreviation Meaning
Approx Approximately
APV Aseptic Product Valve
ASU Automatic Splicing Unit
CIP Cleaning In Place
CofG Centre of Gravity
h Hour, Hours, Height
HI Headspace by Injection
HL Headspace by Low level filling
L Length
LH Left Hand
LS Longitudinal Seal(ing)
min Minimum
max Maximum
OE Optional Equipment
p/h Packages per Hour
Recirc Recirculation, Recirculated
2.282364012.int
RH Right Hand
SA Strip Applicator
Std Standard
TMCC Tetra Pak Multi-purpose Compact Controller
TPIH Tetra Pak Induction Heating
TPMC Tetra Pak Machine Control
TPMS Tetra Pak Maintenance System
TS Transversal Seal(ing)
Standard International System abbreviations are used for all measurements

values.

Safety precautions
To ensure maximum safety, always read this section carefully before doing
any work on the equipment or making any adjustments.
2.282364012.sp

Safety precautions
Hazard information
General
Failure to observe information marked “DANGER!” puts your life in
danger.
DANGER!
Failure to observe information marked “WARNING!” can result in

personal injury and/or serious damage to or destruction of
equipment.
WARNING!
Caution! Failure to observe information marked “Caution!” can result in

damage to equipment.
2.282364012.sp

Safety precautions
Mandatory signs
Wear eye protection Wear hearing protection
Wear head protection Wear protective gloves

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D I SI N F E C
Disinfect hands/gloves

Safety precautions
Warning signs
Risk of entanglement! Risk of corrosion!
Risk of crushing! Risk of cutting/amputation!
Risk of burns! Risk of electrocution! 2.282364012.sp
(Cont'd)

Safety precautions
(Cont'd)
Risk of crushing! Risk of intoxication!

2.282364012.sp
Risk of falling!

Safety precautions
Personnel
Only skilled or instructed persons are allowed to work on the equipment.
The manufacturer declines all responsibility for injury or damage if the
instructions in this manual are not followed.
Personnel are responsible for:
• the equipment and the work area around the equipment
• all personnel in the vicinity of the equipment
• making sure that all safety devices are fully operational
Personnel must regard all electrical equipment as live. Before carrying out
maintenance or repair work, switch the equipment off at the mains power and
padlock the switch.
Electricians should be certified according to local regulations and have
experience of similar types of installations, proven skills in reading and
working from drawings and cable lists, and knowledge of local safety
regulations regarding power and automation. Work with the electrical
equipment must be performed only by skilled or instructed technicians.
According to EN 60204-1, 3.30 an instructed person is:
– An individual adequately advised or supervised by a skilled person to
2.282364012.sp
enable that individual to avoid hazards which electricity can create
(e.g. operating and maintenance staff).
According to EN 60204-1, 3.55 a skilled person is:
– An individual with technical knowledge or sufficient experience to
enable that individual to avoid hazards which electricity can create.

Safety precautions
General safety precautions

Wear hearing protection while the equipment is running.
Hygiene
It is important to keep hands and/or gloves clean.
Disinfect hands and/or gloves before touching the packaging material, the
strip(s) or any other equipment part that may come into contact with the
product.
Clean the platforms, the ladder and the area around the equipment.
To avoid production faults, it is important that the packaging material and the
strip(s) never touch the floor, the platform or the area around the equipment.
High voltage
2.282364012.sp
Work with parts marked with this symbol must be performed by skilled or
instructed persons only.
Make sure that the mains power is disconnected before starting any work on
electrical equipment marked with this symbol.
In case of accident, call for medical attention immediately.

Safety precautions
Electrical cabinet
There is high voltage in the electrical cabinet (up to 400 V).
Work inside the electrical cabinet must be performed by skilled or instructed

persons only.
DANGER!
Electrical cabinet doors locked with screws may be opened only by skilled or
instructed persons.
LH side
2.282364012.sp
RH side
TPIH generator
There is high voltage in the TPIH generator (up to 2 000 V).
Never open the TPIH generator. Remove and return the unit to an authorised
service centre for servicing and repair.
DANGER!

Safety precautions
Machine safety devices

Emergency stop buttons
Learn the position of the Emergency stop buttons in order to stop the
equipment immediately in case of danger to people or damage to the
equipment.
The Emergency stop buttons do not switch off the power at the mains power
switch.
Pushing the Emergency stop buttons will reset the equipment program to
Zero position and deactivate all pneumatic cylinders.
2.282364012.sp
LH side
RH side

Safety precautions
Doors, covers and guards

Make sure that all doors, covers and guards are in place and
functioning.
Never remove covers or guards while the equipment is operating.

WARNING! Certain doors, covers and guards are fitted with safety switches. These
switches are part of the safety system and must never be bridged, by-passed
or otherwise made non-operational.
Never stop the equipment by opening a door or cover with a safety switch.
Some equipment parts protected by doors, covers and guards may be hot.
WARNING!
In case of accident, call for medical attention.
2.282364012.sp
LH side
RH side

Safety precautions
Chemical products
Risk of personal injury!
Certain chemical products are toxic and/or inflammable. Carefully
follow the instructions on the container label.
WARNING! Follow the supplier’s instructions for handling and disposal of the chemical
products.
Personal protective equipment

• Safety goggles, TP No. 779130-102
• Apron, TP No. 90303-5
• Shoes made of PVC, PE plastic or rubber
• Protective gloves made of neoprene, TP No. 90303-4
Before starting work with any chemical products, make sure that:
• the showers work
• a portable, TP No. 90303-6, or wall-mounted eyewash device is available
at or near each machine site
• there are additional washing facilities
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General emergency procedures

If you accidentally swallow chemical products, drink large amounts of
lukewarm water.
If you get splashes or vapour from chemical products in your eyes, wash
your eyes thoroughly with lukewarm water for 15 minutes (keeping eyelids
wide apart).
If chemical products come into contact with skin or clothes:
• rinse immediately with plenty of water
• if skin burns appear, call for medical attention immediately
• thoroughly wash clothes before wearing them again
If you experience irritation or pain due to having inhaled chemical products

vapour:
• leave the affected area and get some fresh air
• if the symptoms get worse, call for medical attention

Safety precautions
Hydrogen peroxide
The liquid used for sterilising the packaging material consist of 35%
hydrogen peroxide (H2O2).
Hydrogen peroxide in liquid and gas form can cause irritation and
injury if it comes into contact with the skin, mucous membranes, the
eyes or clothes. Carefully follow the instructions on the can label.
WARNING! Hydrogen peroxide can
HYDROGEN PEROXIDE:
• 35% w/w Aqueous Solution UN No. 2014
• Corrosive
• Oxidizing
• Causes burns. Contact with combustible materials may cause fire
• Keep in a cool place away from sources of heat
• Avoid contamination
• Wear suitable protective clothing, gloves, and eye/face protection
• After contact with skin, wash immediately with plenty of water and call
for medical attention
• In case of contact with eyes, rinse immediately with plenty of water and
2.282364012.sp
call for medical attention
• In case of spillage or fire, drench with water
Reference: TP document No. M 1751.80
Example of can label
(Cont'd)

Safety precautions
(Cont'd)
Storage of hydrogen peroxide
Make sure that the area or room used for storage is:
• cool, clean and well ventilated
• shielded from direct sunlight
• free from combustible materials
Hydrogen peroxide must be stored only in its original container as delivered

by the suppliers.
Keep the container upright and closed with a proper ventilation cap which
allows oxygen to escape.
Pumps and other equipment used for hydrogen peroxide must be used for
this purpose only.
Never put used hydrogen peroxide back into storage.
Disposal of hydrogen peroxide
Hydrogen peroxide should be sent for destruction by waste disposal
specialists.
Risk of explosion!
Do not pour surplus hydrogen peroxide back into its original container.
2.282364012.sp
Hydrogen peroxide may decompose. In case of accident, call for

medical attention immediately.
WARNING!
In some countries it is permitted to dilute hydrogen peroxide with water to a
concentration below 1% and to dispose of it in the normal waste water drain.
Hydrogen peroxide with a concentration below 1% is considered harmless.

Safety precautions
Coolant
Risk of cooling injury!
If compressor leakage occurs in the service unit, coolant (R 134) may
come into contact with bare skin and cause serious cooling injuries.
WARNING! Contact an authorized local company or dealer for all operations involving
coolant. In case of leakage or damage to the compressor unit, do not take any
action until clear instructions have been given by authorized personnel.
All service and maintenace of the compressor unit must be performed by an
authorized company or dealer. Contact your local Tetra Pak service station
for further information.
2.282364012.sp

Safety precautions
Ink
Risk of personal injury!
Ink is inflammable and can be harmful if it comes into contact with the
eyes or skin. Carefully follow the instructions on the container label.
WARNING! Ink container
• INFLAMMABLE
• Avoid direct contact with the product
• Use gloves and goggles
• Care for good ventilation
• Propylene glycol mono methyl ether >30%
• Ethanol 1-5%
• SHAKE BEFORE USE
2.282364012.sp
BLACK MARKFLEX
MF 7011
INFLAMMABLE
Avoid direct contact with

the product
Use gloves and goggles
Care for good ventilation
Propylene glycol mono
methyl ether >30%
Ethanol 1 - 5%
Manufacturer:
G-man AB
tel. 0410-59200
Trelleborg
SWEDEN
TP No. 90299-72
SHAKE BEFORE USE

Safety precautions
Equipment for lifting and moving

loads
Make sure that the capacity of the lifting equipment is adequate and
that the equipment itself is in good working order.
If lifting tackle has to be joined to make up the necessary lengths, make sure
WARNING! that the joins are secure and have the same lifting capacity as the rest of the
tackle.
Always engage the safety clip on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.
2.282364012.sp

3 Drawings and Technical
data
2.2TB033642.en

3.1 Installation drawings

This section includes drawings showing overall dimensions, connection
positions and dimensions, and access dimensions. Values are in millimetres
unless otherwise stated. All dimensions must be respected.
The following drawings are provided:
• LH view, top view, and machine feet, standard machine
• LH view, top view, and machine feet, machine with PullTab
• Front view, all machine configurations
• RH view, top view, and machine feet, standard machine
• RH view, top view, and machine feet, machine with PullTab
(Cont'd)
2.2TB033642.en

(Cont'd)
LH view, Std machine
Connection plate 3156

Cleaning line (CIP) out 2425
Cleaning line (CIP) in 2073
Steam connection in 2055
Machine body
4994+95
5079+95
Upper side of conveyor chain
Min 5800+95
5655+95
3519+95
2400+95
2340+95
2.2TB033642.en
Leg feet
3489 Min 1500
150+95
757+95
1677
2889 4143
(2400) 4284
Min 3896
(Cont'd)

(Cont'd)
LH view, PT machine
Connection plate 3156

Machine body
4994+95
5079+95
Upper side of conveyor chain
Min 5800+95
5655+95
3519+95
2400+95
2340+95
2.2TB033642.en
150+95
757+95
Leg feet
1677 3489 Min 1500
2889 4143
(2400) 4284
Min 5096
(Cont'd)

(Cont'd)
Top view, all machine configurations and
machine feet view, Std and PT machines
ASU feet (2x)

3125 Drainage ø76
950
Front
Std machine
1097 Height above floor 146+95
1445
1362 894 1250

Machine body feet (6x)
490 150
700
Leg feets (2x) Stair feets (2x)
2221.6
Connection surface for

Product connection In/Out ø51 mm
2.2TB033642.en
1858 3488 the conveyor

(Option ø76 mm = 1858+20 mm)
884
884
connection In/Out 434
Conveyor chain 229
connection In/Out
Right product
Left product
3391
ASU feet (2x) PT 21 feet (2x)
3125 Drainage ø76
950
Front
PT machine
600 Height above floor 146+95
1445
1697 865 894 1250 Machine body feet (6x)

490 150
700
Leg feets (2x) Stair feets (2x)

1637
2221.6
(Cont'd)

(Cont'd)
Front view, all machine configurations
1238
Steam connection in ø12 813.7
Cleaning line (CIP) in ø38 372
Cleaning line (CIP) out ø38 292
Electrical supply ø48 568

Electrical supply 3627
in/out ø51 4129.5+95

Product connection
plate 2608+95
Connection
2.2TB033642.en
Waste outlet
258+95
1100 688
Min 1000
(796) 634 Platform 2476
3906
(4300)
Air in
RP 1/2” (ISO 7/1) Ice water in
Connection plate RP 1/2” (ISO 7/1)
80
40 Ice water out
RP 1/2” (ISO 7/1)
Cold water in
RP 1/2” (ISO 7/1) 21
79 148
9
79
Central refilling H2O 60ø 4
Supply HI and HL
Electrical connections dairy RP 1/4” (ISO 7/1)
ø19 (2x)
ø29 (1x) Hot water in ø70
(Cont'd)

(Cont'd)
System drawings
The system drawings are attached inside the middle LH door of the filling
machine. These include:
• installation drawings
• external cleaning diagram
• aseptic diagram
• filling diagram
• pneumatic diagram, ASU
• pneumatic diagram, superstructure
• pneumatic diagram, machine body
• pneumatic diagram, service unit
• peroxide system diagram
• lubrication diagram
• hydraulic diagram
• water diagram
• extra equipment (if relevant).
2.2TB033642.en

3.2 Basic machine data

Machine configuration Production capacity Notes
TBA/21 Std > 330 ml 7000+1% -0 p/h
< 330 ml 8000+1% -0 p/h
TBA/21 PT > 330 ml 7000+1% -0 p/h
< 330 ml 8000+1% -0 p/h
2.2TB033642.en

3.3 Mass (weight)

Machine configuration Mass (weight) Notes
TBA/21 Std Approx. 7 670kg
(16 915Ibs)
TBA/21 PT Approx. 8 950kg Cannot be lifted as one
(19 735Ibs) unit
Centre of gravity
The following figure shows the approximate location of the centre of gravity.
The superstructure, the electrical cabinet and the service unit all have
calculated lifting positions and no CofG is shown.
Complete machine Std

2.2TB033642.en
Machine body + ASU
Machine body
ASU/PullTab

(Cont'd)
Static load
The following table shows the static load on each machine foot on an
installed and correctly levelled machine. Feet (5) and (10) facing forward.
1 2 3 4 5
6 7 8 9 10
Static load on TBA/21 Std TBA/21 PT

leg – (kg)
1 1180 1180
2.2TB033642.en
2 - 350
3 870 870
4 930 930
5 1100 1100
6 1170 1170
7 - 350
8 1050 1050
9 750 750
10 620 620

3.4 Noise
The tables below gives the noise level measurements for the machine under
the following conditions:
• machine on a concrete floor supported by standard feet
• production under normal operating conditions at 7000 p/h.
Characteristic Symbol Value Notes

Declared maximum LpA 76 dB(A) Determined
emitted sound pressure according to ISO
level, operator position 3746:1995, survey
method grade 3.
Measured A-weighted LWA 95 dB(A) Determined
sound power level according to ISO
11204:1995,
engineering
method grade 2.
2.2TB033642.en

3.5 Emissions and thermal load

Emissions
Characteristic Value Notes

Hydrogen peroxide < 1 ppm TLV - Time Weighted
fumes in operator´s Average value
environment
Hydrogen peroxide ≤ 1%
outlet to drain
Oil fumes in the None
operator´s environment
Oil spillages None
Detergent spillages None
Water spillages None Except during external
cleaning
Product spillages None
Thermal load
Machine configuration Thermal load Notes

TBA/21 PT Approx. 16.2 kW
2.2TB033642.en

3.6 Product
Supply pressure 50 - 250 + 10 kPa
(0.5 - 2.5 + 0.1 bar)
[7 - 36 psi]
2.2TB033642.en

3.7 Utilities
Electrical power specifications

Supply voltage to 400/230 VAC, Other voltages available
machine 3 phase +N + earth to order with transformer.
Max voltage +10%
fluctuation
Frequency 50/60 +2% To be specified on order.
Recommended main 100 A Value for optimum
fuse selectivity at 400/230
VAC.
Control circuits voltage 24 VDC
Electrical power consumption
Consumption during: TBA/21 + PT21

Preheating 30 kW
Sterilisation, spraying 27 kW
Sterilisation, drying 24 kW
Ready for production 17 kW
Production 27 kW
2.2TB033642.en
Production finished 12 kW
Cleaning 10 kW
Compressed air specifications

Supply pressure 600 - 700 kPa
(6 - 7 bar)
[87 - 102 psi]
Max particle size 20 µm
Max particle content 25 mg/m3
Dew point 2°C
(35.6°F)
Oil content 0.01 mg/m3
(Cont'd)

(Cont'd)
Compressed air consumption
Machine configuration Average consumption Peak consumption

during production (duration < 2 secs.)
TBA/21 Std 420 Nl/min. 930 Nl/min.
(14.7 cu.ft/min) (32.6 cu.ft/min)
TBA/21 + PT 21 820 Nl/min. 1 330 Nl/min.
(28.7 cu.ft/min) (46.5 cu.ft/min)
Water supply, cold

(3 - 4.5 bar)
[43.5 - 65 psi]
Max inlet temperature 20°C
(68°F)
Production consumption 8 l/min. Sterile air compressor.
(1.8 imp. galls/min.)
Production consumption 14 - 16 l/min. Cooling system with
(3.1 - 3.5 imp. galls/min.) compressor and
air compressor.
2.2TB033642.en
pH 5-8
Water supply, ice (OE)

(2 - 4 bar)
[29.0 - 58.0 psi]
Max inlet temperature 2 - 5°C
(36 - 41°F)
Consumption 2 - 7 l/min.
(0.45 - 1.55 imp. galls/
min.)
pH 5-8
(Cont'd)

(Cont'd)
Steam

Water quality Drinking water Boiler additives must be
suitable for use with
drinking water.
Supply pressure 170 kPa
(1.7 bar)
[25 psi]
Max pressure fluctuation +30 kPa
+0.3
( bar)
[4.5 psi]
Inlet temperature 130°C Measured after APV.
(266°F)
Consumption 2.4 kg/h
(5.3 Ibs/h)
Hydrogen peroxide

Quality Aseptic grade
Concentration 35%
2.2TB033642.en
Consumption 1.5 - 2.0 l/h
Nitrogen, only for machines with HI (OE)

Quality Food grade Min. purity 99.5%.
No solid particles.
No oil particles.
(4 - 7 bar)
[60 -100 psi]
Consumption 2 - 5 + headspace Depends on headspace
volume Nl/min. volume setting.

3.8 Cleaning
Cleaning in place (CIP)

Max inlet pressure 350 kPa
(3.5 bar)
[50.7 psi]
Min. flow 8000 m3/h
External cleaning

Hot water supply 300 - 450 kPa
pressure (3 - 4.5 bar)
[43.5 - 65 psi]
Hot water max inlet 55 - 60°C
temperature (131 - 140°F)
Hot water consumption: 250 l/cycle Maximum flow 95l/min.
(55 imp. galls/cycle)
Detergent pH 5-8
Detergent consumption 1.2 l/cycle
(0.3 imp. galls/cycle)
2.2TB033642.en
Upgraded cleaning (OE)

Hot water supply 300 - 450 kPa
pressure (3 - 4.5 bar)
[43.5 - 65 psi]
Hot water max inlet 55 - 60°C
temperature (131 - 140°F)
Hot water consumption: Maximum flow 95l/min.
- Alkali 250 l/cycle
(55 imp. galls/cycle)
Detergent consumption
- Alkali 1.8 l/cycle
(0.4 imp. galls/cycle)

3.9 Ambient temperature

Minimum ambient 5°C
temperature (41°F)
Maximum ambient 50°C
temperature (122°F)
Recommended ambient 15°C to 30°C
temperature (59°F to 86°F)
2.2TB033642.en

3.10 Outfeed conveyor

Recommended See PIM Conveyors Width varies according
conveyor make/model manual. to package volume.
Contact service
organisation if
necessary.
Recommended Family packs 25 m/min.
conveyor speed Portion packs 17 m/min.
2.2TB033642.en

2.2TB033642.en

4 Site preparation
2.2TB043642.en

4 Site preparation
4.1 Specific construction details

Hot water supply for external cleaning
The external foam cleaning system needs a substantial amount of hot water
during short periods of cleaning. See 3 Drawings and Technical data for the
correct hot water supply figures.
If the existing water supply system cannot deliver the necessary amount of
water, place a tank or some other kind of vessel with a capacity of at least
250 litres of water above the hot water inlet of the machine. This position
ensures adequate gravity feed pressure. The supply pipe must not be smaller
than ø 48.3 x 3.2 mm (11/2 inch thread). A full tank of this size will manage
one hot water rinse (The normal cleaning has two hot water rinses. A full
cleaning, all the programs after each other, needs four hot water rinses).
Caution! A constant supply to the cleaning pump is essential. Risk of severe
pump damage if the pump runs dry.
The method of water heating may vary depending on local equipment. Note,
however, that there are only 10 minutes for filling and heating a full tank of
water.
2.2TB043642.en
2
1 Hot water
inlet
2 Water tank

5 Crate handling
2.2TB053642.en

5 Crate handling
5.1 Crate data

Additional parts can be included in the crates depending on the machine
configuration (OE). See the Packing List for further details.
Machine type No. of crates

TBA/21 Std 2
TBA/21 PT 3
5.1.1 Main crate (1)

Weight and dimensions
Machine Gross Net weight Length Width Height

type weight kg (lbs) mm mm mm
kg (lbs) (ft.-in) (ft.-in) (ft.-in)
TBA/21 Std 7100 5900 5800 2100 2870
(15650) (13000) (19´0”) (6´10”) (9´6”)
TBA/21 PT 5600 4600 4800 2100 2870
(12350) (10150) (15´9”) (6´10”) (9´6”)
Note! Crate weight can increase significantly if the crate becomes wet.
Contents
2.2TB053642.en
Machine type Contents
TBA/21 Std Machine body
ASU
Platforms
Railings
Stair
Stair support
Doors and covers
Technical documentation box
Accessories
TBA/21 PT Same as above except for the ASU
ASU and the PT unit are assembled in the third crate (3).

5 Crate handling
5.1.2 Second crate (2)


TBA/21 Std 4200 3300 4200 2250 2870
TBA/21 PT (9250) (7300) (13´9”) (7´6”) (9´6”)
Contents
Contents
Superstructure
Electrical cabinet
Service unit
Doors and covers
Accessories
5.1.3 Third crate (3)

2.2TB053642.en

TBA/21 PT 3300 2600 3300 2100 2870
(7300) (5750) (11´) (6´10”) (9´6”)
Contents
Contents
ASU/PullTab

5 Crate handling
5.2 Lifting equipment

Types of lifting equipment
The following types of equipment can be used to lift and move the crates:
• overhead gantry
• mobile crane
• fork lift
Equipment specifications
Make sure that the lifting equipment comply with the specifications given in
the following table.
Equipment or Lifting Notes

tackle capacity
kg (lbs)
Overhead gantry 8 000 9 000 kg (22 000 lbs) required if gantry
(18 000) does not have gradual acceleration decel-
eration ramps.
Mobile crane 8 000 9 000 kg (22 000 lbs) required if crane does
(18 000) not have gradual acceleration deceleration
ramps.
Lifting chains, 8 000 9 000 kg (22 000 lbs) required if lifting
cables, ropes or (18 000) equipment does not have gradual accelera-
2.2TB053642.en
hoist slings tion deceleration ramps.
Min. length hook to hook:

– Main crate: 15 m (50’)
– Second crate: 15 m (50’)
– Third crate: 9 m (30’)
Fork lift 9 000 Higher capacity allows for reach to centre
(20 000) of gravity of 1 000 - 1 500 mm (3’ to 5’).
Lifting forks 9 000 Min. length:
(20 000) – Main crate: 2 000 mm (6’6’’)
– Second crate: 2 000 mm (6’6’’)
– Third crate: 1 500 mm (5’)
Min. setting width:

– Main crate: 2 000 mm (6’6’’)
– Second crate: 2 000 mm (6’6’’)
– Third crate: 1 500 mm (5’)

5 Crate handling
5.3 Unloading
Symbols and warnings used on the crates.
Symbol Meaning
Centre of gravity
Lifting points for chains, cables, ropes, or

slings
This way up
Fragile
Keep dry
Top of crate
‘Fragile’ warning
2.2TB053642.en
‘Handle with care’ warning
‘Not to be dropped’ warning
‘Gross weight’ value
‘Net weight’ value
5.3.1 Inspection
a) Examine the outside of the crates before starting to unload, and record
any damage. This information must later be recorded on the Transport
Damage Report (a section of the Start-up Machine Quality report).
b) Record the readings of the humidity indicators and tipping indicators
attached to the outside of the crates (if present). This information must
later be recorded on the Transport Damage Report (a section of the
Start-up Machine Quality report).

5 Crate handling
5.3.2 Using an overhead gantry or mobile crane

The crates are marked with lifting tackle symbols.
The lifting tackle must be passed under and fixed at these points when lifting
the crate. For capacity and length of the lifting tackle, see 5.2 Lifting
equipment.
Prepare ropes or poles to steady and manoeuvre the load. Do not use hands
or feet.
DANGER!
Tetra Pak
5.3.3 Using a fork lift
2.2TB053642.en
The crates are marked with centre of gravity symbols, the lifting forks must
be distributed at equal distance from the symbol when lifting the crate.
For capacity, length and setting width of the lifting forks, see 5.2 Lifting
equipment.
DANGER!
Tetra Pak

5 Crate handling
5.4 Moving and storage

Make sure that storage areas comply with specifications. See 5 4.2 Storage.
If installation is to start immediately, check whether it is possible to move the
crates to the installation site. Uncrating and installation can then be
performed together.
When moving the crates to the installation site, deposit them so that the
equipment can be lifted out and positioned without being turned around.
Open the customs inspection panels to see inside the crates.
Wait until installation can start before unpacking the crates.
5.4.1 Moving
a) Lift the crate as instructed above, only enough to clear the floor.
See 5.3 Unloading.
b) Make sure that the crate remains stable on the lifting equipment.
Caution! Move the crate slowly and gently.
c) Move the crate to its destination.
d) Look through the customs inspection panel to see in what way the
contents are facing. Position the crate to face the most convenient
2.2TB053642.en
direction.
e) Lower the crate gently to the floor, leaving enough room around it for
easy access to all sides.
f) Make sure that the crate is firmly supported. Place blocks or plates under
it if necessary.
g) Remove the lifting equipment.

5 Crate handling
5 4.2 Storage
Risk of serious equipment damage!
Do not stack the crates on top of each other.
WARNING!
Caution! Store the crates indoors. Exposure to damp or to high or low

temperatures may damage the equipment.
a) Make sure that the storage environment respects the following
conditions:

Min and max 5 - 40 If the water system is drained,
temperatures °C (°F) (40 - 105) the equipment can withstand
freezing conditions.
Max relative humidity % 80 Non-condensing.
b) Store the crates with about 1 000 mm (3 ft) of free access space around
and above for access and ventilation.
c) If the floor under the crates is uneven, place blocks or plates under them
to provide a steady support.
2.2TB053642.en

6 Positioning, assembly and
connections
2.2TB063642.en

6.1 General requirements

Personnel
Only skilled or instructed Tetra Pak installation personnel are allowed to
assemble the machine.
Personnel must know how to use the portable PC computer programs for
modifying PLC program parameters and downloading the TMCC program.
Lifting equipment
The equipment used for lifting and moving the crates can also be used for
unpacking the crates and installing the equipment. See section 5.2 Lifting
equipment for further details.
Equipment or Lifting Notes

tackle capacity
kg (lbs)
Lifting chains, 5000 Machine body, Std (with ASU)
cables, ropes or (11025) Two pcs min. length hook to hook
hoist slings 10.0 m (33’).
4000 Machine body, PT (without ASU)
(8820) Two pcs min. length hook to hook
10.0 m (33’).
3100 ASU/PullTab
2.2TB063642.en
(6840) Two pcs min. length hook to hook
10.0 m (33’).
2000 Superstructure
(4410) lifting tool, TP No. 985818
Min. length using schackles 4.5 m (15’).
1000 Electrical cabinet
500 Service unit
Min. length hook to hook 3.0 m (10’).
Lifting forks 5000 Machine body, Std (with ASU)
(11025) Min. length 1 500 mm (4’11’’).
Min. setting width 1 800 mm (5’11’’).
4000 Machine body, PT (without ASU)
(8820) Min. length 1 500 mm (4’11’’).
3100 ASU/PullTab
(6840) Min. length 1 500 mm (4’11’’).
2000 Superstructure
(4410) (fork tubes dim. = 149 x 70 mm)
Min. length 1 500 mm (4’11’’).
Setting width 613 mm (2’01’’).
1000 Electrical cabinet
(2205) (fork tubes dim. = 175 x 75 mm)
Min. length 1 500 mm (4’11’’).
Setting width 766 mm (2’6’’).
(Cont'd)

(Cont'd)
Tools and materials
The following tools and materials are needed to move and install the
equipment:
• two hydraulic jacks, min. capacity 3 tons
• pallet trolley, capacity 800 kg
• spirit level, TP No. 90243-163
• 2 m step ladder
• Pneumatic or electric powered wrench
• crowbar or strong lever
• large rubber coated mallet
• cable ties
• insulating tape
The following special tools may also be available from the local Service
Organisation:
• wheeled transporter unit, TP No. 582526
• lifting tool, TP No. 985818
(Cont'd)
2.2TB063642.en

(Cont'd)
Unpacking area
The minimum unpacking area must be at least twice the size of the main
crate. This area allows only one crate to be unpacked at a time.
Minimum area: 12 000x 6 000 x 4 000 mm (40’ x 20’ x 14’ h)
The ideal unpacking area permits all crates to be unpacked together.
Installation area
a) Clear all obstacles away from the installation site and, if necessary, clean
the floor of the site before starting to install the machine.
b) Make sure that there is sufficient room to move safely around the
installation site. If machines around the site cannot be stopped, place
guards around them to prevent accidental contact.
WARNING! c) Make sure that lighting is adequate. Arrange additional portable lights if
necessary.
2.2TB063642.en

6.2 Opening the crates

Note! The following instructions apply to all crates.
a) Remove the top of the crate and the reinforcement cross-beams.
b) Unscrew any screws fixing the contents to the front of the crate and
remove the front of the crate.
c) Unscrew any screws fixing the contents to the back of the crate and
WARNING! remove the back of the crate.
d) Unscrew any screws fixing the contents to the sides of the crate and
remove the sides of the crate.
a)
b)
2.2TB063642.en
c) d)
e) Remove all loose boxes and packages.

6.3 Unpacking the main crate (1)

Look through the customs inspection panels to see in which direction the
contents are facing. Position the crate to face the most convenient direction.
Open the crate according to 6.2 Opening the crates.
6.3.1 Inspection
a) Use the packing list to check that nothing is missing.
b) Inspect the machine and the accessories for damage.
c) Open the machine document box and check that the documentation
corresponds with the machine and the machine number.
MACHINE DOCUMENTS
NOT TO BE REMOVED
MACH. NR.................. Tetra Pak
Separate components
2.2TB063642.en
Place all separate component aside in a location where they will not disturb
the installation work and the normal plant activities. If possible do not
remove any transportation protection until the components are required.

6.3.2 Removing the machine body with an

overhead gantry or mobile crane
Risk of serious damage!
Other equipment positions than shown and careless handling when
lifting the machine body can severely damage the machine frame.
WARNING! For the correct lifting equipment, see section 6.1 General requirements.
a) Take care to attach the lifting equipment as illustrated, on the outside of
the machine feet.
Note! If the lifting equipment could damage the steel plates, protect them properly
before lifting the machine body.
b) Lift only enough to clear the crate.
c) Manoeuvre the machine body out of the crate.
d) Lower the machine feet (150 mm) to facilitate the levelling later on.
2.2TB063642.en
TBA/21 Std
150
TBA/21 PT
150

6.3.3 Removing the machine body with a fork lift

a) Place the forks an equal distance from the centre of gravity. See the
illustration for each location.
d) Lower the machine feet (150 mm) to facilitate the levelling later on.
TBA/21 Std
150
2.2TB063642.en
Min. 1 800 mm
TBA/21 PT
150
Min. 1 800 mm

6.3.4 Transport of the machine body

If possible have the machine body transported directly to the installation
area.
When it is not possible to use the uncrating equipment to transport the
machine body a set of wheeled transporters can be used as follows:
a) Remove the wheel assembly from one side of each transporter.
b) Hydraulic jacks can be used to lift the machine body. ONLY use the
jacks on marked places and on one side at a time.
2.2TB063642.en
TBA/21 Std TBA/21 PT
c) Roll the transporters under the machine frame where shown and insatall
each wheel assembly. Raise the machine feet enough to clear variations
in the floor level. For the PT machines the two rear machine feet must be
removed.
TBA/21 Std TBA/21 PT
Caution! Risk of machine damage!

The transporters must be secured to the machine frame with screws
to avoid transport damage.
(Cont'd)

(Cont'd)
Caution! Risk of machine damage
Block the wheels if the machine must be left on the transporters.
d) Move the machine, by manual pushing or towing with a truck, very
carefully to the installation area. Steer with the steering handles.
TBA/21 Std
TBA/21 PT
2.2TB063642.en
e) Place the machine in the exact position according to the site installation
drawing. See also 6.3.5 Positioning.
f) Remove the transporters in the reverse order of the fitting.

6.3.5 Positioning
Set the machine in its exact position if not already done. Put a damper
underneath each machine foot.
Respect minimum distances around the machine.
150+95
TBA/21 Std
Min 5096 3489 Min 1500
150+95
TBA/21 PT
Min 3896 3489 Min 1500

2.2TB063642.en
All configurations
Min 2200 Min 1000

Height
Set the machine to the correct height measurement (150 mm nominal) by
adjusting only the four marked (black) machine feet.
TBA/21 Std
TBA/21 PT

6.4 Unpacking the third crate (3)

(only PT machines)
Note! Ignore this section if the filling machine is not equipped with PT go directly
to 6.6 Unpacking the second crate.
Open the crate according to section 6.2 Opening the crates.
6.4.1 Inspection
b) Inspect the ASU/PullTab for damage.
2.2TB063642.en

6.4.2 Removing the ASU/PullTab with an

a) Take care to attach the lifting equipment as illustrated, on the outside of
the machine feet.
Note! If the lifting equipment could damage the steel plates, protect them properly
before lifting the machine body.
d) Lower the four machine feet, two on each side, to facilitate the levelling
later on.
2.2TB063642.en
150+95

6.4.3 Removing the ASU/PullTab with a fork lift

a) Place the forks as illustrated, equally distributed from the centre of
gravity.
d) Lower the machine feet to facilitate the levelling later on.
150+95
2.2TB063642.en

6.4.4 Transport of the ASU/PullTab unit

If possible have the ASU/PullTab transported directly to the installation area.
When it is not possible to use the uncrating equipment for the transport a set
of wheeled transporters can be used as follows:
a) Remove the wheel assembly on one side of the two transporters.
b) Use a hydraulic jack (1) to lift the ASU/PullTab unit as shown. Remove
the machine feet and fit the transporter. When lifting from the ASU side
make sure to put the jack under the solid frame.
2.2TB063642.en
1
c) Raise the machine feet enough to clear variations in the floor level.
Caution! Risk of machine damage!
The transporters must be secured to the machine frame with screws
to avoid transport damage.
(Cont'd)

(Cont'd)
Caution! Risk of machine damage
Block the wheels if the ASU/PullTab must be left on the transporters.
d) Move the ASU/PullTab, by manual pushing or towing with truck, very
carefully to the installation area. Steer with the steering handles.
e) Place the ASU/PullTab as close as possible to the machine body.

f) Remove the transporters in the reverse order of the fitting.
6.4.5 Docking
Note! An optional leg stand (TP No. 1317468-0100) is available. This option is
designed to support the platform when installing PullTab units on pre-
installed machines. The option is not needed if the PullTab unit is being
2.2TB063642.en
installed together with the machine since the platform is not in position at
this stage.
Fit the ASU/PullTab to the machine body.
The guide pins will give the exact position between the units. Tighten the
four screws.
Put a damper underneath each machine foot.
4x

6.5 Other operations

6.5.1 Levelling TBA/21 Std
Height
Put a damper underneath each machine foot. Set the machine to the correct
height by adjusting the four machine feet shown below.
Levelling
Level the machine exactly with the four shown machine feet. Measure with a
spirit level on the LH side jaw system guide.
Level the machine transversally first with the two rear feet, and then
“lengthwise” with the two front feet. (A pallet truck in the front could be
used to balance the machine for the lengthwise levelling).
Lower the rest of the machine feet carefully.
150+95
2.2TB063642.en

6.5.2 Levelling TBA/21 PT

Height
Put a damper underneath each machine foot. Set the machine to the correct
height by adjusting the four machine feet shown below.
Levelling
Level the machine exactly with the four shown machine feet. Measure with a
spirit level on the LH side jaw system guide.
Level the machine transversally first with the two rear feet, and then
“lengthwise” with the two front feet. (A pallet truck in the front could be
used to balance the machine for the lengthwise levelling).
Lower the rest of the machine feet carefully.
150+95
2.2TB063642.en

6.5.3 Platforms
Take care when working on machines without platforms and railings.
Note! The same platform configuration is used for both the TBA/21 Std and the
TBA/21 PT machines.
WARNING! The stair assembly can be fitted now, but only if it does not interfere with the
remaining installation work.
a) Fit the platform adjusting screws (1) to the rear machine frame.
b) If the machine is equipped with a PT unit, fit the adjusting screw
corresponding to the PT electrical cabinet to the platform frame. Secure
it with the locking screw. This locking screw cannot be fitted once the
platform is in place.
c) Assemble the platform as shown in the drawing below.
d) Check that the ASU splice head moves to the left and right without
interfering with the platform frame.
If necessary, raise the platform frame slightly by means of the adjuster
screws. Tighten the locking screws on completion of adjustment.
2.2TB063642.en
1
2
Platform screws,
torque 44 Nm
Tetra Pak Doc No. IM 82364-0102 71

6.6 Unpacking the second crate

Look through the customs inspection panels to see in which direction the
contents are facing. Position the crate to face the most convenient direction.
Open the crate according to 6.2 Opening the crates.
6.6.1 Inspection
b) Inspect the machine parts and the accessories for damage.
Separate components
Place all separate components aside in a location where they will not disturb
the installation work and the normal plant activities. If possible do not
remove any transportation protection until the components are required.
Caution! To protect vital parts from being damaged, the superstructure is
equipped with transportation supports. Do not remove them until
ready to lift the superstructure up on the machine body.
2.2TB063642.en
72 Doc No. IM 82364-0102 Tetra Pak

6.6.2 Removing the machine parts with an

a) Fit the eye bolts as illustrated. Attach the lifting equipment (a Tetra Pak
tool is illustrated but other equivalent lifting equipment can be used see
6.1 General requirements section for specifications).
Note! The superstructure is shown as a frame to illustrate the eye-bolt fitting.
Supply unit
2.2TB063642.en
Superstructure
Electrical cabinet

c) Manoeuvre each machine part out of the crate.

6.6.3 Removing the machine parts with fork lift

a) Supply unit
Fit the eye bolts and the lifting equipment. Place and lift with the forks as
illustrated.
Superstructure and electrical cabinet
Place the forks in the fork tubes as illustrated. Both sides can be used
depending on access. See 6.1 General requirements section for lifting
specifications.
Supply unit
2.2TB063642.en
613
Superstructure
(tubes 149 x 70 mm)
766
Electrical cabinet
(tubes 175 x 75 mm)

c) Manoeuvre the machine part out of the crate.
6.6.4 Transport of the machine parts

Have the machine parts transported directly to the installation area with the
uncrating equipment.

6.7 Assembly
6.7.1 Supply unit
Have the supply unit lifted up on to the front of the machine body. Tighten
the supply unit to the machine body with the three fastening bolts, as
illustrated.
2.2TB063642.en

6.7.2 Superstructure
a) Before lifting the superstructure:
• find the three peroxide pipe gaskets (3)
• find the seal cloth with holder (2), fit the seal cloth to the superstructure
pipes (1)
• remove the protection plugs of the peroxide pipes (1) and (4).
2.2TB063642.en
4
1 Peroxide pipes,
superstructure
2 Seal cloth with
holder
3 Gasket
4 Peroxide pipes,
machine body
(Cont'd)

(Cont'd)
b) Clear any dirt from the contact surfaces (6).
c) Have the superstructure lifted up on to the machine body. The two guide
pins (7) on the machine body will give the exact position to the
superstructure.
d) Tighten the superstructure to the machine body with the eight screws as
illustrated.
2.2TB063642.en
5 Screws, with spacers, to the frame (2 pcs) 8

6 Contact surfaces (greyed areas)
7 Guide pin
8 Screws to the frame (2 pcs)
9 Screws to the aseptic chamber (4 pcs)

6.7.3 Electrical cabinet

a) Organize all the electrical cables on the machine body roof so they don’t
interfere with the electrical cabinet placement.
b) Make sure that both the front doors (1) are easy to open so the electrical
cables from the ASU and the superstructure can be passed through.
c) Have the electrical cabinet lifted up on to the machine body. The two
guide pins (3) on the machine body will give the exact position for the
electrical cabinet.
d) Tighten the electrical cabinet to the machine body with the four screws
(2) as illustrated.
2.2TB063642.en
1
1 Front door
2 Fastening screws (4 pcs)
3 Guide pin

6.7.4 Stair and railings

Fit the stair assembly if not already done.
Fit the profiles, rims, corner strips, hand rails, and other accessories to the
machine as illustrated. Remember to use the correct torque.
2.2TB063642.en
Platform screws
torque 44 Nm
Hand rail, screws
torque 197Nm
Hand rail. stop screws
torque 44Nm

6.8 Connections
6.8.1 Utility connections
Product connections
Prepare for the connections to the filling system as shown below. See
3.1 Installation drawings for measurements and dimensions.
1 2 3 4
1 CIP in
2 CIP out
3 Product in/out
4 Product in/out
2.2TB063642.en
(Cont'd)

(Cont'd)
Utilities connections
Prepare for the connections to the supply unit as shown below. See
3.1 Installation drawings for measurements and dimensions.
9 2
8 3
7 4
6 5
1 Steam
2 Ice water in (when used)
3 Ice water out (when used)
4 Nitrogen gas (when used)
5 Hot water in
6 Communication cables
2.2TB063642.en
(when used)
7 Spare
8 Cold water in
9 Air in
Drain connections
Connect the drain outlet from the machine to the waste water drain.
Caution! Check on the legal requirements applicable to the disposal of diluted
hydrogen peroxide. A separate drain may have to be used.

6.8.2 Conveyor equipment

The work of connecting the machine to the plant conveyor system could be
started when convenient.
a) Connect the package outfeed conveyor according to the plant installation
and connection drawings. See the package conveyor´s own installation
manual for instructions.
b) Fit the machine queue guard photocells (2) to the package conveyor. Set
the distance A between the package counter photocells (1) and the queue
guard photocells. For configuration instructions see MM section 5.8-7
Outfeed device - Set queue photocells.
Package A (mm)
1000 B 2 400
1000 S 2 200
1000 P 2 400
250 B 1 600
200 B 1 600
200 S 1 200
1 A 2
2.2TB063642.en
1 Package counter photocell
2 Queue guard photocell
c) Make all necessary electrical connections. See the EM for further details.
d) Set the recommended conveyor speed. See the package conveyor´s own
installation manual for instructions.

6.8.3 Supply unit

Fit the connections to and from the supply unit.
Use the list ≤to check that all connections have been made.
1
2
16
15 3
2.2TB063642.en
14
4
5
6
7
8
9
10
11
13 12
1 Drainage from cooling unit tray 10 Air, constant supply
2 Cooling water feed hoses (4) 11 Cable front warning beacon
3 Cooling water return hoses (4) (through the hole)
4 Water flushing final folder 12 External cleaning hoses (3)
5 Drainage from cooling equipment 13 Internal electrical main cable
6 Air, external cleaning unit 14 Electrical connections (6)
7 Cleaning liquid, external cleaning 15 Air gun (blue)
unit 16 Water gun
8 Cold water supply
9 Air, regulated supply

Fit the connections to and from the superstructure.
Use the list to check that all connections have been made.
5
3
2
6
1 7
8
9
10
2.2TB063642.en
1 Air supply (two pcs) 8 Water, compressor
2 Drainage, electrical cabinet and 9 Drainage,
separator product valve group
3 Seal cloth 10 Cooling water hoses,
4 Peroxide pipes with gaskets IH-LS (2 pcs)
(three pcs)
5 Communication cables
6 External cleaning, column
7 Return CIP

6.8.5 Electrical cabinet and other electrical

supplies
a) Fit and secure both cable ducts (1) and (2) to the electrical cabinet.
Remove cover (3) if not already done.
1 RH side cable duct

3 2 LH side cable duct
2
2.2TB063642.en
3 Cover
b) Feed through and connect the internal mains cable to the terminal in the
electrical cabinet.
(Cont'd)

(Cont'd)
c) Connect the electrical cables from the different machine parts to the
electrical cabinet. Take care to match the marking on the cable to the
corresponding marking in the cabinet.
Fasten the cables to the cabinet wall the cable must not hang directly on
the connector <to avoid future bad contacts.
d) Fit the covers (1), (2) and (3) to the electrical cabinet.
2.2TB063642.en
1 Cover, (4 pcs)
2 Cover, cable cabinet
3 Cover, cable trench
2
3
e) Fit and connect the two warning beacons to the machine.
(Cont'd)

(Cont'd)
f) Connect the electrical mains supply cable to the machine.
Make sure that the electrical mains switch is in the Off position.
g) Turn on the electrical power upstream.

h) Put the main switch in On position.
Note! To be performed by authorized electricians only!
Check the rotation direction of the conveyor band for unfilled packages to
see if the mains cable connection must be changed. See the EM for further
details.
2.2TB063642.en

6.9 Final assembly

6.9.1 Automatic splicing unit
Remove the transport device securing the packaging material trolleys.
6.9.2 Machine body

a) Fit the protective cover (1) over the packages outfeed.
2.2TB063642.en
1
b) Locate the peroxide container and put it into the peroxide compartment.
(Cont'd)

(Cont'd)
c) Locate the cleaning liquid containers and put them into the compartment.
6.9.3 Drive and Jaw system

Remove the transport devices securing the Drive unit and the Jaw system.
See the illustration for each location.
2.2TB063642.en

a) Fill the water circulation system with water see
MM, section Superstructure, Water circulation - fill.
b) Fit the filling pipe and the seal ring to the superstructure.
2.2TB063642.en
1
2 1 Filling pipe
3 2 O-ring
3 Ring
4 4 Seal
5 5 Ring
(Cont'd)

(Cont'd)
c) Fit the cover plate to the superstructure as illustrated.
d) Make sure that the filling system protections are fitted as illustrated.
2.2TB063642.en
e) Locate the CIP equipment and check that it is complete as illustrated.

6.9.5 Supply unit

The cooling water system must be filled up with water according to the MM
section 6. Supply unit - 6.1-3 Cooling water system, fill.
6.9.6 Date unit
2.2TB063642.en
Locate the date unit accessories and place them in a suitable place for later
usage.

6.9.7 Covers
Make sure that the covers and railings shown below are fitted to the machine.
1 2 3 4
5
13
12
11
10
8
6
7
9
2.2TB063642.en
1 Top cover 11 Cover dating unit, LH side

2 Railing 12 Cover plate, top cover
3 Cover dating unit, RH side 13 Covers, electrical cabinet cooler
4 Top cover superstructure, RH side
5 Covers, sterile air system
6 Cover frame, sterile air system
7 Front cover, sterile air system
8 Top cover superstructure, LH side
9 Lower cover superstructure
10 Cover pneumatic air panel

6.10 Disposal/return of packing

Note! Packing materials (including the crates, wrapping, and boxes) are not
normally returned to the manufacturer.
a) Check with the customer if there is a special agreement for the return of
packing to the manufacturer.
b) If packing must be returned to the manufacturer, prepare an area to store
the crates and other returnable packing.
c) Check with the customer if there is a special agreement for recycling
packing.
d) If packing is not to be recycled, check with the customer how to separate
and dispose of packing (wood, plastic, paper, etc.).
e) Dispose of pollutant waste (bubble wrapping, plastic bags, expanded
polystyrene, etc.) in accordance with local regulations.
WARNING!
2.2TB063642.en

2.2TB073642.en

7.1 Installation and connection checks

Verify the installation work by following the checklist below.
See section 6 Positioning, assembly and connections for further details.
No. Check Done

1 The machine is level transversally and longitudinally.
2 All railings have been fitted.
3 The utility connections work is done.
4 The conveyor equipment is connected.
5 The connection work to the service unit is finished.
6 The connection work to the superstructure is finished.
7 The electrical power cables are correctly connected:
- in the main switch cabinet
- between the main switch and the electrical cabinet
- in the electrical cabinet
8 All covers are fitted.
9 The water circulation system is filled.
10 The filling pipe and seal ring are fitted.
11 The protective cover for the outfeed is fitted.
12 The peroxide container is in place.
13 The detergent container/containers are installed and filled with
2.2TB073642.en
the correct detergent, see OM.
14 The transport securing devices are removed.
15 The cooling water system is filled.
16 The eject conveyor/bin is connected/positioned.
17 Upstream valves/switches are open/on:
– electrical power
– cold water
– ice water supply and return (OE)
– hot water
– compressed air
– steam
– nitrogen (only machines with HI)
18 There are no leakages from the utility connections.
19 The production line is flushed with water to eliminate welding
residues, and to detect any leakages.
20 The machine crates and other packing has been taken care of
as agreed with the customer.

7.2 Lubricant level checks

See the MM for further details on the following level checks.
No. Check Done

1 Machine body - Hydraulic system
2 Machine body - Lubrication system
3 Drive unit - Worm gear
4 Final folder - Indexing gear
2.2TB073642.en

7.3 Valve checks

No. Check Done
1 The three peroxide valves are in
closed position:
- Peroxide tank, drain valve.
- Peroxide tank, sampling valve.
- Dilution tank, drain valve.
2 The air valve of the PullTab unit is

opened.
3 The air valve and the water valves

of the service unit are opened.
2.2TB073642.en

7.4 Safety checks

No. Check Done
1 All doors open and close correctly.
2 All hatches and safety covers are secured.
3 All the Emergency stop buttons.
See the Safety Precautions section for further details.
Press each emergency stop button and make sure that the
machine steps down to Off.
4 All the doors, covers and guards.
See the Safety Precautions section for further details.
Open each door, cover or guard and make sure that the TPOP
shows the correct one.
5 The machine and the machine area are free from remaining
installation packing and wrapping.
2.2TB073642.en

2.2TB073642.en

8 Preparation for
commissioning
2.2TB083642.en

Note! Commissioning covers only the functioning of the individual machine.

A line performance test is required to check the functioning of the machine
as part of a complete line. Check with the local service organisation as to
what arrangements have been made for a line performance test.
2.2TB083642.en

8.1 Presence and correctness checks

No. Check Done
1 The TP No. on the program diskette corresponds to the TP No.
in the EM.
2 The spare parts have been deposited in the spare parts stores.
3 The accessories are available to the operator:
– apron
– gloves
– goggles.
4 All the documents correspond to the specific machine.
– EM
– IM
– OM
– MM
– SPC
– System drawings
– Machine Specification Document
– Final Inspection Report
– Machine Deviation Report (if relevant).
5 A packaging material trolley must be available and functioning
correctly.
6 The supply and quality of product is sufficient for the purpose of
the commissioning.
2.2TB083642.en
7 All supplies are of the correct type and are available in sufficient
quantities for the purpose of the commissioning:
– Packaging material
– LS strip
– Hydrogen peroxide
– Ink
– Detergents
– Nitrogen (only machines with HI)
– IS patch strip (only machines with PT unit)
– Tab strip (only machines with PT unit)
(Cont'd)

(Cont'd)
No. Check Done

8 The compressed air valve keys in the
service unit are present.
9 The compressed air valve keys in the PT

unit (OE) are present.
10 The electrical cabinet keys are present

– service switch key
– CIP switch key
– time recorder key
2.2TB083642.en

8.2 Product and utility value checks

Make sure that the product and utility values are correct. Ask for the
assistance of the customer’s technical personnel if necessary. If values are
incorrect, inform the customer’s technical personnel.
See section 3 Drawings and Technical data.
No. Check Done

1 Product supply:
– pressure
– max pressure fluctuation
– inlet temperature
– max particle size
2 Electrical power supply:
– voltage
– max voltage fluctuation
– frequency
– fuse rating
3 Cold water supply:
– pressure
– max inlet temperature
– pH
4 Hot water supply:
– pressure
2.2TB083642.en
5 Compressed air supply:

– pressure
– max particle size
– max particle content
– dew point
– oil content
6 Steam supply:
– water quality
– pressure
– max pressure fluctuation
7 Detergents:
– correct type (specifications)
– pH
8 Hydrogen peroxide supply:
– aseptic (food) grade
– concentration (35%)
9 Nitrogen supply (only machines with HI):
– purity
– pressure

8.3 Function checks

8.3.1 Preparation
a) Make sure that the PLC program on the diskette corresponds with that in
the machine PLC. See the EM for further details.
b) Connect a cold water supply to the product inlet connection.
(If the product pipes have been welded have them flushed thoroughly
before using.)
c) Switch on the mains power switch.
(Make absolutely sure that the rotation directions of the electrical motors
are correct. See the EM for further details.)
d) Load the recorders with paper, see the OM for further details on the:
– time recorder
– process recorder (OE)
– cleaning recorder (OE).
e) Perform CIP. See the OM for further details.
f) Prepare the machine for production. See the OM for further details.
g) Make sure that starting up from cold takes less than 35 minutes at an
ambient temperature of no less than 20ºC (68ºF).
h) Start up the package outfeed conveyor (and eject conveyor if present).
2.2TB083642.en
i) Put the machine into Production according to the OM.
8.3.2 Normal operating checks

No. Check Done
1 The first packages during the start sequence must be safely
and distinctly fed into the final folder. Press the package ejector
button a couple of times to verify the function.
2 All flaps of the packages must be correctly sealed.
Check continuously.
3 The package outfeed conveyor speed is set properly.
The packages must enter the conveyor chain without problems.
(Cont'd)

(Cont'd)
No. Check Done

4 Finished packages are correct in terms of:
– size and shape
– longitudinal and transversal sealing
– date code printing
– filled package weight/volume
See the OM for further details.
5 Production capacity is as specified (count the packages
produced in ten minutes and multiply by six.
6 All pressures remain within tolerance. See the MM for further
details.
7 There are no fluid leaks.
8 There are no unusual noises which could indicate loose or
misaligned parts.
9 There are no unusual smells which could indicate internal leaks
or burning of electrical circuits.
10 The peroxide concentration continuously to detect any sign of
degradation.
11 Defective packages are ejected (start up, short stop, material
splice, strip splice, production stop).
12 Perform manual strip splice to verify the function. See the OM
for further details. Two packages shall be discarded, the first
2.2TB083642.en
one with the splice and the following one.

13 Packaging material trolley function.
14 Perform manual package material splice to verify the function.
See the OM for further details. Two packages shall be
discarded, the first one with the splice and the following one.
15 Stop methods. Stop the machine according to the OM to verify
the different stop functions.
16 Perform external cleaning.
For machines with upgraded cleaning (OE), run all the cleaning
programs.
17 The time recorder is functioning and the printout is readable.
18 The cleaning recorder (CIP) is functioning and the printout is
readable (OE).
19 The process recorder is functioning and the printout is readable
(OE).
20 Operate the different TPOP systems to verify the functions. See
the OM for further details.
(Cont'd)

(Cont'd)
Selecting injection nozzles HI (OE)
Apply the following criteria when selecting a new injection nozzle size.
Larger nozzles:
• increase the volume of injected gas
• increase the effect of pressure changes
• produce a coarser foam (with larger, short-life bubbles – useful for
products which foam easily)
Smaller nozzles:
• reduce the volume of injected gas
• reduce the effect of pressure changes
• produce a finer foam (with finer, long-life bubbles – useful for products
which do not foam easily)
8.3.3 Changing PLC parameters

Caution! Do not change the PLC parameters unless absolutely necessary.
Make a copy of the existing parameters before modifying them. Also
keep a copy of the new parameters for future reference.
2.2TB083642.en
TPMC
Only skilled or instructed persons are allowed to make changes to the PLC
parameters.
TMCC
Only skilled or instructed persons are allowed to work with the TMCC.

8.4 Health and safety checks

No. Check Done
1 All the Emergency stop buttons.
See the Safety Precautions for further details.
Press each emergency stop button and make sure that the
machine steps down to Off.
2 All the doors, covers and guards.
See the Safety Precautions for further details.
Open each door, cover or guard and make sure that the TPOP
shows the correct one.
3 The manual strip splice button is disabled when the SA door is
opened.
4 The manual packaging material splice button is disabled when
an ASU door is opened.
5 Filled packages and outlet water samples have the correct
hydrogen peroxide residue/content as measured using:
– Test kit 90298-31 for packages
– Test kit 90298-30 for outlet water.
2.2TB083642.en

8.5 Documentation
Note! No claims will be accepted for machines in commercial production if the
Start-Up Machine Quality Report (SUMQR) has not been returned to the
manufacturer.
a) Compile the Transport Damage Report (a section of the SUMQR).
If no damage has occurred during transport, state “NO TRANSPORT
DAMAGE”.
b) Compile the Feedback from MC form only in case of claims on the
equipment.
For further information about claims see the Claim and Complaint
Handling procedure, available from the local Service Organisation.
c) Compile the Start-Up Machine Quality Report.
List all work, besides the installation work, performed to ensure correct
functioning.
The installation work covered by this manual is now complete.
2.2TB083642.en

2.2TB093642.en

Caution! If the equipment is going to stand or travel in freezing conditions, the

water circuits must be drained to avoid damage from freezing.
The equipment can be moved for short distances without being drained or
disassembled, but only if no freezing conditions will be encountered. The
equipment must be drained before long distance moves or long term storage.
If draining is necessary, perform the draining procedure before disconnecting
the equipment from the mains power supply.
Only skilled or instructed installation technicians are allowed to disassemble
the equipment for moving to other installation positions.
2.2TB093642.en

9.1 Draining
9.1.1 Draining methods
To drain certain circuits, the solenoid valves controlling them must be
energised. This can be done in two ways:
• electronically (using a portable PC to force PLC outputs)
• by manually bridging terminals in the electrical cabinet.
The following is needed for the electronic procedure:

• portable PC running the latest update of TIT software, V 2.0
• TPMC PLC serial cable, TP No. 90025-048
• EM
The following is needed for the manual bridging procedure:

• a piece of cable approximately 2 metres in length
• EM
9.1.2 Preparation
a) Shut off the cold and hot water supplies upstream from the machine.
2.2TB093642.en
Operate the water gun to release the residual pressure from the cold
water circuit.
b) Disconnect the cold water in and hot water in supplies at the connection
panel on the service unit.
Ice-water cooling system (OE):
Also disconnect the ice-water in and ice-water out at the connection
panel on the service unit.
c) Arrange a compressed air line for connection to the water systems.

Use a special adapter if one is available. Otherwise block the pipe around
the air line to prevent the air from escaping.
(Cont'd)

(Cont'd)
d) Prepare for the chosen procedure:
– For the electronic procedure, connect the PC to the PLC unit.
Caution! When bridging control and power terminals, connect the cable to the
control terminal first and then to the power terminal. Take care not to
cause short circuits.
– For the manual bridging procedure, connect the bridge cable from a
control terminal to any free terminal on the +24VDC power terminal
block XL.12 in the electrical cabinet.
e) Turn On the mains power switch.
Make sure that no emergency stops are engaged, all doors with switches
are closed, and no error conditions are present.
9.1.3 Draining procedure

Risk of injury and damage!
Make sure that fluid expelled under pressure cannot cause
injury or damage.
WARNING! Cleaning pump circuit
a) Engage the Hot water supply valve Y3101 (2), and the Rinsing chemical
2.2TB093642.en
parts valve Y3113 (1).
b) Manually open the pneumatic valve, Column cleaning ball/lid MY3116
(10), on the superstructure valve panel.
c) Open drain plug (3) on the back of the cleaning pump to drain the water
out. Close the drain plug.
d) Remove the filter (4) and clean it. Install the filter.
e) Connect the compressed air to the hot water inlet.
f) Slowly open main valve (5) to avoid damage.
Manually open valves:
– flushing Y3103 (6)
– column cleaning Y3110 (7)
– jaw system cleaning Y3111 (8)
– FFU cleaning Y3112 (9).
g) Close the compressed air supply.
h) Open drain plug (3) on the cleaning pump again to drain the remaining
water. Close the drain plug.
i) Restore all parts and reset the valves.
(Cont'd)

(Cont'd)
6 7 8 9
5 1
2
2.2TB093642.en
4 3
1 Valve Y3113
2 Valve Y3101
3 Drain plug
(rear side)
4 Filter
5 Main valve
10 6 Valve Y3103
7 Valve Y3110
8 Valve Y3111
9 Valve Y3112
10 Valve Y3116
(Cont'd)

(Cont'd)
Cold water system circuit
a) Close the valves (1) for incoming cold water.
b) Disconnect hose (7) on valve S2550. Fold the hose in half and use tape to
secure it.
c) Disconnect pipe (8) on the other side of the valve S2550 and drain the
water completely. Fit the pipe again. Tighten carefully.
d) Remove the non-return valve (6).
e) Open valve (5) and drain the water softener completely.
f) Install the non-return valve (6).
g) Remove both water filters (4) and clean them.
Install the water filters.
h) Connect compressed air to the cold water inlet.
i) Slowly open water valves (1).
j) Press the flushing final folder button on the TPOP panel until only dry air
comes out. (Flushing FFU Y2108)
k) Engage the Tube flushing valve Y2106 (3) until only dry air comes out.
l) Operate the water gun until only dry air comes out.
m) Engage the Seal water valve Y1104 (2).
2.2TB093642.en
n) Engage the Cooling water bath valve Y1105 (9).
o) Replace all parts.
(Cont'd)

(Cont'd)
8 7 6 5 4
2.2TB093642.en
3 1 Cold water valves

2 Valve Y1104
3 Valve Y2106
4 Water filter
5 Water softener valve
6 Non return valve
7 Hose, S2550
8 Pipe, S2550
9 Valve Y1105
(Cont'd)

(Cont'd)
Cooling water system, compressor
a) Disconnect one of the cooling hoses (1) to the final folder to release the
system pressure and drain some water. Connect the coupling again.
b) Disconnect the lower hose connection (2) on heat exchanger K2510.
Blow very carefully with compressed air into the hose until the water is
drained out. Check on the flow meters (4).
c) Open drain plug (3) on the circulation pump and drain the water
completely. Close the drain plug.
d) Replace all parts.
2.2TB093642.en
2
1 Cooling hose
3 2 Hose
3 Drain plug
4 Flow meters
(Cont'd)

(Cont'd)
Cooling water system, ice-water (OE)
To be evaluated.
2.2TB093642.en
(Cont'd)

(Cont'd)
Water system, hydrogen peroxide bath
a) Open the valve (3) to the hydrogen peroxide bath water system and drain
the water completely. Leave the valve in open position.
b) Open the screw (1) on top of the hydrogen peroxide bath in order to drain
the water system.
c) When the superstructure is lifted down to the floor, loosen the screw (1)
and remove the drainage plug (2) to drain the water completely from the
bath.
2.2TB093642.en
1 Screw
2 Drainage plug
3 Valve
3
(Cont'd)

(Cont'd)
Compressor
Remove the drain plug and drain the water from the compressor.
Install the drain plug.
Separator
2.2TB093642.en
Remove the float chamber and drain the water.

Install the float chamber.
(Cont'd)

(Cont'd)
Sterilization bath water pump
Open the pump house to drain the water. Close the pump house.
2.2TB093642.en
Peroxide tank
Hydrogen peroxide!
Follow the Safety Precautions.
WARNING! Drain the remaining preoxide from the peroxide tank and rinse the tank with
water to avoid peroxide residues when dismantling the machine. See MM
section: Machine body, Hydrogen peroxide - clean and passivate.
(Cont'd)

(Cont'd)
Final checks
a) Make sure that all the cables used for the draining procedure are
disconnected.
b) Make sure that the cleaning pump filter and the cold water filters are
fitted.
c) Make sure that all involved valve handles are in open position to avoid
freezing damage from water residue.
d) Check that all couplings and adapters on the connection panel of the
service unit have been removed.
2.2TB093642.en

9.2 Moving and transporting the

equipment
9.2.1 Short moves and short-term storage
TBA/21 PT
Risk of serious structural damage!

A fully assembled TBA/21 PT machine must NOT be lifted under any
circumstances.
WARNING! A TBA/21 PT machine must always be disassembled as mentioned in 9.2.2
Long moves and long-term storage even if only a short move is to be done.
TBA/21 Std
Note! The fully assembled equipment can be moved either on the wheeled
transporter (TP No. 1185025, available from the local Service Organisation)
or by forklift. Overhead gantries and mobile cranes cannot be used.
See section 6 Positioning, assembly and connections for further details on
the operations in this section.
To disassemble parts, follow the assembly instructions in the reverse order.
2.2TB093642.en
a) Turn off and padlock the mains power switch.
b) Shut off all the utility and product supplies upstream:
– electrical power
– cold water
– hot water
– compressed air
– product
– steam
– CIP
– communication cables (when used)
– ice-water (OE)
– nitrogen gas (OE)
c) Release pressure from the water and air circuits by operating the water
and air guns. Close the following valves:
– compressed air valve
– cold water valves
– hot water valve
– steam valve
– ice-water valves (OE)
(Cont'd)

(Cont'd)
d) Disconnect the power, utility, drain and product lines:
– electrical power (disconnect at power terminal and remove the cable)
– communication cables (when used)
– cold water
– hot water
– compressed air
– product
– steam
– CIP lines
– drainage
– ice-water lines (OE)
– nitrogen gas (OE)
e) Plug or protect all open connections.
f) Make sure that cables are put away safely.
g) Disconnect the package outfeed conveyor.
h) Disconnect the eject conveyor or remove the eject bin.
i) Remove the stair and the stair support from the platforms.
2.2TB093642.en
Note! The complete TBA/21 Std weighs approximately 7 700 kg (17 000 lbs). Take
great care when fitting the transporters and moving the unit.
j) Fit the transporters to the machine, or position the forks. See 6.3.4
Transport of the machine body.
k) Move the equipment to its new position.
Caution! Do not leave the equipment on the transporters. If the equipment is
not supported evenly, the frame could be subjected to damaging
torsional forces.
l) Level the equipment even if it is not going to be used. See 6.3.5
Positioning.
If the equipment is to be stored for a while make sure to fulfil the storage
conditions, see 5 4.2 Storage.

9.2.2 Long moves and long-term storage

See section 6 Positioning, assembly and connections for further details on
the operations in this section.
a) Drain the equipment. See 9.1 Draining for further details.
b) Perform all the disconnection work mentioned in the 9.2.1 Short moves
and short-term storage section.
c) Empty the cleaning liquid containers. Follow the manufacturer´s
instructions for disposal of the liquid.
d) Dismantle the machine by following the section 6 Positioning, assembly
and connections in reverse order.
Collect all materials such as screws, washers, nuts, cables, etc., grouped as
they are used in marked plastic bags.
The dismantled machine parts shall be:
– the electrical cabinet
– the superstructure
– the service unit
– the machine body and ASU (Std)
– the machine body (PT)
– the ASU/PullTab (PT)
2.2TB093642.en
– railings, platforms, stair and stair support
– non fixed parts such as:
covers
dating unit accessories
CIP equipment
filling pipe (needs proper coverage to protect the level sond)
cleaning liquid containers (emptied)
peroxide container (emptied)
warning beacons
light assembly
etc...
e) Fit transport devices in the same locations from wich they were removed
from when the machine was assembled. The purpose is to prevent
movement during transport.
f) Lubricate all sliding components such as rods, cams, etc.
g) Wrap small components in bubble wrapping or similar to prevent
damage.
(Cont'd)

(Cont'd)
h) The equipment must be packed in suitable crates to ensure safe transport
and the correct storage conditions. Use the original crates and packing if
available. Make sure that the parts are adequately protected from
transport damage. All parts must be fixed to the crates with proper bolts
or similar equipment. Fix any loose sub-crates or boxes to the floors or
walls of the crates to prevent them from moving during transport. The
crates must also be protected from the weather to prevent rain, snow,
sand, etc. from entering the crates.
2.2TB093642.en

9.3 Return to the manufacturer

a) Drain the equipment. See section 9.1 Draining.
b) Prepare the equipment for transport. See section 9.2 Moving and
transporting the equipment.
c) Contact the local service organisation for further instructions and to
arrange shipment.
2.2TB093642.en

9.4 Disposal
If the equipment is to be permanently disposed of, perform the following
operations.
a) Drain the equipment. See section 9.1 Draining.
b) Drain the hydraulic tank and dispose of the hydraulic fluid in compliance
with the local regulations. See MM for further details.
c) Drain the central lubrication tank. Follow the manufacturer´s instructions
for disposal of the liquid.
d) Empty the cleaning liquid containers. Follow the manufacturer´s
instructions for disposal of the liquid.
e) Drain oil from the gear boxes. See MM for further details. Follow the
manufacturer instructions for disposal of the liquid.
f) Remove the packaging material and the LS strip. Dispose of these in
compliance with local regulations.
Cooling media!
Exposure to cooling media can cause personal injury. Follow the
Safety Precautions.
WARNING! g) Cooling equipment containing (any kind of) cooling media must be
dismantled, but only as far as can be considered safe without any cooling
media leakage. Send the cooling media to an authorized company for
2.2TB093642.en
proper handling.
h) Disassemble the machine as far as possible and separate the following
materials:
– stainless steel
– aluminium
– glass panes
– cast iron
– rubber (seals, O-rings, etc.)
– nylon and other plastics
– electrical cables
– hydraulic, central lubrication, and pneumatic hoses
– electrical components
i) Recycle or dispose of all materials, groups and components in
compliance with local regulations.

2.2TB093642.en

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IM

Series No/ Machine No Sign.

Tetra Brik Aseptic

PullTab unit PT21

Cooling system ice water

Headspace by Injection HI21

TPOP Serial communication

Tetra Brik Packaging Systems

General safety precautions . . . . . . . . . . . . . . . . . . . . . 13

Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . 15

Equipment for lifting and moving loads . . . . . . . . . . . 22

Tetra Pak Doc No. IM-82364-0102 i

3 Drawings and Technical data

3.2 Basic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3 Mass (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.5 Emissions and thermal load . . . . . . . . . . . . . . . . . . . . 34

3.9 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.10 Outfeed conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2 Lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ii Doc No. IM-82364-0102 Tetra Pak

5.4 Moving and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6 Positioning, assembly and connections

6.2 Opening the crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.3 Unpacking the main crate (1). . . . . . . . . . . . . . . . . . . . 58

6.4 Unpacking the third crate (3) (only PT machines) . . . 64

6.5 Other operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.6 Unpacking the second crate . . . . . . . . . . . . . . . . . . . . 72

Tetra Pak Doc No. IM-82364-0102 iii

6.9 Final assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

6.10 Disposal/return of packing . . . . . . . . . . . . . . . . . . . . . 94

7 Final installation checks

7.2 Lubricant level checks . . . . . . . . . . . . . . . . . . . . . . . . . 97

7.3 Valve checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

7.4 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

iv Doc No. IM-82364-0102 Tetra Pak

8 Preparation for commissioning

8.2 Product and utility value checks . . . . . . . . . . . . . . . . 105

8.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.4 Health and safety checks . . . . . . . . . . . . . . . . . . . . . . 109

8.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

9 Disassembly and removal

9.1.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

9.2 Moving and transporting the equipment . . . . . . . . . 124

9.3 Return to the manufacturer . . . . . . . . . . . . . . . . . . . . 128

9.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Tetra Pak Doc No. IM-82364-0102 v

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vi Doc No. IM-82364-0102 Tetra Pak

Tetra Pak Doc No. IM-82364-0102 1

2 Doc No. IM-82364-0102 Tetra Pak

Tetra Pak Doc No. IM-82364-0102 3

4 Doc No. IM-82364-0102 Tetra Pak

Tetra Pak Doc No. IM-82364-0102 5

Standard International System abbreviations are used for all measurements

6 Doc No. IM-82364-0102 Tetra Pak

Tetra Pak Doc No. IM-82364-0102 7

Failure to observe information marked “WARNING!” can result in

Caution! Failure to observe information marked “Caution!” can result in

8 Doc No. IM-82364-0102 Tetra Pak

Wear eye protection Wear hearing protection

Wear head protection Wear protective gloves

Tetra Pak Doc No. IM-82364-0102 9

Risk of entanglement! Risk of corrosion!