Course Introduction 1

TBA/8
DIMC TBA/8 DIMC Introduction 2
Adaptation
Training Document TBA/8 DIMC Adaptation 3
This Training Document is intended for
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such. Extended Sterile Air System 4
Note!
For safe and proper procedures, refer to
the equipment specific documentation.

Level Control Spray Unit 5

Name:

................................................................................................................

Peroxide Concentration and Diluting 6

Electrical Configuration of KS40 7

Vision System 8

Troubleshooting the FlexiCap 9

Technical Training Centre

Lund, Sweden
WB-148-01 10
Issue 2/0507
 



 



 

 Information regarding
Safety Regulations at the
Technical Training Centre in Lund
This list summarizes a number of items which may concern you, as a
participant in this training course. Read the list, and if anything re-
mains less than clear, or if you have any questions, feel free to contact
your instructor.

1. Study and follow the sections on Safety in the course literature, for
instance the OM, MM and EM.
2. You are entitled to ask persons who have no business to be near the
machine, to stay at distance, for safety reasons.
3. Never touch any other machines than those used in your own training
course.
4. There may be cables which are still electrically live, although they
have been disconnected from their terminals.
5. In some machines, safety switches may be bridged or disconnected,
for training reasons.
6. Find out exactly where the emergency stop switches for the machine
as well as the conveyor are located.
7. When starting a machine, the person doing the starting must make
absolutely sure that this does not expose anyone else to danger.
8. Certain chemicals, used in your training course, may be hazardous to
your health and constitute a danger of fire or explosion. Make sure
you know how such chemicals are marked and how to handle them.
9. It is strictly prohibited to wear rings, watch, or necktie when working
with the machine. This prohibition also applies to loose-fitting
clothes or anything else that might get caught in the machinery.
10. A first aid kit and stretcher are kept in the machine hall.
11. Study the information on what to do in case of fire and which escape
routes to follow. A diagram of escape and evacuation routes is posted
in every classroom.
12. If you observe or discover anything that might jeopardize safety,
immediately tell your instructor.

Technical Training Centre 1/9701 TM-00001

 Information to Course Participants at
the Technical Training Centre in Lund
Welcome to Technical Training Centre!
Here is some information which might be helpful to you as a
course participant. If you need additional information or help,
feel free to ask your instructor.

Start of course Normally, the first day of your course begins at 08.30. Your instructor will
meet and welcome you in the coffee room.
Daily time schedule
Classes 08.00 - 09.30
Breakfast 09.30 - 10.00
Classes 10.00 - 12.00
Lunch 12.00 - 13.00
Classes 13.00 - 16.00

Your instructor will tell you if there are any changes in the schedule.

Breakfast Breakfast is free of charge and served in the restaurant, where a special area
has been reserved for Technical Training Centre course participants. Breakfast
consists of coffee or tea and bread rolls.
If you want anything in addition, for instance from the serving counters of the
restaurant or cafeteria, you have to pay for it yourself. Your instructor will help
you with the procedure.

Lunch Lunch is served in the restaurant. You can choose among several dishes; men-
us are posted in the restaurant.
If you are a customer course participant, your instructor will give you a cash
card. For participants other than customers, cash cards are for sale in the caf-
eteria. Your instructor will help you with the procedure.

Coffee room You are invited to use the coffee room and the vending machine during all
breaks in classes.

Smoking The entire Tetra Pak plant, outdoors as well as indoors, is a no smoking area.
Smoking is allowed though in special smoking areas.

Telephones If you need to call long-distance within Sweden or abroad, please use the
phone in the telephone room. When using the phone, please be brief, as there
may be others who wish to make calls.

Technical Training Centre 6/1106 TM-00010 1

 Computers There are a number of computers for the use of course participants. The
computers access the Tetra Pak Intranet and the World Wide Web.

ID card On your first day you will receive an ID card. This card must be returned at the
Tetra Pak Main reception at the end of the course. Anyone not handing the
card back will be charged SEK 400.

Safety regulations At the start of the course, your instructor will go through the Safety Regula-
tions (TM-00001). These regulations must be strictly observed. In case you are
uncertain about anything in the regulations, you must have it clarified with
your instructor.

Course evaluation You are requested to write down your comments on the Course Evaluation
form. At the end of the course your instructor will collect all the forms.

Working clothes It is necessary to wear safety shoes in the Technical Training Centre, while
working at the machines. If you didn’t bring your own, safety shoes are for sale
in the Support Centre. Your instructor will take you there. For your use during
the course, you may borrow a set of coveralls.
Each participant is given a locker in the changing-room. The instructor will
hand you the locker key. You may then select a set of coveralls from the cab-
inet in the changing-room. Your instructor will help you if needed.
You may exchange your coveralls for clean ones every Monday morning. Tell
your instructor if you need to change at any other time. Used and soiled cov-
eralls are to be placed in the laundry basket in the changing-room.
At the end of the course you have to empty and lock your locker and return the
key to the instructor. If you wish to retain your locker for a subsequent training
course, tell your instructor.

Valuables You are responsible for your own valuables.

Transport Certain hotels provide free of charge transport to and from Tetra Pak. Ask the
hotel receptionist about this. If you wish to use this service, you must tell the
receptionist the day before.

Medical care For medical care, unless it is an emergency situation, go to Carema Specialist-
vård Lund (Carema healthcare Lund), located in the centre of Lund.

Sport Centre Bookings for the Tetra Pak Sport Centre are free of charge and can be made at
the Main Guard, located next to the Main Reception. If you visit the Sport Cen-
tre, you must enter and leave via the Main Guard.

Technical Training Centre 6/1106 TM-00010 2

 Tetra Pak 1 Main Reception
Part of the plant at 2 Main Guard
Ruben Rausings gata
Lund
3 Technical Training Centre
4 Restaurant
5 Support Centre
6 Sport Centre

1 2
315

305
4 306
313 310
3 101
5 309 311
N
106 6
107

111

Technical Training Centre 6/1106 TM-00010 3

Course Information TC-0057
TBA/8 DIMC Adaptation
Course Content

Course Length z 3 days

Target Group z Tetra Pak Technicians

Previous Knowledge z Participants must have knowledge equivalent to TBA/8

Advanced Maintenance course (former Level II course)
and DIMC Multi 020V.

Course Objectives z To be able to recognize the important differences

between a standard TBA/8 and a DIMC adapted TBA/8.
z To be prepared for what it takes to dock a DIMC Aseptic
unit to an existing TBA/8 on the field.
z To be able to recognize the new components in the sterile
system and to know their functions in the system.
z To be able to set and trouble shoot the new sterile
system to the same extent as on the standard sterile
system.
z To be able to perform maintenance of the diluting
system.
z To be informed about the functions of the option "Vision
System".
z To be able to trouble shoot and set the critical Flexicap
7A related settings, from package integrity and
appearance point of view.

Course- z Introduction to the TBA/8 DIMC Aseptic concept.

Content/Subjects z TBA/8 DIMC adaptation.
z The sterile system.
z Peroxide concentration measures and diluting.
z Design correction update.
z Vision system
z Flexicap aseptic integrity and appearance
 

!" #

 



 

 DIMC Aseptic Project

Verify DIMC technology for aseptic packages:

• Peroxide residues
• Package integrity through distribution
• Machine and package material sterilization
• Oxygen barrier
Other requirements

• Reverse fin kit (1000 slim)

• PLMS
Tetra Pak Carton Ambient
TBA/8 1(4)

No: 5:2/03

Date: February 2003

TECHNICAL BULLETIN
Internal Information

OPTIONAL KIT/EQUIPMENT
DIMC Multi 020V for TBA/8 1528700-0200
Machines affected: TBA/8 100V, 110V
Packages affected: 1000 B, 1000 S

Background
FlexiCap Aseptic has been introduced for use with TBA/8 for white milk applications
and it is now possible to order DIMC for TBA/8 as OE/OK. Please refer to the Product
Release Letter released December 20, 2002, also available on Orbis (Link).
To ensure a successful introduction, a controlled release will be made during 2003,
meaning that only orders for certain markets will be confirmed. A full release is planned
for 2004.

The opening device is FlexiCap STD 7A, where A indicates Aseptic. Caps used for
Chilled applications cannot be used for Aseptic applications.
The plastic material used for FlexiCap A differs from the material used in Chilled
applications. To provide a sufficient light barrier, a small amount of pigment has been
added. The material will be supplied as a premixed compound (not as two components,
as with Chilled applications).
The concept is based on the DIMC Multi 020V Applicator and rebuilding (docking kit)
of the TBA/8.
Note: Release for TBA/8 090V is planned for Q3 2003.

Applicator
The DIMC Multi 020V Applicator is a further development of the DIMC Multi 010V
Applicator, used for TB/8 and TB/21. The major improvements are:
• New Injection system: minimized risk of hydraulic fluid leakage.
• New Hydraulic Unit: improved serviceability.
• Electrical cabinet: the frequency controllers for the extruder motors are now
placed in the electrical cabinet and a cooling unit has been introduced. (similar to
PT/8-020V)
• New Covers: reduced noise level and better access.
• TPOP: new layout and new features to improve the function and operation of the
DIMC.

Issuer: Christer Klein/Ulf Hallesius

Tetra Pak Carton Ambient
DIMC Multi 020V for TBA/8 1528700-0200

DIMC docking kit

• The rebuilding of the TBA/8, in general, follows the path of the packaging
material through the machine to create space for the cap to pass.
• The entire drier is replaced. Hot air is used to remove the excess H2 O2 from the
cap. A blowing system consisting of a fan, pipes and nozzles is included in the
new drier.
• A reverse fin kit is included with the docking kit in order to create enough space
on the top of the package for the FlexiCap A opening.

Prerequisites
For the controlled release, TPCA has defined some prerequisites that must be fulfilled by
the Market Company when introducing FlexiCap Aseptic. These include:
• Appointing a national “technical coordinator” for FlexiCap A.
• Appointing a training responsible (for customer staff).
• Minimum two engineers participating in a special training program for the
FlexiCap A rebuilding and start up (duration two months).
• Upgrading the FlexiCap A lines to a specified minimum level.
• Reporting PLMS, TPMS and spare parts consumption.
• Requesting support from TPCA Field Support for the first rebuilding.
• Using qualified alignment methods to set the TBA/8 properly after rebuilding
(laser in combination with alignment templates).
Further information is available on Orbis (Link), or can be requested from System 8.

Page - 2 -
Tetra Pak Carton Ambient
DIMC Multi 020V for TBA/8 1528700-0200

Publications
OM 1531062-0101 for TBA/8 100V, OM-1531061-0101 for TBA/8 110V
DF-1531063-0101 containing information on preparing and rebuilding the TBA/8
IM-81135-0101 containing information relating to the installation and docking of the
DIMC Applicator
EM-81128-0102 for the DIMC Applicator
MM-81118-0102 for the DIMC Applicator
SPC-81129-0102 for the DIMC Applicator

Accessories

For accurate package checks at the customer’s site, the Opening Force Tester TP No.
2503720-0101 is required. This equipment must be ordered separately from GTS Parts
Supply.

How to order

DIMC as OE/OK should be ordered from Sales Administration Tetra Pak International
SA, Lausanne, Switzerland, via the SAP Ordering system:
http://151.183.2.200/sales/index.htm

OE/OK number 1528700-0200

Document folder No. DF-1531063-0101

Rebuilding time 10 days for 2

Mechanics and 1
Electrician.
NB: not including
general updates of
the TBA/8

Page - 3 -
Tetra Pak Carton Ambient
DIMC Multi 020V for TBA/8 1528700-0200

Technical data, DIMC Multi 020V

Capacity p/h: 6000 Installation time, TBA/8 + DIMC multi
Package size: 1000 S, 1000 3 days for 2 mechanics
B
Installation time, docking kit + DIMC multi
Electricity 10 days for 2 mechanics and 1 electrician
Phase: 3N
Frequency, Hz: 50/60 Rebuilding of TBA/8 (docking kit)
Voltage, V 400/230 Change of programme TBA/8
Main fuse, A: 63 Exchange and alignment of drier, superstructure
Consumption, pre-heating kW: 12.3 Replacement of some rollers in paper path
Consumption, prproduction kW: 14.1 Replacement of parts in jaw system, final folder and
Consumption docking kit TBA/8, kW: 2.5 strip applicator
Installation of kit to monitor and control peroxide
Compressed air concentration
Supply pressure, kPa, (bar): 600-700 (6-7)
Consumption, Nl/min 370 Installation of TBA/8 + DIMC according to drawing
No, 2530370-1
Cooling water
Supply pressure, kPa, (bar): 300-450
(3-4.5)
Max intake temperature, °C (F) 20 (68)
Consumption, l/min 17

Noise level
Incl TBA/8, dB(A) 78.5
According to ISO 4871

FlexiCap material consumption

(preblended compound)
Consumption, kg/h (+-5%) 8.1
Consumption, g/cap 1.35

Page - 4 -
 Mandatory kits DIMC for TBA/8

Winback kits RK No TB
Overload Protection cam kit intoduced 1347400-0101 2:6/98
Paper holder improvment. 1346128-0101 5:11/98
Single piece knives 1347715-0100 5:35/98
Cutting jaw. New Knife holder spring 1285052-0100 5:48/98
Hold-down device. Ball bearing replace bushings 597528-0100 5:21/98
Volume flap springs and stoppers for 1000B 1282642-0100 5:8/97
Volume flap springs 1143615-101 2:2/96

Other kits RK No TB
New TS-Configuration 1369866-0100 5:15/02
New photocells for design correction 2506106-0100 5:6/02
Heat reduction of aseptic chamber *1* 5:23/01
Venting of Aseptic Chamber and C-valve movement *1
Venting of Aseptic Chamber and C-valve... *1
Venting of Aseptic Chamber *1
PLMS upgrade 5.0 *1
PLMS upgrade 5.0 *1
PLMS 090v 2570111-0100 5:32/02
PLMS 100v 2570112-0100 5:32/02
PLMS 110v 2570113-0100 5:32/02
New locking pin and lower filling pipe 1478138-0100 2:4/99
New floating locking pin - 5:3/00
Double-wave formed vol.flaps middle stop 100S 5:3/01
Double-wave formed vol. flapsmiddle stop 100B 5:16/01
New cleaning cup 14787417 5:21/99
New knife holder ASU 5:16/99
1000S New Volume flap stoppers 2:5/99
Cleaning system, nozzle 90424-35, corrective action 2:10/98
Safety discharge for stream taps. 1349022-100 2:3/98
New paper guide introduced. 1346129-0101 5:9/98
Missed splice detector 1346515-0100 5:34/98
Design Control System 8 927477-0103 5:42/98
ASU door, new catches 1347795-0100 5:52/98
New strip guide. 1347803-0100 5:52/98
Volume flap. New shaft screws 5:14/97
TBA/8-090V; Update B-valve 2:13/96
TBA/8-100V; Update B-valve 2:12/96
Reinforcement of Final Folder cover 2:8/96
Safety relay kit. Compulsory program changes. 2:8/94
Updating of Product saftey and Emergency stop chain 2:7/94
TPMC program version: 29 for TBA/8 090V 2:5/94
1000S. 2:3/94
Emergency stop chain 558478-10V 5:2/94
Lime reduction 569402-010 2:1/93
Hold down device. Oil tray for cam roller 5:5/93
Product Safety 572626-010V 5:13/92
*.
*1 Please contact System 8 for further information

Technical Training Centre 1/0504 TM-00825 Training Document. For training purpose only. 1
FlexiCap - Standard 7A

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1437
 Packaging material,
TBA/m and TBA/j

Moisture
or water

Product

Light

Micro
organism

Oxygen

Flavour

Odours

Internal coating 2 Alifoil Paper board Printing

Internal coating 1 Lamination Paper board Outer coating

Technical Training Centre Machine type Issue

Lund, Sweden Tetra Brik Aseptic 1/9501 OH 526
 TBA 1000 S FlexiCap
Package volume
Related Pack. Mat. Drawing: 1134296-x
Size code: 813
Nominal volume (ml) 1000.0
Theoretical crease volume (ml) 1029.0
Underfilling (ml) 29.0
Underfilling (%) 2.8

Web width (mm) 305.0 ± 1

Repeated length (mm) 270.0 ± 0.3
Theoretical LS-Overlap (mm) 8.0

Related documents
Packaging material specification S001
Choice of Packaging material CAPP or
Sales Manual G001
Distribution See ORBIS;
Pallet Pattern

Additional material
Type Quality Consumption/pack Order number

LS strip LHL 7.5x0.1 mm 0.171 g 8891-952-01

8893-952-01
PPP 7.5x0.080 mm 0.131 g 8840-951-01
8842-951-01
FlexiCap White LDPE Preblended Compound 1.35 g to be defined

Issued by: Marcello Barbieri Issue: 1 January 13, 2003 Page: 1.3
Package Data
TBA 1000 S FlexiCap

W
D

Package dimensions
W D H H
Width Depth Height Height with
FlexiCap
(mm) (mm) (mm) (mm)

Crease measurements 90.0 58.5 195.5 -

Package measurements 95.6 61.5 ** 201.7
** Measurements not representative.

Filling machine
(reference filling machine and PullTab unit are the ones used
during the development phase)

Filling machine TBA/8

FlexiCap unit DIMC Multi

Issued by: Marcello Barbieri Issue: 1 January 13, 2003 Page: 2.3
Package Data
TBA 1000 S FlexiCap

Hole dimensions (HOE)

46.4

6.2

18.6
5.33

FlexiCap positioning
B

A = 40.2±0.7
A B = 14.6±1.0

NOTE: All the dimensions referring to creases have to be measured from the centerline of the same crease.

Issued by: Marcello Barbieri Issue: 1 January 13, 2003 Page: 3.3
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Upper platform
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1428
Bending roller
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1427
H2O2 bath entrance
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0308 OH 1440
 DIMC Adaptation
Drier

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1433
Air knife
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1426
Frequency converter
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1435
Environmental gasket
FlexiCap guide

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1424
Cleaning equipment
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1431
 Vision system
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1434
Heat reduction
H2O2 Spray container
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1429
 >
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 Sterile system 24 A 13
72

TBA/8 DIMC
73
22
21
13
23

Lund, Sweden
A4 12 33
11 18 26 31
13
17 25 27
10

Technical Training Centre

20 32 A 11 35

34
A6
14 36
14 29
39
28
15 A5
40 43 Water bath heater
37 44 Peroxide bath temp.
13 13 41

Machine type
19 45 Pressure switch,
30 74 level in water bath
42 46 Venting pipe
16 47 Valve, refilling
5 peroxide
MB18 38 48 Valve, filling
68 peroxide bath
43

TBA/8 DIMC
6 69 A 12 49 Valve, draining
4 peroxide bath
46
50 Safety cap
9 51 Peroxide pump
52 Filter
64 53 Diluting tank
MB 61 44 48
65
54 Peroxide container
67 55 Venting pipe

Issue
56
7 45 diluting tank
49
56 Strainer
3 66 63 57 Lower suction valve

2/0506
2 47
70 58 Preheating valve
62 59 Preset air inlet
60 Air compensation
58
71 61 57 valve
50 52
54 61 Lower filling pipe
62 Upper filling pipe
63 Seal
59 50 64 LS counter roller
1 55
A 10 8 60 51
65 Ejector
66 Pressure relief valve
67 LS short stop element
1 Compressor 10 Silencer 68 LS element
2 Water separator 11 Presterilization temp. 53 69 LS element temp.
3 Level switch 12 Presterilization valve 70 Valve, LS heat

OH 1252:1
4 Vacuum valve 13 Spray nozzle 19 Product valve reduction
5 Sterile air pressure 14 Steam trap 20 Aseptic chamber 24 Air knife temp. 28 Sterilization bath 32 Upper suction valve 35 SA element temp. 40 Valve, filling spray tank/ 71 Scrubber
6 Heat exchanger valve 15 Steam temperature 21 Driven bending roller 25 Level sensor, 29 Water bath temp. (Diversion valve) 36 SA element spraying peroxide 72 Fan
7 Heat exchanger 16 Sterile air valve 22 Air knife peroxide bath 30 Valve, top filling 33 SA pressure− and 37 SA fan 41 Valve, overflow spray 73 Pressure transducer
8 Air superheater temp. 17 Steam barrier valve 23 Squee−gee rollers 26 Seal peroxide bath counter roller 38 Filter tank/compressed air 74 Valve, spraying
9 Air superheater 18 Steam filter and blowing boxes 27 Diaphragm valve 31 Adjustment screw 34 SA short stop element 39 Spray tank 42 Filter blowing system
 Sterile system TBA/8 DIMC

Preheating

Lund, Sweden
Technical Training Centre
Machine type
TBA/8 DIMC
Issue
2/0506
OH 1252:2
Air Steam
Hot air Product Peroxide
Pre−heated air Water Compressed air
alt. cooled air
 Sterile system TBA/8 DIMC

Sterilization 1 − Spraying 1

Lund, Sweden
Technical Training Centre
Machine type
TBA/8 DIMC
Issue
2/0506
OH 1252:3
Air Steam
Hot air Product Peroxide
Pre−heated air Water Compressed air
alt. cooled air
 Sterile system TBA/8 DIMC

Sterilization 1 − Spraying 2

Lund, Sweden
Technical Training Centre
Machine type
TBA/8 DIMC
Issue
2/0506
OH 1252:4
Air Steam
Hot air Product Peroxide
Pre−heated air Water Compressed air
alt. cooled air
 Sterile system TBA/8 DIMC

Production

Lund, Sweden
Technical Training Centre
Machine type
TBA/8 DIMC
Issue
2/0506
OH 1252:5
Air Steam
Hot air Product Peroxide
Pre−heated air Water Compressed air
alt. cooled air
 Sterile system TBA/8 DIMC

Short stop

Lund, Sweden
Technical Training Centre
Machine type
TBA/8 DIMC
Issue
2/0506
OH 1252:6
Air Steam
Hot air Product Peroxide
Pre−heated air Water Compressed air
alt. cooled air
 Start sequence TBA/8
With Heat Reduction Kit

LS

Short Stop
LS

opened
Heat Reduction
Valve
closed

Main Motor

6,5 9,2
9,0 10,0

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0506 OH 1674
 Q
X 

G
J $



 

 Level Relay
Filling spray tank

Lund, Sweden
A1 A1

Technical Training Centre

230V 230V

A2 A2

Machine type
B1 B3 B2 15 16 18 B1 B3 B2 15 16 18

To PLC INPUT To PLC INPUT

L 11 (24 VDC) L 11 (24 VDC)

TBA/8 DIMC Aseptic

Issue
1/0212
OH 1279:1
 Level Relay
Spraying 1

Lund, Sweden
A1 A1

Technical Training Centre

230V 230V

A2 A2

Machine type
B1 B3 B2 15 16 18 B1 B3 B2 15 16 18

To PLC INPUT To PLC INPUT

L 11 (24 VDC) L 11 (24 VDC)

TBA/8 DIMC Aseptic

Issue
1/0212
OH 1279:2
 Level Relay
Spraying 2

Lund, Sweden
A1 A1

Technical Training Centre

230V 230V

A2 A2

Machine type
B1 B3 B2 15 16 18 B1 B3 B2 15 16 18

To PLC INPUT To PLC INPUT

L 11 (24 VDC) L 11 (24 VDC)

TBA/8 DIMC Aseptic

Issue
1/0212
OH 1279:3
   
  
!

A blower system has been added to take away peroxide residue from the flexicap.
The machine sterilisation requires a small amount of peroxide injection (~15ml) in the blowing
system to get the right killing inside the nozzles, how the picture below shows:





 

 

 
A new spray has been installed inside the suction pipe of the blower and connected to a
modified peroxide spray tank according to the following scheme:



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*,, 67 -,, 

5  ,

*,,  67 -
6
,, 

5  ,

*
6
 ,, 67-

,,


 
 6
Peroxid
Concentration and
Diluting

Technical Training Centre

H2O2 Concentration meter
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1430
Temperature regulator
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1432
Concentration meter in peroxide system
DIMC

Water
Peroxide
Compressed air

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 DIMC 2/0504 OH 1441
TECHNICAL DATA Chapter 3

3 - TECHNICAL DATA

3.1 - PERFORMANCE SPECIFICATIONS

Measurement Range : 0…60% p/p H2O2
Scale Amplitude : Minimum 0% p/p H2O2
Maximum 60% p/p H2O2
Accuracy : 0.3% p/p H2O2
Product Temperature : Automatic compensation from -5...+105 °C (23...221 °F).

Line Pressure : -1...10 bar (-14,5...145 psi) at 20 °C (68 °F).

-1.…8 bar (-14,5...116 psi) at 100 °C (212 °F).
Ambient Characteristics : -10...+45 °C (14...113 °F), +5%...+95% RH non-condensing.
Stock Characteristics : -20...+70 °C (-4...158 °F), +5%...+95% RH non-condensing.
****************
Power Supply : AC 18V (12...24V), 50...60Hz, 0.6A.
DC 24V (18...36V), 0.6A.
Interface : • Analog output configurable 0...20mA or 4...20mA on 470Ω.
• Serial output RS422/RS485.
Input/Output : • One line “HOLD” input .
• One n°1 relay output with 24V/500mA-DC/AC load.

3.2 - CONSTRUCTION CHARACTERISTICS

Overall Dimensions : ∅165 (b) x 180 (280) (h) x 130 (w).
Weight : ∼3,3kg (7,28lb)
Protection : IP65 according to EN 60529.
****************
Line Connection : 3” Tri-Clamp.
Light Source : Electronically compensated “LED”.
Prism : Synthetic Sapphire or optical glass.
Measurement Element : 2048 pixel “CCD”.
****************
Command keyboard : Non-scratch Polyester with dome-shaped keys
Visualization : LCD Graphic Display, 128x24 pixels, backlighted
Temperature Sensor : Class “B” AISI 316 st. st. Pt100, per IEC 751.

3.3 - MATERIAL CONTACTING THE PRODUCT

Prism : Optical glass.
Prism Holder : AISI 316 Stainless Steel.
Gaskets : Silicon.

3.4 - CONFORMITY TO DIRECTIVES AND SPECIFICATIONS

LVD : CEE 73/23, 93/68 and following modifications:
EN 61010 1 (1994)
EMC : CEE 89/336, 93/68 and following modifications:
EN 50081-2 (1994); EN 50082-2 (1995); EN 61000-3-2
(1998); EN 61000-3-3 (1995); EN 61000-4-2 (1996); EN
61000-4-3 (1996); EN 61000-4-4 (1996); EN 61000-4-5
(1995); EN 61000-4-6 (1996); EN 61000-4-11 (1995)

Page 3-1 UR-20 Digital Refractometer

WORKING PRINCIPLE Chapter 4

4 - WORKING PRINCIPLE

4.1 - WORKING PRINCIPLE

The working principle of the UR-20 is based on the physical phenomena of total
reflection and refraction of light. It is known that a ray of light that passes from one
medium "A" to another medium "B," each with a different refractive index, does not
proceed in a straight line, but will deflect at the interface of the two media. The extent of
the deflection is a function of the nD (refractive index) of medium "B." The angle at
which the light ray passing through medium "A" strikes the interface is called the "angle
of incidence" and is a fundamental parameter in the study of refraction. This is defined
as the angle formed between the light ray and the axis perpendicular to the interface
plane.

Referring to Figure 4.1.a, the optical section of the digital refractometer includes:
♦ LED light source,
♦ Optical condenser lens,
♦ Image entrance lens,
♦ Measuring prism (medium "A"),
♦ Image exit lens,
♦ CCD assembly for image detection.

Referring to Figure 4.1.a below, if we imagine a series of rays with different angles of
incidence, we notice that, progressing from light source ray 1 to rays 2,3,4 and so on,
we encounter a condition in which the incident ray does not enter medium "B"
(product) but deflects parallel to the surface of the measuring prism (ray 3').
The angle of incidence at which this phenomenon occurs is called the "critical angle,"
and is a characteristic of the two media "A" (measuring prism) and "B" (product).
This value can be computed from the equation:
nDB
 = sin αL
nDA
where αL = the critical angle
Continuing to decrease the angle of incidence beyond the critical angle, upon
reaching medium "B" the rays (1, 2, 3) are reflected as if the surface of medium "B"
were a mirror. The deflection of the incident rays no longer follows the law of
refraction, but rather the law of reflection. That is, the angle of reflection is the same
as the angle of incidence.
If a beam of light rays with different incidence angles reaches the "A/B"
(prism/product) interface, we will observe that those rays with angles of incidence
less than the critical angle will refract and enter medium "B," while those rays having
an angle of incidence greater than the critical angle, as determined by media "A" and
"B," will reflect back into medium "A".
This phenomenon can therefore be used to determine the refractive index of one of
the media. If we consider that the nD of "A" (the measuring prism) ) is a known
constant, and we vary the concentration of medium "B" (the product to be analyzed),
it is possible to calculate the refractive index of the product for any concentration by
simply measuring the critical angle at which reflection first occurs (the reflected ray 3
that is associated with the infinitesimally close incident rays 3 and 3’).

Page 4-1 UR-20 Digital Refractometer

Chapter 4 WORKING PRINCIPLE

Figure 4.1.a - UR-20 Refractometer principle

Referring to the previous formula, if the nD of "A" (the prism) is a constant, we can
conclude that A = K. Therefore:

nDB
 = sin αL nDB = K * sin αL
K

By measuring the critical angle, we can determine the refractive index of the
analyzed product, nD of "B".
In the UR-20 Digital Refractometer, a carefully-selected electronic component
(LED) creates a beam of light which, using a special optical system, passes through
the measurement prism, where it comes into contact with the product to be analyzed.
The interface between the prism and liquid is where the phenomenon of refraction
occurs. The beam of light is split into two parts: one part refracts into the sample,
dispersing, and is absorbed by the product. The other part of the beam reflects at the
product surface as if it were a mirror, following the laws previously described. This
light then falls upon the optical image detection sensor (CCD) inside the instrument.
Analyzing the resulting image of the light beam at this point, one can observe that it is
divided into two parts; one part is bright, while the other part is practically dark. The
position of the separation line between light and shadow is directly proportional to the
refractive index of the product. A very accurate measurement of the position of this
separation line is made using the optical CCD sensor, composed of a series of 2048
individual image sensors (pixels) spaced 14 micron apart.

UR-20 Digital Refractometer Page 4-2

 H2O2 dilution components
• Connections and tap for tapping water from
the filling machine

• Mechanical filter for suspended solids

• Ion-exchange filter for dissolved solids

• Solenoid valve

• Non return valve and connections with

peroxide tank

• Conductivity sensor for checking the filtred

water

Technical Training Centre 1/0307 TM-00564 Training Document. For training purpose only. 1
 Dilution system function
When
• the machine is in production or short-stop

If
• the peroxide concentration is higher than
a specific value (e.g.42%)

And if
• the level in the peroxide tank is too low
due to normal machine consumption

Then
Instead of
• normal refilling with peroxide at 35%
from the peroxide reservoir tank

Put
• pure de-mineralised water from the filter
for restoring default peroxide tank level

Stop
• the machine if concentration reaches 48%

• It’s a slow procedure...

Technical Training Centre 2/0504 TM-00565 Training Document. For training purpose only. 1
Valve panel
DIMC Adaptation

Y29 Y32 Y36 Y33

Standard
RT1

M3
B3 B2
A1

F102
M5

A2 A3
R1 R3
A4 A5

R2
A6 A9 A7

Y29 Y32 Y36 Y33

Modified
RT1

M3
B3 B2
A1
F102

M5

A2 A3
R1 R3
A4 A5

R2
A6 A9 A7

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0309 OH 1442
Ion filter
DIMC Adaptation

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0306 OH 1417
 DIMC Adaptation
Tank connections

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 1/0307 OH 1425
TBA/8 DIMC Diluting System
Water Diluting

Compressed air
Peroxide
Water

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 DIMC 1/0504 OH 1645:1
 TBA/8 DIMC Diluting System
Peroxide Filling

Compressed air
Peroxide
Water

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 DIMC 1/0504 OH 1645:2
 7
Electrical Configuration
Of KS40

Technical Training Centre

 8
Vision System

Technical Training Centre

 Vision System TBA/8 DIMCA

Camera
UV Lamp

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 DIMCA 1/0507 OH 1643
In-Sight Modem

Technical Training Centre Machine type Issue

Lund, Sweden 1/0504 OH 1644
Vision System Program Screen

Technical Training Centre Machine type Issue

Lund, Sweden TBA/8 DIMC 1/0506 OH 1679
 9
Troubleshooting the
FlexiCap

Technical Training Centre

 UNDERSTANDING AND
TROUBLESHOOTING THE
FLEXICAP ASEPTIC

Tetra Pak
Notes:
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Issue:2002/03

Tetra Pak Carton Ambient

Copyright  2002
Tetra Pak Carton Ambient
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 Pak Carton Ambient.
 Table of Contents

Introduction.........................................................1
Overview ..............................................................1
Fault definition ....................................................2

Section 1 Top crease.............................................5

Facts .....................................................................5
Risks .....................................................................5
Delamination ....................................................... 6
Transportation Damage - cracks in the rear .....7
Cap In The Jaws ..................................................8

Section 2 Longitudinal crease .............................9

Facts .....................................................................9
Risks .....................................................................9
Broken Membrane ...............................................10
Poor Characteristics ............................................ 11
Transportation damage - cracks in the front .....12

Section 3 Tools and injection ...............................13

Facts .....................................................................13
Risks .....................................................................15
Tools offset - distance A ......................................16
Tools offset - distance B ......................................17
Tools offset - direction B (cont/d) ........................18
Tools offset - direction B (cont/d) ........................20
Membrane - too thick or too thin ........................21
Overfilled FlexiCap .............................................22
Overfilled FlexiCap (cont/d) ................................23
Underfilled FlexiCap ...........................................25
Tools - function and FlexiCap appearance .........27

Section 4 Hole and Cap positioning ....................29

Facts .....................................................................29
Risks .....................................................................30
Paper inside .........................................................31
Open package ....................................................... 32

Tetra Pak FlexiCap guide

Table of Contents

This page intentionally blank

FlexiCap guide Tetra Pak

 Introduction

OVERVIEW
This guide has been introduced to help Tetra Pak service
personnel and dairy operatives who regularly work with
liquid product filling machines that are producing Tetra
Pak packages with the FlexiCap aseptic opening device.
The guide can be used as a means of familiarizing personnel
with the characteristics of FlexiCaps, providing a greater
understanding of this type of opening.
The main focus of the guide is on the positioning of the
FlexiCap on the packaging material and the relation
between cap positioning and cap faults.
With the ability to identify and diagnose the different types
of faults that can occur and with the knowledge of the
corrective actions needed to resolve problems simply and
quickly, this will undoubtedly lead to a more efficient filling
machine and a more productive dairy.

Tetra Pak FlexiCap guide 1

Introduction

FAULT DEFINITION
FlexiCap faults can be catorgerized into four distinct
groups:
• 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 commonly a result of the
hole and FlexiCap positioning as a combination being
correctly aligned to each other but incorrectly positioned on
the packaging material. Or the result of inaccurately set
moulding tools and/or injection system.
Section 1 of this guide explains the reasons for faults
occurring as a result of the positioning of the FlexiCap and
the punched hole in relation to the Top crease of the
packaging material.
Section 2 of this guide explains the reasons for faults
occurring as a result of the positioning of the FlexiCap and
the punched hole in relation to the Longitudinal crease of
the packaging material.
Section 3 of this guide explains the reasons for faults
occurring as a result of the setting of the moulding tools
and/or injection system.
Section 4 of this guide explains the reasons for faults
occurring as a result of the positioning of the FlexiCap or
punched hole.

2 FlexiCap guide Tetra Pak

 Introduction

FLEXICAP TERMS
1 Lid 7 Tamper evidence 13 Inside sealing area
2 Membrane 8 Punched hole edge 14 Knife
3 Hinge 9 Spider leg 15 Stepped membrane
4 Dog bone 10 Leg 16 Membrane support rib
5 Injection point 11 Membrane support
6 Pull tab 12 Pouring Lip

Tetra Pak FlexiCap guide 3

Introduction

This page intentionally blank

4 FlexiCap guide Tetra Pak

Section 1 Top crease

FACTS
The positioning of the FlexiCap in relation to the top crease
of the packaging material, appears at first glance to be
positioned centrally in the top panel and at equal distances
from both the top fin crease and top crease.
However, the position of the FlexiCap in this direction is
critical to package integrity and during the setting of the
DIMC Multi applicator, the service engineer must achieve
an accuracy of ± 0.2 mm for this setting.
The FlexiCap is actually positioned slightly towards the top
fin crease. See the DIMC Multi maintenance manual,
section 1 Cap and Hole setting for a more detailed look at
the procedure used to achieve the position of the FlexiCap
in this direction.
RISKS
• Delamination
• Transportation damage - cracks in the rear
• Cap in the jaws

Tetra Pak FlexiCap guide 5

Top crease

1. 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. This will occur
when the packaging material is being folded into the
package shape in the filling machines final folder.
ACTION
Check for delamination along the edge of the hole as
indicated in the illustration, figure 1.
To correct this fault, check the position of the punched hole
(distance A) as described in the DIMC Multi Maintenance
Manual, 1-3 Hole position - set. If this distance is correct the
problem is related to the cap forming station. Follow the
procedure to set the FlexiCap position (distance B) as
described in the DIMC Multi Maintenance Manual, 1-7 Cap
forming stations - final set. Also, reduce the amount of
water sprayed on the tube by the tube flushing device and
by the FlexiCap cleaning equipment.

FIGURE 1. Delamination of the edge of the punched hole

6 FlexiCap guide Tetra Pak

 Top crease

2. 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.
Generally this appears as a crack at the rear of the
FlexiCap, see figure 2.
ACTION
To check for cracks in the FlexiCap use the red ink test, as
described in the DIMC Multi Operator Manual, Cap Checks.
To correct this fault, both the punch assemblies and the
moulding tool assemblies must be set. Follow the complete
procedure described in the DIMC Multi maintenance
manual, 1 Cap and hole setting.

FIGURE 2. Transportation damage - crack in the rear

Tetra Pak FlexiCap guide 7

Top crease

3. 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.
ACTION
To correct this fault, both the punch assemblies and the
moulding tool assemblies must be set. Follow the complete
procedure described in the DIMC Multi maintenace
manual, 1 Cap and hole setting.

8 FlexiCap guide Tetra Pak

Section 2 Longitudinal crease

FACTS
The position of the FlexiCap in relation to the longitudinal
crease is critical to package integrity and during the setting
of the DIMC Multi applicator, the service engineer must
achieve an accuracy of ± 0.2 mm for this setting.
When calculating the position of the FlexiCap and the
position of the punched hole, be aware that there is a
difference of 0.5 mm between the position of the upper
longitudinal crease and the longitudinal crease on the
packaging material. Measuring from the longitudinal
crease will result in a false calculation and in an
incorrectly positioned FlexiCap.
RISKS
• Broken membrane
• Poor characteristics
• Transportation damage - cracks in the front

Tetra Pak FlexiCap guide 9

Longitudinal crease

4. 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.
ACTION
To check for a broken membrane, use the red ink test as
described in the DIMC Multi Operator Manual, Cap Checks.
To correct this fault, both the punch assemblies and the
moulding tool assemblies must be set. Follow the complete
procedure described in the DIMC Multi maintenance
manual, 1 Cap and hole setting.

FIGURE 3. Broken membrane

10 FlexiCap guide Tetra Pak

 Longitudinal crease

5. Poor Characteristics
If the FlexiCap is positioned too far in from the longitudinal
crease the quality of product pouring and reclose-ability is
greatly reduced.
Reduced quality of pouring is a result of the FlexiCap being
to far from the package side panel. The FlexiCap has been
designed to be moulded over the edge (longitudinal crease)
and during the design process, it has been acknowledged
that minute changes to the FlexiCap design can have a
dramatic effect on the quality of pouring.
A reduction in the quality of pouring is normally combined
with poor reclose-ability which is also a result of the
package being too far from the package side panel. Without
the support provide by the longitudinal crease the FlexiCap
has a tendency to sink into the top panel when pressure is
applied to reclose the FlexiCap.
As a consequence the tamper evidence will also be badly
positioned and this will lead to a higher occurrence of the
tamper evidence being broken either during package
forming or distribution.
ACTION
To check the FlexiCap open/reclose-ability, see the DIMC
Multi Operator Manual, Cap Checks.
To correct this fault, both the punch assemblies and the
moulding tool assemblies must be set. Follow the complete
procedure described in the DIMC Multi maintenance
manual, 1 Cap and hole setting.

FIGURE 4. Bad pouring

Tetra Pak FlexiCap guide 11

Longitudinal crease

6. Transportation damage - cracks 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.
This is because the edge of the package side panel (longitu-
dinal crease) provides the FlexiCap with a certain amount
of support, 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 5.
ACTION
To check for cracks in the front of the FlexiCap, use the red
ink test as described in the DIMC Multi Operator Manual,
Cap Checks.
To correct this fault, both the punch assemblies and the
moulding tool assemblies must be set. Follow the complete
procedure described in the DIMC Multi maintenance
manual, 1 Cap and hole setting.

FIGURE 5. Crack in the front of the FlexiCap

12 FlexiCap guide Tetra Pak

Section 3 Tools and injection

FACTS
The setting of the moulding tools and the injection system is
as important as the positioning of the FlexiCap and
punched hole in relation to FlexiCap and package integrity.
The setting of the moulding tools by the service engineer
should be performed with extreme attention and a high
degree of precision.
The setting of the injection system temperature zones,
granulate supply and plastic injection can also influence the
attributes of the FlexiCap.
To check the moulding tools, take six packages (two from
each moulding station). Of the two packages from each
moulding station cut one package in the direction illus-
trated in figure 6 and the other package in the direction
illustrated in figure 7.

Tetra Pak FlexiCap guide 13

Tools and injection

PLASTIC
The plastic used to mould the FlexiCaps is a combination of
PE (Polyethylene) which is the main element (95%) and MB
(Master Batch) the colorant (5%) and together they form the
plastic material used to make the FlexiCaps. This plastic
like any other material is affected by heat and if heated for
long periods of time or repeatedly reheated, changes to the
characteristics of the plastic will take place.
These changes normally effect the viscosity of the molten
plastic material, which can then as a consequence result in
underfilled and overfilled FlexiCaps.
After a short stop which exceeds the recommended 15
minutes or if during a maintenance procedure that is
performed with the DIMC Multi unit in preheating or ready
for production, it is recommended to purge this plastic from
the injection system. Placing a piece of packaging material
under the moulding stations and manually injecting each
moulding station will clear this plastic from the system and
avoid the risk of underfilled and overfilled FlexiCaps.
Understanding the properties of the plastic is also useful
when performing FlexiCap tests, as described in the DIMC
Multi Operator Manual.
After the moulding process the FlexiCap cools down over a
period of time. During this time the properties of the plastic
undergo changes and the opening force required to open a
FlexiCap package 10 minutes after production can be
considerably different to a package manufactured two hours
earlier.
The objective is of course to have a FlexiCap which opens
easily, but confusing the results of opening force tests can
result in unnecessary changes to the setting configuration
of the injection system.

14 FlexiCap guide Tetra Pak

 Tools and injection

FIGURE 6. FlexiCap cut to check distance A

Section Y Section X

FIGURE 7. FlexiCap cut to check distance B

RISKS
• Tools offset - distance A
• Tools offset - distance B
• Membrane too thick/thin
• Underfilled FlexiCap
• Overfilled FlexiCap
• Tools Function and FlexiCap appearance

Tetra Pak FlexiCap guide 15

Tools and injection

7. Tools offset - distance A

Distance A as indicated in figure 6 should be equal on both
sides of the FlexiCap. If distance A is not equal, then this is
because the upper and lower moulding tools are not aligned
and the difference in thickness is the result of the moulding
tools being offset.
If the moulding tools have an offset, there is an increased
risk of the FlexiCap having a much poorer reclose-ability
and as a consequence, a reduction in tightness when the
FlexiCap is reclosed.
ACTION
Check distance A as described in the DIMC Multi
maintenance manual 4.1-3 Moulding tool assembly - cap
checks.
To correct this fault, the upper and lower tools must be
aligned. Follow the procedure to align the tools as described
in the DIMC Multi maintenance Manual 4.1-2 Moulding
tool assembly - set.

FIGURE 8. Tools offset in direction A

16 FlexiCap guide Tetra Pak

 Tools and injection

8. Tools offset - distance B

Distance B as indicated in figure 7 should also be equal on
both sides of the FlexiCap. If distance B is not equal then
this is because the upper and lower moulding tools are not
aligned and the difference in thickness is the result of the
tools being offset.
Unlike distance A, this offset can produce a variety of
different FlexiCap faults.
If the offset results in section X being greater than
section Y. A small hole will appear at the back of the
FlexiCap where the membrane starts to turn vertical and
end and where the hinge begins, see figure 9. This is
because, in this situation the upper and lower tools are
extremely close to each other and the plastic injection is
unable to fill this section of the FlexiCap.
ACTION
To correct this fault, the upper and lower tools must be
aligned. Follow the procedure to align the tools as described
in the DIMC Multi maintenance Manual 4.1-2 Moulding
tool assembly - set.

FIGURE 9. Hole in the membrane

Tetra Pak FlexiCap guide 17

Tools and injection

8. Tools offset - direction B (cont/d)

Another consequence of section X being greater than section
Y, is that when the FlexiCap is opened the knife or the pull
tab can break before the membrane. If the knife breaks, it
will continue to tear around the FlexiCap lid, leaving the
membrane intact and still attached to the lower half of the
FlexiCap, see figure 10. If the pull tab breaks, it will tear off
around the sides of the lid see figure 11.
In this situation it is highly likely that the moulding tools
have been in some way accidentally damaged. Either by the
operator closing the moulding tools on the packaging mate-
rial or by the service engineer.
ACTION
To correct this fault, the upper and lower tools must be
aligned. Follow the procedure to align the tools as described
in the DIMC Multi maintenance Manual 4.1-2 Moulding
tool assembly - set. Check the moulding tools for damage
and change if necessary.

FIGURE 10. Broken knife

18 FlexiCap guide Tetra Pak

 Tools and injection

FIGURE 11. Broken pull tab

Tetra Pak FlexiCap guide 19

Tools and injection

8. Tools offset - direction B (cont/d)

If section Y is greater than section X then the FlexiCap
becomes hard to reclose as the knife is oversized and
difficult to push past the pouring lip.
The final risk from having an offset in this direction is to cut
through the foil of the packaging material with the
moulding tools. The moulding tools are designed with a
ridge on the upper tool and a corresponding groove on the
lower tools. This is used to force the packaging material at
the edge of the punched hole in an upward direction, to
counter the effect of the plastic which pushes down on the
packaging material during the plastic injection. If the tools
have an offset then the ridge and the groove act like scissors
cutting through the foil of the packaging material. This
fault is only visible using the red ink test. See figure 12.
ACTION
To correct this fault, the upper and lower tools must be
aligned. Follow the procedure to align the tools as described
in the DIMC Multi maintenance Manual 4.1-2 Moulding
tool assembly - set.

FIGURE 12. Foil cut by the tools offset

20 FlexiCap guide Tetra Pak

 Tools and injection

9. Membrane - too thick or too thin

The thickness of the membrane is not directly measurable
and is not mentioned as a setting in the DIMC Multi
maintenance manual for this reason. Instead the thickness
of the FlexiCap lid is measured as this is a consequence of
the membrane thickness and it is this that is used to gauge
the membrane size.
The membrane size is set by the tools vertical offset which
is created during the moulding tools setting using the tin
wire. See the DIMC Multi maintenance manual, 4.1-2
Moulding tool assembly - set for a more detailed look at the
procedure used to achieve this setting.
If the membrane is too thick (offset to large), then the
FlexiCap is harder to open, as more force is required to tear
through the membrane.
If the membrane is too thin (offset to small), then the risk is
to have the membrane break either in the jaw system as the
tube is grabbed by the folding flaps or during the distribu-
tion of the packages.
ACTION
Set the moulding tools with the tin wire as described in the
DIMC Multi maintenance manual 4.1-2 Moulding tool
assembly - set.

FIGURE 13. Membrane

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Tools and injection

10. 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 4.3-5 Injection system - set
cylinder for more details. The value given in the
maintenance manual is a theoretical value and the correct
amount of plastic needed can only be decided after
producing and testing FlexiCaps.
If too much plastic is injected, splashes of plastic will be
visible around the inside of the FlexiCap, see figure 14.
ACTION
Set the stroke of the injection cylinder, see the DIMC Multi
maintenance manual 4.3-5 Injection system - set cylinder.

FIGURE 14. Overfilled FlexiCap with plastic splashes

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 Tools and injection

10. Overfilled FlexiCap (cont/d)

When the DIMC Multi unit is first started after a period on
non-use, 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.
To avoid producing overfilled FlexiCaps after a period of
non-use or a short stop of more than 15 minutes, always
perform a manual injection on all three moulding stations
to purge the injection system of the plastic.
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 or other
object trapped between the two halves of the lower tools.
This prevents the two halves of the lower tools closing
completely. see figure 15 and 16.
ACTION
Remove any objects from between the lower tools and pro-
duce more FlexiCaps for checking.

FIGURE 15. FlexiCap with fin

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Tools and injection

FIGURE 16. FlexiCap with fin

11. Underfilled FlexiCap

Underfilled FlexiCaps can be the result of a variety of
circumstances. If the injection cylinder is incorrectly set,
the wrong amount of plastic will be injected into the mould-
ing tools and the result can be an underfilled FlexiCap, see
figure 17.
FlexiCaps can also be underfilled for a similar reason to
that of overfilled FlexiCaps. After a period of non-use or
after a short stop longer than 15 minutes, changes in the
characteristics of the plastic can result in viscous (thicker)
plastic surrounding the tip of the injection needle. This
prevents the injection needle from fully injecting the correct
amount of plastic and the result can be an underfilled
FlexiCap.
Always perform a manual injection on all three moulding
stations to purge the injection system of the plastic after the
DIMC Multi unit has been stopped for a period of time
longer than 15 minutes.
ACTION
Set the injection system, see the DIMC Multi maintenance
manual 4.3-5 Injection system - set injection cylinder.
Produce and test the FlexiCaps to determine the correct
amount of plastic needed.

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 Tools and injection

Check the spacer fitted above the injection needle. If its not
possible to freely move this spacer when the injection needle
is in the retracted position, then there is most likely viscous
(thicker) plastic blocking the needle tip. Remove the injec-
tion needle, see the DIMC Multi maintenance manual 4.3-1
Injection system - change needle and clean/scrape away the
excess plastic.

FIGURE 17. Underfilled FlexiCap

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Tools and injection

12. Tools - function and FlexiCap appearance

Watch and check the appearance of the FlexiCaps
immediately as the moulding tools are opening. The
FlexiCap should be stable, correctly formed, symmetrical
and parallel with the packaging material.
If the FlexiCap is not released from the tools smoothly,
there is a risk that the tamper evidence may be broken. The
tamper evidence is an elaborate part of the FlexiCap design,
which can easily remain caught in the lower tools.
ACTION
After each of the following, produce more FlexiCaps and
check the appearance of the FlexiCaps as the moulding
tools open.
Verify the cooling water flow setting, see the DIMC Multi
maintenanace manual 6-2 Cooling system - check coolant
flow. Check the cooling temperature and decrease by a
small amount either by means of the display on the cooling
unit or the PLC. Decrease the plastic temperature on the
injection zones 4 and 5, see the DIMC Multi maintenanace
manual 9.7-2 Control program - set temperatures. Decrease
the amount of plastic being injected. Change the moulding
tools. If none of the above have a positive effect on the
FlexiCap appearance, check the alignment of the packaging
material.

FIGURE 18. Open tools

26 FlexiCap guide Tetra Pak

Section 4 Hole and Cap positioning

FACTS
The setting of the moulding stations for the positioning of
the Flexicap and the setting of the punch units for the posi-
tioning of the hole are an important settings in relation to
FlexiCap and package integrity.
These setting sequences should be carried out with the
utmost of attention and detail. For a more detailed look at
the procedure used to set the position of the moulding
stations and the punch stations, see the DIMC Multi
maintenance manual 1 Cap and Hole setting.
To check the FlexiCap and punched hole positions, take six
packages (two from each moulding station). Of the two
packages from each moulding station cut one package in the
direction illustrated in figure 19 and the other package in
the direction illustrated in figure 20
Distance A (figure 19) and distance B (figure 20) should
always be equal on both sides of the FlexiCap.

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Hole and Cap positioning

FIGURE 19. Package cut to measure Distance A

FIGURE 20. Package cut to measure Distance B

RISKS
• Paper inside
• Open package

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 Hole and Cap positioning

13. Paper inside

If distance A is not equal, there is a risk of the packaging
material being visible inside the package, see figure 21.
This is because the overlap of the FlexiCap is positioned too
far over to one side of the punched hole and the tools are
moulding the FlexiCap over the packaging material.
ACTION
To correct this fault, first check the position of the punched
hole as described in the DIMC Multi Maintenance Manual,
1-3 Hole position - set. Then follow the procedure to set the
FlexiCap position as described in the DIMC Multi Mainte-
nance Manual, 1-7 Cap forming stations - final set.

FIGURE 21. Paper inside the package

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Hole and Cap positioning

14. Open package

Another consequence of distance A not being equal, is to
have a hole or gap at one side of the FlexiCap. Again this is
due to the Flexicap or hole positioning being to far over to
one side. This is an extremely rare occurrence and if left will
more than likely result in damage to the moulding tools.
ACTION
Check the position of the punched hole as described in the
DIMC Multi Maintenance Manual, 1-3 Hole position - set.
Then follow the procedure to set the FlexiCap position as
described in the DIMC Multi Maintenance Manual, 1-7 Cap
forming stations - final set.

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