There's no need to halt production in order to refill with packaging material or strips since both are replaced automatically. Automation also ensures that splices between packaging material reels and strip applications are of consistent, repeatable quality.
The flow of sterile air needed to maintain aseptic conditions is fully controlled in a closed loop, and designed to auto-correct if deviations occur. The smallness of the aseptic zone leads to savings in the consumption of both power and peroxide.
A peroxide bath, as opposed to a spray system, sterilises the packaging material inside and out. A special thermal carpet keeps the peroxide bath at the optimum sterilisation temperature.
Using servo-motors, the jaw system profile is created in a software model rather than mechanically. This facilitates rapid conversion between different kinds of package production. Profiles are optimised to give better looking packages; printed package designs are synchronised to reduce waste.
Packages are released from the machine in an upright position, which simplifies the production process and increases reliability. Servo-motors accelerate the final folding process to give a good package shape and high capacity. They also enable the production flexibility offered by QuickChange and Volume Conversion functions.
As the filling machine is an integrated part of the line it communicates with all the other line equipment. Sterilisation, filling and sealing processes are continuously controlled, increasing the output of 'on-target' packages. This feature also enables selectable capacity for compatibility with existing processing or downstream equipment.
Several factors contribute to the easy operation of this filling machine: the Tetra Pak Operator Panel with its intuitive touch screen interface; large windows through which operators can observe production at first hand, and ground level access to essential working parts.
The PLMS centre automatically collects production data from the automation platform. To this, the operator can add his own observations. Improvements in production efficiency can then be made on the basis of the two.
The module consists of four parts that need to be changed by the filling machine operator. After this has been done, the machine automatically adjusts by applying the servo motor programme for the new volume chosen. Within 20 minutes, the machine can be ready to start production again.
The PullTab Unit punches a hole in the packaging material then applies an Inner PE-Strip and an outer Aluminium Tab (which is later used for opening the package). The opening is hermetically sealed before the packaging material proceeds to forming and filling.
The unit consists of a control cabinet, a heating element to sterilize air (or an inert gas) and a nozzle which injects the sterile air (or inert gas) to the product to create froth. When the froth settles down, it leaves a residual headspace which enables the content to be shaken and mixed. Using this method, products can be filled by weight so the choice of volumes is wider
This is made possible by a synchronous aseptic positive pump which is controlled by the double loop filling control system of the Tetra Pak A3/Compact Flex filling machine. The unit can be connected or disconnected as needed, so producers can alternate easily between viscous and other kinds of products.
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