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Package Integrity

Book of CompetenceBoC

Doc. No. BoC-2712261-0101

WARNINGThis document may not be copied, transferred, or modified without the prior written consent of Tetra Pak Carton Ambient S.p.A.

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Copyright © 2004 Tetra Pak Group

All rights reserved. No part of this document may be reproduced or copied in any form or by any means without written permission from Tetra Pak Carton Ambient

and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.

This document was produced by:

Sara Davolio and Monica MalagoliTetra Pak Carton Ambient Via Delfini 1 41100 MODENA Italy

Additional copies can be requested to the authors or downloaded from the TPCA Package Integrity webpage. When ordering additional copies, always provide the document number. It is printed on the front cover and in the footer on each page of the manual.

Doc. No. BoC-2712261-0101

Issue 2004-11

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BoCBook of Competence

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Package Integrity

Issue 2004-11

Doc. No. BoC-2712261-0101

Tetra Pak Carton Ambient

i Introduction

ii Safety Precautions

iii Getting to know the Package

1 Transversal Seal (TS)

2 Longitudinal Seal (LS/SA)

3 Opening Devices

4 Package Integrity

5 Package Forming

Appendix A: Flowcharts and Troubleshooting

Appendix B: Tools and Chemicals

Appendix C: Data Record

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ForewordThis Book of Competence - Package Integrity is based on the state of the art spread in the Company on Package Integrity Competence.

Major inputs have been received from FiSQA and System Specialists. Among the contributions, a special thanks goes to Kevin, Reinhard Shigeru Okada and Hitoshi Matsumoto for constant inputs and support.

Sara Davolio Monica Malagoli

November 2004

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This chapter contains basic information about this manual.

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Personnel Requirements . . . . . . . . . . . . . . . . . . . i - 5Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . i - 5

Specialized Personnel . . . . . . . . . . . . . . . . . . . . . . . i - 5

How to use this book . . . . . . . . . . . . . . . . . . . . . . i - 6Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8

A: General Information. . . . . . . . . . . . . . . . . . . . . . . . . . i - 8

B: Procedures, Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8

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

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

Reference documents . . . . . . . . . . . . . . . . . . . . . i - 11

Manual Information . . . . . . . . . . . . . . . . . . . . . . . i - 12Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 12

Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13Typographical Conventions . . . . . . . . . . . . . . . . . i - 13Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13

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i Introduction Personnel Requirements

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Personnel RequirementsNote!Personnel includes all persons working with Package Integrity methods and Equipment.

The methods described in this Book of Competence must be performed by qualified or specialised personnel. The level of expertise required is mentioned at the beginning of each method. Training is available at TTC.

Qualified PersonnelQualified means that personnel have received specific training on Package Integrity QC Methods. This level of education is required in most of the methods.

Specialized PersonnelSpecialized personnel are chemists, laboratory technicians which have a professional knowledge of reagents and laboratory techniques. This level of education is required for methods which imply the use of chemicals and solvents.

FiSQA officers and Technical Service Specialists are considered specialized personnel once specific training has been taken.

CAUTIONAlways handle the chemicals carefully and wear protective goggles and gloves. Dispose of chemicals in the manner prescribed by current regulations.

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How to use this bookPurposeThis book is mainly addressed to:• FiSQA Officers• Technical Instructors• System Specialists• Senior Tetra Pak Field Service Engineers• Senior Technical Support Staff.

The aim is to give clear instructions on how to evaluate the integrity of the TPCA packages.

TPCA packages contain and protect the packed product from filling to recommended consumption, at ambient temperature.

A package showing product spills is easy to detect. Less visible defects that jeopardise the protective function of the package can be detected following the correct procedures described in this manual. Package Integrity Quality Methods are systematic, precise and destructive. Samples are no longer available after evaluation, hence the importance of performing them correctly.

Package Integrity Methods must be performed on regular basis during and after Production, to monitor the quality of the packages and the performance of the filling machines. Specific checks must be carried out for special products (e.g. products with fibres) and opening devices (PullTab, FlexiCap).

A defect in the package microbiological barrier does not necessarily imply a microbiological problem, since the following conditions must take place in addition:

• presence of microorganisms in the package surrounding;• favourable environmental conditions;• period of time in which they grow and spoil the product.

On the other hand, when visible integrity problems such as leakage during transportation or package blowing occur, we are sure that the package is defective, and that the packages close to it might be affected by the same defect. In this case, a troubleshooting procedure is needed to investigate the causes of the proven unsterility.

Package Integrity Methods can be grouped into a limited number of procedures as follows, according to the kind of investigation needed.

The Appendix A: Flowcharts and Troubleshooting section includes a step by step description of each procedure.

(Cont'd)

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QC checks during ProductionThese are checks carried out by the operator during production. They are aimed at evaluating the appearance of the package (shape and design, flap sealing, surfaces), the fulfilment of legal requirements (date printing, weight) and the quality of the package sealing (Tranversal Sealing and Longitudinal Sealing tear down). The machine settings (temperatures, pressures, weight and design control settings) can be corrected accordingly, in order to ensure a good production.

Note!This book does not include instructions reported on OM, MM manuals and TTC brochures, such as machine setting procedures or volume dependent values. Refer to these manuals to integrate this kind of information.Laboratory QC checks after ProductionThese checks must be carried out on a regular basis by qualified personnel, in an area appropriately equipped. They are destructive, and imply the use of chemicals or specific laboratory tools. The data are analyzed statistically, in order to evaluate the incidence of defective packages in a population.

Testing products with fibresProducts containing more than 5% of citrus fibres can compromise the integrity of the TS as fibres can be trapped in the sealing creating channels to the outside of the package. A specific procedure must be followed to investigate the performance of the product.

TroubleshootingWhen a production proves defective due to leakages or package blowing, the causes of the unsterility must be investigated. In this case, the analysis is not statistical, but aims at identifying the origin of specific defects. The samples must be prepared so that the package is not cut apart but analyzed as a whole to be able to see if package integrity is the reason for the unsterility.

It is advisable to test a tray of packages where one or more samples are suspected to be defective, so that the overall behaviour of the Production can be assessed.

The test methods are applied in a defined sequence aiming to get an unequivocal answer if package integrity is the main cause for the unsterility in terms of:• Loss of microbiological barrier (corners, K-cracks, fin tears)• PullTab• Longitudinal Sealing• Trasversal Sealing

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StructureThe content of this book is divided into three main groups. They are described below.

B

A

C

1 Transversal Seal (TS) tests(MTD 1201 - 1208 - 1211)

Flowcharts and troubleshooting


A: General InformationThese chapters provide general information, important safety information, and overview of packaging material, strips and package terminology.

These chapters include:• Introduction• Safety Precautions• Getting to know the package.

B: Procedures, TestsThese chapters provide a sequence of instructions for the tests to be performed on the package.

These chapters include:• Transversal Seal• Longitudinal Seal• Opening Devices• Package Integrity• Package Forming.

C: Appendix, additional materialThese chapters provide information about additional material used to carry out the tests and record the results.

These chapters include:• Flowcharts and troubleshooting• Tools and Chemicals• Data recording sheets.

i Introduction iii Getting to know the package

2 Longitudinal Seal (LS/SA) test(MTD 1202)

3 Opening Devices test(MTD 1211)

4 Package Integrity tests(MTD 1203 - 1204 - 1207)

5 Package Forming tests(OM as a reference)

Tools and Chemicals

Data recording sheets

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i Introduction Abbreviations and Terminology

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Abbreviations and Terminology

(Cont'd)

Abbreviation Meaning/Definition NotesAl-foil Aluminium foilAmmeter Instrument measuring electric

current in amperesASU Automatic Splicing UnitB Base (package shape)Blocked Seal Cold SealDE Distribution EquipmentDIMC Direct Injection Moulding Cap Technique used in FlexiCap

applicationFiSQA Field Service Quality AssuranceFlexiCap Flexible Cap It uses DIMC technologyHDPE High Density PolyethyleneIH Induction HeatingLLDPE Linear Low Density PolyethyleneLH Left HandLS Longitudinal Sealingmax Maximummin MinimumMM Maintenance ManualmPE LLDPE syntetized by metallocene

catalyst processMTD MethodOK Optional KitOE Optional EquipmentOM Operation ManualPE PolyethylenePlastic Lumps Hard residue of plastic that

hardens out of the TS sealing area. They might be referred as “walling” (USA terminology)

PLH Pre Laminated HolePM Packaging MaterialPT PullTabQA Quality AssuranceQC Quality ControlRH Right HandS Slim (package shape)SA Strip Applicator

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SM Sealing MonitoringSq Square (package shape)TBA Tetra Brik AsepticTCA Tetra Classic AsepticTFA Tetra Fino AsepticTPA Tetra Prisma AsepticTPCA Tetra Pak Carton AmbientTPCC Tetra Pak Carton ChilledTPIH Tetra Pak Induction HeatingTS Transversal SealingTTC Technical Training CentreTWA Tetra Wedge Aseptic

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i Introduction Reference documents

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Reference documentsRefer to the following other documents:

• OM pecularities of the filling machine• TTC Package Integrity Compact Disk

CD-00002-01• TTC TS evaluation brochure 1991

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Manual InformationPage LayoutEvery main page in this manual contains a header and a footer. The page header contains the section name (1) and the chapter name (2). The page footer contains the manual’s document number (3), and the page number (4). See also the section Page Numbering.

1.2 Transversal Seal - Evaluation by tearing (P 1201)

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Prepare samples for TS accurate check1Cut off the top and bottom of the packages at a distance of about 25-30 mm from the top and bottom creases.

Rinse the samples and dry them with compressed air.

2Cut off 1 mm maximum from the edges.

21

341 Section name2 Chapter name3 Document number4 Page number

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i Introduction Manual Information

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Page NumberingA page number has three parts:• chapter number (1)• consecutive page number (2) within the chapter• total number of pages (3) in the chapter.

Typographical ConventionsCross-references are underlined.

SymbolsThe following symbols are used in illustrations:• A pointer arrow (1) indicates the position of an object• A zoom arrow (2) indicates that an object view is enlarged. The arrow

points towards the enlarged view of the object• A rotation movement arrow (3) indicates rotational movement of an

object. The arrow points in the direction of rotation• A straight movement arrow (4) indicates movement of an object.

The arrow points in the direction of movement

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1 32

1 Chapter number2 Consecutive page number3 Total number of pages

1 2 3

4 5

1 Pointer arrow2 Zoom arrow3 Rotation movement arrow4 Straight movement arrow

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Safety Messages Description ii Safety Precautions

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Safety Messages DescriptionA safety message is always accompanied by a safety alert symbol and a signal word.

This is the safety alert symbol. It is used to alert about potential personal injury hazards. To avoid hazards, obey all safety messages that follow this symbol.

The following safety alert symbols and signal words are used in this manual to inform the user of hazards.

WARNINGWarning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONCaution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.CAUTIONCaution without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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This chapter contains basic information on how a TPCA package is sealed and formed; which are the major differences on packaging materials, and where the defects are located.

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Aseptic Packaging. . . . . . . . . . . . . . . . . . . . . . . . iii - 5

Packaging Material . . . . . . . . . . . . . . . . . . . . . . . iii - 6Packaging Material Layers . . . . . . . . . . . . . . . . . . iii - 7

Guidelines for the choice of Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii - 9Packaging Material Reel . . . . . . . . . . . . . . . . . . . iii - 10

Pre-Laminated Hole . . . . . . . . . . . . . . . . . . . . . . . iii - 11

Package Terminology . . . . . . . . . . . . . . . . . . . . iii - 12

Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii - 14LS Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii - 14PT Strips (Tab, Patch, Outer Patch) . . . . . . . . . . iii - 15

Identification of package defects . . . . . . . . . . . iii - 16

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iii Getting to know the Package Aseptic Packaging

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Aseptic PackagingAseptic packaging prevents microbes and bacteria from getting in once the package is closed. Obviously, this is a great advantage for foods and drinks. For packaged foods and drinks to be completely free from infection, the product itself must also be sterile. In other words the following conditions must be achieved:• Sterile product: The product itself must be sterile. • Sterile product supply: The equipment delivering the product to the

filling machine must be sterile.• Sterile packaging material: The packaging material must be sterile

when it comes in contact with the product.• Sterile filling environment: The part of the filling machine where

package filling actually takes place must be sterile.• Aseptic packages: Packages must be tight, so that microbes and bacteria

cannot get in from the outside.

The diagram below illustrates the aseptic packaging process.

Sterile packaging

material

Sterile product

Sterile product supply

Sterilefilling

environment

Aseptic package

This is taken care of by the filling machine.

This is taken care of by the processing equipment in the factory.

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Packaging MaterialThe packaging material protects the product inside the package from the environment outside.

It also needs to be firm enough to give the package a good shape.This is essential for transport and handling. The packaging material is also printed with information about the contents of the package.

The packaging material used in the filling machines is a very special laminate material. “Laminate” means that the material is made up of several different layers. Though different products may require slightly different packaging materials, all TPCA Packaging Materials are “laminate”.

When the packaging material is shaped into packages it is folded along pre-formed creases. The heavy gray lines in the drawing to the right show the crease pattern for one package.

TBA package is shown

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Packaging Material LayersThe packaging material used is multilayer. The different combination of layers determines the type of material.

All of the packaging materials contain a paperboard layer (2), an Al-foil layer (4) and a variable number of plastic based (usually LDPE or me-PE) layers.

The paperboard gives stability to the package and allows printing of the design and data.

The Al-foil acts as a barrier against aroma, oxygen and light. It also protects the flavour of the product and it is used to seal, by induction heating, layers (3), (1).

The polyethylene (LDPE, m PE) allows the adhesion of the different materials, seals in the liquid and protects the package from external moisture.

The package microbiological barrier is composed by layers (6), (5), (4), (3).

(Cont'd)

1. Outside plastic layer/Decor layerProtects the package against external humidity. Also allows sealing of the package (Flaps and Overlap).

2. Paperboard and printingStrengthens the package and offers a good printing surface.

3. LaminationA plastic layer which allows the paperboard to stick to the al-foil.

4. Al-foilProtects the product against oxygen and light.

5. Internal coatingA coating that offers adhesion between the al-foil and the inside plastic layer.

6. Inside plastic layerPrevents the liquid contents from soaking into the material. Also allows sealing of the package (SA, LS, TS).

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The picture below describes what type of effects the different layers in the Packaging material protect against.

7

6

5

4

2

3

1

Light, Aroma, Oxygen

Inner Sealing External

moisture

Package Stability

Microbiological barrier

1 Outer coating2 Paperboard3 Lamination4 Al-foil5 Internal Coating 16 Internal Coating 27 Product

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Guidelines for the choice of Packaging MaterialThis is an extract from the Carton Ambient Product Portfolio booklet (FDM 11th edition).

Please refer to it for any official info about Filling and Distribution Machines, Packaging Material and Strips.

(1) The use of --/lk materials is equivalent to --/jk, --/tk and --/wk materials. (2) MPM and MSE to improve the strip sealability. MPM strip does not impart higher barrier properties than PPP, such as MSE has the same barrier properties as LSE. (3) According to the specific formulation per each different product. (4) The use of --/j material for packing wine and alcoholic drinks <20% is approved. The --/w material production will be discontinued.

Product type --/m --/j --/aqk --/ok--/olk

--/lk(1) LS strips

Plain milk, sweetened milk

x PPP (or MPM (2))

Flavoured milk Recombined milk

x PPP (or MPM (2))

UHT Cream and non-dairy milk

x PPP (or MPM (2))

Coconut drinks, soy bean drinks, rice drinks

x PPP (or MPM (2))

Formulated tomato x PPP (or MPM (2))Fruit and vegetable juices and drinks

x PPP (or MPM (2))

Teas and coffees x PPP (or MPM (2))Wine x(4) Wine

Alcohol drinks <20 % x(4) Wine

Alcohol drinks >20 % x Wine

Dressing x PPP (or MPM (2))Soups and Sauces x PPP (or MPM (2))/

LSE (or MSE)Oil x PPP (or MPM (2))Vinegar products max.1.0% acetic acid

x PPP (or MPM (2))

Products for hot-vending machines

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

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

Special dietetic products x PPP (or MPM (2))Water x PPP (or MPM (2))Flavoured water x PPP (or MPM (2))

iii - 9 (16)Doc. No. BoC-2712261-0101


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Packaging Material ReelA label indicating packaging material type (i.d. TBA/m, TBA/j, TBA/jl, TBA/lk) and Production Order is attached to each reel. Always keep the label and quote the data when performing package integrity tests.

� ��

12345678910 11121314151617181920

REEL NoVOLUME

TYPE

QUANTITY PROD DATE

ID No

CUST No

TP ORDER TP PRODUCT

Tetra Pak Carton Ambient S.p.AVia Delphini 1MODENA

Photocell TBA/J FCD

Tetra PakD00-0000-01P202-0123456

123-4567

123456789

TBA/J

1000 ml 01-0001

7500 25-MAY-2008

3

2

45678

9

10 11

1

1 Customer address2 Tetra Pak product code3 Tetra Pak Production Order number4 Customer code5 Identification number6 Type of Packaging Material7 Volume of package8 Quantity of packages on the reel9 Reel number

10 Date of Production11 Bar code containing parts of the above

information

iii - 10 (16) Doc. No. BoC-2712261-0101

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Pre-Laminated HoleThe Pre-Laminated Hole is presently used for packages with Post-applied Caps. The hole is punched and laminated during converting. The cap is applied after product filling and package leaving the Filling Machine.

Note!The PLH does not require dedicated package evaluation procedures for Package Integrity tests (as for PullTab and FlexiCap).

2 1

inside of package

outside of package

456 3

Pre-Laminated Hole

Post-applied cap

1 Outside plastic layer (decor layer)2 Paperboard3 Laminate layer4 Alu-foil5 Inner layer 16 Inner layer 2

iii - 11 (16)Doc. No. BoC-2712261-0101

Package Terminology iii Getting to know the Package

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Package Terminology• Longitudinal creases, top creases and bottom creases: These are the

pre-formed folds in the packaging material. They give the package its final squared form.

• Top fin and bottom fin.: These are the top and bottom areas of the package where it is sealed and cut.

• Transversal seal (TS): Seals the package at the top and bottom.

(Cont'd)

Longitudinal sealing

Top fin

Transversal seal (TS)

Bottom fin

Transversal seal (TS)

Top longitudinal creases

Top longitudinal creases

iii - 12 (16) Doc. No. BoC-2712261-0101

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(Cont'd)

• Longitudinal seal (LS): Seals the package along the long side.• LS strip: A strip of laminated plastic applied on the inside of the

longitudinal seal. Prevents the product from soaking into the edge of the packaging material.

• LS overlap: The area over which the two edges of packaging material overlap down the long side of the package. Ensures that the longitudinal seal is rigid and does not leak.

• Top and bottom flaps: The corners of the package that are folded and sealed to the package body.

inside of package

outside of package

LS stripLongitudinal seal (LS)

LS overlap

LS strip

Bottom flap

Bottom flap

Top flap

Top flap

Bottom crease

Top creases

iii - 13 (16)Doc. No. BoC-2712261-0101

Strips iii Getting to know the Package

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StripsLS StripThe LS strip has the following tasks:• it prevents liquid from being absorbed by the packaging material edge;• it prevents micro-organisms which could be present on the packaging

material edge from contaminating the product;• it creates a gas barrier in the longitudinal seal which prevents both

aromatic substances from escaping through the seal and air (oxygen) from penetrating and affecting the product;

• it reinforces the longitudinal seal.

LS strips are formed by different layers and have different utilisation depending of the product and package type. Here below some examples:

(Cont'd)

LDPE

HDPE

LHL PPP/PPPw

LSE MPM

LDPE

LDPE

Primer

PET

EVOH

Primer

Primer

Primer

LDPE

Primer

PET

Primer

mLLDPELDPE

LDPEmLLDPE

LDPE

LDPE

MilkJuice / Wine

Special products

TBA/jl (TBA Wide)

iii - 14 (16) Doc. No. BoC-2712261-0101

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(Cont'd)

A label identifying strip type (i.d. PPP, MPM) and lot number is attached to every strip reel. Take note of these data and quote them when performing package integrity tests.

PT Strips (Tab, Patch, Outer Patch)A label identifying strip type and lot number is attached to every strip box. Take note of these data and quote them when performing package integrity tests.

PPP-STRIPS7,5/0,075

449732:16:3lot number

PEP-STRIP29/0,050

12345678910 11121314151617181920

ART. NO

1234-123USE BEFORE DATE

12341212

LOT NO. REELS

PALLET - BOX NO.

NET WEIGHT KG

123456 10 123456123456

UNIFIED TAB STRIP

12345678910 11121314151617181920

1234-123

Quantity� 1234 m�Lot. No.� 123345678�Prod. date � 1234-12-12 Use before: 1234-12-12

iii - 15 (16)Doc. No. BoC-2712261-0101

Identification of package defects iii Getting to know the Package

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Identification of package defectsThe following table summarizes the defect location on the package and which MTD has to be followed to identify them:

Pos Defect location Defect name MTD1 LS - not sealed

- blisters- channels

1202

2 Corners - red ink leakage 1203 - 12043 TS - channel / blocking

- plastic lumps- overheating- Af-foil TS crack- fibres trapped in TS

1201 (Production)1208 (QC, Troubleshooting)1210

4 TS/LS cross - channels- plastic lumps

1208 (QC)1201 (Production)

5 PullTab / Opening - red ink leakage 12116 Fin - top fin tearing

- bottom fin tear (TWA only)1204

7 Bottom flap - k-cracks leakage 1203 - 1204

2

1

34

5

7 inside of package

6

iii - 16 (16) Doc. No. BoC-2712261-0101

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1 - 1 (42)Doc. No. BoC-2712261-0101

Methods: 1 Transversal Seal (TS)

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Methods:MTD 1201 - Transversal Seal Tearing PersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.

Tools and ChemicalsRefer to section B.2 Tools and Equipment, page Appendix-6 for details on the tools used.

Reference Documents• Previous version, MTD 1201, issued by Sara Davolio, 1996/02/27.• TTC TS evaluation brochure 1991.

MTD 1208 - Transversal Seal Dissolving and Red InkPersonnelThis method must be performed by Specialized personnel. Refer to section Personnel Requirements, page i-5 for details.


Reference DocumentsPrevious version, MTD 1208 issued by Sara Davolio, 1996/11/19.

MTD 1210 - Transversal Seal Al-foil cracksPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.

ToolsRefer to section B.2 Tools and Equipment, page Appendix-6 for details on the tools used.

Reference DocumentsPrevious version, MTD 1210, issued by Sara Davolio, date 1996/02/29.

1 - 2 (42) Doc. No. BoC-2712261-0101

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1.1 Transversal Seal - General information. . . . . . . 1 - 5

1.2 Transversal Seal - Tearing (MTD 1201) . . . . . . . 1 - 71.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

1.2.2 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 81.2.3 Preparation of the Samples. . . . . . . . . . . . . . . . . . 1 - 91.2.4 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

1.2.5 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 13

1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 161.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 161.3.2 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 171.3.3 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 19

1.3.3-1 Cut packages . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19

1.3.3-2 Dissolving of packages . . . . . . . . . . . . . . . . . . . 1 - 22

1.3.3-3 Drying the samples . . . . . . . . . . . . . . . . . . . . . . 1 - 29

1.3.3-4 Red Ink Tightness . . . . . . . . . . . . . . . . . . . . . . . . 1 - 30


1.4 Transversal Seal - Al-Foil Cracks (MTD 1210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 371.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 371.4.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 38

1.4.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 391.4.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 40

1 - 3 (42)Doc. No. BoC-2712261-0101

Table of Contents

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1 Transversal Seal (TS) 1.1 Transversal Seal - General information

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1.1 Transversal Seal - General informationThe Transversal Seal is formed in the jaw system by two jaws working in pairs (e.g. Tetra Pak A3/Flex and TBA/21) or in 10 jaws linked in chain working in pairs (e.g. Tetra Pak A3/Speed and TBA/22).

• the sealing jaw (A) contains the inductor• the pressure jaw (B) contains the pressure rubber dollies and the cutting

knife plus the cutting rail.

Note!In some filling machine applications the names of Sealing Jaw and Pressure Jaw can be different (Cutting Jaw is also used).

(Cont'd)

1

2

3 4

5

6

7

89

10

1

2

34

5

6

7

89

10

C

A B

1

2

1

2

2 Jaws working in pair 10 Jaws linked as chain

A Sealing JawB Pressure JawC Volume Flap

1 - 5 (42)Doc. No. BoC-2712261-0101

1.1 Transversal Seal - General information 1 Transversal Seal (TS)

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(Cont'd)

The inductor on the sealing jaw induces eddy currents into the Al-foil of the packaging material, producing a heat that melts the plastic layers in the area where the sealing is needed.

The rubber dollies on the pressure jaw exert pressure, allowing the plastic layers to be sealed together. The pressure is produced hydraulically or mechanically depending on the machine type. The knife cuts the packaging material tube separating the packages.

Each pair of jaws makes two seals, i.e. the bottom seal of one package and the top seal of the next one.

Most applications use Ridge inductor, but in most of TCA, TFA and some TWA applications inductors with lower ridge might be used.

1 4

5

67

8

9

10

6

11

2

3

1

10

9

10

10

10

4

11

1 Dolly2 Cutting rail3 Knife4 Upper package5 Heat pattern6 Inductor coil

7 Inductor body8 Cutting groove9 PM cutting line

10 Ridge11 Lower package

1 - 6 (42) Doc. No. BoC-2712261-0101

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1 Transversal Seal (TS) 1.2 Transversal Seal - Tearing (MTD 1201)

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1.2 Transversal Seal - Tearing (MTD 1201)

1.2.1 IntroductionThe method consists in pulling the transversal sealing apart using the stretch pliers and examining how the seal separates.

By visually checking the seal, it is possible to notice the presence of plastic ridges or lumps along it. These ridges could punch the packaging material layers, compromising the integrity of the package.

The seal must be mechanically stronger than the packaging material. If the sealing is good, the packaging material layers (plastic film, Al-foil or paperboard) break while the seal does not separate.

1 Filling product2 Al-foil3 Paperboard4 Cutting line5 Plastic film,

double layers6 Blocked area7 Sealed area8 Ridge9 Outer coating

10 Stretch pliers

6

7 8

6

1

2

3

4

5

9

10

Upp

er P

acka

geLo

wer

Pac

kage

TOP TS

BOTTOM TS

Upper Package

Lower Package

1 - 7 (42)Doc. No. BoC-2712261-0101

1.2 Transversal Seal - Tearing (MTD 1201) 1 Transversal Seal (TS)

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1.2.2 DefinitionsBlocked sealBlocked seals are often called cold sealings. Since the reason for a blocked sealing might be either low setting or low pressure the term cold sealing refers mainly to energy.

Note!The only way to detect a blocked seal it is the manual Tear Down during Production. Conductivity test and Red ink test would not detect a blocked seal.

DecayThe TS with a good heat pattern will progressively tend to appear as blocked, when torn by means of the stretch pliers or by hand. This effect, called decay, typical of wet sealings, depends on the filling product (water included), sealing settings, packaging material and storage time. For this reason during troubleshooting and after production (1 week is the reference interval considered), dissolving and heat pattern analysis is the only reliable method to access the TS quality.

6

7

6

4

2

8

3

5

9

1

1 Filling product2 Al-foil3 Paperboard4 Cutting line5 Plastic film, double layers6 Blocked area7 Sealed area8 Ridge impression9 Outer coating

1 - 8 (42) Doc. No. BoC-2712261-0101

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1.2.3 Preparation of the SamplesNote!The test must be performed during Production. If special activities are planned on the samples (i.e. sealing window), the test can be carried out within 1 week from production.

Prepare samples for TS rough checkUnfold the top and bottom flaps of the package.

Check if the package has product leakages from the TS by gently squeezing the package with the fingers.

If there is product leakage, the TS has a gross defect (most likely a dolly is missing).

If any product leakage is found stop the machine and call a technician.

Note! If there is any leak from between the PLH and the package, it is not due to the TS sealing. Call a service technician.

1 - 9 (42)Doc. No. BoC-2712261-0101


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Prepare samples for TS accurate check1Cut off the top and bottom of the packages at a distance of about 25-30 mm from the top and bottom fin creases.

Rinse the samples and dry them with compressed air.

Note! Use compressed air with care since it might damage the sample.

2Cut off 1 mm maximum from the edges.

1 - 10 (42) Doc. No. BoC-2712261-0101

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1.2.4 Procedure

TS rough TS checkCheck the integrity of the TS by gently squeezing the package with the fingers.

If there is product leakage, the TS has a gross defect (most likely a dolly is missing).

TS accurate check1Run you finger over the TS and check if there are plastic lumps or ridges.

Plastic lumps and ridges show that the sealing is not correct. See section 1.2.5 Evaluation of the Samples for further details.

2Place the sample in the stretch pliers and gently stretch the TS.

1 - 11 (42)Doc. No. BoC-2712261-0101


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3Stretch by pressing the plier handles along the whole length of the sample

Stretch a little bit at a time, from both ends (1) towards the LS/TS cross (3). Stretch the LS/TS cross last.

CAUTIONRisk of sample damage.Take a lot of care in the point where the TS and LS cross and on the edges, since the magnetic field and heat pattern is weaker in these areas. The cross might be the last part stretched to enable a better evaluation.

1

1 1

1

2 2

2 23 3

WRONG

CORRECT

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1.2.5 Evaluation of the SamplesThe seal can be either good or defective. A seal is good when it is mechanically more resistant than the packaging material. If a seal is defective, it could easily cause unsterility.

The first sign of a good seal is stretched plastic film. Breakage in the Al-foil and paperboard layers also shows that the seal is stronger than the packaging material. The rules apply also in the TS/LS cross where the strip is part of the seal.

Here you have some representative examples of good and defective seals.

1Before pulling the seal apart, it is easier to notice the presence of plastic ridges or lumps along it.

Plastic lumps are a potential danger in the aseptic package. The hard residue might punch the PM layers during distribution of the package compromising the package integrity.

Defective sealPlastic lumps are the signal of a too high or uneven sealing temperature, too high pressure or wrong jaw system alignment.

2The seal does not come apart; the plastic film stretches and breaks, leaving the paperboard uncovered.

Good seal

1

Typical behaviour of TBA/lk and TBA/jl

1 - 13 (42)Doc. No. BoC-2712261-0101


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3The case described above applies also to the cross, where TS and LS meet. The LS must be considered and additional plastic multi-layer.

The picture shows the LS which stretches and delaminates.

Good seal

4The seal does not come apart; the plastic film breaks leaving the paperboard fibres and the Al-foil uncovered.

Good seal

5The plastic film layers separate from the Al-foil, leaving it uncovered and shiny.

Good seal

Typical behaviour of TBA/j (that has high adesion to Al-foil)

Typical behaviour of TBA/jm (that has low adesion to Al-foil)

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6The seal separates; no rupture occurs in the packaging material layers. The seal appears mattish or greyish. This is a so called blocked seal.

Defective sealBlocked seals are often due to too low sealing temperature or too low pressure during sealing. Energy settings must be adjusted, inductors and dollies checked and jaw pressure verified.

7The seal is overheated; the two PE layers are burnt and the Al-foil shows micro-cracks and cuts.

Defective seal Overheated seals are often due to too high sealing temperature or by excessive pressure. Sealing settings, cooling water temperature or jaw pressure must be adjusted.

8The Al-foil is cracked in the ridge area.

Defective sealFurther investigate the packages to detect Al-foil cracks along the TS, see 1.4 Transversal Seal - Al-Foil Cracks (MTD 1210).

1 - 15 (42)Doc. No. BoC-2712261-0101

1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208) 1 Transversal Seal (TS)

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1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208)

1.3.1 IntroductionThis section describes the method to evaluate the Transversal Seal (TS) by dissolving the Al-foil (2) with chemical agents and separating the inner plastic layers (5) from the other package layers, obtaining a inner plastic bag.

The inner plastic bag (see picture below) is then analysed to check the heat distribution along the TS (heat pattern). The TS tightness is tested using the leakage detection fluid (red ink).

(Cont'd)

6

7 8

6

1

2

3

4

59

1 Filling product2 Al-foil3 Paperboard4 Cutting line5 Plastic film, double

layers

6 Blocked area7 Sealed area8 Ridge impression9 Outer coating

TOP TS

BOTTOM TS

TOP TS

BOTTOM TS

Upper Package

Lower Package

Upp

er P

acka

geLo

wer

Pac

kage

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1 Transversal Seal (TS) 1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208)

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1.3.2 DefinitionsHeat patternThe heat pattern is the mark left by the inductor on the packaging material during sealing. The pictures below shows the Heat pattern areas.

(Cont'd)

LS

Bending OffLower Blocked area

Ridge impression

Upper Blocked areaLS / TS cross

Air channel

Ridge impressionHeat pattern

= heat pattern

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(Cont'd)

The heat pattern can be analysed with the use of a zonoscope and a magnifier. The heat pattern must be symmetrical with respect to the LS and the cutting line and fulfil the geometrical measurements shown below. The causes of uneven distribution are mostly unparallel pressure distribution, banana shaped inductors or dollies status.

Note!These dimensions are in general not influenced by the filling machine (e.g. the heat pattern of a TBA/21 is similar to the heat pattern of a TBA/22 given the package size). D, usually, is wider than C.

Dimension Acceptable (mm) NOT Acceptable (mm)

A 0 > 0

B ≥ 0.2 < 0.2

C ≥ 1 < 1

D ≥ 1 <1

B

D C

A

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1.3.3 Preparation of the Samples1.3.3-1 Cut packages

1

CAUTIONRisk of sample damage!Always handle the samples with care. Mechanical stress due to improper handling can compromise the results of the test.

Unfold all the flaps and flatten the package. Cut the package in a I shape, as shown in the picture.

The along the TS should be about 50 mm wide with the LS at its central axis.

Cut out the front panel of the package at approximately 25 mm from the top and bottom TS.

2Mark each sample in order to distinguish the Top and Bottom seal after dissolution. For example, write T (for Top) and B (for Bottom) on the inside of the package with a permanent marker.

Mark the samples with progressive numbers.

Note! If packages was containing high fat products it might be difficult to use the permanent marker.

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3If possible, cut the top of the package using the pinking scissors for an easy identification of the top.

The scheme below shows the PM layers before starting the procedure:

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1 Outer coating2 Paperboard3 Lamination4 Al-foil5 Inner coating 16 Inner coating 2

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4Carefully peel off the external packaging material layers (starting from the LS overlapping), as shown in the top picture.

The outer polyethylene layer and part of the paperboard layer will come off.

The sample in the bottom picture will be obtained.

Note! TFA packages do not need this step since the paperboard is too thin to peel apart.

The PM layers left, at this stage, on the sample are the following:

TCA packagesPrepare the packages as shown in the picture.

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2 Paperboard3 Lamination4 Al-foil5 Inner coating 16 Inner coating 2

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1.3.3-2 Dissolving of packagesPackages can be dissolved either using an acid or an alkaline solution. See chapter 1.6 Preparation of Chemicals for details on the composition and preparation of the solutions.

There are three methods that can be followed according to the urgency of results:

• The acid agent (very fast method) acts fast, therefore it is advisable when the results of the test are urgent (e.g. during Production). A fume extractor and a water bath are needed for preparation and usage.

• The acid agent (fast method) acts slower that the above solution, but is faster than the alkaline solution. With this method is possible to obtain the samples in less than one hour. Fume extractor is highly recommended.

• The alkaline agent (slow method) acts more slowly; the samples must stay immersed in the solution for at least 6 hours. This method is advisable when there are many samples to evaluate (e.g. during troubleshooting).

(Cont'd)

Dissolving of packages methods

Acid agent method 1 (very fast)

Acid agent method 2 (fast) *

Alkaline agent (slow)

Solutions used

Advantages

Disadvantages

- HCl 1:1 solution - HCl 1:3 solution - Neutralizing solution

- HCl 30% solution - Neutralizing solution

- Alkaline solution - Neutralizing solution

very fast (sample ready in 15 min)

risk of spoiling of the sample with too long immersion in solution

fast (sample ready in less than one hour)

slow (sample ready in 6 hours)

safer (no acid solutions involved)

go to page 1-23 go to page 1-26 go to page 1-28

not very fast as Acid agent method 1

* used in Tetra Recart applications

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(Cont'd)

Acid agent method 1 (very fast)

WARNINGRisk of personal injury!Observe safety regulations when working with acids. Preparation and handling of HCl solutions must be carried out in a well-ventilated environment, as fumes may be given off. Always wear protective goggles and gloves. Use heat resistant beakers for preparation and storage. Exhausted chemicals must be disposed of in accordance with current regulations.

1Note! Always use the tongs to immerse and remove the sample from the solutions, avoiding the contact with the hands.

Immerse the samples in HCl 1:1 solution one at a time for approximately 4 minutes at temperature between 55° C and 60° C. Use a water bath.

Note! Temperature settings might need adjustments given the equipment used.

2Remove the samples from HCl 1:1 solution and immerse them in the Neutralizing Solution to neutralize the acid.

Neutralizing Solution solution should bubble as soon as the samples are immersed; if not, prepare a new solution.

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3The external lamination layer should easily separate from the Al-foil by mechanical hand action.

The inner plastic layers and the Al-foil are left. The Al-foil will be dissolved in the next step.

The PM layers left, at this stage, on the sample are the following:

4Note! This step is the most sensitive.

The temperature of HCl 1:3 solution increases when samples are immersed into it, therefore there is a high risk of burning the packages.

CAUTIONRisk of sample damage!Bath 2 must be at room temperature.

Immerse the samples into HCl 1:3 solution, no more than two at a time, until Al-foil is dissolved. Keep the samples in motion to reduce the temperature.

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4 Al-foil5 Inner coating 16 Inner coating 2

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5The Al-foil comes off. The inner plastic bag, eventually isolated, must be first neutralized in the Neutralizing solution, then rinsed carefully under tap water.

The PM layers left at the end of the dissolving are the following:

6Dry the samples, see 1.3.3-3 Drying the samples.

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5

5 Inner coating 16 Inner coating 2

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Acid agent method 2 (fast)

WARNINGRisk of personal injury!Observe safety regulations when working with acids. Preparation and handling of HCl solutions must be carried out in a well-ventilated environment, as fumes may be given off. Always wear protective goggles and gloves. Use heat resistant beakers for preparation and storage. Exhausted chemicals must be disposed of in accordance with current regulations.

1Note! Always use the tongs to immerse and remove the sample from the solutions, avoiding the contact with the hands.

Immerse the samples in the HCl 30% solution one at a time for approximately 1 hour.

2Remove the samples fromthe HCl 30% solution and immerse them in Neutralizing solution to balance acidity.

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3Rinse the samples under tap water. The external lamination layer and the Al-foil should easily separate from the inner plastic layer.



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5 Inner coating 16 Inner coating 2

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Alkaline agent (slow)

1Carefully immerse all the samples in the dissolving solution. Leave the beaker uncovered to allow hydrogen fumes to be ventilated.

If fresh, the solution should immediately start to bubble. If not, prepare a new solution.

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

2Make sure the Al-foil has dissolved completely; if not leave the samples in the solution a little longer or prepare a fresh one.

15% of citric acid solution might be used to neutralize the samples.

Rinse the samples under tap water and carefully separate the inner plastic bag.



6

5 5 Inner coating 16 Inner coating 2

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1.3.3-3 Drying the samples 1Carefully dry the inside of the samples with paper tissue (1) and dry thoroughly on filter paper, in a well ventilated area. The presence of water may interfere with the results of the test.

CAUTIONRisk of sample damage!Do not reverse the bags while drying them, or they could be spoilt.

2Spoiled samples must be discarded.

The picture shows a sample that has been heated too much during the chemical exposure, becoming unreliable.

1

WRONG

CORRECT

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1.3.3-4 Red Ink Tightness1CAUTIONRisk of sample damage!Handle the samples with care. Mechanical stress due to improper handling can compromise the results of the test.

Take one sample at a time, make sure that it is completely dry.

Put some red ink with a plastic pipette inside the plastic bag along the TS.

2Let the red ink spread along the TS.

Hold the sample with both hands and visually check it.

If the TS is not tight and there are channels in it, the red ink will pass to the outside of the bag.

If the result is doubtful, let the samples dry and repeat the red ink test, at room temperature.

Filter paper can be used to see spots of red ink passing through the sealing.

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1.3.4 Evaluation of the SamplesIrregularities of the TS which are easy to notice at this point are the following:• plastic lumps;• Al-foil TS cracks;• product residue;• overheated seal;• channels (unsealed spots)• cuts in the ridge area.• bending off• sealing simmetry

Here you have some representative examples of TS.

1The sealing is even, the heat pattern is regular, no cracks are visible.

The sample shows bubbles that might appear after the dissolving due to the chemical exposure. Those bubbles are not evidence of anomalies in the sample.

Good seal

2The sealing is smooth, the heat pattern is regular, no cracks are visible.

Good seal

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3The sealing is smooth, the heat pattern is regular, no cracks are visible.

Good seal

4The heat pattern is not regular towards the cutting side suggesting jaw pressure or knife problems, however, this sealing is still acceptable for package integrity but defect might arise.

Good seal

5The sealing shows cuts in the ridge area that might be due to dissolving procedure or high pressure.

Good seal

6The sealing shows tiny bubbles toward the product side that do not reach the ridge (very typical for TBA/22 040).

Good seal

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7Solid LDPE can be found at the fin, at the cutting side. Pressure and cutting might need verification.

Good seal

8Trapped product might be spotted in the sealing. Further analysis could be needed. If the red ink does not pass through, the sealing is good.

Good seal

9Al-foil TS cracksThe TS shows lack of PE along the ridge. This rupture corresponds to a crack occurred in the Al-foil during the sealing pulse, which caused and interrupted the resulting heat pattern. Refer to MTD 1210 for details.

Defective seal

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10Plastic lumpsThe TS shows plastic lumps.

Defective seal

11Product residueProduct resides (e.g. fruit juice fibres) are trapped into the TS and pass the ridge. Fibres can create channels inside it or perforate the TS up to the paperboard.

Defective seal

12OverheatingThe seal shows bubbles and melted spots. This indicates that the sealing temperature setting was too high or unparallel jaw pressure.

Defective seal

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13Cutting knife and pressure problemsThe seal shows channels from the cutting area towards the product side.

Defective seal

14Cutting knife and pressure problemsThe seal shows channels from the cutting area towards the product side.

Defective seal

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Here you have some examples of good and defective heat patterns.

A

Good sealDefective seal

B

Good seal Defective seal

C


D


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1 Transversal Seal (TS) 1.4 Transversal Seal - Al-Foil Cracks (MTD 1210)

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1.4 Transversal Seal - Al-Foil Cracks (MTD 1210)Note!This procedure is very uselful as troubleshooting procedure.

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

At the present level of knowledge, the occurrence of cracks depends on:• packaging material;• status of the sealing components;• TS configuration;• tolerances of the machine settings (i.e. design correction and folding

flaps);• TS power setting;• jaw pressure.

A

Good

Defective

A

Defective

1 - 37 (42)Doc. No. BoC-2712261-0101

1.4 Transversal Seal - Al-Foil Cracks (MTD 1210) 1 Transversal Seal (TS)

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1.4.2 Preparation of the Samples1Unfold all the flaps of the package samples.

2Make a cut, either with scissors or a cutter, 5 cm long, on one side of the package to empty it from its content.

3Starting from the LS overlap, tear away the outer layers of packaging material over the top and bottom TS.

Mark top and bottom of the package to identify them.

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1.4.3 Procedure1If a very bright lamp is available, put the edge of the sample against the light source. The area in which the light passes through the packaging material corresponds to a crack in the Al-foil.

2If the light source at your disposal is not powerful enough, dip the packages in warm water and carefully remove the paperboard layers covering the Al-foil in the TS area with an abrasive sponge.

3Put the samples against the light source and look for cracks in the Al-foil along the ridge.

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1.4.4 Evaluation of the Samples

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

Cracks are due to problems connected with:• packaging material;• machine settings (design correction

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

Defective seal

2Defects are visible also with the aid of a magnifying lens or microscope.

This seal shows a crack due to excessive pressure of the dollies or knife return problems, which does not cause a magnetic field interruption. The heat pattern is regular.

This is NOT a TS Al-foil crack (cracks out of the ridge area).

Good seal

3This crack compromises the distribution of heat along the TS; the heat pattern will consequently be irregular.

This is a TS Al-foil crack in the ridge area.

Defective seal

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4For further investigation dissolve the packages, see 1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208) and analyse the heat pattern, to confirm its irregularity.

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2 - 1 (24)Doc. No. BoC-2712261-0101

Methods: 2 Longitudinal Seal (LS/SA)

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Methods:MTD 1202 - Longitudinal Seal TearingPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.



MTD 1202 - Longitudinal Seal by Red InkPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.



2 - 2 (24) Doc. No. BoC-2712261-0101

Table of ContentsTe

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2.1 Longitudinal Seal - General information . . . . . . 2 - 5

2.2 Longitudinal Seal (LS/SA) - Tearing (MTD 1202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 72.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7

2.2.2 Preparation of the Samples. . . . . . . . . . . . . . . . . . 2 - 82.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

2.2.3-1 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

2.2.3-2 Mechanical test . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12

2.2.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 2 - 142.2.4-1 Rolling ball point pen test

(after mechanical tear down) . . . . . . . . . . . . . . . 2 - 17

2.3 Longitudinal Seal - Red Ink Injection. . . . . . . . 2 - 182.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 182.3.2 Preparation of the Sample. . . . . . . . . . . . . . . . . . 2 - 19

2.3.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 212.3.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 2 - 22

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Methods: 2 Longitudinal Seal (LS/SA)

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2 Longitudinal Seal (LS/SA) 2.1 Longitudinal Seal - General information

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2.1 Longitudinal Seal - General informationThis seal creates the tight tube of packaging material just before product filling. A strip of PE (LS strip) is attached to one edge of the packaging material before sterilization by the Strip Applicator (SA) (Figure 1) by hot air or induction heating depending on the machine type.

During tight tube forming, the edge of packaging material without the strip is heated by induction or hot air depending on the machine type; the two edges are then overlapped and pressed together to create the sealing (Figure 2).

The Strip Applicator side (SA side) (4) of the seal is where the strip was attached to the packaging material by the Strip Applicator; the packaging material edges overlap in this area.

The LS side (1) is where the strip was attached to the packaging material during tight tube forming; the packaging material is single. An air gap (3) is present in the middle of the seal.

(Cont'd)

Figure 1 Figure 2

2

31 4

TBA package is shown

outside package

inside package

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2.1 Longitudinal Seal - General information 2 Longitudinal Seal (LS/SA)

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(Cont'd)

The following table shows the type of sealing (hot air or induction heating) used in TBA machines for the sealing of SA and LS.

Note!Induction heating and hot air give different results in terms of visual appearance, therefore it is important to bear in mind which kind of sealing system is used in the packages under investigation. IH Sealing produces wrinkles on the Alu-foil. Higher sealing settings would not eliminate, but increase them. Hot air, on the contrary, does not usually creates wrinkles in the Alu-foil unless excessively high settings are used.

Filling Machine SA LSTBA/3 hot air hot air

TFA/3 hot air hot air

TBA/9 - TWA hot air hot air

TBA/8 hot air hot air

TBA/19 induction heating

hot air


induction heating


induction heating

Tetra Pak A1 hot air hot air

Tetra Pak A3/Flex induction heating

induction heating

Tetra Pak A3/Speed induction heating

induction heating

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2.2 Longitudinal Seal (LS/SA) - Tearing (MTD 1202)Note!This test can be carried out during or after Production.

2.2.1 IntroductionThe quality of the seal is tested by tearing the LS strip manually. The seal must be mechanically stronger than the packaging material. If the sealing is good, the packaging material layers (plastic film, Al-foil or paperboard) come apart together with the strip.

The heat distribution along the seal can be examined with the use of a zonoscope to detect possible asymmetry.

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2.2 Longitudinal Seal (LS/SA) - Tearing (MTD 1202) 2 Longitudinal Seal (LS/SA)

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2.2.2 Preparation of the Samples1

CAUTIONRisk of sample damage!Do not stress or flatten the samples since channel leaks might be induced.

Unfold the flaps of the package samples.

2Cut two opposite corners (top right, bottom left), empty the package content, and cut the sample corner to corner in a diagonal, across the front panel of the package, leaving the LS intact.

3Open up the sample, rinse it with water and dry it.

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2.2.3 Procedure2.2.3-1 Visual checks

1Strip positionNote!The LS side (2) of the seal is where the packaging material (1) is single. The SA side (4) is where the packaging material is double.

TBA, TPA, TWA, TFA packagesCheck that the strip is centred in the seal.

An air gap (3) must be present in the centre of the seal.

TCA packagesIn TCA packages, the strip is off-centred with respect to the seal; 2/3 of the strip cover the SA side.

Note! When the risk of strip folding is reported the strip (2) can be more on the SA side (naturally 2/3) than on the LS (the remaining 1/3). This is recommended for MPM type strip.

= =

LS SA

2 31 4

1/3 2/3

LS SA

2 31 4

2

TBA,TPA,TWA,TFA

TCA

2 - 9 (24)Doc. No. BoC-2712261-0101


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2BlisteringCheck for any blister or bubble along the heated zone of strip.

The presence of blisters in the LS side of the strip indicates too high sealing setting.

The presence of blisters in the SA side of the strip indicates too high sealing setting of the Strip Applicator.

Defective seal

3PE residueLDPE residue are trapped below the strip affecting the sealing.

Defective seal

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4Overheated LSExcessive settings or uneven pressure (LS roller not in control) result in risk of affecting the performance.

Defective seal

5Heat distributionUse the zonoscope to examine the heat distribution along the LS/SA. The heat pattern must be present even on the packaging material beyond the edge of the strip.

Refer to Use of the Zonoscope, page Appendix-11, when using the Zonoscope.

Defective seal

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2.2.3-2 Mechanical test1Cut the package sample along the middle of the LS (1) and LS air channel (2).

Cutting line is (3).

2Pull off the outer layer of packaging material where it is double, to check the overlap.

1

32

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3Pull the strip slowly, at an angle of 90°, 20 mm at the time.

Note! Best results are achieved if the sample is pulled on a flat surface (table).

2 - 13 (24)Doc. No. BoC-2712261-0101


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2.2.4 Evaluation of the SamplesNote!Evaluate the samples soon after preparation as the sealing could be affected by the environment conditions.When pulling the LS strip (1), it must be mechanically stronger than the packaging material (2). If the sealing is good, the packaging material layers (plastic film, Al-foil or paperboard) come apart together with the strip.

Delamination of the strip up to PET layer, or delamination of material up to Al-foil, are easy to see due to the shining surfaces of PET and Al-foil. Delamination of the strip layers and the internal of the PM layer is more difficult to notice.

Note!In the drawing below, the LS strip is shown in three layers for easier reading.

1

2

21

3

3

1 LS Strip2 Packaging Material3 Cutting line

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1Separation between the two inner coatingsWhen the strip is pulled off and one of the inner coatings comes off with the strip (1) leaving a rupture edge (2) along the seal:

Good seal

2Separation between the Al-foil and the inside coatingsWhen the strip (1) is pulled off and the two inner coatings come off leaving the Al-foil bare

Good seal

3Rupture in the paperboardWhen the strip is pulled outwards and all inner layers including the Al-foil come off with the strip (1),possibly leaving paperboard fibres (3).

Good seal

4Rupture in the paperboardStretch of the Polymer and rupture to the paperboard

Good seal

1

2

1

TBA/j packaging material with PPP strip

1

3

TBA/jl packaging material with MPM strip

1

3

TBA/jl packaging material with MPM strip

2 - 15 (24)Doc. No. BoC-2712261-0101


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5Separation in the LS stripWhen the strip (1) is pulled off and one of the strip layers is left on the packaging material (i.e. strip de-lamination). This can happen also in the cross, where LS and TS meet.

Good seal

6Separation of inner PEWhen all inner layers including the Al-foil come off with the strip (1) possibly leaving part of the inner LDPE layer (lamination layer) (4) on the paperboard.

Good seal

7Cold or blocked sealWhen the strip (1) is pulled off and it comes off leaving the inner coatings unaffected or with a greyish surface

Defective seal

1

1

4

1

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2.2.4-1 Rolling ball point pen test (after mechanical tear down)1Note! After the strip has been pulled away, take care not to touch the spot with fingers.

Press a rolling ball point pen (see 1.5 Tools and Equipment for details) on a point of the LS edge after pulling it.

Red colour pens are the best performing.

2If the sealing is good, the ink moves along the sealing fracture point by capillary action.

Good seal

3If the sealing is defective, the ink does not move. This means that the seal is blocked (cold).

Defective seal (blocked)

Edge

Pulled strip

2 - 17 (24)Doc. No. BoC-2712261-0101

2.3 Longitudinal Seal - Red Ink Injection 2 Longitudinal Seal (LS/SA)

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2.3 Longitudinal Seal - Red Ink Injection2.3.1 Introduction

The quality of the LS is tested by injecting Red Ink into the air channel in the middle of the seal. The Red Ink must run along the entire channel without interruption. Any transversal channels of ink would indicate a defective seal (see section 2.3.4 Evaluation of the Samples).

LS Ink Injection and Mechanical Tear Down are pointing at different properties. The Red Ink Injection does not substitute the Mechanical Tear Down.

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2 Longitudinal Seal (LS/SA) 2.3 Longitudinal Seal - Red Ink Injection

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2.3.2 Preparation of the Sample1

CAUTIONRisk of sample damage!Do not stress or flatten the samples.

Unfold the flaps of the package samples.

2Cut two opposite corners (top right, bottom left), empty the package content, and cut the sample corner to corner in a diagonal, across the front panel of the package, leaving the LS intact.

3Open up the sample, rinse it with water and dry it.

2 - 19 (24)Doc. No. BoC-2712261-0101


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4Make an oblique cut across the LS as shown.

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2.3.3 ProcedureBy red ink injection

CAUTIONRisk of sample damage!Do not stress or flatten the samples.

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

By red ink contact1Evaluation can be done also by applying the red ink on the inside of the package, outside of the LS strip, by means of a pipette.

2Leave the sample to dry or wipe the excess of red ink before looking for leakages.

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2.3.4 Evaluation of the Samples1Check that the strip is tight and no transversal air channels are present

Critical points are where the LS and the TS meet, and on the top and bottom creases.

2This picture shows a good seal, in which the LS induction heating setting is at acceptable values.

Good seal

3This picture shows a good seal, in which the LS induction heating setting is at acceptable values.

Good seal

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4The Red ink flows straight in the air channel and there are no deviations.

Good seal

5This picture shows a seal in which the ink flows in the air channel showing deviations that are not compromising package integrity yet.

Good seal

6This picture shows a seal in which the deviations of the ink in the air channel are worsened making a leaking channel.

Defective seal

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7This picture shows wrinkles and transversal air channels running across the LS.

This is typical of the LS made by Induction Heating when the settings of the inductors are too high.

Defective seal

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3 Opening Devices

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Methods: 3 Opening Devices

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Methods:MTD 1211 - Opening Device PullTab and FlexiCapPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.

ToolsRefer to section B.2 Tools and Equipment, page Appendix-6 for details on the tools used.


3 - 2 (24) Doc. No. BoC-2712261-0101

Table of ContentsTe

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3 Opening Devices

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3.1 Opening Devices - General Information . . . . . . 3 - 5

3.2 Opening Devices - PullTab (MTD 1211) . . . . . . . 3 - 63.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6

3.2.2 Preparation of the Samples. . . . . . . . . . . . . . . . . . 3 - 73.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83.2.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . . 3 - 9

3.3 Opening Devices - FlexiCap (MTD 1211) . . . . . . 3 - 113.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11

3.3.1.1 FlexiCap top crease faults . . . . . . . . . . . . . . . . . . 3 - 133.3.1.2 FlexiCap longitudinal crease faults . . . . . . . . . . . 3 - 153.3.1.3 FlexiCap injection faults . . . . . . . . . . . . . . . . . . . . 3 - 173.3.1.4 Underfilled FlexiCap . . . . . . . . . . . . . . . . . . . . . . . 3 - 19

3.3.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 3 - 203.3.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21


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3.1 Opening Devices - General InformationThe methods reported in this section are aimed at assessing the integrity of TPCA opening devices.

PullTab and FlexiCap are two opening devices made in the filling machine. To allow these applications, the packaging material is punched and sealed again to restore integrity during the production cycle.

The integrity of the PT application is ensured by the PEP strip (Inner Patch) sealed in the inside of the package, which isolates the product from paperboard fibres around the punched hole.

For the FlexiCap, the PE and the MasterBatch granulate of the cap is melted and injected so that it is sealed to the inner PE layer of the packaging material, restoring the microbiological barrier.

Opening such as StreamCap and SpinCap are applied over a PLH (Pre Laminated Hole) after the package leaving the Filling Machine and not treated in the manual. Check also section Pre-Laminated Hole at page iii-11.

PullTab FlexiCap

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3.2 Opening Devices - PullTab (MTD 1211) 3 Opening Devices

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3.2 Opening Devices - PullTab (MTD 1211)3.2.1 Introduction

This document describes a method to evaluate the integrity of the PullTab (PT) opening by means of the leakage detection fluid (Red Ink).

A PT opening consists in a hole punched in the packaging material (3). The hole is then closed on the outside by an aluminium Tab (1) and on the inside by a multi-layer plastic strip (Inner Patch, IP) (4). Tab and Inner Patch are sealed together before forming the package.

In TPA portion packages, a plastic unilateral strip (Outer Patch, OP) (2) is applied onto the external surface of the packaging material before punching the hole, to cover the paperboard fibres when the PT is opened for consumption.

An air gap (5) is present around the entire perimeter of the hole. This free space prevents packaging material fibres from coming into contact with the inner patch (4) since it could eventually damage or perforate it. The Inner Patch seals the punched hole, isolating the product from the rest of the packaging material layers. This restores the microbiological barrier and ensures package integrity.

The overall PT quality is also given by PullTab position, Tab folding and Sealing/Heat pattern.

(Cont'd)

3

5

21

4

3

5

1

4

1 Tab2 Outer patch3 Packaging material4 Inner patch5 Air gap

TBA, TCA and TPA Family packages

TPA Portion packages

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3.2.2 Preparation of the Samples1Select a suitable number of packages according to the level of accuracy needed.

Cut the packages into two halves with a cutter; only the top parts will be used for the test.

Rinse the package samples and let them dry in a well ventilated area or using compressed air.

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3.2.3 Procedure1Apply red ink over the inner surface of the PT hole with a plastic pipette, covering the inner patch completely.

Leave the red ink inside the package for at approximately 5 minutes.

Remove the excess of red ink with the pipette.

Note! Do not pour red ink out of the package as this could lead to false positive reading.

2Clean the inside of the package with a dry paper towel or let it dry thoroughly in a well ventilated area.

Note! Flushing with water might give problems if water is not carefully dried before unfolding the flaps and splitting the packaging material.

3Flatten the package by opening the flaps.

Carefully, starting from the LS overlap, split the paperboard and remove the outer layer.

Continue peeling the package. Some paperboard will come off together with the outer layer of PE and the PT will open up.

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3.2.4 Evaluation of the Samples

4Continue peeling the package.

Some paperboard will come off together with the outer layer of PE and the PT will open up.

Note! If the ink is still in the package before performing this operation, artifact defects might be created.

1The PullTab sealing is good if there are no red ink spots on the paperboard layer around the PullTab hole.

Good application

2The PullTab sealing is defective if there are red ink spots on the paperboard layer around the PullTab hole.

Defective application

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3This is typical problem due to confetti removal failure. The confetti waste box and waste tube are filled up and their presence in the system create this defect in the application.


4Check if there is a residue of PE all around the PT hole, measure A (see table below). This residue corresponds to the unsealed area of the strip, it is to say the air gap.

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

If the PE residue is too wide, pressure or heat, during application, was too low and pouring performances can be affected.

Note! TPA packages, having a wider hole might show more residue than TBA packages. If ReCap is present the cap helps in getting improved pourability.

Note! Refer to the Filling Machine Operation Manuals for related measures A.

A A

A

A

TBA

TPA

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3.3 Opening Devices - FlexiCap (MTD 1211)3.3.1 Introduction

This chapter describes how to evaluate the quality of the FlexiCap openings. FlexiCap Opening, like PT Opening, consists in a hole which is punched in the packaging material; the hole is then hermetically closed on the outside by a cap which is injection-moulded directly on to the packaging material before forming the packages.

The FlexiCap integrity is tested by the leakage detection fluid (red ink), by visually checking the cap and testing the FlexiCap opening force.

FlexiCap faults can be categorized 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:• result of the hole and FlexiCap positioning,• combination being correctly aligned to each other but incorrectly

positioned on the packaging material,• inaccurately set moulding tools and/or injection system.

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FlexiCap Terms

1 Lid2 Membrane3 Hinge4 Dog bone5 Injection Point6 PullTab7 Tamper evidence8 Punched hole edge

9 Spider leg10 Leg11 Membrane support12 Pouring lid13 Inside sealing area14 Knife15 Stepped membrane16 Membrane support rib

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3.3.1.1 FlexiCap top crease faults

DelaminationIf the FlexiCap is positioned too close to the top crease there is an increased risk of delamination of the packaging material at the edge of the punched hole, see Figure 1. This will occur when the packaging material is being folded into the package shape in the filling machines final folder.

figure 1

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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.

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.

figure 2

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3.3.1.2 FlexiCap longitudinal crease faults

Broken membraneIf the FlexiCap is positioned too far over the longitudinal crease there is an increased risk of the membrane being broken at the front of the FlexiCap, see figure 3. This happens when the folding flaps of the jaw system grip the packaging material to keep the tube within design.

It is acceptable for the folding flaps to pinch the end of the FlexiCap tab, but if the FlexiCap is positioned too far over the longitudinal crease the folding flaps will pinch too much of the FlexiCap and as a result the membrane can be broken.

figure 3

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Positioning impactIf the FlexiCap is positioned too far from the longitudinal crease both pouring performance and closure after opening performance are affected and tamper evidence might get broken during package forming in the line.

The FlexiCap has been designed to be moulded over the edge (longitudinal crease). Pouring performance is also affected by FlexiCap positioned far from the side panel. The longitudinal crease gives the proper support to allow reclosability.

Transportation damage - crack in the frontIf 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 (longitudinal crease) supports the FlexiCap, but if the FlexiCap is positioned too far from this extra support, cracks in the front of the FlexiCap can form under the pouring lip, see figure 4.

figure 4

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3.3.1.3 FlexiCap injection faultsOverfilled FlexiCap

The amount of plastic used in each FlexiCap is regulated by adjusting the stroke of the injection cylinder, see the DIMC Multi maintenance manual Injection system - set cylinder for more details.

If too much plastic is injected, splashes of plastic will be visible around the inside of the FlexiCap, see figure 5.

(Cont'd)

figure 5

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(Cont'd)

The first FlexiCaps produced can be overfilled. This is due to a change in the characteristics of the plastic left in the injection system from the previous production, which allows more plastic to be injected. This is normal and no corrective action is required.

If the FlexiCaps have a fin along the top of the lid, this too could be the result of too much plastic being injected. But it is more likely to be a small amount of cured plastic trapped between the two halves of the lower tools stopping the two halves of the lower tools from closing completely. See figure 6 and 7.

figure 6

figure 7

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3.3.1.4 Underfilled FlexiCapUnderfilled FlexiCaps are a direct result of an incorrectly set injection system, see figure 8.

figure 8

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3.3.2 Preparation of the Samples1Select a suitable number of packages according to the level of accuracy needed.

Note! At least 1 package produced by each moulding station must be sampled and checked.

If the test is applied during troubleshooting take a tray of packages in which at least 1 appears defective.

2Cut the packages into two halves with the scissors. Only the top parts will be used for the test.

Rinse the package samples and let them dry in a well ventilated area or using compressed air.

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3.3.3 ProcedureFlexiCap Integrity Check1Note! If the check is being carried out after a packaging material splice check the FlexiCap forming as described in the FlexiCap forming

Apply red ink to the inside of the package in the area indicated in the illustration with a plastic pipette, covering the FlexiCap completely.

Leave the red ink inside the package for at approximately 5 minutes. Remove the excess of red ink with the pipette.

Wait for the ink to completely dry.


2Break the tamper evidence of the FlexiCap and lift it just enough to see inside. Check that the red ink has not passed through the membrane (in the area indicated on the illustration).

If the red ink has passed through the membrane, corrective action shall take place.

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3Carefully peel off the outer layer of PE starting from the LS overlap. Some paperboard will come off together with PE.

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3.3.4 Evaluation of the Samples1Check for any red spots around the application. Absence of red spots indicates that the FlexiCap application is good.

Good application

2Red spots indicate that the FlexiCap application is defective.

Note! Problems with FlexiCap sealing may result in unsterile packages and corrective action shall take place.


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4 Package Integrity

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Methods:MTD 1203 - Package Integrity - Conductivity testPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.



MTD 1207 - Package Integrity - Copper testPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.


Reference DocumentsPrevious version, MTD1207, issued by Sara Davolio, date 2002/03/05.

MTD 1204 - Package Integrity - Red Ink testPersonnelThis method must be performed by Qualified personnel. Refer to section Personnel Requirements, page i-5 for details.


Reference DocumentsPrevious version, MTD1204, issued by Sara Davolio, date 1996/04/20.

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4.1 Package Integrity - General Information . . . . . . 4 - 5

4.2 Package Integrity - Conductivity Test (MTD 1203) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 64.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

4.2.2 Preparation of the Samples. . . . . . . . . . . . . . . . . . 4 - 74.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 84.2.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . . 4 - 9

4.3 Package Integrity - Copper Test (MTD 1207). . 4 - 104.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10

4.3.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 4 - 114.3.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 124.3.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 4 - 14

4.4 Package Integrity - Red Ink Test (MTD 1204) . 4 - 154.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15

4.4.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 4 - 164.4.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17


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4.1 Package Integrity - General InformationThe present chapter reports test methods aimed at the microbiological barrier of a TPCA package.

The microbiological barrier consists of the inner plastic layer, the Al- foil and the lamination layer between the Al- foil and the paper board.

All three layers have to be broken before the microbiological barrier is lost.

By definition, aseptic package integrity requires, beside sealing quality as described in the dedicated chapters, an intact microbiological barrier.

The tests are:• Conductivity Test (MTD 1203)• Copper Test (MTD 1207)• Red Ink Test (MTD 1204)

Defects are detected according to the table below.

Depth of defect

Conductivity Test

Red Ink Test

Copper Test

Tight Package

Corrective actions needed

A X X X NO YESB X - X YES YESC X - X YES YESD - - - YES NO

A

B C D

3 4 5 6

211 Inner layer (PE, m-PE)2 Adhesion layer3 Al-foil4 PE Lamination5 Paperboard6 Outer layer

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4.2 Package Integrity - Conductivity Test (MTD 1203)

4.2.1 IntroductionThis chapter describes how to detect ruptures of the inner PE layer, which leave the Al-foil uncoated.

The package is immersed in an electrolytic solution (salt solution). If there is a crack in the PE layers, an electrical contact is established between the electrolytic solution outside the package and the package content, which is measured by an ammeter (electrolytic tester).

This method can be used for packages containing liquid products such as water, wine or fruit juice.

Packages filled with fat products should not be checked with this method after storage, as the greasy components could create an insulating layer on the inside of the package, preventing current from circulating. Adopt the Red Ink Integrity test, instead.

Note!The only way to detect a blocked seal it is the manual Tear Down during Production. Conductivity test and Red ink test would not detect a blocked seal.

To detect where the rupture is located, the test must be followed by the 4.3 Package Integrity - Copper Test (MTD 1207) or by the 4.4 Package Integrity - Red Ink Test (MTD 1204).

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4.2.2 Preparation of the Samples

1Cut all the selected packages in two halves with a sharp cutter or scissors.

Note! The best procedure is anyway to keep the package in one sample only.

2Rinse the packages and wipe the cut edges thoroughly with a paper tissue or let them dry before testing; a wet edge might cause a false current deflection.

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4.2.3 Procedure1Put table salt (10 g per litre of water) into a plastic water basin.

Fill a third of each package sample with the NaCl solution. Make sure the solution reaches the weak areas of the package, such as corners and creases.

Put the sample carefully into the bowl, so that the outside corners are fully covered.

Note! The black probe (negative) has to be placed in the water, the red probe (positive) in the package sample.

Dip the positive probe (Red) of the ammeter inside the package and the negative one (Black) outside of it, into the NaCl solution.

CAUTIONRisk of false readings!Keep the package cut edges dry to prevent them from acting as a bridge and giving false deflections. Be careful not to scratch the inside of the packages with the electrodes.

Note! The electrodes can be connected to the ammeter by wires, in order to facilitate the work.

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4.2.4 Evaluation of the Samples1Read the deflection of the ammeter:• If the reading is 0 µA, the sample has

no ruptures in the internal PE coating; (negative samples).

• If the ammeter reading is unsteady and greater than 0 µA, wipe the edge once more and make a new reading; if still unsteady, let the sample dry.

• If the deflection is quick and steady and the reading is greater than 0 µA, it means that there is contact to the Al-foil (i.e. a hole on the inner PE layers). Those samples shall be submitted to further investigations, (positive samples).

Note! A reading below half scale is almost always a wet paper edge.

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4.3 Package Integrity - Copper Test (MTD 1207)

4.3.1 IntroductionThis document describes a method to locate ruptures in the inner layers of the Tetra Pak Carton Ambient packages.

Ruptures in the inner PE layers can be detected by the conductivity test (MTD 1203). The package is immersed in an electrolytic solution (i.e. salt solution). In case of a crack in the PE layers, which leave the Al-foil uncovered, an electrical contact is established between the electrolytic solution outside the package and the package content.

If some copper solution is poured into the package, the copper oxide solidifies in the area of the cracks when a copper tester is used, allowing to locate the fault.

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4.3.2 Preparation of the Samples1Cut all the selected packages in two halves with a sharp cutter or scissors.


2Rinse the packages and wipe the cut edges thoroughly with a paper tissue or let them dry before testing; a wet edge might cause a false current deflection.

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4.3.3 ProcedureNote!If the Red ink test (MTD 1204) is going to be performed on the packages, do it before the copper test. The copper test can cause an enlargement of the cracks in the packaging material, compromising the results of the ink penetration.

1Put some NaCl solution (approx. 10%) into a plastic water basin.

Put some copper solution into the sample package, to cover corners and creases, and dip it carefully into the basin, so that it is steady.

Put the red electrode into the sample package and the black one in contact with the salt solution.

Refer to Use of the Electrolyte Copper Tester, page Appendix-12, when using the Tester.

2Press the Push button for approximately four seconds to turn on the tester.

If the ammeter shows a current deflection over 50 µA, there might be the presence of a crack in the inner layer up to the Al-foil.

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3Press the button Push once again. Electrolysis starts. The red LED lights up.

4Move the red electrode around the inner corners of the packages for approximately 3 minutes; the copper will deposit on the cracks, making them visible.

Mark the areas of deposition with a permanent marker.

Repeat the test with all the packages, on both halves.

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4.3.4 Evaluation of the Samples1After the copper test has been performed, rinse the sample packages with water.

Let them dry thoroughly; use compressed air to speed the process.

Unfold the flaps and peel off the outer layers.

2Look for red ink spots on the paperboard.

3If no red ink is found on the packaging material, the contact was due to a rupture of the plastic layers up to the Al-foil (3) (cases B, C or D).

If red ink spots are visible, in correspondence of a copper deposition area (7), a rupture of the plastic layers and Al-foil occurred, causing a defect (case A).

Count the number of packages with exposed Al-foil, packages with red ink failures that compromise the package integrity and the total number of tested packages. Record the data.

D

3 4 5 6

217

B

A

C

1 Inner layer (PE, m-PE)2 Adhesion layer3 Al-foil4 PE Lamination5 Paperboard6 Outer layer7 Copper deposition

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4.4 Package Integrity - Red Ink Test (MTD 1204)

4.4.1 IntroductionAn aseptic package is conventionally defined as leaking when Red Ink penetrates the coating layers and stains the paperboard. According to this definition, a package is defective when it is positive to the Red Ink Test, since all the microbiological barriers performed by the Al-foil and inner PE layers are broken: integrity is therefore not guaranteed.

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4.4.2 Preparation of the Samples1During troubleshootingCut out a hole in the front panel of the package.

This allows to investigate the package as a whole, identifying the defective areas in an accurate way.

Note! TFA packages should be cut into halves, making sure not to cut on damaged spots.

2During Production or After Production Laboratory checksCut the packages in two halves using a cutter.


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4.4.3 Procedure1Apply red ink over the critical points of the package, such as corners, TS, crosses. Leave the red ink inside the package for approximately 5 minutes.

Remove the excess of red ink with the pipette.


2Clean the inside of the package with a dry paper towel or let it dry thoroughly in a well ventilated area.

3Once samples are dry, unfold the flaps and carefully peel off the outer layer of PE starting from the LS overlap. Some paperboard will come off together with the PE.

Note! If ink is still present in the package, leakage can be caused by opening the flaps and breaking the inner PE layer.

4 - 17 (20)Doc. No. BoC-2712261-0101


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4.4.4 Evaluation of the Samples1Check for any red ink spots on the paperboard layer on the corners, TS, and crosses areas.

Any red ink leakage corresponds to a defect in the package.

Defective

Fin tearingFin tear can develop into integrity defects.

TBA and TPA packages can be affected by fin tears in the top due to interactions between the PM and folding flaps.

TWA packages are affected by fin tears in the bottom (since the folding flaps act on the bottom).

Check for any red ink spots on the fins.

Any red ink leakage corresponds to a defect in the package.

Defective TWA package shown

4 - 18 (20) Doc. No. BoC-2712261-0101

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2If the red ink spot is larger on the peeled external layer than on the package side, it means that the ink has leaked from the OUTSIDE of the package to the INSIDE.

This is NOT an integrity defect but simply and artifact by applying the procedure. See diagram.

4

5

3

21

1 Larger red ink spot2 PM external layer3 Split paperboard4 Smaller red ink spot5 PM internal layers

4 - 19 (20)Doc. No. BoC-2712261-0101


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5 Package Forming

5 - 1 (8)Doc. No. BoC-2712261-0101

5 Package Forming

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The methods reported in this section are additional checks which are not aimed at assessing package integrity, but other important aspects of the packages such as flap sealing, data printing, weight. They are included here to give a complete picture of what is a good package, also from appearance’s point of view.

5 - 2 (8) Doc. No. BoC-2712261-0101

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5.1 Package Forming. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Date Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Flap Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Crease lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6

LS Overlap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

5 - 3 (8)Doc. No. BoC-2712261-0101

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5.1 Package FormingNote!The machine OMs always report an updated and exhaustive version of package appearance and forming checks.

Date PrintingCheck the date and code printing.

If necessary, stop the filling machine and adjust the date printing according to the instructions supplied with the printer.

WeightWeigh the packages.

Record their weight and weight deviations.

After setting, pick out new packages and check them.

Flap SealingUnfold the flaps and check that they are properly sealed.

On the bottom flaps the heat should not be directed on the TS.

Burnt marks might impact on package integrity.

5 - 5 (8)Doc. No. BoC-2712261-0101

5.1 Package Forming 5 Package Forming

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Crease linesLift the package top or bottom fin (1).

Note! To correct check crease lines alignment it is important to lift the flaps, since closed flaps might give indication of wrong set of creases lines, but due to package folding.

Check the position of the preformed crease lines (2).

The position is acceptable if • the creases are opposite one another

(fig.1) either parallel (fig.2) or at an angle (fig.3).

The position is not acceptable if• the preformed crease lines are not

opposite one another (fig.5 and 6).

If there are any defects, corrective actions should be taken.

After adjustment, pick out new packages and check them.

Note! To correct assess crease lines alignment it is important to lift the flaps, since closed flaps might give indications of wrong set of creases lines, but they are due to package folding in the Final Folder Unit, as shown the picture below.

fig.1

1

2

2

2

2

2

2

fig.1

fig.2

fig.3

Bottom view of package

2 2

2 2

fig.4

fig.5

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LS OverlapWith the aid of a vernier calliper check the width of the packaging material overlap, distance B.

If the overlap is out of the range indicated, corrective actions should be taken.

Note! Refer to the Filling Machine Operation Manuals for related measures B.

SurfacesCut two opposite corners (fig.1) and empty the content of the package (fig.2)

Cut transversally the front panel of the package, from the lower cut corner to the opposite one (fig.2 and 3).

Split the TS apart and open the package (fig.4).

Rinse and dry the package with compressed air from the filling machine.

Check the outside and inside surfaces of the package for scratches.

Inside deep scratches might cause package integrity problems.

If there are any defects, corrective actions should be taken.

B

fig.1

fig.2

fig.3

fig.4

5 - 7 (8)Doc. No. BoC-2712261-0101

5.1 Package Forming 5 Package Forming

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5 - 8 (8) Doc. No. BoC-2712261-0101

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Appendix A: Flowcharts and

Troubleshooting

Appendix - 1 (14)Doc. No. BoC-2712261-0101

Appendix A:Flowcharts and Troubleshooting

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Appendix - 2 Doc. No. BoC-2712261-0101

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A.1 Operator Checks . . . . . . . . . . . . . . . . . . Appendix - 5A.1.1 Checking scheme. . . . . . . . . . . . . . . . . . . Appendix - 5

A.1.2 Flowchart of the Production Quality Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 7

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

A.3 Products with Fibres Checks . . . . . . . Appendix - 10

A.4 Troubleshooting . . . . . . . . . . . . . . . . . Appendix - 12A.4.1 Homogeneous (Water-based)

Products . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 13A.4.2 Viscous and Fatty Products . . . . . . . . . Appendix - 14



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A.1 Operator ChecksA.1.1 Checking scheme

The Checking Scheme, present in the OM of the filling machine, describes the recommended sequence of checks to be done on the packages.

The Checking Scheme table explains:

• the event which it is recommended that the package checks are performed immediately after, e.g. Production Start (1).

• the number of packages needed for checks according to which event has prompted the package checks (2).

• the number of packages on which to perform the individual checks (3).• the check to be performed (4).• the page number of the check instructions (5).• to mark the check box when the check has been completed (6)

Note!For some checks, the number of packages checked depends on the number of jaws of the filling machine. This variable is identified as X. X is equal to the number of jaws of the FM (e.g. 2 jaws in TBA/19 and TBA/21, and 10 jaws in Tetra Pak A3/Speed and TBA/22). X+1 means that the number of packages to be checked are equal to the number of jaws plus one package. Refer to the specific machine OM for instructions on how to select and mark the packages for quality checks.

(Cont'd)

1

3

12

3 4 5 6

Production Start

Date Print

Extract from the Checking Scheme schedule

page 123


A.1 Operator Checks


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(Cont'd)

Here below an example of Checking Scheme as you can find it in the OM. These checks can be carried out by the operator in the machine area, during Production. These checks are Filling Machine and PullTab unit dependent due to number of jaws (X variant) of the FM or/and PullTab unit with single or double index (Y variant). Please refer to the machine OM as detailed reference.

1

X

X

X

1

Y

1

1

1

1

1

1

X

X

X

1

Y

1

1

1

1X

Y

Y

Y

Y

Y

Y

1

Y

1

Y

1

X+1

TS (Accurate)

Production start

After a raw material splice

Shape & design

Date print

Weight

Flap sealing

Hole position

Crease lines

Overlap

Surfaces

LS/SA

After a LS strip splice

LS/SA

Shape & design

Date print

Weight

Flap sealing

Hole position

Crease lines

Overlap

Surfaces

LS/SA

Patch & tab sealing

TS TS

TS (Accurate)

Tab position*

Tab position

Patch & tab sealing

After a patch or tab strip splice

Tab position

Patch & tab sealing

Hole position


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A.1.2 Flowchart of the Production Quality ChecksThe Flowchart of Production Quality Checks displays:• the checks to be performed in the sequence described in the checking

scheme table (1)• the type of check (2)• the necessary actions (if any) to be taken depending on the result of the

completed check (3).

Note!For some checks, the number of packages checked depends on the number of jaws of the filling machine. This variable is identified as X. X is equal to the number of jaws of the FM (e.g. 2 jaws in TBA/19 and TBA/21, and 10 jaws in Tetra Pak A3/Speed and TBA/22). X+1 means that the number of packages to be checked are equal to the number of jaws plus one package. Refer to the specific machine OM for instructions on how to select and mark the packages for quality checks.

(Cont'd)

1

1

1

1

2

3

2

3 3

Flap Sealing

TS Rough

Stop Production

TPOP Setting

Call a Technician

OK?

OK?

No

Yes

No

Yes

Extract from Flowchart of operator quality checks

= Legal requirement related check

= Package integrity related check

= Package appearance and line efficiency related check


A.1 Operator Checks


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(Cont'd)

Here below an example of Production Quality Check Flowchart as you can find it in the OM. These checks can be carried out by the operator in the machine area, during Production. These checks are Filling Machine and PullTab unit dependent due to number of jaws (X variant) of the FM or/and PullTab unit with single or double index (Y variant). Please refer to the machine OM as detailed reference.

1

X

X

X

1

1

1

1

1

1

X+1

Shape and design

Date print

Weight

Flap sealing

TS (rough)

Crease lines

Overlap

Surfaces

LS/SA

TS (accurate)

Machine setting

Stop Production

Stop Production

Machine setting

Machine setting

call a technician

Ok?

Ok?

Ok?

Ok?

Ok?

Ok?

Machine setting

Stop Production

Ok?

Ok?

Ok?

call a technician

call a technician

Ok?call a technician

continue Production

additional packages to Laboratory QA checks

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

Stop Production

Machine setting

Stop Production

Stop Production

call a technician


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A.2 Laboratory QC ChecksThese checks must be carried out on regular basis by qualified personnel, in an area appropriately equipped. This allows to constantly monitor the quality of the packages.

X 1

X

X

X

?X

Conductivity test

test ok?no

yes

Leakages by red ink test ok?

no

yes

corrective actions

record results

record results

yes

LS by red ink injection test ok?

no

yes

corrective actions

record results

MTD 1203

MTD 1204

MTD1202

Dissolve packages

urgent check?

noyes

method 1: dissolving in acid solution

method 2: dissolving in alkaline solution

obtain samples

TS integrity by red ink

test ok?

no

MTD 1208

MTD 1208

record results

Heat pattern MTD 1208

Alu-foil TS cracks

MTD 1210

defect found

defect found

defect found

corrective actions

yes


A.3 Products with Fibres Checks


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A.3 Products with Fibres ChecksThese checks can be of help to investigate the behaviour of products containing fibres. Due to the fact that the Transversal Sealing takes place in the product flow, fibres can be trapped in the TS (usually bottom seal for TPA, TBA, TCA and TFA packages, top seal for TWA packages), causing unsterility during storage and transportation.

By definition, the filled product should be homogenous, i.e. no particles must be retained on a sieve 0.6 span.The only non-homogeneous products accepted by TPCA are citrus juices with a maximum fibre content of 5%. Fibres hardness is a parameter that can highly influence performance even though it is not measurable and specified.

Special equipment and packaging material have been designed to reduce the risks of defective seals when packing fibrous products, see table below. For further information, refer to the TPCA Sealing Technology and Food Technology Departments.

(Cont'd)

Item Description Packaging LinesHVA (High Viscosity Aseptic) kit

Helps the product run through the filling system avoiding valve clogging

TBA/8TBA/19

Special packaging material TBA/lk-25 and TBA/lk-36

The LLDPE film improves packing of hard particles

All except TBA/3

Modified counter pressure rubber dollies in combination with modified jaw system settings

Help to free the sealing area from particles

TBA/3TBA/8TBA/9TBA/19TBA/21

Non-trapped fibre

Trapped fibre

Bottom seal

Top sealUpper package

Lower package


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(Cont'd)

The following flowchart represent part of a test procedure which should be carried out on a representative batch of at least 6000 packages to get reliable results. The procedure should be performed before and after full distribution (i.e. transportation).

300

100 ?

Conductivity test.

MTD 1203

test ok?no

yes

Dissolve packages

no

yes

Dissolve packages

no yes

fibres are not a problem


fibres may be a problem

fibres in TS?

fibres in TS?

test ok?

no

fibres may become problem

yes

fibres are not a problem

defective packages

fibres are a problem

Appendix - 11Doc. No. BoC-2712261-0101

A.4 Troubleshooting


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A.4 TroubleshootingThese checks take place during troubleshooting to investigate if the unsterility is due to package integrity. Care in every step of the evaluation is important since the methods are destructive and packages will not be available for further checks afterwards.

Package forming and data printing should be analysed and recorded since they may add relevant information to find the cause of unsterility.

The procedure is slightly different for homogeneous (water-based) products (e.g. water, fruit juice) and viscous or fatty products (e.g. cream, tomato sauce).

The Conductivity Test is not effective with packages filled with fat products, as fat can create a layer which covers the defects and does not allow the flow of current. The Red Ink Test is performed instead. Products like cream might interact with packaging material causing a phenomenon called Environmental Stress Cracking.

The optimal population to investigate consists of the blown package (which most likely will show also burst spots on the TS) and the packages produced close to it (most likely belonging to the same tray).

The overall troubleshooting procedure should be performed by:• FiSQA Officers• System Specialists• Senior Tetra Pak Field Service Engineers• Senior Technical Support Staff.


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A.4.1 Homogeneous (Water-based) Products

X

X

X

X

X

?

X

Conductivity test

test ok?no

yes

Dissolve packages

urgent check?

noyes

method 1: dissolving in acid solution

* method 2: dissolving in alkaline solution

get samples


test ok?

no yes

corrective actions

MTD 1203

MTD 1208

MTD 1208

packages are integer


Weight, date print

perform A.1 Operator Checks

(*) Recommended

MTD 1210

Alu-foil TS cracks

Leakages by red ink test ok?

yes

record results and corrective actions

MTD1204

no

test ok?

yes

nodefect found

defect found

defect found

corrective actions

Appendix - 13Doc. No. BoC-2712261-0101

A.4 Troubleshooting


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A.4.2 Viscous and Fatty ProductsWash the inside of the packages with warm water and alcohol before performing the test, to take away as much product residue as possible, at ambient temperature.

X

X

X

X

X

X

X

Leakages by red ink

Dissolve packages

urgent check?

noyesmethod 1: dissolving in acid solution

* method 2: dissolving in alkaline solution

obtain samples


test ok?

MTD 1204

MTD 1208

MTD 1208

packages are integer


Date, Printing, Forming

MTD 1210

Alu-foil TS cracks

(*) Recommended

yes

test ok?

yes

no

no

test ok?

yes

no

corrective actions

defect found

defect found

corrective actions

defect found

corrective actions

Crease, Flap alignment

perform A.1 Operator Checks


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Appendix B: Tools and Chemicals


Appendix B:Tools and Chemicals

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This chapter contains description and materials used in Package Integrity test methods.

Appendix - 2 (24) Doc. No. BoC-2712261-0101

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B.1 Area Requirement . . . . . . . . . . . . . . . . . Appendix - 5

B.2 Tools and Equipment . . . . . . . . . . . . . . Appendix - 6

B.3 Preparation of Chemicals . . . . . . . . . . Appendix - 13B.3.1 Copper Solution . . . . . . . . . . . . . . . . . . . Appendix - 14B.3.2 Dissolving Solutions . . . . . . . . . . . . . . . Appendix - 16

B.3.2.1 Acid Dissolving Solution (very fast method) . . . . . . . . . . . . . . . . . . Appendix - 17

B.3.2.2 Acid Dissolving Solution (fast method) . . . . . . . . . . . . . . . . . . . . . . Appendix - 19

B.3.2.3 Alkaline Dissolving Solution (slow method) . . . . . . . . . . . . . . . . . . . . . Appendix - 20

B.3.3 Leakage Detection Fluid . . . . . . . . . . . . Appendix - 21B.3.3.1 Red Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 21B.3.3.2 Blue Ink. . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 23



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Appendix B:Tools and Chemicals B.1 Area Requirement

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B.1 Area RequirementAn adequately equipped area must be available to carry out integrity tests. The area must be ventilated and with good illumination.

A fume extractor is needed for the preparation of the dissolving solutions. Running water is needed. Compressed air can be useful.

1 56

233

4

1 Conductivity2 Water3 Magnifying lenses4 Compressed air5 Microscope6 Dissolving station


B.2 Tools and Equipment Appendix B:Tools and Chemicals

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B.2 Tools and EquipmentHere you have a list of tools and equipment used in Package Integrity Methods, with reference to the specific method in which they are needed and item code.

Name Picture Supplier and code Used inRolling ball point pen (felt tip pen (red)

Any 2.2.4-1 Rolling ball point pen test (after mechanical tear down)

Permanent pen Any All

Scissors Fiskars

No. 9451-7097

All

Pinking scissors

Fiskars

No. 9445-7097


1.4 Transversal Seal - Al-Foil Cracks (MTD 1210)

Cutter Any

Note! Snap off blades are not used in many food industries. Refer to local regulation.

All

Paper towels Any All


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Light source Any 1.4 Transversal Seal - Al-Foil Cracks (MTD 1210)

Beakers Any B.3 Preparation of Chemicals

Pipettes Any B.3 Preparation of Chemicals

Water tray Any

Note! Cat litter tray (HDPE) can work very well.



Name Picture Supplier and code Used in



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Disposable syringe

needle ø 0.4-0.5 mm 2.3 Longitudinal Seal - Red Ink Injection

Gloves Any All

Safety goggles Any 1.3 Transversal Seal - Dissolving and Red Ink (MTD 1208)B.3.1 Copper Solution

Tongs Any (wooden material is preferable)




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Abrasive sponges

Any 1.4 Transversal Seal - Al-Foil Cracks (MTD 1210)

Magnifying lamp with in-built light

Any(this model is PEAK)


Magnifying lenses

Peak

Scale Lupe 10X No.2028 (78073-101)

Zoom Lupe 816 No.2044

Scale Lupe 10X No.1983

Light Lupe 15XTP No. 1326015



Stretch pliers Tetra Pak

No.78073-0101

Spare parts:Small spring No.566772Big SpringNo.566773





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Zonoscope Tetra Pak

No.90243-0203


2.2 Longitudinal Seal (LS/SA) - Tearing (MTD 1202)

PullTab positioning (OM)

Ammeter Tetra Pak

No.90243-0110


Copper tester Tetra Pak

No.90459-0095


Water bath (bain-marie)

Dinkelberg

No.ATH232319




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Use of the ZonoscopeThe zonoscope is a polarizer which allows to better enhance and analyse the heat pattern of the LS. It does not give any indication on the quality of the sealing as far as distribution of pressure is concerned.

When analysing the LS through the zonoscope, a different range of colours appear (dark blue and brown); this is due to the fact that the multilayer plastic of which it is made filters the light reflected from the Al-foil differently from the PE of the LS.

The zonoscope has two sides. The one marked with a double circle is designed for TBA/K packaging material; turn this side facing upwards when analysing TBA/K. The other, marked with two lines, is intended for all the other packaging materials.

Either way, turning the zonoscope only changes the range of visible colours as light is filtered differently; therefore choose the side which better enhances the heat pattern under investigation.

The zonoscope is also widely used in PT applications to locate heat distribution.

(Cont'd)

TBA/lk

TBA/j



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(Cont'd)

Use of the Electrolyte Copper Tester

CAUTIONRisk of instrument damage.Never switch On the tester when the electrodes are in short circuit.

Press the Push button for approximately four seconds to turn on the tester.

The green LED 100µA lights up; the tester acts as voltage generator and detects the current loss between two liquids by the two electrodes. The display shows the value of the current deflection.

Press the Push button once again to make the tester produce electrolysis acting as current generator. The red LED 100mA lights up. The display shows the value of the current circulating between the two liquids.

The tester switches off automatically if there is no current circulating for 5 minutes.

To switch off the instrument manually, press the button Push for five seconds.


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Appendix B:Tools and Chemicals B.3 Preparation of Chemicals

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B.3 Preparation of ChemicalsHere you have a list of the chemicals used in Package Integrity Methods. Specific information about each chemical preparation and usage follow.

Name Picture Supplier and code Used in Copper solution Preparation is required,

see B.3.1 Copper Solution


Dissolving solutions(alkaline or acid)

Preparation is required, see B.3.2 Dissolving Solutions


Leak detection fluid(red ink)

Can be ordered from Tetra Pak on TP No.90298-26 or prepared according to section B.3.3 Leakage Detection Fluid


2.3 Longitudinal Seal - Red Ink Injection

3.2 Opening Devices - PullTab (MTD 1211)

4.4 Package Integrity - Red Ink Test (MTD 1204)

Leak detection fluid(blue ink)

Preparation is required, see B.3.3.2 Blue Ink

Not used in TPCA Package Integrity Methods


B.3 Preparation of Chemicals Appendix B:Tools and Chemicals

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B.3.1 Copper SolutionRuptures in the inner PE layers can be detected by the conductivity test (MTD 1203). The package is immersed in an electrolytic solution (i.e. salt solution). In case of a crack in the PE layers, which leave the Al-foil uncovered, an electrical contact is established between the electrolytic solution outside the package and the package content. If some copper solution is poured into the package, the copper concentrates in the area of the cracks when a copper tester is used, allowing to locate the fault.

Ingredients• Cu2SO4.5H2O• Emulsifying agent• Distilled water• HNO3 (concentrated 65%)

1Weight 100 g of Cu2SO4.5H2O in a plastic beaker.

2Put a 1 l flask on the scale. Reset and add 0.5-1.0 g of any emulsifying agent using a pipette.

Add 200 cm3 distilled water.


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3Mix the solution well with a magnetic agitator. Add the Cu2SO4.5H2O.

Add 800 cm3 of distilled water while mixing. Make sure that the Cu2SO4.5H2O is completely dissolved.

4

CAUTIONRisk of personal injury!Use protective goggles and gloves when handling HNO3; put the acid into the solution, never the other way round

Add 2.6 g of concentrated (65%) HNO3 with a syringe and mix for additional 5 minutes.

The copper solution is ready.

Store the solution in a glass bottle, filter or decant it after usage.



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B.3.2 Dissolving SolutionsThese solutions can be used to dissolve the Al-foil and separate the internal polyethylene bag from the remainder of packaging material layers, when the Transversal Seal is under investigation.

1) Acid solution (very fast method), follow B.3.2.1 Acid Dissolving Solution (very fast method).

2) Acid solution (fast method), follow B.3.2.2 Acid Dissolving Solution (fast method).

3) Alkali solution (slow method), follow B.3.2.3 Alkaline Dissolving Solution (slow method).

Refer to the 1.3.3-2 Dissolving of packages chart at page 1-22 for determine which type of solution is more suitable:

Note!Hydrofluoric Acid is used in local applications but fumes that give off are of health concern.

(Cont'd)


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(Cont'd)

B.3.2.1 Acid Dissolving Solution (very fast method)

WARNINGRisk of personal injury!Observe safety regulations when working with acids. Preparation and handling of HCl solutions must be carried out in a well-ventilated environment, as fumes may be given off. Always wear protective goggles and gloves. Use heat resistant beakers for preparation and storage. Exhausted chemicals must be disposed of in accordance with current regulations. Never poor water into the acid but always acid in water.

Three different solutions are used, which we will call:1) HCl 1:1 Solution,2) HCl 1:3 Solution,3) Neutralizing Solution.This method is very fast, therefore it is advisable when the results of the test are urgent. A fume extractor and a water bath are needed.

Ingredients:• HCl (37% - starting solution as commercially available),• Distilled water (1:1),• CuCl2,• Na2CO3 in cristals.

(Cont'd)



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(Cont'd)

1) HCl 1:1 Solution (Hydrochloric acid at 60° C)Note!The solution is prepared at room temperature but must be heated using a water bath at 60° C when in use.

a) Dilute the concentrated HCl in distilled water (1:1) at room temperature.b) Add 1wgt % CuCl2 (e.g. 1 l. HCl, 1 l. distilled water, 20 g. CuCl2) at

room temperature.c) Store the solution in a glass container with a glass lid when not in use.

The bath can be filtered at room temperature and reused.

2) HCl 1:3 Solution (Hydrochloric acid at room temperature)

a) Dilute the concentrated HCl in distilled water (1:3).b) Add 0.5 wgt % CuCl2 (e.g. 250 cm3 HCl, 750 cm3 distilled water,

5 g.CuCl2);c) Store the chemical in a glass container with a glass lid. The bath can be

filtered at room temperature and reused for several TS examinations.

3) Neutralizing Solution (Sodium Carbonate at room temperature)Note!Bath 3 spoils very quickly. If the solution does not start to bubble as soon as the samples are immersed into it, prepare a new one.

a) Prepare 10 wgt % solution of Na2CO3 in distilled water (e.g. 100 g. Na2CO3, 1 l. distilled water) at room temperature.

b) Store the chemical in a glass container with a glass lid. The bath can be filtered at room temperature and reused.


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B.3.2.2 Acid Dissolving Solution (fast method)

WARNINGRisk of personal injury!Observe safety regulations when working with acids. Preparation and handling of HCl solutions must be carried out in a well-ventilated environment, as fumes may be given off. Always wear protective goggles and gloves. Use heat resistant beakers for preparation and storage. Exhausted chemicals must be disposed of in accordance with current regulations. Never poor water into the acid but always acid in water.

Two different solutions are used:1) Acid Solution,2) Neutralizing Solution.This method is fast, but slower than the method at B.3.2.1 Acid Dissolving Solution (very fast method). A fume extractor is needed.

Ingredients:• HCl (37% - starting solution as commercially available),• Distilled water (1:1),• Na2CO3 in cristals.

1) Acid Solution (Hydrochloric acid)Prepare an acid solution of HCl 30% (e.g. for 3 litres solution put 600 ml of water in a beaker and add carefully 2400 ml of HCl 37%).

2) Neutralizing solutionPrepare 10 wgt% Na2Co3 in distilled water (e.g. 100 g Na2Co3 and add water until the solution is 1 litre.



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B.3.2.3 Alkaline Dissolving Solution (slow method)Ingredients:• Distilled water,• NaOH

Prepare a 15% NaOH solution with distilled water. Stir the solution while adding water to the NaOH pellets. The solution warms up while adding water. Do not wait too long before using the solution or it may lose its efficiency.

Note!CIP solution (normally 30% with no added cleaning agents) can be used after dilution 1:1


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B.3.3 Leakage Detection FluidB.3.3.1 Red Ink

Red ink is pure isopropanol based solution (99.5%), which has the characteristic of penetrating the small cracks and pinholes which can be present inside the package. The red colour is due to the addition of erithrosine, and it allows to visually detect the ink leakage, which simulates the penetration of microorganisms across the packaging material layer. Isopropanol has a high capillary action but does not interact, at room temperature, with the internal plastic layers of the package.

Other solvents, like turpentine, would damage PE and therefore give false results, whereas Ethylic Alcohol (Ethanol) cannot be used worldwide due to special local regulations.

Ingredients• Erythrosin β, sodium salt• Isopropyl alcohol (99.5 %, commercial purity)

1Weight approximately 1.5 g of powder Erythrosin β.



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2Mix the Erythrosin β with 1 l. of Isopropyl alcohol.

Shake well and leave to decant overnight.

3Filter the solution with a funnel covered with a paper towel, into a spare container.

The red ink is ready to be used.

Store the red ink in a convenient cabinet at room temperature, in a closed container to reduce evaporation.


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

Ingredients• Methylene blue• Emulsifying agent• Ethanol (95%, commercial purity).• Distilled water

1Weight 5 g of Methylene blue.

2Warm up 1 l. distilled water in a heat resistant flask at about 45 °C.

Dilute the Methylene blue into the distilled water.

Mix the solution using a magnetic agitator.



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3Add 5 cm3 of emulsifying agent (Polyoxyethylene (20) Sorbitan Mono-oleate) using a pipette and mix well with the magnetic agitator.

4Remove the flask from the agitator and add 200 cm3 Ethanol.

Close tight and shake the solution well.

Blue ink is ready.

Store it at room temperature in a closed container to reduce evaporation.


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Appendix C: Data Record


Appendix C:Data Record

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Documenting and recording any changes related to package integrity tests are of the utmost importance at any stage of the product cycle, i.e. during Production and during laboratory checks.

If unsterility problems occur and a troubleshooting procedure is needed, it is vital to trace back past production parameters and events to have a complete picture of the situation.

In some countries, such as USA, Regulatory Agencies require the documentation of the defects detected and of all the related corrective actions.

This section includes examples of forms which can be used as reference.


Table of ContentsTe

chP

ub_2

6143

45_0

103

- A3_

2712

261_

01_e

n.fm


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C.1 Production Package Recording Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 5

C.2 Laboratory Package Recording Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 6

C.3 Sample Collection Form . . . . . . . . . . . . Appendix - 7

C.4 Troubleshooting General Data Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix - 8



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Appendix C:Data Record C.1 Production Package Recording Sheet

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C.1 Production Package Recording SheetP

rod

uct

ion

Pac

kag

e R

eco

rdin

g S

hee

t

Dat

eID

eve

nt

Pac

kag

esco

des

Pro

du

ctP

ML

Sle

gen

d

Mac

hine

type

type

tem

pera

ture

type

P.O

.ty

peP

.O.

V =

pass

ed

Mac

hine

num

ber

KO

= n

ot p

asse

d

Ope

rato

r si

gnat

ure

X =

not p

erfo

rmed

Not

e: p

acka

ges

test

ed a

s fr

om e

vent

sch

eme

on O

M p

acka

ge c

heck

s

Ch

ecks

lab

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ate

pri

nt

Wei

gh

tT

S r

ou

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TS

acc

ura

teS

hap

e an

d

des

ign

Fla

p s

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gC

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e lin

esO

verl

apS

urf

aces

LS

/SA

IDti

me

even

tn

.pac

ksta

ken

chec

k bo

xch

eck

box

chec

kbo

xse

tting

chec

k bo

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tting

chec

k bo

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eck

box

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ara

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agol

i

EXAMPLE

EXAMPLE


C.2 Laboratory Package Recording Sheet Appendix C:Data Record

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C.2 Laboratory Package Recording SheetL

abo

rato

ry P

acka

ge

Rec

ord

ing

Sh

eet

Dat

eID

eve

nt

Pac

kC

od

es

Pro

du

ctP

ML

S

Mac

hine

type

Typ

eT

empe

r.T

ype

P.O

.T

ype

P.O

.C

hec

k b

ox

leg

end

Mac

hine

num

ber

V =

pas

sed

Ope

rato

r si

gnat

ure

KO

= N

OT

pas

sed

X =

not

per

form

ed

Ch

ecks

Pac

kag

e in

teg

rity

TS

qu

alit

y b

y d

isso

lvin

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by

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ink

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Sam

ple

IDC

ondu

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ityR

ed in

kH

eat p

atte

rnR

ed In

k

Top

Bot

tom

Top

Bot

tom

Top

Bot

tom

Top

Bot

tom

IDev

ent

link

n.da

tem

achi

nech

eck

box

chec

k bo

xch

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box

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k bo

xch

eck

box

chec

k bo

xch

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box

chec

k bo

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eck

box

01 02 03 04 05 06 07 08 09 10 01 02 03 04 05 06 07 08 09 10

LabC

heck

For

m1.

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agol

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EXAMPLE


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Appendix C:Data Record C.3 Sample Collection Form

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C.3 Sample Collection Form

Sample Collection SheetMachine Type DateMachine Number TimeOperator Name Batch No.

Link No.

TOP

BOTTOM

Comments:

updated 13/09/2004

monica malagoli

sara davolio

EXAMPLE


C.4 Troubleshooting General Data Form Appendix C:Data Record

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C.4 Troubleshooting General Data Form

Troubleshooting Sheet - General Data

Test Code (if more than one)

Date

Report Reference

Package VolumeFamily

Opening

Filling Machine TypeDevelopment Step

Serial number

Customer Filling productProduction Date

Exp.DateProduct temperature (C)

Packaging Material DesignPackaging MaterialConverting factory

P.OrderLS Strip

Al-FoilThickness(µ)

Sealing Configuration Cutting RailEnd Pieces

InductorsDollies

Pulse TimeTS Setting

Jaw pressure (bar)Jaw Gap (mm) if not standard

TS working window performed?TS working window settings and location

Purpose of the Test Short descriptionAmount of Samples

Package Integrity Unsterility RateRed Ink

TS CracksInner bags

heat Pattern

Numbering ProgressiveProject number

Notes

EXAMPLE


This

is a

n u

nco

ntr

olle

d p

rin

t o

ut

of t

he

do

cum

ent


This

is a

n u

nco

ntr

olle

d p

rin

t o

ut

of t

he

do

cum

ent