Nestle Binh An Growth: Aseptic System Training

Nestle Binh An
GROWTH
Aseptic system
Training
August 25th 28th, 2014
TM-TPVN/HT
7/23/16
Agenda: 4 days
Day 1: Milk & Aseptic technology

08:00 08:30: Introduction
08:30 09:30: Aseptic processing systems
09:30 10:00: Thermal treatment definitions
10:00 10:30: Break
10:30 11:00: Basic microbiology
11:00 12:00: Time-temperature combinations
12:00 13:00: Lunch
13:00 13:30: Time-temperature combinations
13:30 13:45: Milk properties
13:45 14:00: Type of milk
14:00 14:30: Alcohol stability
14:30 14:45 : UHT systems
14:45 15:00: Types of UHT
15:00 15:30: Break
15:30 15:45: Available TP portfolios
15:45 16:00: Selection guide
16:00 17:00: Processing parameters
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Agenda: 4 days
Day 2: UHT
08:00 08:30: UHT Operation
08:30 09:00: Technical data
09:00 09:30: Main components & functions
09:30 10:00: Break
10:00 10:30: Process steps
10:30 12:00: P&ID detailed tracing - Use colored P&ID
12:00 13:00: Lunch
13:00 13:15: Critical control points
13:15 13:30: Cleaning
13:30 14:00: Activation chart
14:00 14:45: Alarm handling
14:45 15:15: Break
15:15 15:30: Recording
15:30 17:00: Hands-on
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Agenda: 4 days
Day 3: UHT (cont.)

08:00 09:00: The operator manual
09:00 10:00: Basic instructions to use
10:00 10:30: Break
10:30 11:00: Maintenance UHT
11:00 12:00: The maintenance manual
12:00 13:00: Lunch
13:00 13:15: Knowing the preventive maintenance system
13:15 13:30: Basic instructions to use Spare parts catalogue
13:30 14:30: Trouble shooting
14:30 15:00: Break
15:00 16:00: Trouble shooting
16:00 17:00: Hands-on
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Agenda: 4 days
Day 4: Aseptic Tank

08:00 08:15: Aseptic tank systems
08:15 08:45: Operations, processing parameters
10:00 10:30: Break
11:00 11:30: Process steps
11:30 11:45: P&ID detailed tracing Use colored P&ID
12:00 13:00: Lunch
13:00 13:15: Cleaning
13:15 14:00: Trouble shooting & Alarm Handling
14:00 14:30: Break
14:30 15:00: Operation manual
15:00 15:15: Maintenance Aseptic Tank
15:15 15:30: Preventive maintenance system
15:45 16:15: Hands-on
16:30 17:00: Summary & Evaluation
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Day 1:
Milk & Aseptic technology
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Aseptic processing systems

Absolute sterility not possible
Bacteria
N
Logarithmic destruction
Time/temperature would be
too drastic
Not possible to prove
by random testing
Not possible to prove sterility
(prove absence)
t Time
PSD.TPD&B.TH.3.02, AA05
Sterilization of food requires that all living

microorganisms be inactivated, including the
pathogens.
Product remains fresh for months without
refrigeration and preservatives.
Product:
Low acid (food pH > 4.5, milk pH > 6.5)
High acid (food pH < 4.5, milk pH < 6.5)
Product
Temp(C)
Time
Low acid
135-140
A few seconds
High acid
90-95
15-30 seconds
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UHT - Ultra High Temperature
Vegetative cells
Yeast
Spores
Pathogenes
Mould
Virus

UHT - Ultra High Temperature
Vegetative
cells
Pathogenes
Spores
Yeast
Mould
Virus

Ultra High Temperature processes
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Machine Introduction General

Product lifetime
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Pre-processing
Deaeration
Separation
Standardization
Homogenization
Pasteurization
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Deaeration with Tetra Alrox
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Homogenization
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Homogenization of dairy products
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Thermal treatment definitions
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Sterilization
A process applied to a product with the object of

destroying all micro-organisms (by heat treatment
exceeding 100C)
Sterile
Condition in which living cells are absent or killed.
Sterilizer
Equipment used for sterilization: autoclave, hydrostatic

sterilizer or aseptic processing plant
Commercially sterile product
Product which is free from micro-organisms that can

grow and contribute to its deterioration under the
intended storage conditions
Aseptic
Condition to prevent bacteriological contamination

The commercially sterile product must
Keep without deterioration
Remain stable and good commercial

value during storage
Free from micro-organisms and toxins

harmful to the health of consumers
Absolute sterility not possible
Thermal destruction is logarithmic
Not possible to prove by

random testing

D-Value
The express D65 = 1 min
means that the number of organisms is
reduced with 1 D when treated one minute
at a processing temperature of 65 C.
2 minutes exposure results in 2D
1D = 90% reduction = 1 LCR
2D = 99% reduction = 2 LCR
3D = 99,9% reduction = 3 LCR
4D = 99,99% reduction = 4 LCR
LCR: Logarithmic Reduction

Sterilization Efficiency
The Sterilization Efficiency of a
process is the number of LCR that
it gives on the most resistant
microorganism.

z-Value
Is the change in temperature in C required
to cause 10 fold change in D-value
z = (T1-T2)/(logD1-LogD2)
A certain micro-organism is
characterized by a z-value of 10 C

Most heat resistant of spores
Bacteria
D90-value (hrs)
B. Stearothermophilus
B. Subtilis
B. Cereus
> 100
30
C. Botulinum, strains A
D121-value (sec)
300
60
3
C. Botulinum, strains B/E <0,02
12
1,4
< 0,05

Typical killing data for some micro-organisms
Group of Orgsm
D-value (min)
Vegetative Bacteria
(heat sensitive)
65
Vegetative bacteria
(heat resistant)
10
65
Bateria spores
0,2
121
Yeast and Mould
65
Mould
3
(heat resistant ascospores)
90
Temp (C)

Definition of F0-value
The F0 makes it possible to compare the effect
of different time/temperature combinations
t
= sterilization time (s)
T = sterilization temperature, (C)

z = the increase in temperature
necessary to obtain the same
effect in one tenth of the time
F0 = 1 when heated one minute at 121.1C
F0 3 to achieve a commercially sterile product

Definition of C*-value
C*-value is an indicator of chemical
changes in the product associated
with heat treatment
C* = 1
= heat treatment at 135C for 30.5 s.
and z = 31.4C
= 3% destruction of thiamine

Lactulose value
Indirect measurement of chemical changes
Lactulose is a type of milk sugar formed at

elevated temperatures and indicates the
extent of chemical changes to the product
e.g. the heat load
Lactulose is the way of measuring the

heat load on UHT milk, and also has
the advantage that its formation is
possible to calculate theoretically,
given the time-temperature curve
UHT treatment
Finding the optimal combination

of temperature and time
Sterilization effect
Chemical changes
Break
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Basic microbiology
Bacteria
Yeasts
Moulds
Basic microbiology
Multiplication of bacteria
1024
10 000 000
bacteria bacteria
30 min.
Generation time
30 min
11,5
hours
Basic microbiology
Temperature
conditions for
Maximum
Optimum
bacterial
growth
Minimum
Basic microbiology
Classification
of bacteria
by temperature
preference
Thermophilic
45 C
Mesophilic
20 C
Psychrophilic
7 C
Psychrotrophic
Basic microbiology
The influence of Temperature
Bacterial development in raw milk
Mio Bact/ml
Hours
Time-temperature combinations
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Time-temperature
Lethal effect on bacteria
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Time-temperature
Destruction of enzymes and micro-organisms
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Time-temperature
Combinations needed for destruction of spores
Lunch
Milk properties
Analyse of milk
The common tests carried out
on milk supplies are:
taste and smell

cleaning
sediment
somatic cell count
bacteria count
protein content
fat content
freezing point
Milk properties
Composition of Cow's Milk
Fat 4.1%
Protein 3.4%
Lactose 4.8% MSNF
Salt 0.7%
Water 87%
Total solid
=
Dry matter
Milk properties
Size of Cow's Milk Constituents
Whey Proteins
Bacteria
Lactose
Casein
Fat
Salts
0,0001
0,001
0,01
0,1
1,0
10,0
Particle size
100,0
Milk properties
Structure of milk
Fat globule
Skim milk
Milk properties
Raw milk quality
for processability:
pH
alcohol stability
6.65-6.80
>75%
for sterility level:

limit of heat resistant spores
Milk properties
Comparison of processability of Buffalo milk and Cows milk
Quality
Cows milk
Buffalo milk
Fat content (%)
3,2 - 4,8
6-7
Protein content (%)
3,2 - 3,4
4,3 - 4,5
Casein content (%)
2,6 - 2,8
3,51 - 4,36
Whey proteins (%)
0,6 - 0,8
0,53
75
142,2
6,65 - 6,80
6,9
80
72
Colloidal Ca (mg/100ml)
pH
Alcohol stability (%)
Milk properties
Quality parameters for raw material UHT products
Improvement of
hygienic
conditions in raw
material
production
Total Count
Flavour
Adulteration
Somatic Cell Count
Etc.
Factors pertaining to
the suitability of
production
Spore Count
Protein Stability
pH
Dirt particles
Thermoresistant
enzymes
Etc.
Types of milk
UHT systems
UHT systems
Full range of solutions
Direct heating
Injection
Infusion
Indirect heating
PHE
THE
UHT systems Selection guide

Objective advice!
Premium
quality
4 UHT technologies
Tetra Pak masters
them all
Your demands
decide!
DIRECT
DIRECT
UHT UHT Product
properties
injection
infusion UHT
INDIRECT
INDIRECT
UHT
PHE
THE
Outstanding
efficiency
Types of UHT
Direct or indirect?
Direct UHT
Steam injection or steam infusion
Almost instantaneous heating & cooling
Low impact on quality
Higher operating cost
160C
Direct
Indirect
140C
120C
100C
Indirect UHT
80C
Tubular or plate heat exchanger

Somewhat slower heating and cooling
Somewhat higher impact on quality
Lower operating cost
60C
40C
20C
Pasteurization
20
40
60
80
100
120
SEC
Available TP Portfolios
Indirect systems
Tetra Therm Aseptic Flex
Direct systems
Tetra Therm Aseptic VTIS
Aseptic tank system
Tetra Alsafe LA
Aseptic dosing
Tetra Aldose
Aseptic dosing
Tetra FlexDos
Cost-effective
Efficient operation by indirect

heating in tubular heat exchanger
Applications from white milk to
high viscous ice cream mix
Capacities from 2,000 - 40,000l/h
TA Flex Simplified flowchart
Tetra Spiraflo
Tubular heat exchanger (THE)

Floating ends for thermal expansion
Tetra Alex homogenizers
Improved efficiency
with counter-pressure
Efficient break-up of
clusters
Minimal number of
spare parts
Premium product quality
Direct heating by steam injection or

steam infusion
Applications from white milk to high
viscous ice cream mix
Capacities from 2,000 - 30,000l/h
TA VTIS
Simplified flowchart
Direct steam injection
Instant heating, temperature equilibrium and condensation

Very low fouling outstanding cleanability
Unique verified performance
Steam infusion
Patented air
insulation design
reduces fouling
Patented, even
steam distribution
Flash cooling
High-precision temp. control
Large product surface gives

instant cooling
Low carry-over
Unique, built-in condenser

gives short pre-sterilization
and cleaning times
Extremely low hold-up

volume
Easy access for inspection,

service and maintenance
Processing principles
UHT milk manufacturing process
Pre-sterilization
Production
(Aseptic Intermediate CIP AIC)
CIP
Day 2:
UHT
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UHT Operation
Tetra Therm Aseptic Flex - NG CM

Ser. No.: T5844151227
Indirect UHT
Continuous aseptic processing module
Using Tubular Heat Exchanger (THE)
Product: Milo
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Technical data
Tetra Therm Aseptic Flex - NG CM

Ser. No.: T5844151227
Indirect UHT
Continuous aseptic processing module
Using Tubular Heat Exchanger (THE)
Product: Milo
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Technical data
Noise Emission
Product configuration
Connection data
Specification, heat exchanger
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Main components and functions
Feed module
Booster module
THE
Homogenizer
Local control panels (FCP)
Motor panels (MCC)
Homogenizer panel (MCC)
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Main components and functions
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P&ID detailed tracing - Use colored P&ID

Main sides
Pre-heating
Holding cell
Aseptic side
Cooling
Balance Tank
Hot water side
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Measuring points
TC67
TC44
TSL42
PC78
PT05
TT08
PC74
PC68
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Hot water circuit
M10
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Hot water circuit
M9
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Machine Introduction Main steps
Sterilizing
Production
AIC
CIP
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Activations diagram
Sterile water Production AIC Shutdown EM Emptying
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Activations diagram
Full CIP
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Activations diagram
Adapted Cleaning
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Activations diagram
Header batch sub-program
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Machine steps
Process cycle: Phases and Steps
Step 1 17: Sterile water
Step 21 45: Production
Step 51 55: AIC
Step 70 71: Shutdown
Step 80 85: Emergency emptying
Step 101 149: CIP (Full cleaning)
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Machine steps Sterile water

Step 1 - 17
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Step 1: Activate Valves
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Step 2: Activate Pumps
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Step 3: Fill up Plant
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Step 4: Active Steam
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Step 5: Heating
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Step 6: Sterilizing
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Step 7: Cooling 1
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Step 10: Cooling 2
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Step 11: Cooling 3
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Step 12: Stabilizing
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Step 17: Sterile Water
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Step 17: Hibernation ( Be skipped if no time)
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Machine steps Production

Step 21 - 45
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Step 21: Prepare Production
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Step 24: BTD Emptying
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Step 26: Fill BTD over Low Level
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Step 27: Fill Machine, Mix to Dest.
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Step 28: Fill Machine, Pure to Dest.
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Step 29: Production
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Step 41: Fill. Mix in BTD
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Step 42: Empty BTD
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Step 43: Empty. Machine to Dest.
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Step 43: Empty. Machine to Dest.
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Step 44: Empty. Machine to Reclaim
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Step 45: Rinsing
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Machine steps AIC

Step 51 - 55
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Machine steps AIC

Step 51: Wait for Metering
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Machine steps AIC

Step 52: Caustic Dosing
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Machine steps AIC

Step 53: Caustic Circulation
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Machine steps AIC

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Machine steps AIC

Step 55: Rinsing
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Machine steps Shutdown

Step 70 - 71
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Step 71: Rinsing
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Machine steps Emergency emptying

Step 80 - 85
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Step 80: Act. Valves
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Step 84: Empty. Machine to Reclaim
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Step 85: Rinsing
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Machine steps CIP (Full cleaning)

Step 101 - 149
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Machine steps Full Cleaning

Step 101: Activate Valves
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Step 102: Activate Pumps
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Step 103: Fill up Plant
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Step 104: Activate Steam
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Step 111: Rinsing + Metering
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Step 113: Caustic Dosing
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Step 114: Caustic Circulation
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Step 121: Rinsing + Metering
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Step 124: Acid Dosing
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Step 125: Acid Circulation
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Step 148: Rinsing LT
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Step 149: Rinsing
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Critical control points (CCP)
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Sterilization temperature TC44, TSL42:
Return line temperature TSL71
Sterilization Water Sterile Production AIC
Homogenizer pressure PT827, 827.2
Production
Product side flow-rate FC06, FC04
Product holding tube pressure PSL05
Sterilization, CIP
Homo steam barrier temperature TSL30, TSL831
Production
Product temperature at outlet TC26, TI06
Production
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Care and Cleaning
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Care and Cleaning

Verify Cleaning
Daily check
Check recorder to see if cleaning completed correctly
Lye/Acid concentration
Homogenizer dampers: Disassemble dampers to ensure an air
cushion inside and:
No product residues after cleaning
Manually cleaning if necessary
Balance tank CIP nozzles
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Care and Cleaning

Verify Cleaning
Recommended check
Regularly weekly/monthly verify the cleaning result at critical points

such as Holding cell.
Visual check for any product residues after cleaning.
Make a swab test to check to cleaning result.
If necessary, adjust the cleaning circulation time and detergent
concentration.
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Care and Cleaning

Cleaning CPP
Holding cell (HC)

Homogenizer dampers
V51
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Care and Cleaning

Recommended detergents & Concentration
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Care and Cleaning

External cleaning
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Alarms
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Alarms
Fault indication
When a fault occurs, the alarm lamp will start to

flash
Red lamp: Danger indication
o Flashing or continuous
Yellow: Fault indication
o Flashing light: unacknowledged alarm
o Continuous light: acknowledged alarm
Green: Normal operation
o Flashing: Attention required, function
o Continuous: Function in operation
ends
Always investigate the cause of fault indication. Otherwise you

may endanger the equipment or the product.
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Alarms
Alarm Handling
Divided into 2 categories: A, B and C alarms

A Faults that will cause an alarm only, they are not critical
but it will make the operator aware of an incident.
B Faults that will start corrective actions in the control
system. These actions are described in Alarm list.
C Faults that start interlock
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Alarms
Alarm list & Troubleshooting
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Alarms
Alarm list & Troubleshooting
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Recording
Logoscreen 500CF
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Day 3 - Operation Manual

Control panel
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Control Panel
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Operator Panel (TPOP, HMI)

General
HMI is link between TTA Flex PLC and operator
Operator -> PLC:

Enter necessary commands
Enter parameters (process & system parameters)
PLC -> Operator:
Retrieve system status information (steps, phase, alarms, )
TTA Flex PLC can also connect to overall control system

(SCADA)
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HMI
Access levels
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HMI Menu tree

Menu is available from any screen picture
Overview menu
Operating menu
Process values
Alarm list
Trend
Service menu
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TPOP Layout
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TPOP Layout
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TPOP Layout
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HMI Button and symbols
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Button
With 3D effect
Type of button:
Navigation
Function
Process
Dialog
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Button
Navigation button:
Call
up screen picture
Example: Home button call up Overview screen
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Button
Navigation button:
Call
up screen picture
Example: Home button call up Overview screen
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Button
Function button: Select machine function. Different

color code: different status. Ex:
1.
2.
3.
4.
Not selected and not selectable

Not selected and selectable
Connected but not selected, selectable
Selected but not correctly connected,
selectable
Connected but not selected, not
selectable (Remote control)
Selected but not correctly connected, not
selectable (Remote control)
Selected and correctly connected,
selectable
Selected and correctly connected, not
selectable
5.
6.
7.
8.
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Button
Process button: Select process sequences. Ex:

Push button positions
Not selectable
Selectable
Selectable and
pressed
Idle
Process phase not selected
Process
status
Queued
Process phase selected but not yet
active
Held
Process phase active but paused
Run
Process phase selected and active
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Button
Dialog button: Perform different operations, such

as validating, pause or cancelling any commands
Ex: Dialog buttons are used to Start, Pause, Abort and
Finalize a function
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Symbol
Local/Remote control
Select by key switch on control panel
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Symbol
Process value indicator

Indicate the measured values (temperature, pressure, )
Example:
Touch to change controller values: Controller parameters

(TC, LC, ) and quantity value limits (TSL, PSH, )
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Symbol
Data input: Indicated by data field showing the

current value.
Example:
Indication on Set Point Buttons
Active set point

(green)
Inactive set point

(grey)
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HMI Menu screen picture
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Overview menu
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Operating menu
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Operating menu
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Operating menu
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Operating menu
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Operating menu
Flush product (option)
CIP supply line

V15 to drain
V15 to reject
Disable hibernation
Fill aseptic damper (option)
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Start condition window
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Start check picture
General Start Conditions
1 All controllers in Auto
2 All EMERGENCY STOP released
3 No alarms: LL BTD, Air pressure, Homogenizer, Temperature fault
4 All toggle switches in Auto
5 Connection and selection match
6 Local/Remote selector in LOCAL
7 Steam selector ON
Pre-sterilization Start Condition
8 CIP memory
CIP/AIC Start Conditions
9 CIP HB ready
10 BTD cover closed (option)
TM-TPVN/HT
7/23/16

Process value window
TM-TPVN/HT
7/23/16

Alarm list
TM-TPVN/HT
7/23/16

Alarm list
TM-TPVN/HT
7/23/16

Trend diagram
TM-TPVN/HT
7/23/16

Pen and variables select picture
TM-TPVN/HT
7/23/16

Product and Capacity
TM-TPVN/HT
7/23/16

Service menu window
TM-TPVN/HT
7/23/16

Service menu
TM-TPVN/HT
7/23/16

Force main window
TM-TPVN/HT
7/23/16

Force I/O menu Activations picture
Grey : not activated

Green: activated
TM-TPVN/HT
7/23/16

Force I/O menu
TM-TPVN/HT
7/23/16

Force I/O Motor faceplate window
TM-TPVN/HT
7/23/16

Force I/O Motor faceplate window
TM-TPVN/HT
7/23/16

Force I/O Valve faceplate window
TM-TPVN/HT
7/23/16

Force I/O Valve faceplate window
TM-TPVN/HT
7/23/16

Analog input force window
TM-TPVN/HT
7/23/16

Analog input force window
TM-TPVN/HT
7/23/16

Volume setup
TM-TPVN/HT
7/23/16

Recipe edit
TM-TPVN/HT
7/23/16

Recipe edit
TM-TPVN/HT
7/23/16

Recipe edit
TM-TPVN/HT
7/23/16

PID controller window
TM-TPVN/HT
7/23/16

PID parameter window
TM-TPVN/HT
7/23/16

PID parameter window
TM-TPVN/HT
7/23/16

CIP Concentration
TM-TPVN/HT
7/23/16

Pressure homogenizer stage 1
TM-TPVN/HT
7/23/16

Pressure homogenizer stage 2
TM-TPVN/HT
7/23/16

TC44 parameters picture
TM-TPVN/HT
7/23/16

Temperature Guard TSL42
TM-TPVN/HT
7/23/16

Temperature Guard TSL71
TM-TPVN/HT
7/23/16

Differential pressure guard PSL61, PSL 64
TM-TPVN/HT
7/23/16

Differential pressure guard PSL61, PSL 64
TM-TPVN/HT
7/23/16

Pressure guard PSL847
TM-TPVN/HT
7/23/16

Pressure switch PS66
TM-TPVN/HT
7/23/16

Pressure switch high PSH60 (after M4)
TM-TPVN/HT
7/23/16

Flow and holding cell time guard
TM-TPVN/HT
7/23/16

Level switch LS08
TM-TPVN/HT
7/23/16

TS Stepforward
TM-TPVN/HT
7/23/16

Event log
TM-TPVN/HT
7/23/16

Sterilization cycle report
TM-TPVN/HT
7/23/16

Sterilization cycle report 2/2
TM-TPVN/HT
7/23/16

Product cycle report
TM-TPVN/HT
7/23/16

Product cycle report 2/2
TM-TPVN/HT
7/23/16

PAC CIP setup
TM-TPVN/HT
7/23/16
Preparations Operation Shutdown
TM-TPVN/HT
7/23/16
Preparations
Check points
Before starting the plant, perform checking:
o Connecting points are correctly fitted
o Supply line of power, steam, water, air, SA,
o Steam switch, Remote/Local switch
o All Emergency Stop buttons are released
o Holding cell for correct connection
o Correct connections for Homogenizer,
o Upstream/ Downstream equipments
TM-TPVN/HT
7/23/16
Operation
Content
Start sterilizing
Start production
Stop production
Sterile water
Emergency stop
Cleaning (AIC, CIP)
Cleaning supply line
Emergency emptying
TM-TPVN/HT
7/23/16
Operation
Start Sterilization
Selection/setting prior to start

Do
not start when personnel is present in risk area
TM-TPVN/HT
7/23/16
Operation
Start Sterilization
Start conditions:
Check
Check
no alarms are active

conditions in interlocks menu
TM-TPVN/HT
7/23/16
Operation
Start Sterilization
Start sequence
Checks/Operation during sequence

Heating - Sterilizing Cooling Stabilizing
Water seal for motors, Homogeniger,
Watch out for any alarms
Sterile Water
Sequence completed
Continue
with desired sequence: Production, AIC, CIP, Stop
TM-TPVN/HT
7/23/16
Operation
Star Production sequence
Start sequence
Start Production sequence in Operation menu
Cooling down (TSL71), prepare production
Automatically empty BTD, run product supply pump
Product is filled into the plant
When plant is ready for production, signals are given
to the
destinations (AFMs, Alsafe)

Note: If a disturbance occurs during Production, the plant will
automatically proceed to Emptying and end up in Sterile
water.
TM-TPVN/HT
7/23/16
Operation
Start Production sequence
Checking during sequence

Regular
check on the process values (flow, temp., pressure,
..)
Recommended max time for production

During
production, deposit may build up on the heat

exchanger surfaces and in product holding cell.
Check the pressure drop over the heat exchanger. If it is too
big, production must be stopped and cleaning has to be
done.
Check the temperature different between the heating
medium (TE08) and the products (TE44).
TM-TPVN/HT
7/23/16
Operation
Stop Production sequence
Select following function to stop the Production

Sterile
AIC
CIP
STOP
Water: see Revert to Sterile Water
TM-TPVN/HT
7/23/16
Operation
Revert to Sterile Water
During any kind of disturbance in production

sequence, the plant can be reverted to Sterile
Water.
Max time for Sterile Water:

It
depends on the product temperature in supply pipe to the

balance tank. At temp. of 15 C the milk can stand about 6
hours before it is destroyed and the TA Flex unit has to be
cleaned and re-sterilized.
TM-TPVN/HT
7/23/16
Operation
Stop sequence (Shut down)
Can be ordered from all program steps

Start sequence:
The
BTD is empty and water rinse sequence is started. The

plant is cooling down and ended up in Parking position.
TM-TPVN/HT
7/23/16
Operation
Emergency Stop
Sequence
Push EMERGENCY STOP on the control panel to stop the plant

immediately. All pumps will stop and all valves will be deactivated.
Warning
The machine may contain hot liquid or cleaning solution,
handle with outmost care to avoid exposure.
Start after Emergency Stop
Release all Emergency Stop buttons
Reset on Homogenizer control panel and FCP
The plant must be emptied by means of Emergency
Emptying function
Note: CIP must be ordered if product has entered the plant
TM-TPVN/HT
7/23/16
Operation
Aseptic Intermediate Cleaning AIC
Sequence
AIC
can be ordered to extend the production period before

Full Cleaning (CIP) is required.
AIC takes about 40 minutes, the plant remains sterile in its
aseptic part.
Start Conditions
From Sterile Water or from
HB tank is ready
BTD cover closed (option)
Production
Start sequence
Select AIC lye/lye-acid mode
Press AIC - Start button
TM-TPVN/HT
7/23/16
Operation
Full Cleaning (CIP)
Sequence
Select CIP directly after finish production
The CIP takes about 120 minutes.
Start conditions
From
From
From
Parking position
Sterile Water
Production
Danger: Chemical hazard. Do not start CIP when theres

personnel in the risk area.
TM-TPVN/HT
7/23/16
Operation
Full Cleaning (CIP)
Start sequence
Select CIP lye, lye/acid or PAC mode
Press CIP - Start button
Function button is Indicated with white
When completed, CIP indication goes off
and the plant
stops.
TM-TPVN/HT
7/23/16
Operation
Full Cleaning (CIP)
Halt sequence
Press
CIP - Pause button
Restart sequence
Press
CIP - Restart button
TM-TPVN/HT
7/23/16
Operation
Emergency Emptying
Sequence
Use
function to
Flush out the plant

Emptying after Emergency Stop to cool down the equipment
Start conditions
From Parking position
All general conditions are
full-filled
Start sequence
TM-TPVN/HT
7/23/16
Operation
Cleaning of product inlet transfer line
Sequence
The cleaning is carried out by inlet transfer line system.
Cleaning solution will be directed through V15 & V12.
V15 will pulse to drain 10s every 5 minutes, V13 will lower-
seat lift 2s every 60s.
Condition:
The
Start sequence
V15
plant is in Parking position or not in Production steps.
& V12 activated
Sequence finished
TM-TPVN/HT
7/23/16
Shutdown
Plant shutdown sequence
Check points
Close air supply
Close steam supply
Close water supply
Switch OFF the main
switch in Control panel
TM-TPVN/HT
7/23/16
Maintenance UHT
TM-TPVN/HT
7/23/16
Maintenance UHT
Maintenance Manual
Heat exchanger
Pumps
Valves
Sensors and transmitters
Other process components
TM-TPVN/HT
7/23/16
Maintenance UHT
Preventive maintenance system
TM-TPVN/HT
7/23/16
Maintenance UHT
Preventive maintenance recommendations

specifies:
Activities (what to do)
Service interval (when to do)
Spare parts (what to change)
TM-TPVN/HT
7/23/16
Maintenance UHT
Spare parts
TM-TPVN/HT
7/23/16
Maintenance UHT
Components instructions
TM-TPVN/HT
7/23/16
Maintenance UHT
Troubleshooting
Mechanical system
Electrical system
Automation
TM-TPVN/HT
7/23/16
Maintenance UHT
Hands-on
TM-TPVN/HT
7/23/16
Day 4:
Aseptic Tank system
TM-TPVN/HT
7/23/16
Agenda: 4 days
Day 4: Aseptic Tank

08:00 08:15: Aseptic tank systems
08:15 08:45: Operations, processing parameters
10:00 10:30: Break
11:00 11:30: Process steps, activations
11:30 11:45: P&ID detailed tracing Use colored P&ID
12:00 13:00: Lunch
13:00 13:15: Cleaning
13:15 13:45: Trouble shooting & Alarm Handling
13:45 14:00: Recording
14:00 14:30: Break
14:30 15:00: Operation manual
15:00 15:15: Maintenance Aseptic Tank
15:15 15:30: Preventive maintenance system
15:45 16:15: Hands-on
16:30 17:00: Summary & Evaluation
TM-TPVN/HT
7/23/16
Machine Introduction
TM-TPVN/HT
7/23/16
Introduction Machine in processing line
TM-TPVN/HT
7/23/16
Machine Introduction Main components
TM-TPVN/HT
7/23/16
Machine Introduction Technical data
TM-TPVN/HT
7/23/16
Machine Introduction Technical data
TM-TPVN/HT
7/23/16
Machine Introduction Operations
Sterilizing
Cooling
Filling
Fill pipe
Emptying
CIP
TM-TPVN/HT
7/23/16
Process steps
Process cycle: Phases and Steps
Step 1 10: Pre-sterilization
Step 12 14: Cooling
Step 101 105: Production (Emptying)
Step 601 604: CIP (Full cleaning)
Step 501 502: Shutdown (Depressurize)
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7/23/16
Activation diagram
TM-TPVN/HT
7/23/16
Activation diagram
TM-TPVN/HT
7/23/16
Activation diagram
TM-TPVN/HT
7/23/16
Machine steps Pre-sterilization
TM-TPVN/HT
7/23/16

Step 1 Drain 1.0 bar steam
TM-TPVN/HT
7/23/16

Step 2 Drain 2.7 bar steam
TM-TPVN/HT
7/23/16

Step 3 Pressurize
TM-TPVN/HT
7/23/16

Step 9 Heating
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7/23/16

Step 10 Sterilizing
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7/23/16

Step 12 Cooling 1
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7/23/16

Step 13 Cooling 2
TM-TPVN/HT
7/23/16

Step 14 Condensate drain
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7/23/16
TM-TPVN/HT
7/23/16

Step 101 Ready for Production
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7/23/16

Step 102 Filling to Low Level
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7/23/16
Machine steps - Pre-sterilization

Step 103 Filling above Low Level
TM-TPVN/HT
7/23/16

Step 104 Filling pipe to EVC
TM-TPVN/HT
7/23/16

Step 105 Ready for Emptying
TM-TPVN/HT
7/23/16
Machine steps CIP
TM-TPVN/HT
7/23/16
Machine steps CIP

Step 601 Pressurizing
TM-TPVN/HT
7/23/16
Machine steps CIP

Step 603 Circulation tank
TM-TPVN/HT
7/23/16
Machine steps CIP

Step 701 (604) Flip 1 V101-V125
TM-TPVN/HT
7/23/16
Machine steps CIP

Step 702 (604) Flip 2 V120-V600
TM-TPVN/HT
7/23/16
Machine steps CIP

Step 703 (604) Flip 3 V126-CR127
TM-TPVN/HT
7/23/16
Machine steps CIP

Step 704 (604) Flip 4 V101A
TM-TPVN/HT
7/23/16
Sub Program 1 Filling Sequence
TM-TPVN/HT
7/23/16

Step 200 Idle
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7/23/16

Step 201 Deact. V101F
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7/23/16

Step 202 Drain condensate
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7/23/16

Step 203 Act. V101G
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7/23/16

Step 204 Act. V101D
TM-TPVN/HT
7/23/16

Step 205 Act. V164
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7/23/16

Step 206 Deact. V164
TM-TPVN/HT
7/23/16

Step 207 Deact. V101D
TM-TPVN/HT
7/23/16

Step 208 Prepare to drain.
TM-TPVN/HT
7/23/16

Step 209 Flush out product
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7/23/16
Sub Program 2 Filling/Emptying line
TM-TPVN/HT
7/23/16

Step 300 Idle
TM-TPVN/HT
7/23/16

Step 301 Prepare line for acting V121
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7/23/16

Step 302 Act V121
TM-TPVN/HT
7/23/16

Step 303 Product. line open to drain
TM-TPVN/HT
7/23/16

Step 304 Product. line close to drain
TM-TPVN/HT
7/23/16

Step 305 Flush out product Drain
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7/23/16

Step 306 Flush out product Steam rinse
TM-TPVN/HT
7/23/16
TM-TPVN/HT
7/23/16
Pre-sterilization:
Production:
TSL140, TSL160,TSL150, PSL130
Shutdown
TSL101, TSL140, TSL160, TSL170, TSL150

SA filter cartridge counter
PSL130
CIP
TT150, LT110, TSL140
TM-TPVN/HT
7/23/16

Exchange of the filter cartridges
The
PLC system is counting each pre-sterilizing step and will

give an alarm after 50 pre-sterilizing cycles.
Replacements:
Exchange filter cartridge B with a new filter cartridge
Move the old filter cartridge B to position A
Discard the old filter cartridge A
TM-TPVN/HT
7/23/16
Lunch
TM-TPVN/HT
7/23/16
Care and Cleaning
TM-TPVN/HT
7/23/16
Care and Cleaning

Verify Cleaning
Daily check
Check recorder to see if cleaning completed correctly

Lye/Acid concentration
TM-TPVN/HT
7/23/16
Care and Cleaning

Verify Cleaning
Recommended check
Regularly weekly/monthly verify the cleaning result at critical points

such as V101 .
Visual check for any product residues after cleaning.
Make a swab test to check to cleaning result.
If necessary, adjust the cleaning circulation time and detergent
concentration.
TM-TPVN/HT
7/23/16
Care and Cleaning

Cleaning CPP
V101 inside
V121 inside
Agitator propeller Visco Jet
Spray balls
TM-TPVN/HT
7/23/16
Care and Cleaning

Recommended detergents & Concentration
TM-TPVN/HT
7/23/16
Care and Cleaning

External cleaning
TM-TPVN/HT
7/23/16
Alarms & Troubleshooting
TM-TPVN/HT
7/23/16
Alarm list
TM-TPVN/HT
7/23/16
Alarm list
TM-TPVN/HT
7/23/16
Alarm list
TM-TPVN/HT
7/23/16
Alarm list
TM-TPVN/HT
7/23/16
Alarm list
TM-TPVN/HT
7/23/16
Operation Manual
TM-TPVN/HT
7/23/16
Operation Manual - TPOP

Menu tree
TM-TPVN/HT
7/23/16

Overview menu
TM-TPVN/HT
7/23/16

Operating menu
TM-TPVN/HT
7/23/16

Start check menu
TM-TPVN/HT
7/23/16

Process value menu
TM-TPVN/HT
7/23/16

PID menu
TM-TPVN/HT
7/23/16

PID parameters menu
TM-TPVN/HT
7/23/16

Alarm list menu
TM-TPVN/HT
7/23/16

Trend diagram menu
TM-TPVN/HT
7/23/16

Service menu 1
TM-TPVN/HT
7/23/16

Service menu 2
TM-TPVN/HT
7/23/16

Force select menu
TM-TPVN/HT
7/23/16

Temperature guard menu
TM-TPVN/HT
7/23/16

Level guard menu
TM-TPVN/HT
7/23/16

Pressure guard menu
TM-TPVN/HT
7/23/16

Recipe edit menu
TM-TPVN/HT
7/23/16

Agitation speed
TM-TPVN/HT
7/23/16
Operation Manual Preparation

General check points
TM-TPVN/HT
7/23/16
Operation Manual Operation

General check points
TM-TPVN/HT
7/23/16
Operation Manual Operation

Tank operation
Start tank (Pre-sterilization)

Stop tank
Emergency Stop
Agitation
Emptying Manual emptying
Cleaning of tank
TM-TPVN/HT
7/23/16
Operation
Selection/setting prior to start

Check the sterile air filter if it need to be replaced
Do not start when personnel is present in risk area
Start conditions:
Check
Check
no alarms are active

conditions in Start check menu
TM-TPVN/HT
7/23/16
Operation
Start/Command sequence
Select Operation menu
Press Pre-sterilizing button
Press Start button (3)
(2)
TM-TPVN/HT
7/23/16
Operation
Checks/Operation during sequence

Step No. and actual program
Watch out for any alarms
step are indicated
Sequence completed
Go to step 101 Ready for Filling
If necessary, reset load cell (Service
menu 1)
TM-TPVN/HT
7/23/16
Operation
Filling & Emptying
Sequence
When
product is detected at inlet, filling of the tank starts.
When
level reached above Low Level set point, the outlet

pipe will be filled with product.
If the filling stop before Low Level is reached and no more
product is available, apply temporary Low Level set point to
make the program advance:
o
At the Level guard LS 110 menu, set the Low Level set point
lower than the normal value. Program will advance to step 103,
then104.
TM-TPVN/HT
7/23/16
Operation
Filling & Emptying
Step advance to 103
TM-TPVN/HT
7/23/16
Operation
Filling & Emptying
Sequence
After
step 104 completed, Emptying sequence is ready and

will start when filling machines request.
Filling
and Emptying sequence can take place at the same
time:
Filling sequence stops when tank gets high level or
product is not available at inlet.
Emptying sequence stops when tank gets empty or FMs
stop requesting product.
TM-TPVN/HT
7/23/16
Operation
Manual emptying
Start sequence
Stop sequence
TM-TPVN/HT
7/23/16
Operation
Agitation (Option)
Conditions
In
production, agitator is running with speed relevant to tank

level.
During CIP, the agitator will run during specific steps
regardless of operator selections and tank level.
Start sequence
Stop sequence
TM-TPVN/HT
7/23/16
Operation
Stop tank
Sequence conditions
If
Finalize is ordered in program step Heating or Sterilizing,

the tank will bi cooled down before function is activated.
The
Finalize function can not be ordered when theres

product in the tank.
If Abort is chosen, the sequence is stopped at once.
TM-TPVN/HT
7/23/16
Operation
Hold process
Hold command (Pause)

Go to Operation menu
Select function to Hold
Press Hold button
TM-TPVN/HT
7/23/16
Operation
Restart
Restart after Pause

Go to Operation menu
Select function to restart
Press Restart button
TM-TPVN/HT
7/23/16
Operation
Cleaning (CIP)
General
Tetra
Alsafe must be cleaned before Pre-sterization and

Production.
The
system must be cleaned direct after each production

and if the system has been closed down for a lone time.
The system must be cleaned with lye every cleaning time
and at least one a week with lye and acid.
TM-TPVN/HT
7/23/16
Operation
Cleaning (CIP)
Conditions (in Start check menu)
The tank is empty
No function is selected
or program is in step Ready for
Filling 101
The CIP unit is not occupied
TM-TPVN/HT
7/23/16
Operation
Cleaning (CIP)
Sequence commands
Start
Hold
/ Abort
TM-TPVN/HT
7/23/16
Operation
Emergency Stop
Sequence
Push
EMERGENCY STOP button to stop the tank

immediately
Push and release EM button

The program will go to Step 0 if its in following sequences:
Pre-sterilizing: Step 1 14
Depressurizing: Step 501 502
The program will continue from where it was stopped if its in
following sequences:
Production: Step 101 105
CIP: Step 601 632
(Need to push restart button to continue)
TM-TPVN/HT
7/23/16
Shutdown
Plant shutdown sequence
Check points
Close air supply
Close steam supply
Close water supply
Switch OFF the main
switch in Control panel
TM-TPVN/HT
7/23/16
Maintenance Aseptic tank
TM-TPVN/HT
7/23/16

Maintenance Manual
Valves
Sensors and transmitters
Tanks and vessels
Other components
TM-TPVN/HT
7/23/16

TM-TPVN/HT
7/23/16

Preventive maintenance recommendations

specifies:
Activities (what to do)
Service interval (when to do)
Spare parts (what to change)
TM-TPVN/HT
7/23/16

Spare parts list
TM-TPVN/HT
7/23/16

Components instructions
TM-TPVN/HT
7/23/16

Troubleshooting
Mechanical system
Electrical system
Automation
TM-TPVN/HT
7/23/16

Hands-on
TM-TPVN/HT
7/23/16
Final
Summary, Q&A
Evaluation Test
TM-TPVN/HT
7/23/16
Thank you!
TM-TPVN/HT
7/23/16

Nestle Binh An Growth: Aseptic System Training

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Nestle Binh An Growth: Aseptic System Training

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Nestle Binh An

Day 1: Milk & Aseptic technology

Day 3: UHT (cont.)

Day 4: Aseptic Tank

Aseptic processing systems

Aseptic processing systems

Sterilization of food requires that all living

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Machine Introduction General

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Thermal treatment definitions

Thermal treatment definitions

A process applied to a product with the object of

Condition in which living cells are absent or killed.

Equipment used for sterilization: autoclave, hydrostatic

Commercially sterile product

Product which is free from micro-organisms that can

Condition to prevent bacteriological contamination

Thermal treatment definitions

Keep without deterioration

Remain stable and good commercial

Free from micro-organisms and toxins

Absolute sterility not possible

Thermal destruction is logarithmic

Not possible to prove by

Thermal treatment definitions

Thermal treatment definitions

Thermal treatment definitions

Thermal treatment definitions

C. Botulinum, strains B/E <0,02

Thermal treatment definitions

Yeast and Mould

Thermal treatment definitions

= sterilization time (s)

T = sterilization temperature, (C)

Thermal treatment definitions

Thermal treatment definitions

Indirect measurement of chemical changes

Lactulose is a type of milk sugar formed at

Lactulose is the way of measuring the

Finding the optimal combination

taste and smell

for sterility level:

Fat content (%)

Protein content (%)

Casein content (%)

Whey proteins (%)

UHT systems Selection guide

Tubular or plate heat exchanger

Tetra Therm Aseptic Flex

Tetra Therm Aseptic VTIS

Efficient operation by indirect

Tubular heat exchanger (THE)

Tetra Alex homogenizers

Premium product quality

Direct heating by steam injection or