Tetra Pak Tetra Alex 25 User manual
2.244364-01.fro
OM
Doc
No.
OM-1244364-01
GF201862
Tetra
Alex®
25
Operation
Manual
This
document
is
valid
for:
Series
No/
Machine
No
OM
Operation
Manual
2.244364-01.fro
Tetra
Alex®
25
Issue
2001-04
Tetra
Pak
Processing
Components
AB
Doc
No.
OM-1244364-01
Table
of
contents
i
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.244364-01.TOC
Introduction
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1
Equipment
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1
Document.
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Safety
precautions
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3
Use
of
hazard
information
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3
General
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4
Cleaning
solution
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5
Handling
of
cleaning
solution.
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5
Emergency
precautions.
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5
General
description.
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7
Applications
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7
Process
description
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7
Denominations.
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8
Main
components
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8
Control
panel .
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8
Cooling
water
system
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9
Operation .
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11
Preparations.
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11
Start .
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12
Sterilisation.
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12
Production
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13
Check
during
production
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13
Stop
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13
Emergency
stop.
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13
Cleaning .
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15
Lubrication.
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17
Recommended
oil
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17
Oil
amount
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18
Introduction
1
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201628.en
Introduction
This
section
contains
basic
information
about
this
manual
and
the
Tetra
Pak
equipment
described.
To
ensure
maximum
safety,
always
read
the
section
Safety
precautions
before
carrying
out
any
work
on
the
unit.
Equipment
Intended
use
of
this
Tetra
Pak
equipment
This
unit
is
intended
for
use
according
to
the
specifications
in
Technical
data
(see
Technical
Manual)
and
related
documents.
Tetra
Pak
will
not
be
held
responsible
for
injury
or
damage
if
the
equipment
is
used
for
any
other
purpose.
Service
If
problems
are
encountered
when
operating
the
unit,
contact
the
nearest
Tetra Pak
service
station.
Manufacturer
This
Tetra
Pak
equipment
was
produced
by:
Tetra
Pak
Processing
Components
AB
Bryggaregatan
S-221
00
LUND
Sweden
Unit
identification
All
units
carries
a
machine
plate
stating:
– unit
identification
–data
unique
to
the
unit
Have
this
information
available
before
contacting
Tetra
Pak
concerning
this
particular
unit.
WARNING!
Machine Type
Drawing Spec.
Machine No.
Manufacturer
Year of manufacture
Tetra Pak
Introduction
2Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201628.en
Document
Operation
Manual
(OM)
The
purpose
of
this
Operation
Manual
is
to
provide
the
operator
with
information
on
how
to
operate
the
machine.
Tetra
Pak
recommend
that
you
study
it
carefully,
and
-
above
all
-
ensure
its
availability
to
those
who
will
be
operating
the
unit.
Furthermore,
it
is
important
that
you:
– keep
the
manual
for
the
life
of
the
equipment
–pass
the
manual
on
to
any
subsequent
owner
or
user
of
the
equipment.
Tetra
Pak
will
not
be
held
responsible
for
any
breakdown
of
the
equipment
caused
by
the
owner’s
failure
to
follow
the
instructions
given
in
this
manual.
Design
modifications
The
information
given
in
this
document
is
in
accordance
with
the
design
and
construction
of
the
machine
at
the
time
it
was
delivered
by
the
Tetra
Pak
machine
production
facility.
Further
copies
Additional
copies
can
be
ordered
from
the
nearest
Tetra
Pak
service
station.
When
ordering
technical
publications,
always
quote
the
document
number
printed
on
the
front
cover
of
the
document
concerned.
Document
producer
This
document
was
produced
by:
Tetra
Pak
Processing
Components
AB
Bryggaregatan
S-221
00
LUND
Sweden
Number
of
pages
This
document
contains
a
total
of
20
pages.
Copyright
ã
2001
Tetra
Pak
Processing
Systems
Division
All
rights
reserved.
No
part
of
this
document
may
be
reproduced
or
copied
in
any
form
or
by
any
means
without
the
written
permission
of
Tetra Pak Processing Systems Division.
Safety
precautions
3
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201472.en
Safety
precautions
To
ensure
maximum
safety
for
the
operator,
always
read
this
section
carefully
before
carrying
out
any
work
on
the
equipment.
Use
of
hazard
information
Hazard
information
in
this
documentation
is
defined
as
follows:
Failure
to
observe
this
information
results
in
immediate
danger
to
life.
Failure
to
observe
this
information
can
result
in
major
personal
injury
or
loss
of
life
Caution! Failure
to
observe
this
information
can
result
in
minor
personal
injury
or
damage
to
the
equipment.
DANGER!
WARNING!
Safety
precautions
4Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201472.en
General
Only
trained
personnel
are
allowed
to
operate
the
machine.
The
machine
may
only
be
used
in
accordance
with
the
instructions
given
in
the
manuals
delivered
with
the
equipment.
If
the
Safety
precautions
are
not
followed,
there
is
risk
of
personal
injury.
The
machine
is
normally
started
by
an
external
signal,
therefore:
•always
keep
all
covers
closed
during
operation,
rotating
wheels
and
moving
pistons
may
cause
severe
injuries
•make
sure
the
mains
power
is
turned
off
and
secured
before
the
service
covers
are
opened/removed
•regard
all
electrical
equipment
as
live,
make
sure
the
doors
for
the
starter
panel
are
closed
During
operation:
•stay
outside
the
safety
area
(approximately
1m
(3
feet)
around
the
machine)
•regard
all
pipes
including
pulsation
dampers
as
hot
• watch
out
for
leakage/blasts
from
hot
media
at
pipe
connections
and
from
pressurized
parts
of
the
machine
•always
use
hearing
protection
•never
throttle
down
the
product
flow
to
or
from
the
machine
Risk
of
explosion
-
Immediate
danger
to
life
Make
sure
that
the
product
outlet
pipes
not
are
blocked
in
any
way.
Due
to
high
pressure,
this
will
make
a
high
risk
of
exploded
pipes
and
dampers.
Before
carrying
out
maintenance
and
repair:
• read
the
Safety
precautions
in
the
Technical
Manual
and
follow
instructions
given
DANGER!
Safety
precautions
5
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201472.en
Cleaning
solution
Handling
of
cleaning
solution
Cleaning
solutions
normally
contain
caustic
soda
(NaOH)
or
nitric
acid
(HNO3).
These
chemicals
may
cause
burning
to
skin
and
eyes.
Follow
the
instructions
given
by
the
supplier.
Whenever
there
is
a
risk
of
exposure
to
these
chemicals,
always
wear:
•safety
glasses
• protective
gloves
• shoes
made
of
PVC
or
PE
plastic,
or
rubber
• apron.
In
the
case
of
an
accident
involving
cleaning
solution,
the
basic
rule
is
to
rinse
the
affected
area
as
soon
as
possible
with
as
much
water
as
possible.
For
this
reason,
always
make
sure
that
the
showers
work,
that
there
are
additional
washing
facilities,
and
that
an
eyewash
device
is
available
at
or
near
each
machine
site.
Emergency
precautions
If
swallowed
If
you
happen
to
swallow
cleaning
solution:
•drink
large
amounts
of
lukewarm
water
(in
order
to
dilute
the
cleaning
solution);
then
seek
medical
attention
immediately.
Contact
with
eyes
If
cleaning
solution
is
splashed
into
your
eyes:
•wash
the
eyes
thoroughly
with
lukewarm
water
for
15
minutes
(keep
eyelids
widely
apart);
then
seek
medical
attention
immediately.
Contact
with
skin
or
clothes
If
cleaning
solution
comes
into
contact
with
skin
or
clothes:
•rinse
immediately
with
plenty
of
water
• thoroughly
wash
the
clothes
before
they
are
worn
again.
If
skin
burns
appear,
seek
medical
advice
immediately.
If
inhaled
If
you
experience
irritation
or
pain
due
to
having
inhaled
vaporized
cleaning
solution:
•leave
the
affected
area
to
get
fresh
air.
If
the
symptoms
become
worse,
seek
medical
advice.
Safety
precautions
6Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201472.en
This
page
intentionally
left
blank
General
description
7
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201339.en
General
description
Applications
High
pressure
homogenisation
of
liquid
food.
Process
description
The
high
pressure
homogeniser
functions
as
a
positive
displacement
pump.
It
forces
the
product
through
a
narrow
adjustable
gap
under
high
pressure.
The
resulting
high
velocity
and
turbulence
in
the
gap
effectively
reduce
the
size
of
liquid
droplets.
DAIRY OTHER
Pasteurized
milk Beverages
UHT
milk Concentrates
Cream Fruit
juices
Yoghurt Baby
food
Condensed
milk Dressings
Tomato
juice
and
ketchup
GF201506
General
description
8Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201639.en
Denominations
Main
components
Control
panel
1Drive
motor
2 Reducing
gearbox
3 Crankcase
4 Wetend
5 Homogenising
head
6 Hydraulic
unit
7 Control
panel
GF201504
3
6
5
4
21
7
1Start
button
2Stop
button
3 Emergency
stop
button
4 Homogenisation
pressure
gauge
5 Pressure
adjusting
valve
1st
stage
(Remote
control
as
option)
6 Pressure
adjusting
valve
2nd
stage
(Remote
control
as
option)
GF201521
2
3
4
5
6
1
General
description
9
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201372.en
Cooling
water
system
Description Function
1a Cooling
water
valve,
solenoid
(standard) Shut
of
valve,
controlled
by
electrical
signal
1b Cooling
water
valve,
pneumatic
(optional) Shut
of
valve,
controlled
by
compressed
air
2 Cooling
water
flow
meter
(optional) Indicates
flow
rate
and
accumulated
value
Flow
rate,
see
Technical
Data
in
the
Technical
Manual
3 Cooling
water
regulating
valve Regulation
of
crankcase
oil
temperature
Max.
55
°C
(131
°F)
4 Cooling
water
regulator
(optional) Automatic
control
of
crankcase
oil
temperature
5 Cooling
water
regulating
valve Regulation
of
gearbox
oil
temperature
GF201613
1
2
3
4
5
5
2
3
1a
1b
4
General
description
10 Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201372.en
This
page
intentionally
left
blank
Operation
11
Tetra
Alex®
25
Doc
No.
OM-1244364-01
2.2
tf201631.en
Operation
Preparations
•Check
that
the
mains
power
switch
is
turned
off
•Check
oil
levels
and
top
up
if
required
–Crank
case
– Reducing
gear
box
– Hydraulic
unit
Type
of
oil:
see
Lubricants
•Drain
the
dampers
(1)
•Close
all
covers
• Open
external
cooling
water
valve
• Turn
on
the
external
mains
power
switch
Risk
of
explosion
-
Immediate
danger
to
life
Make
sure
that
the
outlet
pipes
not
are
blocked
in
any
way.
Due
to
high
pressure,
this
will
make
a
high
risk
of
exploded
pipes
and
dampers.
GF201447
90
1
DANGER!
Operation
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Alex®
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Start
•Start
the
product
feed
pump
/
Start
by
external
signal
Check
that
the
inlet
pressure
corresponds
to
the
table
below:
• Push
the
start
button
/
Start
by
external
signal
–The
drive
motor
starts
– Cooling
water
valve
opens
–The
hydraulic
unit
starts
Check
for
flow
at
cooling
water
outlet.
Sterilisation
Before
production
the
machine
must
be
sterilized.
This
is
done
in
line
with
the
surrounding
process
systems.
Recommended
inlet
pressures
Product P1
bar
(psi)
Low
viscous
products
e.g.
milk,
juice 3
-
10
(45
-
150)
High
viscous
products
e.g.
sauces,
ketchups 4
-
10
(60
-
150)
Operation
13
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Alex®
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Production
•Set
the
homogenising
pressure
a) Adjust
the
2nd
stage
pressure
adjusting
valve
to
desired
value
or
20%
of
the
homogenisation
pressure.
b) Adjust
the
1st
stage
pressure
valve
to
the
decided
value.
Check
during
production
• Homogenising
pressure
Fine
tune
by
help
of
the
1st
stage
pressure
adjusting
valve.
• Crankcase
oil
temperature,
maximum
55
ºC
(131
ºF)
Risk
of
jam.
Avoid
getting
in
contact
with
the
pistons
• Product
inlet
pressure
•If
a
fault
occurs,
see
section
Trouble
shooting
in
the
Technical
Manual.
Stop
• Turn
off
the
pressure
adjusting
valves
for
a) 1st
stage
b) 2nd
stage
• Push
the
stop
button
/
Stop
by
external
signal
Emergency
stop
• Push
the
emergency
stop
button
only
if
there
is
a
risk
of
damage
to
personnel
or
property.
Emergency
stopped
The
machine
may
contain
hot
liquid
or
cleaning
solution.
Handle
with
outmost
care
to
avoid
exposure.
• Eliminate
the
cause
for
the
emergency
stop.
• Turn
off
the
pressure
adjusting
valves
for
a) 1st
stage
b) 2nd
stage
• Release
the
emergency
stop
button
and
perform
a
normal
start
according
Start
and
Production.
WARNING!
WARNING!
Operation
14 Tetra
Alex®
25
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page
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Cleaning
15
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Alex®
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Cleaning
The
machine
is
cleaned
in
line
with
the
surrounding
systems.
Check
cleaning
of
pulsation
dampers
at
least
once
a
week.
Clean
manually
if
required.
GF201447
90
Cleaning
16 Tetra
Alex®
25
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