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CUSTOMERTRAINING

Your competence guide to food safety and operational efficiency

Customer training

Your competence guide to food safety and operational efficiency

invest in key skills for ensuring food safety and operational efficiency

Tetra Pak offers a complete range of tailored training services and solutions that maximize your uptime, reduce your costs and help you reach and sustain your desired performance levels.

Our experts provide the latest training methods, technologies and tools to help you increase productivity and ensure food safety through trained operator, maintenance, quality and management personnel.

WelcOme

customized, professional training from Tetra Pak helps you:

•Ensureproductqualityandfoodsafety•Reachandsustaindesiredproductivityandperformancetargets•Reducemaintenancecostsanddowntime•Ensurestaffsafety,skillsandmotivation

Our training services cover Tetra Pak® filling machines and distribution equipment and target all levels of customer personnel. Our unique operator certification verifies that operators have the required skills to run equipment in the safest and most efficient way.

adapted to your specific needs

Take advantage of our 60 years of experience in the food and beverage industry. Our 50 certified technical training instructors and 1,600 accredited field service engineers use well-proven methodologies combined with practical hands-on training. courses includes workbooks, textbooks, videos and self-study aids, covering every aspect of aseptic and safe food production.

Our training courses include equipment-specific introductions that give all staff a better understanding of the complete production line. They are normally held on-site using your equipment, adapted to your needs. They cover the key areas of operation, maintenance and quality control/assurance.

We also offer a wide range of competence development programmes off-site at our 17 Technical Training centres around the world. Together we can plan and provide customized training that ensures problem-free production for your plant.

You’ll find an overview of our complete range of training services on the following pages.

If you have any questions, or want to talk to us about tailoring courses to your exact requirements, please contact your nearest Tetra Pak Technical Service representative. We’ll get back to you immediately.

Thomas BorgströmDirector Technical Support, Tetra Pak

January 2014

Training porTfolio overview

WH

AT

WH

O

Operator trainingOperator certification

OPERATE YOUR EQUIPMENT

MAINTAIN YOUR EQUIPMENT

ENSURE QUALITY ANd FOOd SAFETY

Quality assurance trainingmanage aseptic production

maintenance training

Filling and distribution equipment operators

Technical staff involved in the maintenance of filling and

distribution equipment

Senior management middle management

Operational staff Quality assurance/ quality control staff

1. Operateyourequipment

Operator training

Operator certification

2. Maintainyourequipment

maintenance training

– Filling machines

– Distribution equipment

3. Ensurequalityandfoodsafety

Quality assurance training

manage aseptic production

4. Alwaysclosetoyou

5. abbreviations

contents

We’ve had great co-operation With tetra pak When it comes to the training of our personneleuropean customer

1

operaTe your equipmenT

Our professional operator training gives your staff the skills they need to safely and efficiently operate filling and distribution equipment.

1

GeNeRAl INTRODUcTION

FIllING mAcHINe INTRODUcTION

FIllING mAcHINe OPeRATION

DISTRIBUTION eQUIPmeNT OPeRATION

SAFeTY ANDHYGIeNe

Newly employed or experienced? The above training modules help your operators acquire and maintain all the skills they need to perform their duties in the best way.

ope

ra

Tor

Tr

ain

ing

1

Benefits:•Ensurethecompetencelevelneededforoperating

Tetra Pak® filling and distribution equipment

•Meetrequirementsforproductsafety

•Buildthefoundationforfurthercompetencedevelopment

Operatortrainingoverview

FIllING mAcHINeS

Operator training on filling machine includes the following modules, which can be tailored to your operators’ specific training needs:

• Generalintroduction• Fillingmachineintroduction• Fillingmachineoperation

Depending on previous experience, we recommend participation in all three modules above.

DISTRIBUTION eQUIPmeNT

Operator training on distribution equipment includes the following modules, which can be tailored to your operators’ specific training needs:

• Generalintroduction• Fillingmachineintroduction• Distributionequipmentoperation

Depending on previous experience, we recommend participation in all three modules above.

Based on your needs we also provide training on “Safety and hygiene” focusing on food safety and personnel safety.We specify a recommended number of hours for each module.

OPeR ATOR TR AINING

1

This training module provides participants with general information about Tetra Pak services and systems.

Whoisitfor?All participants in Tetra Pak technical training.

subjects

Hours

• TetraPakorganizationandproducts• TetraPakdocumentation• Technicaltrainingservices• TetraPakMaintenanceSystem(TPMS)• PackagingLineMonitoringSystem(PLMS)• Hygieneaspects• Whataffectsshelflifeandhowcanshelflifebeprolonged?• Asepticandnon-asepticpackaging

4

OPeR ATOR TR AINING

general introduction

1

Thistrainingmoduleisdesignedtointroduceparticipantstothefillingmachine(FM)anditscomponents. It also provides a short introduction to other units in the filling line.

Whoisitfor?mechanics, electricians and operators involved in the operation of the filling line.This introduction also benefits quality control personnel and supervisors.

subjects

Hours

• Machinecomponentsandfunctions.• Basicknowledgeofhowtooperatethemachine.

See table on next page

OPeR ATOR TR AINING

Fillingmachineintroduction

1OPeR ATOR TR AINING


operator training on all tetra Pak®fillingmachinesystemsIn the table below you will find information on the duration of the filling machine introduction training module for each filling machine system in our equipment portfolio.

Fillingmachinesystem Hours

Tetra Pak® A1 for Tetra classic® Aseptic 14

Tetra Pak® A1 for Tetra Fino® Aseptic 12

Tetra Pak® A3/Flex PullTab™ 20

Tetra Pak® A3/Flex DImc 20

Tetra Pak® A3/Speed 14

Tetra Pak® A3/compactFlex 18

Tetra Pak® A6 N/A

Tetra Pak® Simply 8 18

TBA/8 14

TBA/8 PullTab™ 14

TBA/8 DImc 14

TBA/19 14

Tetra Pak® c3/Flex 16

Tetra Rex®/27 and Tetra Rex®/28 extended Hygiene 14

Tetra Top®/3 extended Hygiene 10

Tetra Pak® R1 8

Tetra Pak® R2 8

Tetra Rex®/7 14

Tetra Rex®/8 14

Tetra Rex®/18 14

Tetra Rex®/22 12

TB/19 8

TB/21 24

TBA/3 10

TBA/3 for Tetra Fino® Aseptic 10

TFA/3 10

TBA/9 10

TBA/21 20

TBA/22 14

TcA/65 8

1

This training module helps operators perform their regular duties according totheoperationmanual(OM),includingpackagechecksanddaily/weeklycare.

Whoisitfor?mechanics, electricians and operators involved in the operation of the filling line.This introduction also benefits quality control personnel and supervisors.

subjects

Hours

• Safetyandhygiene• Productionpreparation• Production• Dailycare• Weeklycare• Packageevaluation


Weprovideoperatortrainingonourentirefillingmachineportfolio(seenextpage).

Fillingmachineoperation

OPeR ATOR TR AINING


Fillingmachineoperation

operator training on all tetra Pak®fillingmachinesystemsIn the table below you will find information on the duration of the filling machine introduction and filling machine operation training module for each filling machine system in our equipment portfolio.


Tetra Pak® A1 for Tetra classic® Aseptic 20

Tetra Pak® A1 for Tetra Fino® Aseptic 20

Tetra Pak® A3/Flex PullTab™ 26

Tetra Pak® A3/Flex DImc 28

Tetra Pak® A3/Speed 26

Tetra Pak® A3/compactFlex 24

Tetra Pak® A6 24

Tetra Pak® Simply 8 24

TBA/8 24

TBA/8 PullTab™ 22

TBA/8 DImc 28

TBA/19 28

Tetra Pak® c3/Flex 20

Tetra Rex®/27 and Tetra Rex®/28 extended Hygiene 20

Tetra Top®/3 extended Hygiene 16

Tetra Pak® R1 8

Tetra Pak® R2 8

Tetra Rex®/7 22

Tetra Rex®/8 22

Tetra Rex®/18 20

Tetra Rex®/22 16

TB/19 19

TB/21 20

TBA/3 18

TBA/3 for Tetra Fino® Aseptic 18

TFA/3 18

TBA/9 24

TBA/21 28

TBA/22 26

TcA/65 16

1 OPeR ATOR TR AINING

Distributionequipmentoperation

Weprovideoperatortrainingonourentiredistributionequipment(DE)portfolio.This training module gives De operators the skills to perform their regular duties accordingtotheoperationmanual(OM),includingdaily/weeklycare.

subjects:•Safetyandhygiene•Productionpreparation•Production•Dailycare•Weeklycare

In the table below you will find information on the duration of the De operation training block for every piece of distribution equipment in our portfolio.

Pallet Wrapper 30 8

Robot Palletizer 30 8

Robot Pallet Wrapper 30 8

Straw Applicator 1 4


Straw Applicator 30 for Tetra classic® Aseptic 4

Straw Applicator 30 for Tetra Prisma® Aseptic 4

Straw Applicator 30 for Tetra Wedge® Aseptic 4

Tetra cardboard Packer 12 8





Tetra cap Applicator 21 4





Tetra crate Packer 83 6

Distribution Equipment

Hours

Tetra easy Ride 4

Tetra Film Wrapper 32 6



Tetra Handle Applicator 32 4

Tetra Helix 21 5

Tetra Helix 22 2

Tetra Roll container Packer 85 6

Tetra Straw Applicator 21 4

Tetra Straw Applicator 22 High Speed 4


Tray Shrink 30 6

Tray Shrink 51 6

Once your operators have passed a De operation training block on a specific piece of distribution equipment, they can also attend the De line operation training block.


Hours


Hours

Accumulator easy Ride Plus 4

Accumulator for Tetra Wedge® Aseptic 4

Accumulator Helix 10 2

Accumulator Helix 30 for Tetra Prisma® Aseptic 2


CapApplicator30(ReCap) 6

cap Applicator 30 (ScrewCap) 6

capper 25 2

cardboard Packer 30 8


cardboard Packer 32 lid 4


Film Wrapper 68 8

line controller 30 4

line controller 30 Plus 6

multi Shrink 30 Speed 8

multi Shrink 62 6

Package Divider 122 4

Palletizer 30 8


In this training block participants gain an understanding of how to operate the complete De line smoothly. It will also prepare them for operator certification on the De line.

Whoisitfor?For De operators.Prior to this training block participants should attend the De Operation training block for each piece of distribution equipment included in the De line they will operate.

subjects

Hours

• Safety• Differentwaystostopamachine• Linecomponents• Conveyorlubrication• Hotmelt• Supplyofmaterials• Packagechecks• Careandcleaning• Startup

6

Distributionequipmentlineoperation

1 OPeR ATOR TR AINING

Safety is fundamental when it comes to both packaged food and the personnel involved in operations. That’s why this training module puts extra focus on safety and hygiene.

Whoisitfor?Package evaluation: All personnel involved in the operation and maintenance of the filling machine. laboratory and quality control personnel will also benefit from this training.We recommend that participants have taken part in the filling machine introduction prior to this module.Safeperoxidehandling: For all filling machine personnel who can come in contact with peroxide.

Block subjects

Hours

Package evaluationThis block is designed to give participants theoretical and practical knowledge of package integrity checks.

• Asepticproduction• Packageforming• Transversalsealing• Longitudinalsealing• Insidelayerruptures• PullTab

12

Safe peroxide handling This block is designed to train participants in handling peroxide in a safe way.

• Useofperoxide• Safetyregulations• Basicpropertiesofperoxide• Riskswithperoxide• Protectiveequipment• Actionsatpersonalinjuries• Disposalanddilution• Filling• Concentrationmeasuring

6

Safetyandhygiene

the operators noW find it a lot easier to perform their duties. it’s less stressful for them and they feel more confident in their skills. they knoW hoW to control, run and shut doWn the machines.

Asian customer

1

Based on your needs, we can provide:

• Fillingequipmentoperatorcertification

• Distributionequipmentoperatorcertification

Operator certification verifies that an operator has the right competence to run a filling line correctly and safely.

OPeR ATOR ceRTIFIcATION

ope

ra

Tor

ce

rT

ific

aT

ion

1

Benefits:•Verifiesyouroperators’competenceontheentirefillingline

•Providesacomprehensiveevaluationofoperators’competence,including an online theoretical test and an on-site practical skills assessment under the supervision of Tetra Pak experts

•Identifiespossiblecompetencegaps

WRITTeN ASSeSSmeNT

This part consists of a multiple-choice test on operating specific equipment. The operator must pass this written assessment before proceeding to the practical assessment.

PRAcTIcAl ASSeSSmeNT

According to a global standardized assessment, a Tetra Pak assessor supervises the operator during normal production to verify that the operator can safely and correctly run a specific line/equipment. The practical test covers three areas:

• Productionstart-up• Productionandproductioncontrol• Weeklycare

Thetestfollowsapredefinedchecklisttoensureobjectivity.

ceRTIFIcATION

Operators who pass the certification process successfully receive a certificate which proves that they can operate the equipment in a safe and correct way.

OPeR ATOR ceRTIFIcATION

2

mainTainyour

equipmenTmechanical, electrical and automation training from Tetra Pak gives your staff the skills to safely and cost efficiently maintain filling machines and distribution equipment. Usually held on-site, we adapt our maintenance training to your specific needs. Qualified Tetra Pak Technical Service staff provide all training materials and instructions.

2 GeNeRAl INTRODUcTION

FIllING mAcHINe INTRODUcTION

FIllING mAcHINe mAINTeNANce, elecTRIcAl AND AUTOmATION

DISTRIBUTION eQUIPmeNT mAINTeNANce

SAFeTY ANDHYGIeNe

Newly employed or experienced? The above training modules help your maintenance staff acquire and maintain all the skills they need to perform their duties in the best way.

ma

inT

en

an

ce

Tr

ain

ing

2Benefits:•Ensurethecompetencelevelneededformaintaining

Tetra Pak® filling and distribution equipment

•Securesafetyforstaffandequipment

•Buildthefoundationforfurthercompetencedevelopment

Maintenancetrainingoverview

FIllING mAcHINeS

maintenance training on the filling machine includes the following modules, which we tailor to your staff’s specific training needs:

• Generalintroduction• Fillingmachineintroduction• Fillingmachinemaintenance,electrical

andautomation

DISTRIBUTION eQUIPmeNT

maintenance training on distribution equipment includes the following modules, which we tailor to your operators’ specific training needs:

• Generalintroduction• Fillingmachineintroduction• Distributionequipmentmaintenance

Depending on previous experience, we recommend participation in all maintenance training modules above in the order they are listed.

Based on your needs, we also provide a training module on “Safety and hygiene” focusing on food safety and personnel safety. We specify a recommended number of hours for each module.

mAINTeNANce TR AINING

2

This training module provides participants with general information about Tetra Pak services and systems.

Whoisitfor?All participants in a Tetra Pak training programme.

subjects

Hours

• TetraPakorganizationandproducts• TetraPakdocumentation• Technicaltrainingservices• TetraPakMaintenanceSystem(TPMS)• PackagingLineMonitoringSystem(PLMS)• Hygieneaspects• Whataffectsshelflifeandhowcanshelflifebeprolonged?• Asepticandnon-asepticpackaging

4

general introduction


2

This training module is designed to introduce participants to the filling machine and its components. It will also provide a short introduction to other units in the filling line.

Whoisitfor?mechanics, electricians and operators involved with the operation of the filling line. The introduction will also benefit quality control personnel and supervisors.

subjects

Hours

• Machinecomponentsandfunctions.• Basicknowledgeofhowtooperatethemachine.




2

In the table below you will find information on the duration of the filling machine introduction training module for each filling machine system in our equipment portfolio.

Fillingmachineintroduction on all tetra Pak®fillingmachinesystems



Tetra Pak® A1 for Tetra classic® Aseptic 14Tetra Pak® A1 for Tetra Fino® Aseptic 12Tetra Pak® A3/Flex PullTab™ 20Tetra Pak® A3/Flex DImc 20Tetra Pak® A3/Speed 14Tetra Pak® A3/compactFlex 18Tetra Pak® A6 – Tetra Pak® Simply 8 18TBA/8 14TBA/8 PullTab™ 14TBA/8 DImc 14TBA/19 14Tetra Pak® c3/Flex 16Tetra Rex®/27 –Tetra Rex®/28 extended Hygiene 14Tetra Top®/3 extended Hygiene 10Tetra Pak® R1 8Tetra Pak® R2 8Tetra Rex®/7 14Tetra Rex®/8 14Tetra Rex®/18 14Tetra Rex®/22 12TB/19 8TB/21 24TBA/3 10TBA/3 for Tetra Fino® Aseptic 10TFA/3 10TBA/9 10TBA/21 20TBA/22 14TcA/65 8

2

This training module contains two parts –Fillingmachinemaintenance –Electricalandautomation

Fillingmachinemaintenance is intended for your maintenance staff and includes practical work needed to perform maintenance on the equipment. It enables participants to perform all tasks according to the TPmS customer lists and use the TPmS checklists. It also lays the foundation for performing basic troubleshooting on mechanical parts.

Electricalandautomation is designed for your technical staff involved in maintenance of the machine and it helps them understand the safety system of the equipment. It also teaches them to use the machine manuals and replace and set electrical components that do not require special software.

mAINTeNANce TR AINING FIllING mAcHINeS

Fillingmachinemaintenance, electricalandautomation

2

Tetra Pak® A1 for Tetra classic® Aseptic

Tetra Pak® A1 for Tetra Fino® Aseptic

Tetra Pak® A3/Flex

Tetra Pak® A3/Speed

Tetra Pak® A3/compactFlex

Tetra Pak® A6

Tetra Pak® Simply 8

Tetra Pak® TBA/8

TBA/19

Tetra Pak® c3/Flex

Tetra Rex®/27 extended Hygiene and Tetra Rex®/28 extended Hygiene

Tetra Top®/3

Tetra Pak® R1

Tetra Pak® R2

Other Tetra Pak® filling machine systems

maintenance training for

filling machines

2Fillingmachinemaintenance,electricalandautomation

Fillingmachinemaintenance

This training module provides participants with theoretical and practical knowledge of the different parts and functions of the filling machine.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra classic® Aseptic.

Block subjects

Hours

Mechanical 1* • AutomaticSplicingUnit(ASU)• Drivesystem• Jawsystem

28

Mechanical 2* • Sterileairsystem• Boxcooling• Peroxideconcentrationgassensor

24

Mechanical 3* • Supplysystems• Fillingsystem

14

Mechanical 4* • Tubeforming• Peroxidesystem

12

design correction/Package integrity

• Designcorrection• Packageevaluation• Sealingsystems

14

* These blocks should be taken in the order indicated here.

tetra Pak® a1 for tetra Classic aseptic


continued


Electricalandautomation

This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A1 for Tetra classic® Aseptic.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra classic® Aseptic.

Block subjects

Hours

Electrical and automation • Electricalequipment• Safetyprecautions• Howtoreadtheelectricalmanual

8

tetra Pak® a1 for tetra Classic aseptic





Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra Fino® Aseptic.

Block subjects

Hours

Mechanical 1* • AutomaticSplicingUnit(ASU)• Drivesystem• Jawsystem

28

Mechanical 2* • Sterileairsystem• Boxcooling• Peroxideconcentrationgassensor

24

Mechanical 3* • Supplysystems• Fillingsystem

14

Mechanical 4* • Tubeforming• Peroxidesystem

12



14


tetra Pak®A1forTetraFino® aseptic


continued



This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A1 for Tetra Fino® Aseptic.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A1 for Tetra Fino® Aseptic.

Block subjects

Hours

Electrical and automation • Electricalequipment• Safetyprecautions• Howtoreadtheelectricalmanual

8

tetra Pak®A1forTetraFino® aseptic


2


Fillingmachinemaintenance,electricalandautomation



Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A3/Flex.

Block subjects

Hours

Mechanical 1* • Documentation• Supplysystems

22

Mechanical 2* • Drivesystem• Jawsystem• FinalFolderUnit(FFU)• Designcorrection

22

Mechanical 3* • Sterileairsystem• Peroxidesystem• Fillingsystem• CleaningInPlace(CIP)• Externalcleaningsystem

16


tetra Pak®A3/Flex

continued


Block subjects

Hours

Optional equipment DImc Flex

• Machineoperation• Supplysystems• Paperweb• Punch• Capforming

24

Optional equipment PullTab

• Operation• Serviceandsettings• Sealingevaluation

22

Optional equipment HI

• HeadspacebyInjection(HI) 8

design correction/package integrity • Designcorrection• Packageevaluation• Sealingsystems

14

Troubleshooting and preventive maintenance according to Tetra Pak Maintenance System

• Maintenanceconcepts• Maintenancechecklist

10

tetra Pak®A3/Flex


continued

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A3/Flex.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A3/Flex.

Block subjects

Hours

iLine automation • Lineintegration• Electricalequipment• Machinecontrol• Networks• Drivesystems

12

Machine automation • TMCC• Sealingsystems• Fillingsystem• Designcorrectionsystem• Machineprocessinstruments• TPOP

10

tetra Pak®A3/Flexcont’d




Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A3/Speed.

Block subjects

Hours


20

Mechanical 2* • Jawsystem• Designcorrection

12


16


tetra Pak® a3/speed


continued


tetra Pak® a3/speed


Block subjects

Hours

Optional equipment HI

• HeadspacebyInjection(HI) 4

Optional equipment TPA FFU

• TPAFinalFolderUnit(FFU) 8

design correction/package integrity • Designcorrection• InductiveHeating(IH)principal

10



8

continued

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A3/Speed.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A3/Speed.

Block subjects

Hours


12


10

tetra Pak® a3/speedcont’d




Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A3/compactFlex.

Block subjects

Hours


22

Mechanical 2* • Drivesystem• Jawsystem• Designcorrection• AutomaticSplicingUnit(ASU)• AutomaticStripSplicingUnit(ASSU)• StripApplicator(SA)

22


16


tetra Pak®A3/CompactFlex


continued


tetra Pak®A3/CompactFlex


Block subjects

Hours


14



10

continued

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A3/compactFlex.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A3/compactFlex.

Block subjects

Hours


12


10

tetra Pak®A3/CompactFlexcont’d




Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A6.

Block subjects

Hours

Mechanical 1* • AutomaticSplicingUnit(ASU)• ReadyToFill(RTF)• Sleeveforming• Supplysystems

30

Mechanical 2* • InjectionMouldingUnit(IM) 18

Mechanical 3* • SterilisationFillingSealing(SFS)• Cleaning

30


tetra Pak® a6


continued


tetra Pak® a6


Block subjects

Hours

Package integrity • Packageevaluation• Packagingmaterial• Packagingmateriallayerfunction• Packagingmaterialreellabel• Packageterminology• LS-stripstructure

12



8


This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® A6.

Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® A6.

Block subjects

Hours

Electrical • Machinecontrol• Electricalequipment• Troubleshooting

18

cont’d

2




Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® Simply 8.

Block subjects

Hours


18

Mechanical 2* • Drivesystem• Jawsystem• FinalFolderUnit(FFU)• Automaticsplicingunit(ASU)• StripApplicator(SA)• Designcontrolsystem

24

Mechanical 3* • Sterileairsystem• Peroxidesystem• Stepupconditions• CIPandExternalCleaning

16



12


tetra Pak®Simply8

2


TBA/8Fillingmachinemaintenance,electricalandautomation



Whoisitfor?Technical staff involved in the maintenance of TBA/8.

Block subjects

Hours

Mechanical 1* • Drivesystem• Jawsystem• TPMSservice

20

Mechanical 2* • FinalFolderUnit(FFU)• Automaticsplicingunit(ASU)• AutomaticStripSplicingUnit(ASSU)• StripApplicator(SA)

20

Mechanical 3* • Sterileairsystem• Peroxidesystem• Stepupconditions• Supplysystems

14


continued


TBA/8


Block subjects

Hours

Optional equipment PullTab

• Serviceandsettings• Operation• Sealingevaluation

20

Optional equipment DImc

• Machineoperation• Supplysystems• Paperweb• Punch• Capforming

24


12



12

continued

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the TBA/8.

Whoisitfor?electrical: Technical staff involved in the maintenance of TBA/8.PLms: Production supervisors and production managers.

Block subjects

Hours

Electrical • Electricalequipment• Machineprocessinstruments• TMCC• PLC• TPIHgenerator• Drivesystems• Barcodephotocells

12

PLMS • PLMSofflinesoftware 4

TBA/8cont’d




Whoisitfor?Technical staff involved in the maintenance of TBA/19.

Block subjects

Hours

Mechanical 1* • Drivesystem• Jawsystem

20

Mechanical 2* • FinalFolderUnit(FFU)• Papertracking• AutomaticStripSplicingUnit(ASSU)

16

Mechanical 3* • Sterileairsystem• Peroxidesystem• Stepupconditions• Supplysystems

14


tBa/19


continued


tBa/19


Block subjects

Hours

Optional equipment ASU, HI and PullTab

• AutomaticSplicingUnit(ASU)• HeadspacebyInjection(HI)• PullTab(PT)

16

design correction/package integrity • Designcorrection• FillingControlSystem(FCS)• Packageevaluation• Sealingsystems

18



14

continued

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the TBA/19.

Whoisitfor?electrical: Technical staff involved in the maintenance of TBA/19.PLms: Production supervisors and production managers.

Block subjects

Hours

Electrical • Electricalequipment• Machinecontrol• TPIH2500generator• Machineprocessinstruments• TMCC• Brakesystems• Barcodephotocells

12


tBa/19cont’d




Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® c3/Flex.

Block subjects

Hours


22

Mechanical 2* • Drivesystem• Jawsystem• Designcorrection

22


16


tetra Pak®C3/Flex


continued


tetra Pak®C3/Flex


Block subjects

Hours

Optional equipment DImc Flex

• Supplysystems• Paperweb• Punch• Capforming

22


14

continued

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Pak® c3/Flex.

Whoisitfor?electrical: Technical staff involved in the maintenance of Tetra Pak® c3/Flex.PLms: Production supervisors and production managers.

Block subjects

Hours

Electrical • Electricalequipment• Machineprocessinstruments• TMCC• GE-Fanuc• USTSGenerator• Drivesystems• Sensors

20


tetra Pak®C3/Flexcont’d




Whoisitfor?Technical staff involved in the maintenance of Tetra Rex®/27 extended Hygiene and Tetra Rex®/28 extended Hygiene.

Block subjects

Hours

Mechanical 1* • Documentation• Supplysystems• Drivesystem• Heatingsystem

18

Mechanical 2* • Bottomforming• Magazine• Cartontransport• Topforming

26

Mechanical 3* • Fillingsystem• Cartonlifter• Cleaningsystem

14

Package integrity • Packageevaluation• Sealingsystems

6


tetra rex®/27 extended Hygiene and tetra rex®/28ExtendedHygiene


continued

2tetra rex®/27 extended Hygiene and tetra rex®/28ExtendedHygiene




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Rex®/27 extended Hygiene and Tetra Rex®/28 extended Hygiene.

Whoisitfor?Technical staff involved in the maintenance of Tetra Rex®/27 extended Hygiene and Tetra Rex®/28 extended Hygiene.

Block subjects

Hours

Electrical • Electricalequipment• Howtoreadtheelectricalmanual• Safetyprecautions• Circuitdiagram• Mainsconnections• Safetyrelays

10

cont’d

2


tetra top®/3Fillingmachinemaintenance,electricalandautomation



Whoisitfor?Technical staff involved in the maintenance of Tetra Top®/3.

Block subjects

Hours

Mechanical 1* • AutomaticSplicingUnit(ASU)• Cartonsection• Supplysystems

20

Mechanical 2* • LidFormingUnit(LFU) 18

Mechanical 3* • PackageSection• ExtendedHygiene(XH)• Filling• Cleaning

16


continued


tetra top®/3


continued

Block subjects

Hours

Optional equipment cap Applicator Unit

• CapApplicatorUnit(CAU) 18

Package integrity • Packageevaluation 12



8

cont’d

2




This training module is designed to provide machine-specific theoretical and practical knowledge of the electrical system of the Tetra Top®/3.

Whoisitfor?Technical staff involved in the maintenance of Tetra Top®/3.

Block subjects

Hours

Electrical • Electricalequipment• Machinecontrol• Drivesystems• Troubleshooting

18

tetra top®/3cont’d




Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® R1.

Block subjects

Hours

Mechanical 1* • Documentation• TPMS• Supplysystems• Drivesystem• Heatingsystem

22

Mechanical 2* • Infeedunit• Carriertransport• TransversalSealing(TS)• TPOP• TPMSlist

26

Mechanical 3* • Packagehandling(pusherandelevatorunit)• FinalFolderUnit(FFU)• Daily/weeklyandmonthlycare

22

Package evaluation • Toolsandenvironment• Basic–Packageevaluation• Extended–Packageevaluation• Troubleshooting–Packageevaluation

12


tetra Pak® r1





Whoisitfor?Technical staff involved in the maintenance of Tetra Pak® R2.

Block subjects

Hours

Mechanical 1* • Documentation• Supplysystems• Bottomflapheater

16

Mechanical 2* • Drivesystem• Bottomformerunit• FinalFolderUnit(FFU)

24

Mechanical 3* • Fillingsystems• Pistonfiller• Pocketfiller• Liquidfiller

16

Package evaluation • Toolsandenvironment• Basic–Packageevaluation• Extended–Packageevaluation• Troubleshooting–Packageevaluation

12


tetra Pak® r2


2

WealsoprovidemaintenancetrainingonthefollowingTetraPak®equipment:

Fillingmachinesystem

Tetra Rex®/7

Tetra Rex®/8

Tetra Rex®/18

Tetra Rex®/22

TB/19

TB/21

TBA/3

TBA/3 for Tetra Fino® Aseptic

TFA/3

TBA/9

TBA/21

TBA/22

TCA/65

For further information, please contact your nearest Tetra Pak Technical Service representative.

MaintenancetrainingonotherTetraPak® fillingmachinesystems


2

mAINTeNANce TR AINING DISTRIBUTION eQUIPmeNT

Distributionequipmentlinemaintenance

We provide maintenance training on our entire distribution equipment portfolio. This training is designed for technicians and electricians involved in the maintenance of distribution equipment.

subjects:•Safetyprecautions•OperationaccordingtotheOM•Machinefunction•ZeroSettingSequence•SettingsaccordingtoSettingSequenceintheMM•CapPositioningSystem(CPS)

In the table below you will find information on the duration of the De maintenance training block for each piece of distribution equipment in our portfolio.

Pallet Wrapper 30 –

Robot Palletizer 30 6

Robot Pallet Wrapper 30 –



Straw Applicator 30 for Tetra classic® Aseptic 8

Straw Applicator 30 for Tetra Prisma® Aseptic 8

Straw Applicator 30 for Tetra Wedge® Aseptic 8











Tetra crate Packer 83 18

Tetra easy Ride 12




Tetra Handle Applicator 32 6

Tetra Helix 21 6

Tetra Helix 22 6

Tetra Roll container Packer 85 20


Tetra Straw Applicator 22 High Speed 6


Tray Shrink 30 10

Tray Shrink 51 20

Once your technicians and electricians have passed a De maintenance training block for a specific piece of distribution equipment, they can also attend the De line maintenance training block.


Hours


Hours


Hours

Accumulator easy Ride Plus 8

Accumulator for Tetra Wedge® Aseptic 6



Accumulator Helix 30 for Tetra Prisma® Aseptic 6

CapApplicator30(ReCap) 16

cap Applicator 30 (ScrewCap) 20

capper 25 8



cardboard Packer 32 lid 22


Film Wrapper 68 26

line controller 30 16

line controller 30 Plus 18

multi Shrink 30 Speed 24

multi Shrink 62 20

Package Divider 122 10

Palletizer 30 8

2The De line maintenance training block is designed to give participants an understanding of how to get the entire De line to function smoothly.

Whoisitfor?customer maintenance staff.Prior to this training block, participants should attend the De maintenance training block for each piece of distribution equipment included in the De line they will work on.

Distributionequipmentlinemaintenance

Block subjects

Hours

dE line maintenance • Safety• Differentwaystostopamachine• Linecomponents• Conveyorlubrication• Hotmelt• Supplyofmaterials• Packagechecks• Careandcleaning• Startup

6

mAINTeNANce TR AINING DISTRIBUTION eQUIPmeNT

2Safety is fundamental when it comes to packaged food and the personnel involved in operations. That’s why this training module puts extra focus on safety and hygiene.

Whoisitfor?Package evaluation: All personnel involved in the operation and maintenance of the filling machine. It will also benefit laboratory and quality control personnel.We recommend that participants take part in the Filling machine Introduction prior to this block.Safeperoxidehandling: All filling machine personnel who come into contact with peroxide.

Block subjects

Hours

Package evaluationThis block is designed to give participants theoretical and practical knowledge of the Package Integrity checks.

• Asepticproduction• Packageforming• Transversalsealing• Longitudinalsealing• Insidelayerruptures• PullTab

12

Safe peroxide handling This block is designed to train the participants in handling peroxide in a safe way.

• Useofperoxide• Safetyregulations• Basicpropertiesofperoxide• Riskswithperoxide• Protectiveequipment• Actionsatpersonalinjuries• Disposalanddilution• Filling• Concentrationmeasuring

6

Safetyandhygiene


our staff gained better aWareness of quality procedures, Which helped them to discover problems earlier

American customer

3

ensure qualiTy and food safeTy

Our Quality Assurance training helps you minimize product quality problems. We offer six targeted modules tailored specifically for senior management, middle management and operational staff, including quality assurance and quality control personnel. The modules cover the entire production process from raw material to finished product. They are conducted by skilled instructors providing best practice and expert knowledge within each area.

3

INTRODUcTION TO lONG-lIFe PRODUcTION

HIGH AcID PRODUcTS

lOW AcID PRODUcTS

lOW AcID PRODUcTS EXTENDED

HYGIeNIc PROceSSING AND PAckAGING

TROUBleSHOOTING

Newly employed or experienced? The above training blocks help all staff in the Quality Assurance/Quality control area acquire and maintain the skills they need to perform their duties in the best way.q

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3

Benefits:•Minimizingproductqualityproblemsthatcoulddamagebrand

value and impact sales if experienced by retailers and/or consumers

•Reducingcostsandwasteduetoqualityproblems

•Meetingstrengthenedlegislationforfoodsafetyandfoodquality

•Increasingawarenessandunderstandingoftheimportanceofquality assurance

Thefollowingmodulesareincludedinqualityassurancetraining:

•Introductiontolong-lifeproduction

•Highacidproducts

•Lowacidproducts

•Lowacidproductsextended

•Hygienicprocessingandpackaging

•Microbiologicaltroubleshooting

QUAlIT Y ASSUR ANce TR AINING

3This training module provides an introduction to long-life production.

Whoisitfor?Senior management.No prior experience is required.

subjects

Hours

• Roleofseniormanagementinconnectionwithproductquality• Differencebetweenqualityassuranceandqualitycontrol• Introductiontolong-lifeproduction

4

Introductiontolong-lifeproduction


We specify a recommended number of hours for each module.

3This training module covers aseptic processing and packaging of high acid products, quality assurance/quality control, cleaning/cIP and package integrity test methods.

Whoisitfor?middle management and operational staff.No prior experience is required.

subjects

Hours

• Asepticprocessingandpackagingofhighacidproducts, covering the production line from raw material to finished product

• Qualitycontrolversusqualityassurance• Cleaning/CIP• Packageintegritychecks

8

Highacidproducts


3This training module covers aseptic processing and packaging of low acid products, quality assurance/quality control, cleaning/cIP and package integrity test methods.

Whoisitfor?middle management and operational staff.No prior experience is required.

subjects

Hours

• Asepticprocessingandpackagingoflowacidproducts,coveringtheproductionlinefrom raw material to finished product

• Qualitycontrolversusqualityassurance• Cleaning/CIP• Packageintegritychecks

8

Lowacidproducts


3This training module covers processing and packaging from raw material to finished product, basic microbiology theory, quality assurance and quality control, troubleshooting, cleaning/cIP and package integrity test methods.

Whoisitfor?middle management and operational staff, including quality assurance/quality control personnel.No prior experience is required.

subjects

Hours

• Asepticprocessingandpackagingoflowacidproducts, covering the production line from raw material to finished product

• Qualitycontrolversusqualityassurance• Basicmicrobiology• Cleaning/CIP• Microbiologicaltroubleshooting• Packageintegritychecks

24

Lowacidproductsextended


3This training module covers processing from raw material to finished product, basic microbiology theory, aseptic technology, quality assurance and quality control, critical control points concept, cleaning and package integrity.

Whoisitfor?Operational staff including quality assurance/quality control personnel.knowledge of dairy processing and experience from aseptic production is required.

subjects

Hours

• Equipmentforasepticprocessing• Aseptictechnology• Basicmicrobiology• Qualityassuranceandqualitycontrol• Criticalcontrolpointsconcept• Cleaning• Packageintegrity

40

Hygienic processing and packaging


3 This training module provides participants with a good understanding of the principles of systematic troubleshooting.

Whoisitfor?Operational staff including quality assurance/quality control personnel.This module requires knowledge of aseptic processing and at least three years’ experience in aseptic production.

subjects

Hours

• Casesfrombothtechnicalandmicrobiologicaltroubleshooting• Generalmicrobiology• Roughidentificationofspoilageflora• Generalaspectsofqualitycontrolandqualityassurance• Criticalcontrolpoints• Productsterilization• Aseptictransfer• Asepticpackaging• HazardAnalysisCriticalControlPoints(HACCP)Concept• CleaningandCIP• Packageintegrity

40

Troubleshooting


3

manage Aseptic Production is a three-day training programme for mid-level managers who want to increase their knowledge of aseptic production to improve performance in their plants.

By analyzing real-world examples, you gain insight into the leading factors that impact aseptic product quality and production performance, and ultimately influenceoperationalcost.

mANAGe ASePTIc PRODUcTION

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ion

several years ago We had difficulties reaching a defect rate of 1:1,000! today our average defect rate based on our incubation results is less than 1:20,000.

european customer

3

Benefits:•Makemoreinformedbusinessdecisionstoloweroperationalcosts

•Achievehighandconsistentproductquality

•Understandandapplybestpracticestopreventunsterilities

•Planproductionmoreefficientlytoensureyoumeetyour delivery deadlines


all of us in the management team attended training on aseptic production Where We got to meet some of our competitors and exchanged ideas and experiences With them

european customer

3


How does the quality of raw materials affect the end product? Are your operational costs in line with industry benchmarks? Which key factors impact performance of an aseptic filling operation? Attending the manage aseptic production course will give you answers to these questions as well as a thorough understanding of how to attain and sustain aseptic performance.

Whoisitfor?This course is designed for plant managers, production managers, quality managers, service managers and others interested in a deeper understanding of aseptic technology. It is recommended that participants have basic knowledge of aseptic technology. Participants should have at least six months’ experience of working in a long-life production environment.

Block subjects Hours

After this session, you will understand how to:

A practical approach to aseptic production

• ApplyTetraPakbestpracticestoyourownoperation• Assesstheimpactofpreventivemeasurestoavoidquality

related mishaps• Identifywhereintheproductlinetheriskismajor• Implementcost-efficientpreventivemeasures

8

Quality systems, competence development and maintenance management

• Workwithcontinuousimprovementtoavoid, rather than detect, unsterilities

• Aligncompetencedevelopmenttomatchyourperformanceambitions• Improvemaintenanceroutinestoreduceimpactonproduction

8

Operational cost analysis • Startanalyzingavailabledatatoidentifypotentialimprovements and “quick wins”

• Investigatetheneedforathoroughcostmapping,improvedanalysisand/or changes in production planning

• Evaluatethecostimpactofimplementingimprovements

8

manage aseptic production

4

always close

To youexpertly trained and certified staff are vital for maximizing uptime, reducing costs and ensuring product quality.

In addition to our dedicated competence development programmes for operators and other staff in maintenance and quality assurance/ quality control, we provide tailor-made training solutions for these key competence areas.

4If what you’ve found so far doesn’t match your needs, get back to us, tell us what you’re looking for and we will find the best way to support you.

Our global Quality Assurance management network of approx. 100 people can support you on any food quality and food safety questions you may have.

Our 17 Technical Training centres around the world provide off-site technical training on our latest equipment as well as on older systems within the Tetra Pak equipment portfolio.

Our1,600certifiedtrainersFieldServiceEngineersprovideon-the-jobtrainingatyoursite,tailored to your staff’s specific needs.

We provide tailored competence development programmes for all members of your personnel.

Please contact your nearest Tetra Pak Technical Service representative for more information about our training services.

adapting training to your specific needs

AlWAYS clOSe TO YOU

5

ASSU Automatic Strip Splicing Unit

ASU Automatic Splicing Unit

cAU cap Applicator Unit

cIP cleaning In Place

De Distribution equipment

DImc DirectInjectionMouldingConcept

em electrical manual

FcS Filling control System

FFU Final Folder Unit

Fm Filling machine

HI HeadspacebyInjection

IH Inductive Heating

ImU InjectionMouldingUnit

lFU lid Forming Unit

mm maintenance manual

Om Operation manual

PlmS Packaging line monitoring System

PT PullTab

QA Quality Assurance

Qc Quality control

RTF Ready To Fill

SA Strip Applicator

SFS Sterilisation Filling Sealing

SPc Spare Parts catalogue

Tmcc Tetra Pak multi-purpose compact controller

TPmS Tetra Pak maintenance System

TPOP Tetra Pak Operator Panel

TS Transversal Sealing

XH extended Hygiene

ABBREVIATIONS

Tetra pak®, , proTecTs whaT’s good, Tetra Brik, Tetra rex, Tetra Top, Tetra fino, Tetra classic and Tetra recart are trademarks belonging to the Tetra pak group.

www.tetrapak.com

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OPERATE YOUR EQUIPMENT

MAINTAINYOUR EQUIPMENT

ENSURE QUALITY AND FOOD SAFETY

We help you to build-up the competence of your personnel

Our global network of trainers offers best-in-class competence training. In fact the figures speak for themselves.

We have a dedicated staff of 50 global instructors specialized in the area of operation, maintenance and automation, more than 1,600 certified trainers, and a quality assurance management network of approx. 100 people operating. Our 17 Technical Training Centres around the world provide off-site technical training on our latest equipment as well as on older systems within the Tetra Pak equipment portfolio. All with one aim, to increase the competence of your staff, and the efficiency of your business.

More skilled people, in more placesWe’re proud to say that we deliver more than 7,800 delivered operator and maintenance training days, and 1,200 delivered quality related training days every year. For us it’s all about enhancing people’s performance, increasing their motivation, and sustaining productivity.

Tetra Pak Technical ServiceRuben Rausings Gata221 86 LundSweden+46 (0)46 36 1000

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, without the previous written approval of Tetra Pak®. All intellectual property rights, including copyright, are reserved by Tetra Pak®.

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