BoC

Book of Competence
Package Integrity
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WARNING
This document may not be copied, transferred, or modified
without the prior written consent of Tetra Pak Packaging
Solutions S.p.A.

Doc. No. BoC-2712261-0103

 TechPub_2614345_0103 - BoC_2712261_0103_fro.fm
Copyright © 2007 Tetra Pak Group
All rights reserved. No part of this document may be reproduced or copied in any form or by any means
without written permission from Tetra Pak Packaging Solutions.

and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
This document was produced by:
Sara Davolio and Monica Malagoli
Tetra Pak Packaging Solutions S.p.A.
Via Delfini 1
41100 MODENA
Italy
Additional copies can be requested to the authors, to Technical Training Centre or downloaded from the
Tetra Pak Packaging Solutions - Package Integrity webpage. When ordering additional copies, always
provide the document number. It is printed on the front cover and in the footer on each page of the
manual.
Doc. No. BoC-2712261-0103
Issue 2007-01
 i Introduction

ii Safety Precautions

iii Getting to know the

Package
BoC
Book of Competence
1 Transversal Seal
(TS)

2 Longitudinal Seal
Package Integrity (LS/SA)

3 Opening Devices

4 Integrity

5 Package Forming
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Appendix A:
Flowcharts and
Troubleshooting

Appendix B:
Tools and Chemicals

Appendix C:
Data Record

Doc. No. BoC-2712261-0103

Issue 2007-01

Tetra Pak Packaging Solutions

 TechPub_2614345_0103 - BoC_2712261_0103_fro.fm
Foreword to the Blue Edition
The 3rd edition of the Book of Competence received valuable and vital
inputs from several experienced colleagues. A special mention and
thanks go to Erling, Thomas, and Eugenio, while Carlos and Reinhard
initiated and drove a translation into Spanish and German languages.
Sara Davolio
Monica Malagoli January 2007

Foreword to the Red edition

This Book of Competence - Package Integrity is based on the state of the art spread in the
Company on Package Integrity Competence.
Major inputs have been received from FiSQA and System Specialists.
Among the contributions, a special thanks goes to Kevin, Reinhard Shigeru Okada and Hitoshi
Matsumoto for constant inputs and support.

Sara Davolio
November 2004
Monica Malagoli
 Update Log for Doc. No. BoC-2712261-0103
This table shows major changes made to this manual, such as corrections
and items added or removed.

Date Page Section Modification

Nov. 2006 iii-5 Getting to know the package Definition of Commercial Sterility added

Nov. 2006 iii-9 Getting to know the package Updated Guideline for choice of Packaging
Material table

Nov. 2006 iii-14 Getting to know the package Updates of Strips graphics

Nov. 2006 1-5 / 1-10 Transversal Seal Changed flow of graphics when describing
Transversal Seal and preparation of
samples

Nov. 2006 2-5 Longitudinal Seal Updated graphics in General Information

Nov. 2006 2-9 Longitudinal Seal Changed strip position reference measures

Nov. 2006 2-12 Longitudinal Seal Added check of LS Overlap

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Nov. 2006 3-2 Opening Devices Added LightCap and PLH description,
faults, procedures and integrity evaluation

Nov. 2006 4-5 Package Integrity Changed numbering of graphics for

consistency with previous chapters

Nov. 2006 4-10 Package Integrity Changed Copper test photos and
procedure due to changed instrument

Nov. 2006 4-18 Package Integrity Picture of K-crack inserted

Nov. 2006 5-6 Package Forming Crease lines graphics improved

Nov. 2006 A-10 Appendix A: Flowcharts and Improved section Product with Fibres
Troubleshooting Checks

Nov. 2006 B-8 Appendix B: Tools and Removed wrong numbers for Peak lenses.
Chemicals Reference to Supplier added.

Nov. 2006 B-10 Appendix B: Tools and Changed Copper test instrument
Chemicals

Nov. 2006 B-10 Appendix B: Tools and Added Portable Micro-Scope (IPM)
Chemicals instrument

Nov. 2006 B-10 Appendix B: Tools and Added Hot wire instrument
Chemicals

Nov. 2006 C-9 Appendix C: Data Record Added PLH Integrity Report template
 Date
Page
Section
Modification

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 i Introduction
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Doc. No. BoC-2712261-0103 i - 1 (14)

 i Introduction

This chapter contains basic information about this manual.

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i - 2 (14) Doc. No. BoC-2712261-0103

 Table of Contents
i Introduction

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

How to use this book . . . . . . . . . . . . . . . . . . . . . . i - 6

Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8

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

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

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

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

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

Manual Information . . . . . . . . . . . . . . . . . . . . . . . i - 12
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 12
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13
Typographical Conventions . . . . . . . . . . . . . . . . . i - 13
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 13

Doc. No. BoC-2712261-0103 i - 3 (14)

 i Introduction

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i - 4 (14) Doc. No. BoC-2712261-0103

 i Introduction Personnel Requirements

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

The methods described in this Book of Competence must be performed by

qualified or specialised personnel. The level of expertise required is
mentioned at the beginning of each method. API (Advanced Package
Integrity) and MMI (Machine Material Interaction) Trainings is available at
Technical Training Centre.

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

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

QAM (Quality Assurance Management) officers and Technical Service
Specialists are considered specialized personnel once specific training has
been taken.

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

Doc. No. BoC-2712261-0103 i - 5 (14)

How to use this book i Introduction

How to use this book

Purpose
This book is mainly addressed to:
• Quality Assurance Management Officers
• Technical Instructors
• System Specialists
• Senior Tetra Pak Field Service Engineers
• Senior Technical Support Staff.

The aim is to give clear instructions on how to evaluate the integrity of the
roll fed Tetra Pak Packaging Solutions (TPP) aseptic packages that contain
and protect the packed product from filling to recommended consumption, at
ambient temperature.
A package showing product spills is easy to detect. Less visible defects that
jeopardise the protective function of the package can be detected following
the correct procedures described in this manual. Package Integrity Quality
Methods are systematic, precise and destructive. Samples are no longer
available after evaluation, hence the importance of performing them

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correctly.
Package Integrity Methods must be performed on regular basis during and
after Production, to monitor the quality of the packages and the
performance of the filling machines. Specific checks must be carried out for
special products (e.g. products with fibres) and opening devices (PullTab,
FlexiCap).
A defect in the package microbiological barrier does not necessarily imply a
microbiological problem, since the following conditions must take place in
addition:
• presence of microorganisms in the package surrounding;
• favourable environmental conditions;
• period of time in which they grow and spoil the product.

On the other hand, when visible integrity problems such as leakage during
transportation or package blowing occur, we are sure that the package is
defective, and that the packages close to it might be affected by the same
defect. In this case, a troubleshooting procedure is needed to investigate the
causes of the proven unsterility.
Package Integrity Methods can be grouped into a limited number of
procedures as follows, according to the kind of investigation needed.
The section Appendix A: Flowcharts and Troubleshooting includes a step by
step description of each procedure.
(Cont'd)

i - 6 (14) Doc. No. BoC-2712261-0103

 i Introduction How to use this book

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

Note!
This book does not include instructions reported on OM, MM, EM
manuals, such as machine setting procedures or volume dependent
values. Refer to these manuals to integrate this kind of information.
Laboratory QC checks after Production
These checks must be carried out on a regular basis by qualified personnel, in
an area appropriately equipped. They are destructive, and imply the use of
chemicals or specific laboratory tools. The data are analyzed statistically, in
order to evaluate the incidence of defective packages in a population.
Testing products with fibres
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Products containing more than 5% of citrus fibres can compromise the

integrity of the TS as fibres can be trapped in the sealing creating channels to
the outside of the package. A specific procedure must be followed to
investigate the performance of the product.
Troubleshooting
When a batch of a production proves to be defective due to leakages or
package blowing, the causes of the unsterility must be investigated. In this
case, the analysis is not statistical, but aims at identifying the origin of
specific defects. The samples must be prepared so that the package is not cut
apart but analyzed as a whole to be able to see if package integrity is the
reason for the unsterility.
It is advisable to test a tray of packages where one or more samples are
suspected to be defective, so that the overall behaviour of the Production can
be assessed.
The test methods are applied in a defined sequence aiming to get an
unequivocal answer if package integrity is the main cause for the unsterility
in terms of:
• Loss of microbiological barrier (corners, K-cracks, fin tears)
• PullTab, FlexiCap
• Longitudinal Sealing
• Trasversal Sealing
• PLH

Doc. No. BoC-2712261-0103 i - 7 (14)

How to use this book i Introduction

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

A: General Information
A These chapters provide general
i Introduction ii Safety iii Getting to information, important safety
Precautions know the
package information, and overview of packaging
material, strips and package
terminology.
These chapters include:
• Introduction
B 1 Transversal Seal (TS) tests
(MTD 1201 - 1208 - 1211) • Safety Precautions
• Getting to know the package.
2 Longitudinal Seal (LS/SA) test B: Procedures, Tests
(MTD 1202)
These chapters provide a sequence of
instructions for the tests to be performed

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3 Opening Devices test on the package.
(MTD 1211)
These chapters include:
4 Package Integrity tests
• Transversal Seal
(MTD 1203 - 1204 - 1207) • Longitudinal Seal
• Opening Devices
5 Package Forming tests • Package Integrity
(OM as a reference)
• Package Forming.

C: Appendix, additional
C material
These chapters provide information
Flowcharts and Tools and Data recording about additional material used to carry
troubleshooting Chemicals sheets out the tests and record the results.
These chapters include:
• Flowcharts and troubleshooting
• Tools and Chemicals
• Data recording sheets.

i - 8 (14) Doc. No. BoC-2712261-0103

 i Introduction Abbreviations and Terminology

Abbreviations and Terminology

Abbreviation Meaning/Definition Notes
Al-foil Aluminium foil
Ammeter Instrument measuring electric
current in amperes
API Advanced Package Integrity
ASU Automatic Splicing Unit
B Base (package shape)
Blocked Seal Cold Seal
DE Distribution Equipment
DIMC Direct Injection Moulding Cap Technique used in FlexiCap
application
QAM Quality Assurance Management
FlexiCap Flexible Cap It uses DIMC technology
HDPE High Density Polyethylene
IH Induction Heating
LLDPE Linear Low Density Polyethylene
LH Left Hand
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LS Longitudinal Sealing
max Maximum
min Minimum
MM Maintenance Manual
MMI Material Machine Interaction
mPE LLDPE syntetized by metallocene
catalyst process
MPM LS Strip with mPE sealing layer see Strips section, page iii-16
and PET oxygen barrier
MTD Method
OK Optional Kit
OE Optional Equipment
OM Operation Manual
PE Polyethylene
Plastic Lumps Hard residue of plastic that
hardens out of the TS sealing
area. They might be referred as
“walling” (USA terminology)
PLH Pre Laminated Hole
PM Packaging Material
PPP LS Strip with LDPE sealing layer see Strips section, page iii-16
and PET oxygen barrier
PT PullTab
QA Quality Assurance
QC Quality Control
RH Right Hand

(Cont'd)

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Abbreviations and Terminology i Introduction

(Cont'd)

S Slim (package shape)

SA Strip Applicator
SM Sealing Monitoring
Sq Square (package shape)
TBA Tetra Brik Aseptic
TCA Tetra Classic Aseptic
TFA Tetra Fino Aseptic
TPA Tetra Prisma Aseptic
TPIH Tetra Pak Induction Heating
TPP Tetra Pak Packaging Solutions
TS Transversal Sealing
TTC Technical Training Centre
TWA Tetra Wedge Aseptic

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i - 10 (14) Doc. No. BoC-2712261-0103

 i Introduction Reference documents

Reference documents
Refer to the following other documents:
• OM pecularities of the filling machine
• TTC Package Integrity Compact Disk
CD-00002-01 (on revision - to be released 2007)
• TTC TS evaluation brochure 1991
• Understanding and Troubleshooting the FlexiCap Aseptic
• Understanding and Troubleshooting the LightCap Aseptic
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Doc. No. BoC-2712261-0103 i - 11 (14)

Manual Information i Introduction

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

1 2

1.2 Transversal Seal - Evaluation by

tearing (P 1201) 1 Transversal Seal (TS)

Prepare samples for TS

accurate check
1
Cut off the top and bottom of the
packages at a distance of about 25-30
mm from the top and bottom creases.
Rinse the samples and dry them with
compressed air.

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2
Cut off 1 mm maximum from the edges.

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Issue 1

1 - 10 (36) Doc. No. BoC-81865-0102

4 3
1 Section name
2 Chapter name
3 Document number
4 Page number

i - 12 (14) Doc. No. BoC-2712261-0103

 i Introduction Manual Information

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

4 - 11 (18) 1 Chapter number

2 Consecutive page number
1 2 3 3 Total number of pages

Typographical Conventions
Cross-references are underlined.

Symbols
The following symbols are used in illustrations:
• A pointer arrow (1) indicates the position of an object
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• A zoom arrow (2) indicates that an object view is enlarged. The arrow
points towards the enlarged view of the object
• A rotation movement arrow (3) indicates rotational movement of an
object. The arrow points in the direction of rotation
• A straight movement arrow (4) indicates movement of an object.
The arrow points in the direction of movement

1 2 3

1 Pointer arrow
2 Zoom arrow
3 Rotation movement arrow
4 5 4 Straight movement arrow

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Manual Information i Introduction

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i - 14 (14) Doc. No. BoC-2712261-0103

 ii Safety Precautions
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Doc. No. BoC-2712261-0103 ii - 1 (2)

Safety Messages Description ii Safety Precautions

Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.

This is the safety alert symbol. It is used to alert about potential personal
injury hazards. To avoid hazards, obey all safety messages that follow this
symbol.
The following safety alert symbols and signal words are used in this manual
to inform the user of hazards.

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

CAUTION
Caution indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be

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used to alert against unsafe practices.
CAUTION
Caution without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property
damage.

ii - 2 (2) Doc. No. BoC-2712261-0103

 iii Getting to know the
Package
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Doc. No. BoC-2712261-0103 iii - 1 (20)

 iii Getting to know the Package

This chapter contains basic information on how a roll fed

aseptic package of the TPP portfolio is sealed and formed;
which are the major differences on packaging materials,
and where the defects are located.

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iii - 2 (20) Doc. No. BoC-2712261-0103

 Table of Contents
iii Getting to know the Package

Aseptic Packaging. . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Packaging Material . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Packaging Material Layers . . . . . . . . . . . . . . . . . . 1 - 8
Guidelines for the choice of Packaging Material 1 - 10
Packaging Material Reel . . . . . . . . . . . . . . . . . . . 1 - 12
Pre-Laminated Hole . . . . . . . . . . . . . . . . . . . . . . . 1 - 13

Package Terminology . . . . . . . . . . . . . . . . . . . . 1 - 14

Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
LS Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
PT Strips (Tab, Patch, Outer Patch) . . . . . . . . . . 1 - 18

Identification of package defects . . . . . . . . . . . 1 - 19

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 iii Getting to know the Package

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iii - 4 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Aseptic Packaging

Aseptic Packaging
Aseptic packaging prevents microbes and bacteria from getting in once the
package is closed. Obviously, this is a great advantage for foods and drinks.
For packaged foods and drinks to be completely free from infection, the
product itself must also be sterile. In other words the following conditions
must be achieved:
• Commercially sterile product: The product itself must be
commercially sterile. See next page for the definition of Commercial
Sterility.
• Sterile product supply: The equipment delivering the product to the
filling machine must be sterile.
• Sterile packaging material: The packaging material must be sterile
when it comes in contact with the product.
• Sterile filling environment: The part of the filling machine where
package filling actually takes place must be sterile.
• Aseptic packages: Packages must be tight, so that microbes and bacteria
cannot get in from the outside. The package is impervious to
microorganisms.
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The diagram below illustrates the aseptic packaging process.

This is taken care of by

the filling machine.

Sterilized
packaging
material

Sterile
surrounding

Commercially Aseptic
sterile transfer
food
Aseptic package

This is taken care of by

the processing equipment
in the factory.

(Cont'd)

Doc. No. BoC-2712261-0103 iii - 5 (20)

Aseptic Packaging iii Getting to know the Package

(Cont'd)
Commercial Sterility definition

Code of Federal Regulations, Title 21, Part 113.3 Definitions:

[…]
(e) Commercial sterility:
(1) ‘‘Commercial sterility’’ of thermally processed food means the condition
achieved:
(i) By the application of heat which renders the food free of:
(a) Microorganisms capable of reproducing in the food under normal
nonrefrigerated conditions of storage and distribution; and
(b) Viable microorganisms (including spores) of public health significance;
or
(ii) By the control of water activity and the application of heat, which renders
the food free of microorganisms capable of reproducing in the food under
normal nonrefrigerated conditions of storage and distribution.
(2) ‘‘Commercial sterility’’ of equipment and containers used for aseptic

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processing and packaging of food means the condition achieved by
application of heat, chemical sterilant(s), or other appropriate treatment that
renders the equipment and containers free of viable microorganisms having
public health significance, as well as microorganisms of nonhealth
significance, capable of reproducing in the food under normal
nonrefrigerated conditions of storage and distribution.
[…]

iii - 6 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Packaging Material

Packaging Material
The packaging material protects the product inside the package from the
environment outside.
It also needs to be firm enough to give the package a good [Link] is
essential for transport and handling. The packaging material is also printed
with information about the contents of the package.
The packaging material used in the filling machines is a very special
laminate material. “Laminate” means that the material is made up of several
different layers. Though different products may require slightly different
packaging materials, all roll fed aseptic packages of the TPP portolio are all
made with “laminated” Packaging Material.
When the packaging material is shaped into packages it is folded along pre-
formed creases. The heavy gray lines in the drawing to the right show the
crease pattern for one package.
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TBA package is shown

Doc. No. BoC-2712261-0103 iii - 7 (20)

Packaging Material iii Getting to know the Package

Packaging Material Layers

The packaging material used is multilayer. The different combination of
layers determines the type of material.
All of the packaging materials contain a paperboard layer (2), an Al-foil
layer (4) and a variable number of plastic based (usually LDPE or m-PE)
layers.
The paperboard gives stability to the package and allows printing of the
design and data.
The Al-foil (4) acts as a barrier against aroma, oxygen and light. It also
protects the flavour of the product and it is used to seal, by induction heating,
layer (6) (Transversal Sealing).
The polyethylene (LDPE, m PE) allows the adhesion of the different
materials, seals in the liquid and protects the package from external moisture.
The package microbiological barrier is composed by layers (6), (5), (4), (3).

1. Outside plastic layer/Decor layer 2. Paperboard and printing 3. Lamination

Protects the package against external Strengthens the package and A plastic layer which allows the

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humidity. Also allows sealing of the offers a good printing surface. paperboard to stick to the al-foil.
package (Flaps and Overlap).

1 2 3

4 5 6
4. Al-foil 5. Internal coating 6. Inside plastic layer
Protects the product against A coating that offers adhesion Prevents the liquid contents from
oxygen and light. between the al-foil and the soaking into the material. Also allows
inside plastic layer. sealing of the package (SA, LS, TS).

(Cont'd)

iii - 8 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Packaging Material

(Cont'd)
The picture below describes what type of effects the different layers in the
Packaging material protect against.

Light,
Aroma,
Oxygen

Inner External
Sealing moisture

5
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6
2

Package
Stability
7

Microbiological
barrier

1 Outer coating
2 Paperboard
3 Lamination
4 Al-foil
5 Internal Coating 1
6 Internal Coating 2
7 Product

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Packaging Material iii Getting to know the Package

Guidelines for the choice of Packaging Material

Scope
To recommend packaging material having a predictable and stable
performance (regarding product-packaging material interaction, barrier and
functional properties) throughout the product shelf life.
Shelf life is determinated by, and is under the complete responsibility of, the
food producer. Shelf life requirements are related to legislation, food quality,
consumer acceptance, storage environment, etc.
Disclaimer
For products not mentioned in the list, film based packaging material is
recommended.
Product type --/ml --/jl --/jl-H --/aqk --/jk --/lk LS strip
Plain milk, sweetened milk • MPM
Flavoured milk Recombined milk • MPM
UHT Cream and non-dairy milk • MPM
Coconut cream • MPM
•

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Coconut drinks, soy bean drinks, rice drinks MPM
Formulated tomato (including tomato juice) • 1) • 2) MPM or MSE (8)
Fruit and vegetable juices and drinks • MPM or MSE (8)
Teas and coffees • MPM or MSE (8)
Citrus juices with collapsed vesicles up to • 5) MPM or MSE (8)
5% (w/w)
Alcohol drinks <20% (inclusing wine) O 4) • MWM
Alcohol drinks >20% • MWM
Dressing O 7) • MPM
Soups and Sauces • MPM or MSE (8)
Oil • 6) • MPM
Vinegar products max.1.0% acetic acid • MPM
Products for hot-vending machines • MPM or MSE (8)
Nutritional products O 7) • MPM or MSE (8)
Special dietetic products • MPM
Water • 3) MPM

• = Official recommendation
O = Local validation is necessary
(Cont'd)

iii - 10 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Packaging Material

(Cont'd)
Table legenda
(1 ) Less than 1% salt and less than 12 months storage at 25ºC.
(2)
The /lk material should be used for longer shelf life and higher salt
content.
(3)
Flavoured water can be packed in TBA/jl, acceptance to be judged by
customer.
(4)
Portion packages approved globally for TBA/jl, family packages case by
case.
(5)
Products with particles should be avoided. Only citrus juices with
collapsed vesicles and berries jiuce containing very small hard particles.
(6)
/jk is needed for Oil Cap.
(7) /jl-H can be used depending on customer sensitivity and complexity

products.
(8)
MSE in case of oxygen sensitive high quality products,
More detailed info in the document Recommended Choice od Packaging
Material for Ambient packages (revision 2, updated 2006-03-05).
TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm

Doc. No. BoC-2712261-0103 iii - 11 (20)

Packaging Material iii Getting to know the Package

Packaging Material Reel

A label indicating packaging material type (e.g. TBA/m, TBA/jl,
TBA lk...etc.) and Production Order is attached to each reel. Always keep the
label and quote the data when performing package integrity tests.

2 1

3
Tetra Pak
TP ORDER TP PRODUCT

4 P202-0123456 D00-0000-01
CUST No
Tetra Pak Carton Ambient S.p.A
123-4567
5 ID No
Via Delphini 1
MODENA
123456789
6 TYPE
Photocell TBA/J FCD

TBA/Jl
7 VOLUME REEL No

1000 ml 01-0001
8 QUANTITY PROD DATE

7500 25-MAY-2008

TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm
9 12345678910 11121314151617181920

10 11
1 Customer address
2 Tetra Pak product code
3 Tetra Pak Production Order number
4 Customer code
5 Identification number
6 Type of Packaging Material
7 Volume of package
8 Quantity of packages on the reel
9 Reel number
10 Date of Production
11 Bar code containing parts of the above
information

iii - 12 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Packaging Material

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

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

Post-applied cap
TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm

2 1

outside of package

inside of package

6 5 4 3 1 Outside plastic layer (decor layer)

2 Paperboard
3 Laminate layer
4 Alu-foil
5 Inner layer 1
6 Inner layer 2

Doc. No. BoC-2712261-0103 iii - 13 (20)

Package Terminology iii Getting to know the Package

Package Terminology
• Longitudinal creases, top creases and bottom creases: These are the
pre-formed folds in the packaging material. They give the package its
final squared form.
• Top fin and bottom fin: These are the top and bottom areas of the
package where it is sealed and cut.
• Transversal seal (TS): Seals the package at the top and bottom.

Top longitudinal
creases
Top fin

Transversal seal (TS)

Top longitudinal
creases

TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm
Rear side of
package

Longitudinal Bottom fin

sealing

Transversal seal (TS)

(Cont'd)

iii - 14 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Package Terminology

(Cont'd)
• Longitudinal seal (LS): Seals the package along the long side.
• LS strip: A strip of laminated plastic applied on the inside of the
longitudinal seal. Prevents the product from soaking into the edge of the
packaging material.
• LS overlap: The area over which the two edges of packaging material
overlap down the long side of the package. Ensures that the longitudinal
seal is rigid and does not leak.
• Top and bottom flaps: The corners of the package that are folded and
sealed to the package body.

Top creases

Top flap
TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm

Top flap

inside of package
Longitudinal seal
(LS) LS strip

Bottom flap

LS overlap

outside of package Bottom flap

Bottom crease

Front side of
package

LS strip

Doc. No. BoC-2712261-0103 iii - 15 (20)

Strips iii Getting to know the Package

Strips
LS Strip
The LS strip has the following tasks:
• it prevents liquid from being absorbed by the packaging material edge;
• it prevents micro-organisms which could be present on the packaging
material edge from contaminating the product;
• it creates a gas barrier in the longitudinal seal which prevents both
aromatic substances from escaping through the seal and air (oxygen)
from penetrating and affecting the product;
• it reinforces the longitudinal seal.

Tetra Pak uses two different strips core polymers, depending on the oxygen
permeability desired:
PET PolyEthylene Terephtalate
EVOH Ethylene Vinyl Acetate with Alcohol groups

From these polymers three basic types of LS strips are available:

PPP has a core of PET, coated with primed layers of LDPE. This strip is

TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm
suitable for products that require a dense oxygen barrier.
MPM has a core of PET, coated with primed layers of LDPE. The
MWM outermost layers consist of mPE. This strip has to be used together
with Tetra Wide packaging material but is also suitable for standard
materials. MPM/MWM is suitable for aggressive and alcoholic
products. It also constitutes a tougher seal.
MSE has a core of EVOH, coated with primed layers of LDPE. The
outermost layers consists of mPE. This strip is suitable for products
that require a high oxygen barrier.

(Cont'd)

iii - 16 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Strips

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

PPP MPM
mLLDPE
LDPE
LDPE
Primer Primer

PET PET

Primer Primer
Juice
LDPE Juice
LDPE
mLLDPE

MSE/LSE MWM/PPPw
mPE/LDPE
mPE/LDPE
TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm

LDPE
Primer Primer

EVOH PET

Primer Primer
LDPE Special
products mPE/LDPE Wine
mPE/LDPE

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

PPP-STRIPS MPM-STRIPS
7,5/0,075 7,5/0,080
44[Link] 12[Link]
lot number lot number

(Cont'd)

Doc. No. BoC-2712261-0103 iii - 17 (20)

Strips iii Getting to know the Package

(Cont'd)

PT Strips (Tab, Patch, Outer Patch)

A label identifying strip type and lot number is attached to every strip box.
Take note of these data and quote them when performing package integrity
tests.

OPP/PE-STRIPS
28/0,064
GTIN EAN/UCC-14

1234
TP MTRL NO. LOT NO. REELS NET WEIGHT KG

1234 1234 1234 1234

USE BEFORE DATE LOT NO. REELS BATCH NO.

1234 1234 1234 1234

BOX NO.

3
12345678910 11121314151617181920

12345678910 11121314151617181920

PEP-STRIP UNIFIED TAB STRIP

29/0,050 1234-123
ART. NO LOT NO. REELS NET WEIGHT KG

1234-123 123456 10 123456 Quantity 1234 m

USE BEFORE DATE PALLET - BOX NO. Lot. No. 123345678
12341212 123456 Prod. date 1234-12-12 Use before: 1234-12-12

TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm
12345678910 11121314151617181920 12345678910 11121314151617181920

iii - 18 (20) Doc. No. BoC-2712261-0103

 iii Getting to know the Package Identification of package defects

Identification of package defects

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

Pos Defect location Defect name MTD

1 LS - not sealed 1202
- blisters
- channels
2 Corners - red ink leakage 1203 - 1204
3 TS - channel / blocking 1201 (Production)
- plastic lumps 1208 (QC,
- overheating Troubleshooting)
- Af-foil TS crack 1210
- fibres trapped in TS
4 TS/LS cross - channels 1208 (QC)
- plastic lumps 1201 (Production)
5 PullTab / Opening - red ink leakage 1211
6 Fin - top fin tearing 1204
- bottom fin tear (TWA only)
7 Bottom flap - k-cracks leakage 1203 - 1204
TechPub_2614345_0103 - BoC_2712261_0103_gtk.fm

3 6

4
2 5

7 inside of package

Doc. No. BoC-2712261-0103 iii - 19 (20)

Identification of package defects iii Getting to know the Package

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iii - 20 (20) Doc. No. BoC-2712261-0103

 1 Transversal Seal (TS)
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Doc. No. BoC-2712261-0103 1 - 1 (44)

Methods: 1 Transversal Seal (TS)

Methods:
MTD 1201 - Transversal Seal Tearing
Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
• Previous version, MTD 1201, issued by Sara Davolio, 1996/02/27.
• TTC TS evaluation brochure 1991.

MTD 1208 - Transversal Seal Dissolving and Red Ink

Personnel
This method must be performed by Specialized personnel. Refer to section

TechPub_2614345_0103 - 01_2712261_03_en.fm
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD 1208 issued by Sara Davolio, 1996/11/19.

MTD 1210 - Transversal Seal Al-foil cracks

Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD 1210, issued by Sara Davolio, date 1996/02/29.

1 - 2 (44) Doc. No. BoC-2712261-0103

 Table of Contents
1 Transversal Seal (TS)

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

1.2 Transversal Seal - Tearing (MTD 1201) . . . . . . . 1 - 9

1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
1.2.2 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
1.2.3 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 11
1.2.4 Check of the samples . . . . . . . . . . . . . . . . . . . . . 1 - 12
1.2.5 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 14

1.3 Transversal Seal - Dissolving and Red Ink

(MTD 1208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
1.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
1.3.2 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
1.3.3 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 21
TechPub_2614345_0103 - 01_2712261_03_en.fm

1.3.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 33

1.4 Transversal Seal - Al-Foil Cracks (MTD 1210). 1 - 39

1.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39
1.4.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 40
1.4.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 41
1.4.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 42

Doc. No. BoC-2712261-0103 1 - 3 (44)

Table of Contents 1 Transversal Seal (TS)

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1 - 4 (44) Doc. No. BoC-2712261-0103

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

1.1 Transversal Seal - General information

The Transversal Seal is formed in the Jaw System by two jaws working in
pairs (e.g. Tetra Pak A3/Flex and TBA/21) or in 10 jaws linked in chain
working in pairs (e.g. Tetra Pak A3/Speed and TBA/22).
• the Volume Flaps (2) hold and preform the package in the packaging
material tube
• the inductor jaw (3) contains the inductor (6)
• the cutting jaw (4) contains the pressure rubber dollies (7) and the
cutting knife (5) plus the cutting rail.
Note!
Inductor jaw is called as well Sealing jaw or Pressure jaw in different
machines systems (e.g. A1).
Cutting jaw is called as well Pressure jaw in machines with 10 jaws
linked in chain and A1 system.
2 Jaws working in pair 10 Jaws linked as chain
J4 J4
J3 J3

J5 J5
TechPub_2614345_0103 - 01_2712261_03_en.fm

J2 J2
J2 J2
J6 J6
J1 J1

J1 J1
J7 J7
J10 J10

J8 J8
8 9 J9 J9

2 1
Jx Jaw pair 8 2
1 Filling product
2 Volume Flap 7
3 Inductor Jaw
4 Cutting Jaw
5 Knife
6 Inductor
7 Rubber Dolly
8 Package 2 (upper)
9 Package 1 (lower)
5 4 9 6 3

(Cont'd)

Doc. No. BoC-2712261-0103 1 - 5 (44)

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

(Cont'd)
Each pair of jaws makes two seals, i.e. the bottom seal (10) of one package
(8) and the top seal (11) of the next package (9).

Note!
The picture below shows, as example, the inductor at the jaw pair
number J2 (12) and the TS between packages 1 and 2.

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

1
8 10

15 13

12 (J2)

TechPub_2614345_0103 - 01_2712261_03_en.fm
16 14
9 11
8

10

13
1 Filling product
+
-

8 Package 2 (upper)
+
+

9 Package 1 (lower)
-

10 Bottom Seal on Package 2

14 (upper)
11 Top seal on Package 1
(lower)
11 12 Jaw Pair No.2
13 Coil: Upper part
14 Coil: Lower part
15 Upper Dolly
9 16 Lower Dolly

(Cont'd)

1 - 6 (44) Doc. No. BoC-2712261-0103

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

(Cont'd)
The rubber dollies (14) and (15) on the cutting jaw exert pressure, allowing
the plastic layers to be sealed together. The pressure is produced
hydraulically or mechanically depending on the machine type. The knife (4)
cuts the packaging material tube separating the packages.
Most applications use ridge inductor, but in most of TCA, TFA and some
TWA applications inductors with lower ridge might be used.

22 15
8
17 18
13
8
19
5
22 20
21 21
TechPub_2614345_0103 - 01_2712261_03_en.fm

22 22
14

9
9
16

22
5 Knife 17 Cutting rail
8 Package 2 (upper) 18 Heat pattern
9 Package 1 (lower) 19 Inductor body
13 Coil: Upper part 20 Cutting groove
14 Coil: Lower part 21 PM cutting line
15 Upper dolly 22 Ridge
16 Lower dolly

(Cont'd)

Doc. No. BoC-2712261-0103 1 - 7 (44)

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

(Cont'd)

1
8
23
26
22
24 22
27 28

9 1
26

21
25
26 23

TechPub_2614345_0103 - 01_2712261_03_en.fm
29

27 28

1 Filling product 26 24
8 Package 2 (upper)
9 Package 1 (lower)
21 PM cutting line 25
22 Ridge impression
23 Al-foil 29
24 Paperboard 21
25 Plastic film, double layers
26 Blocked area
27 Sealed area
28 Ridge impression
29 Outer coating

1 - 8 (44) Doc. No. BoC-2712261-0103

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

1.2 Transversal Seal - Tearing

(MTD 1201)
1.2.1 Introduction
The method consists in pulling the transversal sealing (1) apart using the
stretch pliers (2) and examining how the seal separates.
By visually checking the seal, it is possible to notice the presence of plastic
ridges or lumps along it. These ridges could punch the packaging material
layers, compromising the integrity of the package.
The seal must be mechanically stronger than the packaging material. If the
sealing is good, the packaging material layers (plastic film, Al-foil or
paperboard) break while the seal does not separate.

1
TechPub_2614345_0103 - 01_2712261_03_en.fm

1 TS
2 2 Stretch pliers

Doc. No. BoC-2712261-0103 1 - 9 (44)

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

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

Note!
The only way to detect a blocked seal it is the manual Tear Down
during Production. Conductivity test and Red ink test would not detect
a blocked seal.
Decay
The TS with a good heat pattern will progressively tend to appear as blocked,
when torn by means of the stretch pliers or by hand. This effect, called decay,
typical of wet sealings, depends on the filling product (water included),
sealing settings, packaging material and storage time.
For this reason during troubleshooting and after production (1 week is the
reference interval considered), dissolving and heat pattern analysis is the
only reliable method to access the sealing quality.
Plastic lump

TechPub_2614345_0103 - 01_2712261_03_en.fm
Plastic lump is a plastic residue that solidifies out of the dolly area.
Plastic lumps are a potential danger in the aseptic package. The hard residue
might punch the Packaging Material layers during the distribution of the
package compromising the package integrity.

1 - 10 (44) Doc. No. BoC-2712261-0103

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

1.2.3 Preparation of the Samples

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

Prepare samples for TS rough

check
1
Unfold the top and bottom flaps of the
package.

Prepare samples for TS

accurate check
TechPub_2614345_0103 - 01_2712261_03_en.fm

1
Cut off the top and bottom of the
packages at a distance of about 25-30
mm from the top and bottom fin creases.
Rinse the samples and dry them with
compressed air.
Note! Use compressed air with care
since it might damage the sample.

2
Cut off 1 mm maximum from the edges.

Doc. No. BoC-2712261-0103 1 - 11 (44)

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

1.2.4 Check of the samples

TS rough TS check
1
Check if the package has product
leakages from the TS by gently
squeezing the package with the fingers.
If there is product leakage, the TS has a
gross defect (most likely a dolly is
missing).
If any product leakage is found stop the
machine and call a technician.
Note! If there is any leak from
between the PLH and the package, it
is not due to the TS sealing. Call a
service technician.

TechPub_2614345_0103 - 01_2712261_03_en.fm
TS accurate check
1
Run you finger over the TS and check if
there are plastic lumps or ridges.
Plastic lumps and ridges show that the
sealing is not correct. See section 1.2.5
Evaluation of the Samples for further
details.

1 - 12 (44) Doc. No. BoC-2712261-0103

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

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

CORRECT
3
Stretch by pressing the plier handles
1 1
along the whole length of the sample
2 2 Stretch a little bit at a time, from both
ends (1) towards the LS/TS cross (3).
3 3
TechPub_2614345_0103 - 01_2712261_03_en.fm

CAUTION
2 2 Risk of sample damage.
1 1 Take a lot of care in the point where
the TS and LS cross and on the
edges, since the magnetic field and
heat pattern is weaker in these areas.
The cross might be the last part
stretched to enable a better
evaluation.

WRONG

Doc. No. BoC-2712261-0103 1 - 13 (44)

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

1.2.5 Evaluation of the Samples

The seal can be either good or defective. A seal is good when it is
mechanically more resistant than the packaging material. If a seal is
defective, it could easily cause unsterility.
The first sign of a good seal is stretched plastic film. Breakage in the Al-foil
and paperboard layers also shows that the seal is stronger than the packaging
material.
The rules apply also in the TS/LS cross where the strip is part of the seal.
Here you have some representative examples of good and defective seals.

1 1
Before pulling the seal apart,
it is easier to notice the
presence of plastic ridges or
lumps along it.
Plastic lumps (1) are a
potential danger in the
aseptic package. The hard
residue might punch the PM

TechPub_2614345_0103 - 01_2712261_03_en.fm
layers during distribution of
the package compromising
the package integrity.

Defective seal
Plastic lumps are the signal
of a too high or uneven
sealing temperature, too high
pressure or wrong jaw
system alignment.
1 2
The wave (1) is still
encapsulated in the heated
area and will not determine
integrity issues.

Good seal
On the contrary the plastic
lump defined as “hard
residue exceeding the heated
area” might jeopardize
package integrity
performance during
distribution.

1 - 14 (44) Doc. No. BoC-2712261-0103

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

3
The seal does not come
apart; the plastic film
stretches and breaks, leaving
the paperboard uncovered.

Good seal

Typical behaviour of TBA/lk and TBA/jl

4
The case described above
applies also to the cross,
where TS and LS meet. The
LS must be considered and
TechPub_2614345_0103 - 01_2712261_03_en.fm

additional plastic multi-

layer.
The picture shows the LS
which stretches and
delaminates.

Good seal

5
The seal does not come
apart; the plastic film breaks
leaving the paperboard fibres
and the Al-foil uncovered.

Good seal

Typical behaviour of TBA/j

(that has high adesion to Al-foil)

Doc. No. BoC-2712261-0103 1 - 15 (44)

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

6
The plastic film layers
separate from the Al-foil,
leaving it uncovered and
shiny.

Good seal

Typical behaviour of TBA/m

(that has low adesion to Al-foil)

7
The seal separates; no
rupture occurs in the
packaging material layers.
The seal appears mattish or
greyish. This is called

TechPub_2614345_0103 - 01_2712261_03_en.fm
blocked seal.

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

1 - 16 (44) Doc. No. BoC-2712261-0103

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

8
The seal is overheated; the
two PE layers are burnt and
the Al-foil shows micro-
cracks and cuts.

Defective seal
Overheated seals are often
due to too high sealing
temperature or by excessive
pressure. Sealing settings,
cooling water temperature or
jaw pressure must be
adjusted.
TechPub_2614345_0103 - 01_2712261_03_en.fm

9
The Al-foil is cracked in the
ridge area.

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

Doc. No. BoC-2712261-0103 1 - 17 (44)

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

1.3 Transversal Seal - Dissolving and Red Ink

(MTD 1208)
1.3.1 Introduction
This section describes the method to evaluate the Transversal Seal (TS) by
dissolving the Al-foil (4) with chemical agents and separating the inner
plastic layers (5) and (6) from the other package layers, obtaining a inner
plastic bag (7).
The inner plastic bag (7) is then analysed to check the heat distribution along
the TS (heat pattern).
The TS tightness is tested using the leakage detection fluid (red ink).

6
5
4 7
3
2

TechPub_2614345_0103 - 01_2712261_03_en.fm
1

1 Outer coating
2 Paperboard
3 Lamination
4 Al-foil
5 Inner Coating 1
6 Inner coating 2

(Cont'd)

1 - 18 (44) Doc. No. BoC-2712261-0103

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

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

Heat pattern
Ridge impression
TechPub_2614345_0103 - 01_2712261_03_en.fm

= heat pattern

Ridge impression LS Air channel

Lower Blocked area LS / TS cross Upper Blocked area Bending Off

(Cont'd)

Doc. No. BoC-2712261-0103 1 - 19 (44)

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

(Cont'd)
The heat pattern must be symmetrical with respect to the LS and the cutting
line and fulfil the geometrical measurements shown below.
The causes of uneven distribution are mostly unparallel pressure distribution,
banana shaped inductors or dollies status.

Note!
These dimensions are in general not influenced by the filling machine
(e.g. the heat pattern of a TBA/21 is similar to the heat pattern of a
TBA/22 given the package size).
D, usually, is wider than C.
Dimension Acceptable (mm) NOT Acceptable (mm)
A 0 >0
B ≥ 0.2 < 0.2
C ≥1 <1
D ≥1 <1

D C

TechPub_2614345_0103 - 01_2712261_03_en.fm
B

1 - 20 (44) Doc. No. BoC-2712261-0103

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

1.3.3 Preparation of the Samples

1.3.3-1 Cut packages
1

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

Unfold all the flaps and flatten the

package. Cut the package in a I shape, as
shown in the picture.
The along the TS should be about 50 mm
wide with the LS at its central axis.
Cut out the front panel of the package at
approximately 25 mm from the top and
TechPub_2614345_0103 - 01_2712261_03_en.fm

bottom TS.

2
Mark each sample in order to distinguish
the Top and Bottom seal after dissolution.
For example, write T (for Top) and B (for
Bottom) on the inside of the package
with a permanent marker.
Mark the samples with progressive
numbers.
Note! If packages was containing
high fat products it might be difficult to
use the permanent marker.

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

3
If possible, cut the top of the package
using the pinking scissors for an easy
identification of the top.
The scheme below shows the PM layers
before starting the procedure:

1 Outer coating
2 Paperboard
3 Lamination
4 Al-foil
5 Inner coating 1
6 Inner coating 2

TechPub_2614345_0103 - 01_2712261_03_en.fm
1
2
3
4
5
6

1 - 22 (44) Doc. No. BoC-2712261-0103

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

4
Carefully peel off the external packaging
material layers (starting from the LS
overlapping), as shown in the top picture.
The outer polyethylene layer and part of
the paperboard layer will come off.
The sample in the bottom picture will be
obtained.
Note! TFA packages do not need this
step since the paperboard is too thin
to peel apart.

The PM layers left, at this stage, on the

sample are the following:

2 Paperboard
3 Lamination
4 Al-foil
TechPub_2614345_0103 - 01_2712261_03_en.fm

5 Inner coating 1
6 Inner coating 2

2
3
4
5
6

TCA packages
Prepare the packages as shown in the
picture.

Doc. No. BoC-2712261-0103 1 - 23 (44)

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

1.3.3-2 Dissolving of packages

Packages can be dissolved either using an acid or an alkaline solution. See
section B.3 Preparation of Chemicals for details on the composition and
preparation of the solutions.
There are three methods that can be followed according to the urgency of
results:
• The acid agent (very fast method) acts fast, therefore it is advisable
when the results of the test are urgent (e.g. during Production). A fume
extractor and a water bath are needed for preparation and usage.
• The acid agent (fast method) acts slower that the above solution, but is
faster than the alkaline solution. With this method is possible to obtain
the samples in less than one hour. Fume extractor is highly
recommended.
• The alkaline agent (slow method) acts more slowly; the samples must
stay immersed in the solution for at least 6 hours. This method is
advisable when there are many samples to evaluate (e.g. during
troubleshooting).

Dissolving of

TechPub_2614345_0103 - 01_2712261_03_en.fm
packages methods

Acid agent method 1 Acid agent method 2 Alkaline agent

(very fast) (fast) * (slow)

- HCl 1:1 solution - HCl 30% solution - Alkaline solution

Solutions - HCl 1:3 solution - Neutralizing solution - Neutralizing solution
used - Neutralizing solution

very fast (sample ready fast (sample ready in

Advantages safer (no acid solutions
in 15 min) less than one hour)
involved)

risk of spoiling of the not very fast as Acid

Disadvantages slow (sample ready in 6
sample with too long agent method 1 hours)
immersion in solution

go to page 1-25 go to page 1-28 go to page 1-30

(Cont'd)

1 - 24 (44) Doc. No. BoC-2712261-0103

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

(Cont'd)
Acid agent method 1 (very fast)

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

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

Immerse the samples in HCl 1:1 solution

one at a time for approximately 4 minutes
at temperature between 55° C and 60° C.
TechPub_2614345_0103 - 01_2712261_03_en.fm

Use a water bath.

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

2
Remove the samples from HCl 1:1
solution and immerse them in the
Neutralizing Solution to neutralize the
acid.
Neutralizing Solution solution should
bubble as soon as the samples are
immersed; if not, prepare a new solution.

Doc. No. BoC-2712261-0103 1 - 25 (44)

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

3
The external lamination layer should
easily separate from the Al-foil by
mechanical hand action.
The inner plastic layers and the Al-foil
are left. The Al-foil will be dissolved in
the next step.
The PM layers left, at this stage, on the
sample are the following:

4 Al-foil
5 Inner coating 1
6 Inner coating 2

4
5

TechPub_2614345_0103 - 01_2712261_03_en.fm
6

4
Note! This step is the most sensitive.

The temperature of HCl 1:3 solution

increases when samples are immersed
into it, therefore there is a high risk of
burning the packages.

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

Immerse the samples into HCl 1:3

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

1 - 26 (44) Doc. No. BoC-2712261-0103

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

5
The Al-foil comes off. The inner plastic
bag, eventually isolated, must be first
neutralized in the Neutralizing solution,
then rinsed carefully under tap water.
The PM layers left at the end of the
dissolving are the following:

5 Inner coating 1
6 Inner coating 2

5
6
TechPub_2614345_0103 - 01_2712261_03_en.fm

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

Doc. No. BoC-2712261-0103 1 - 27 (44)

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

Acid agent method 2 (fast)

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

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

Immerse the samples in the HCl 30%

solution one at a time for approximately
1 hour.

TechPub_2614345_0103 - 01_2712261_03_en.fm
2
Remove the samples from the HCl 30%
solution and immerse them in
Neutralizing solution to balance acidity.

1 - 28 (44) Doc. No. BoC-2712261-0103

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

3
Rinse the samples under tap water. The
external lamination layer and the Al-foil
should easily separate from the inner
plastic layer.
The PM layers left at the end of the
dissolving are the following:

5 Inner coating 1
6 Inner coating 2
TechPub_2614345_0103 - 01_2712261_03_en.fm

5
6

4
Dry the samples, see 1.3.3-3 Drying the
samples.

Doc. No. BoC-2712261-0103 1 - 29 (44)

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

Alkaline agent method (slow)

1
Carefully immerse all the samples in the
dissolving solution. Leave the beaker
uncovered to allow hydrogen fumes to be
ventilated.
If fresh, the solution should immediately
start to bubble. If not, prepare a new
solution.
Leave the samples in the dissolving
solution for at least 6 hours, or until no
Al-foil is visible on the upper samples.

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

TechPub_2614345_0103 - 01_2712261_03_en.fm
fresh one.
15% of citric acid solution might be used
to neutralize the samples.
Rinse the samples under tap water and
carefully separate the inner plastic bag.
The PM layers left at the end of the
dissolving are the following:

5 Inner coating 1
5 6 Inner coating 2
6

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

1 - 30 (44) Doc. No. BoC-2712261-0103

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

1.3.3-3 Drying the samples

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

CAUTION
Risk of sample damage!
Do not reverse the bags while drying
them, or they could be spoilt.
TechPub_2614345_0103 - 01_2712261_03_en.fm

WRONG

2
Spoiled samples must be discarded.
The picture shows a sample that has been
heated too much during the chemical
exposure, becoming unreliable.

Doc. No. BoC-2712261-0103 1 - 31 (44)

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

1.3.3-4 Red Ink Tightness

1
CAUTION
Risk of sample damage!
Handle the samples with care.
Mechanical stress due to improper
handling can compromise the results
of the test.

Take one sample at a time, make sure that

it is completely dry.
Put some red ink with a plastic pipette
inside the plastic bag along the TS.

TechPub_2614345_0103 - 01_2712261_03_en.fm
Let the red ink spread along the TS.
Hold the sample with both hands and
visually check it.
If the TS is not tight and there are
channels in it, the red ink will pass to the
outside of the bag.
If the result is doubtful, let the samples
dry and repeat the red ink test, at room
temperature.
Filter paper can be used to see spots of
red ink passing through the sealing.

1 - 32 (44) Doc. No. BoC-2712261-0103

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

1.3.4 Evaluation of the Samples

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

Here you have some representative examples of TS.

1
The sealing is even, the heat pattern is
regular, no cracks are visible.
The sample shows bubbles that might
TechPub_2614345_0103 - 01_2712261_03_en.fm

appear after the dissolving due to the

chemical exposure. Those bubbles are
not evidence of anomalies in the sample.

Good seal

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

Good seal

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

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

Good seal

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

Good seal

TechPub_2614345_0103 - 01_2712261_03_en.fm
5
The sealing shows cuts in the ridge area
that might be due to dissolving
procedure, high pressure or setting of the
TPIH.

Good seal

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

Good seal

1 - 34 (44) Doc. No. BoC-2712261-0103

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

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

Good seal

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

Good seal
TechPub_2614345_0103 - 01_2712261_03_en.fm

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

Defective seal

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

10
Plastic lumps
The TS shows plastic lumps.

Defective seal

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

TechPub_2614345_0103 - 01_2712261_03_en.fm
Defective seal

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

Defective seal

1 - 36 (44) Doc. No. BoC-2712261-0103

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

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

Defective seal

14
Cutting knife and pressure
problems
The seal shows channels from the cutting
area towards the product side.
TechPub_2614345_0103 - 01_2712261_03_en.fm

Defective seal

Doc. No. BoC-2712261-0103 1 - 37 (44)

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

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

Good seal
Defective seal

TechPub_2614345_0103 - 01_2712261_03_en.fm
Good seal Defective seal

Good seal Defective seal

Good seal Defective seal

1 - 38 (44) Doc. No. BoC-2712261-0103

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

1.4 Transversal Seal - Al-Foil Cracks

(MTD 1210)
Note!
This procedure is very uselful as troubleshooting procedure.

1.4.1 Introduction
The purpose of this method is to detect cracks which can occur in the Al-foil
along the ridge, mainly at the TS fin corners. This method has been
developed for filled packages produced in filling machines with ridge
inductor.
Package integrity can be compromised if the crack arises at the ends of the
seal, before or during the pulse. The current circulation in the Al-foil is
interrupted by the crack and the sealing is not performed correctly. As a
result, the heat pattern (distance A) does not comply with the minimum
required values.
At the present level of knowledge, the occurrence of cracks depends on:
• packaging material;
• status of the sealing components;
• TS configuration;
TechPub_2614345_0103 - 01_2712261_03_en.fm

• tolerances of the machine settings (i.e. design correction and folding

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

Good
A

Defective Defective

Doc. No. BoC-2712261-0103 1 - 39 (44)

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

1.4.2 Preparation of the Samples

1
Unfold all the flaps of the package
samples.

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

3 TechPub_2614345_0103 - 01_2712261_03_en.fm

Starting from the LS overlap, tear away

the outer layers of packaging material
over the top and bottom TS.
Mark top and bottom of the package to
identify them.

1 - 40 (44) Doc. No. BoC-2712261-0103

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

1.4.3 Procedure
1
If a very bright lamp is available, put the
edge of the sample against the light
source. The area in which the light passes
through the packaging material
corresponds to a crack in the Al-foil.

2
If the light source at your disposal is not
TechPub_2614345_0103 - 01_2712261_03_en.fm

powerful enough, dip the packages in

warm water and carefully remove the
paperboard layers covering the Al-foil in
the TS area with an abrasive sponge.

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

Doc. No. BoC-2712261-0103 1 - 41 (44)

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

1.4.4 Evaluation of the Samples

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

Defective seal

2
Defects are visible also with the aid of a

TechPub_2614345_0103 - 01_2712261_03_en.fm
magnifying lens or microscope.
This seal shows a crack due to excessive
pressure of the dollies or knife return
problems, which does not cause a
magnetic field interruption. The heat
pattern is regular.
This is NOT a TS Al-foil crack (cracks
out of the ridge area).

Good seal
3
This crack compromises the distribution
of heat along the TS; the heat pattern will
consequently be irregular.
This is a TS Al-foil crack in the ridge
area.

Defective seal

1 - 42 (44) Doc. No. BoC-2712261-0103

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

4
For further investigation dissolve the
packages, see 1.3 Transversal Seal -
Dissolving and Red Ink (MTD 1208) and
analyse the heat pattern, to confirm its
irregularity.
TechPub_2614345_0103 - 01_2712261_03_en.fm

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

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1 - 44 (44) Doc. No. BoC-2712261-0103

 2 Longitudinal Seal (LS/SA)
TechPub_2614345_0103 - 02_2712261_03_en.fm

Doc. No. BoC-2712261-0103 2 - 1 (24)

Methods: 2 Longitudinal Seal (LS/SA)

Methods:
MTD 1202 - Longitudinal Seal Tearing
Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD 1202, issued by Sara Davolio, date 1996/11/18.

MTD 1202 - Longitudinal Seal by Red Ink

Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on

TechPub_2614345_0103 - 02_2712261_03_en.fm
the tools used.
Reference Documents
Previous version, MTD 1202, issued by Sara Davolio, date 1996/11/18.

2 - 2 (24) Doc. No. BoC-2712261-0103

 Table of Contents
2 Longitudinal Seal (LS/SA)

2.1 Longitudinal Seal - General information . . . . . . 1 - 5

2.2 Longitudinal Seal (LS/SA) - Tearing (MTD 1202) 1 - 7

2.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
2.2.2 Preparation of the Samples. . . . . . . . . . . . . . . . . . 1 - 8
2.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
2.2.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 14

2.3 Longitudinal Seal - Red Ink Injection. . . . . . . . 1 - 18

2.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
2.3.2 Preparation of the Sample. . . . . . . . . . . . . . . . . . 1 - 19
2.3.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 21
2.3.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 22
TechPub_2614345_0103 - 02_2712261_03_en.fm

Doc. No. BoC-2712261-0103 2 - 3 (24)

Methods: 2 Longitudinal Seal (LS/SA)

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2 - 4 (24) Doc. No. BoC-2712261-0103

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

2.1 Longitudinal Seal - General information

This seal creates the tight tube of packaging material just before product
filling. The LS strip (1) is attached to one edge of the packaging material (2)
by the Strip Applicator (SA) (3) by hot air or induction heating depending on
the machine type.

1 Strip
2 Packaging Material 2
TechPub_2614345_0103 - 02_2712261_03_en.fm

3 Strip Applicator

During tube forming, the edge of packaging material (2) without the LS
strip (1) is heated by induction or hot air depending on the machine type; the
two edges are then overlapped and pressed together by counter roller (4) and
the pressure roller (5) to create the sealing.

5 2

5 2

4 1 Strip 1
2 Packaging Material
4 Counter roller 4
5 Pressure roller

(Cont'd)

Doc. No. BoC-2712261-0103 2 - 5 (24)

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

(Cont'd)
The Strip Applicator side (SA side) (6) of the seal is where the strip (1) was
attached to the packaging material (2) by the Strip Applicator; the packaging
material edges overlap in this area.
The LS side (7) is where the strip was attached to the packaging material
during tube forming; the packaging material is single.
An air gap (8) is present in the middle of the seal.

outside package

7 8 6

1 inside package 2

TechPub_2614345_0103 - 02_2712261_03_en.fm
TBA package is shown

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

Filling Machine SA LS
TBA/3 hot air hot air
TFA/3 hot air hot air
TBA/9 - TWA hot air hot air
TBA/8 hot air hot air
TBA/19 induction heating hot air
TBA/21 induction heating induction heating
TBA/22 induction heating induction heating
Tetra Pak A1 (030V) hot air hot air
Tetra Pak A1 (080V) induction heating hot air
Tetra Pak A3/Flex induction heating induction heating
Tetra Pak A3/Speed induction heating induction heating

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

2 - 6 (24) Doc. No. BoC-2712261-0103

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

2.2 Longitudinal Seal (LS/SA) - Tearing

(MTD 1202)
Note!
This test can be carried out during or after Production.

2.2.1 Introduction
The quality of the seal is tested by tearing the LS strip manually. The seal
must be mechanically stronger than the packaging material. If the sealing is
good, the packaging material layers (plastic film, Al-foil or paperboard)
come apart together with the strip.
The heat distribution along the seal can be examined with the use of a
zonoscope to detect possible asymmetry.
TechPub_2614345_0103 - 02_2712261_03_en.fm

Doc. No. BoC-2712261-0103 2 - 7 (24)

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

2.2.2 Preparation of the Samples

1

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

Unfold the flaps of the package samples.

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

TechPub_2614345_0103 - 02_2712261_03_en.fm
3
Open up the sample, rinse it with water
and dry it.

2 - 8 (24) Doc. No. BoC-2712261-0103

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

2.2.3 Procedure
2.2.3-1 Visual checks
1
Strip position
Note!
The LS side (2) of the seal is where the
packaging material (1) is single. The SA
side (4) is where the packaging material
PPP is double.
LS strip type

1 2 3 4
Packages with PPP LS strip type
Check that the strip is centred in the seal.
An air gap (3) must be present in the
centre of the seal.

LS SA
TechPub_2614345_0103 - 02_2712261_03_en.fm

50% 50%

MPM
LS strip type
Packages with MPM LS strip type
1 2 3 4 In any package with MPM LS strip type,
the strip is off-centred with respect to the
seal; 60-70% of the strip covers the SA
side.

Note! When the risk of strip folding is

reported the strip (2) can be more on
LS SA the SA side (naturally 60-70%) than
on the LS (the remaining 40-30%).
30% 70% This is recommended for MPM type
40% 60% strip.

Doc. No. BoC-2712261-0103 2 - 9 (24)

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

TCA packages
In TCA packages the strip is off-centred
1 2 3 4 with respect to the seal; 60-70% of the
strip covers the SA side.

Note! When the risk of strip folding is

reported the strip (2) can be more on
the SA side (naturally 60-70%) than
on the LS (the remaining 40-30%).
This is recommended for MPM type
LS SA strip.
30% 70%
40% 60%
TCA packages

TechPub_2614345_0103 - 02_2712261_03_en.fm
2

2
Blistering
Check for any blister or bubble along the
heated zone of strip.
The presence of blisters in the LS side of
the strip indicates too high sealing
setting, either energy or pressure.
The presence of blisters in the SA side of
the strip indicates too high sealing
setting, either energy or pressure, of the
Strip Applicator.

Defective seal

2 - 10 (24) Doc. No. BoC-2712261-0103

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

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

Defective seal
TechPub_2614345_0103 - 02_2712261_03_en.fm

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

Defective seal

Doc. No. BoC-2712261-0103 2 - 11 (24)

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

2.2.3-2 Mechanical test

1
Cut the package sample along the middle
2 3 of the LS (1) and LS air channel (2).

1 Cutting line is (3).

TechPub_2614345_0103 - 02_2712261_03_en.fm
2
Pull off the outer layer of packaging
material where it is double.
Check that the overlap is properly sealed
since is giving strength to the final
package.

2 - 12 (24) Doc. No. BoC-2712261-0103

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

3
Pull the strip slowly, at an angle of 90°,
20 mm at the time.
Note! Best results are achieved if the
sample is pulled on a flat surface
(table).
TechPub_2614345_0103 - 02_2712261_03_en.fm

Doc. No. BoC-2712261-0103 2 - 13 (24)

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

2.2.4 Evaluation of the Samples

Note!
Evaluate the samples soon after preparation as the sealing could be
affected by the environmental conditions.
When pulling the LS strip (1), it must be mechanically stronger than the
packaging material (2). If the sealing is good, the packaging material layers
(plastic film, Al-foil or paperboard) come apart together with the strip.
Delamination of the strip up to PET layer, or delamination of material up to
Al-foil, are easy to see due to the shining surfaces of PET and Al-foil.
Delamination of the LDPE strip layers and the internal of the PM Plastic
layer is more difficult to notice.

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

3
3
1

TechPub_2614345_0103 - 02_2712261_03_en.fm
2
1

1 LS Strip
2 Packaging Material
3 Cutting line

2 - 14 (24) Doc. No. BoC-2712261-0103

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

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

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

Good seal
TechPub_2614345_0103 - 02_2712261_03_en.fm

TBA/j packaging material with PPP strip

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

Good seal
TBA/jl packaging material with MPM strip

1 4
Rupture in the paperboard
Stretch of the Polymer and
rupture to the paperboard.
3
Good seal

TBA/jl packaging material with MPM strip

Doc. No. BoC-2712261-0103 2 - 15 (24)

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

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

Good seal

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

TechPub_2614345_0103 - 02_2712261_03_en.fm
Good seal

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

Defective seal

2 - 16 (24) Doc. No. BoC-2712261-0103

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

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

Pulled Press a rolling ball point pen (see

strip B.2 Tools and Equipment for
details) on a point of the LS edge
after pulling it.
Red colour pens are the best
performing.

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

Good seal
TechPub_2614345_0103 - 02_2712261_03_en.fm

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

Defective seal
(blocked)

Doc. No. BoC-2712261-0103 2 - 17 (24)

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

2.3 Longitudinal Seal - Red Ink Injection

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

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

TechPub_2614345_0103 - 02_2712261_03_en.fm

2 - 18 (24) Doc. No. BoC-2712261-0103

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

2.3.2 Preparation of the Sample

1

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

Unfold the flaps of the package samples.

2
Cut two opposite corners (top right,
bottom left), empty the package content,
and cut the sample corner to corner in a
TechPub_2614345_0103 - 02_2712261_03_en.fm

diagonal, across the front panel of the

package, leaving the LS intact.

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

Doc. No. BoC-2712261-0103 2 - 19 (24)

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

4
Make a cut across the LS as shown.

TechPub_2614345_0103 - 02_2712261_03_en.fm

2 - 20 (24) Doc. No. BoC-2712261-0103

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

2.3.3 Procedure
By red ink injection

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

Inject 1 ml of red ink into the air channel

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

By red ink contact

1
Evaluation can be done also by applying
the red ink on the inside of the package,
TechPub_2614345_0103 - 02_2712261_03_en.fm

outside of the LS strip, by means of a

pipette.

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

Doc. No. BoC-2712261-0103 2 - 21 (24)

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

2.3.4 Evaluation of the Samples

1
Check that the strip is tight and no
transversal air channels are present
Critical points are where the LS and the
TS meet, and on the top and bottom
creases.

TechPub_2614345_0103 - 02_2712261_03_en.fm
This picture shows a good seal, in which
the LS induction heating setting is at
acceptable values.

Good seal

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

Good seal

2 - 22 (24) Doc. No. BoC-2712261-0103

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

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

Good seal

5
This picture shows a seal in which the ink
flows in the air channel showing
deviations that are not compromising
package integrity yet.
TechPub_2614345_0103 - 02_2712261_03_en.fm

Good seal

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

Defective seal

Doc. No. BoC-2712261-0103 2 - 23 (24)

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

7
This picture shows wrinkles and
transversal air channels running across
the LS.
This is typical of the LS made by
Induction Heating when the settings of
the inductors are too high.

Defective seal

TechPub_2614345_0103 - 02_2712261_03_en.fm

2 - 24 (24) Doc. No. BoC-2712261-0103

 3 Opening Devices
TechPub_2614345_0103 - 03_2712261_03_en.fm

Doc. No. BoC-2712261-0103 3 - 1 (40)

Methods: 3 Opening Devices

Methods:
MTD 1211 - Opening Device PullTab and FlexiCap
Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
• Previous version, MTD 1211, issued by Sara Davolio, date 1996/11/27.
• Understanding and Troubleshooting the FlexiCap Aseptic
• Understanding and Troubleshooting the LightCap Aseptic
• Checking the Integrity of packages with PLH Guideline

TechPub_2614345_0103 - 03_2712261_03_en.fm

3 - 2 (40) Doc. No. BoC-2712261-0103

 Table of Contents
3 Opening Devices

3.1 Opening Devices - General Information . . . . . . 1 - 5

3.2 Opening Devices - PullTab (MTD 1211) . . . . . . . 1 - 6

3.2.1 Introduction and description . . . . . . . . . . . . . . . . 1 - 6
3.2.2 Preparation of the Samples. . . . . . . . . . . . . . . . . . 1 - 7
3.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
3.2.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . . 1 - 9

3.3 Opening Devices - Direct Injected

Moulded Openings (MTD 1211) . . . . . . . . . . . . . 1 - 11
3.3.1 FlexiCap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
3.3.2 LightCap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 20
3.3.3 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 26
3.3.4 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 27
TechPub_2614345_0103 - 03_2712261_03_en.fm

3.3.5 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 30

3.4 Opening Devices - PLH . . . . . . . . . . . . . . . . . . . 1 - 32

3.4.1 Introduction and description . . . . . . . . . . . . . . . 1 - 32
3.4.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 37
3.4.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 38
3.4.4 Evaluation of Samples. . . . . . . . . . . . . . . . . . . . . 1 - 40

Doc. No. BoC-2712261-0103 3 - 3 (40)

Table of Contents 3 Opening Devices

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3 - 4 (40) Doc. No. BoC-2712261-0103

 3 Opening Devices 3.1 Opening Devices - General Information

3.1 Opening Devices - General Information

The methods reported in this section are aimed at assessing the integrity of
TPCA opening devices.
PullTab, FlexiCap and LightCap are opening devices made in the filling
machine. To allow these applications, the packaging material is punched and
sealed again to restore integrity during the production cycle.
The integrity of the PT application is ensured by the PEP strip (Inner Patch)
sealed in the inside of the package, which isolates the product from
paperboard fibres around the punched hole.
For the FlexiCap and the LightCap, the PE and the MasterBatch granulate of
the cap is melted and injected so that it is sealed to the inner PE layer of the
packaging material, restoring the microbiological barrier.
Opening such as StreamCap and SpinCap are applied over a PLH (Pre
Laminated Hole) after the package leaving the Filling Machine and not
treated in the manual. Check also section 3.4 Opening Devices - PLH at page
3-32.
TechPub_2614345_0103 - 03_2712261_03_en.fm

PullTab FlexiCap LightCap Pre-Laminated

Hole with Post
Applied Cap

Doc. No. BoC-2712261-0103 3 - 5 (40)

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

3.2 Opening Devices - PullTab (MTD 1211)

3.2.1 Introduction and description
This document describes a method to evaluate the integrity of the PullTab
(PT) opening by means of the leakage detection fluid (Red Ink).
A PT opening consists in a hole punched in the packaging material (3).
The hole is then closed on the outside by an aluminium Tab (1) and on the
inside by a multi-layer plastic strip (Inner Patch, IP) (4).
Tab and Inner Patch are sealed together before forming the package.
In TPA portion packages, a plastic unilateral strip (Outer Patch, OP) (2) is
applied onto the external surface of the packaging material before punching
the hole, to cover the paperboard fibres when the PT is opened for
consumption.
An air gap (5) is present around the entire perimeter of the hole. This free
space prevents packaging material fibres from coming into contact with the
inner patch (4) since it could eventually damage or perforate it. The Inner
Patch seals the punched hole, isolating the product from the rest of the
packaging material layers. This restores the microbiological barrier and
ensures package integrity.

TechPub_2614345_0103 - 03_2712261_03_en.fm
The overall PT quality is also given by PullTab position, Tab folding and
Sealing/Heat pattern.

4
5
TBA, TCA and TPA Family packages

1
2
3

4
5 1 Tab
2 Outer patch
TPA Portion packages 3 Packaging material
4 Inner patch
5 Air gap

(Cont'd)

3 - 6 (40) Doc. No. BoC-2712261-0103

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

3.2.2 Preparation of the Samples

1
Cut the packages to be tested into two
halves with a cutter; only the top parts
will be used for the test.
Rinse the package samples and let them
dry in a well ventilated area or using
compressed air.
TechPub_2614345_0103 - 03_2712261_03_en.fm

Doc. No. BoC-2712261-0103 3 - 7 (40)

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

3.2.3 Procedure
1
Apply red ink over the inner surface of
the PT hole with a plastic pipette,
covering the inner patch completely.
Leave the red ink inside the package for
at approximately 5 minutes.
Remove the excess of red ink with the
pipette.
Note! Do not pour red ink out of the
package as this could lead to false
positive reading.

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

TechPub_2614345_0103 - 03_2712261_03_en.fm
a well ventilated area.
Note! Flushing with water might give
problems if water is not carefully
dried before unfolding the flaps and
splitting the packaging material.

3
Flatten the package by opening the flaps.
Carefully, starting from the LS overlap,
split the paperboard and remove the outer
layer.
Continue peeling the package. Some
paperboard will come off together with
the outer layer of PE and the PT will open
up.

3 - 8 (40) Doc. No. BoC-2712261-0103

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

4
Continue peeling the package.
Some paperboard will come off together
with the outer layer of PE and the PT will
open up.
Note! If the ink is still in the package
before performing this operation,
artifact defects might be created.

3.2.4 Evaluation of the Samples

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

Good application
TechPub_2614345_0103 - 03_2712261_03_en.fm

2
The PullTab sealing is defective if there
are red ink spots on the paperboard layer
around the PullTab hole.
Defective application
Note! A positive to conductivity in
PullTab area can mean PE residue
on a sealing plate.

Doc. No. BoC-2712261-0103 3 - 9 (40)

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

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

Defective application

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

TechPub_2614345_0103 - 03_2712261_03_en.fm
air gap.
If the PE residue is completely missing,
the pressure or heat, during application,
A A was too high and Package Integrity can
be affected.

TBA If the PE residue is too wide, pressure or

heat, during application, was too low and
pouring performances can be affected.
Note! TPA packages, having a wider
hole might show more residue than
TBA packages. If ReCap is present
the cap helps in getting improved
pourability.

Note! Refer to the Filling Machine

Operation Manuals for related
measures A.

A
TPA

3 - 10 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

3.3 Opening Devices - Direct Injected

Moulded Openings (MTD 1211)
This chapter describes how to evaluate the quality of the Direct Injected
Moulded openings such as FlexiCap and LightCap. Direct Injected Moulded
Opening, consists in a hole which is punched in the packaging material (as
for the PT Opening) and then hermetically closed on the outside by a cap
which is injection-moulded directly on to the packaging material before
forming the packages.
The FlexiCap and LightCap integrity is tested by the leakage detection fluid
(red ink), by visually checking the cap and testing the FlexiCap and
LightCap opening force.
FlexiCap/LightCap faults can be categorized into four distinct groups:
• faults which are a result of the positioning of the punched hole,
• faults which are a result of the positioning of the FlexiCap/LightCap,
• faults which are a result of a combination of the positioning of both the
punched hole and the FlexiCap/LightCap,
• faults which are a result of the setting of the moulding tools and/or
injection system.
TechPub_2614345_0103 - 03_2712261_03_en.fm

In general, FlexiCap/LightCap faults are:

• result of the hole and FlexiCap/LightCap positioning,
• combination being correctly aligned to each other but incorrectly
positioned on the packaging material,
• inaccurately set moulding tools and/or injection system.

Doc. No. BoC-2712261-0103 3 - 11 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

3.3.1 FlexiCap

TechPub_2614345_0103 - 03_2712261_03_en.fm

1 Lid 9 Spider leg

2 Membrane 10 Leg
3 Hinge 11 Membrane support
4 Dog bone 12 Pouring lid
5 Injection Point 13 Inside sealing area
6 PullTab 14 Knife
7 Tamper evidence 15 Stepped membrane
8 Punched hole edge 16 Membrane support rib

3 - 12 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

[Link] FlexiCap top crease faults

Delamination
If the FlexiCap is positioned too close to the top crease there is an increased
TechPub_2614345_0103 - 03_2712261_03_en.fm

risk of delamination of the packaging material at the edge of the punched

hole, see Figure 1. This will occur when the packaging material is being
folded into the package shape in the filling machines final folder.

figure 1

Doc. No. BoC-2712261-0103 3 - 13 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

Transportation damage - cracks in the rear

If the FlexiCap is positioned too close to the top fin crease then there is a
higher risk of FlexiCap damage during transportation.
Typically the packages are stacked on top of each other and then distributed
on pallets. If the FlexiCap is too close to the top fin crease, there is an
increased load applied to the FlexiCap from the packages stacked above and
this combined with the vibration and motion of the truck during
transportation creates a fault in the FlexiCap.
Generally this appears as a crack at the rear of the FlexiCap, see figure 2.

TechPub_2614345_0103 - 03_2712261_03_en.fm
figure 2

Cap in the Jaws

Although this is a very uncommon problem, if the FlexiCap is positioned

extremely close to the top fin crease there is a risk of the FlexiCap being
trapped between the inductors of the filling machines jaw system.

3 - 14 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

[Link] FlexiCap longitudinal crease faults

Broken membrane
TechPub_2614345_0103 - 03_2712261_03_en.fm

If the FlexiCap is positioned too far over the longitudinal crease there is an
increased risk of the membrane being broken at the front of the FlexiCap, see
figure 3. This happens when the folding flaps of the jaw system grip the
packaging material to keep the tube within design.
It is acceptable for the folding flaps to pinch the end of the FlexiCap tab, but
if the FlexiCap is positioned too far over the longitudinal crease the folding
flaps will pinch too much of the FlexiCap and as a result the membrane can
be broken.

figure 3

Doc. No. BoC-2712261-0103 3 - 15 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

Positioning impact
If the FlexiCap is positioned too far from the longitudinal crease both
pouring performance and closure after opening performance are affected and
tamper evidence might get broken during package forming in the line.
The FlexiCap has been designed to be moulded over the edge (longitudinal
crease). Pouring performance is also affected by FlexiCap positioned far
from the side panel. The longitudinal crease gives the proper support to allow
reclosability.

TechPub_2614345_0103 - 03_2712261_03_en.fm
Transportation damage - crack in the front
If the FlexiCap is positioned too far in from the longitudinal crease,
occasionally cracks are formed in the front of the FlexiCap, normally the
cracks appear after and as a result of transportation and distribution of the
packages.
This is because the edge of the package side panel (longitudinal crease)
supports the FlexiCap, but if the FlexiCap is positioned too far from this
extra support, cracks in the front of the FlexiCap can form under the pouring
lip, see figure 4.

figure 4

3 - 16 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

[Link] FlexiCap injection faults

Overfilled FlexiCap

The amount of plastic used in each FlexiCap is regulated by adjusting the

stroke of the injection cylinder, see the DIMC Multi maintenance manual
Injection system - set cylinder for more details.
If too much plastic is injected, splashes of plastic will be visible around the
inside of the FlexiCap, see figure 5.
TechPub_2614345_0103 - 03_2712261_03_en.fm

figure 5

(Cont'd)

Doc. No. BoC-2712261-0103 3 - 17 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

(Cont'd)
The first FlexiCaps produced can be overfilled. This is due to a change in the
characteristics of the plastic left in the injection system from the previous
production, which allows more plastic to be injected. This is normal and no
corrective action is required.
If the FlexiCaps have a fin along the top of the lid, this too could be the result
of too much plastic being injected. But it is more likely to be a small amount
of cured plastic trapped between the two halves of the lower tools stopping
the two halves of the lower tools from closing completely. See figure 6 and 7.

figure 6

TechPub_2614345_0103 - 03_2712261_03_en.fm

figure 7

3 - 18 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

[Link] Underfilled FlexiCap

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

figure 8
TechPub_2614345_0103 - 03_2712261_03_en.fm

Doc. No. BoC-2712261-0103 3 - 19 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

3.3.2 LightCap

2 3
1

5 4

1 Pouring lip
2 Pull-ring

TechPub_2614345_0103 - 03_2712261_03_en.fm
3 Membrane
4 Crown
5 Packaging Material grip seal
6 Threads

[Link] LightCap faults

Cap not Injected
Causes:
• the injection gate is clogged due to residue of hard plastic,
• the extruder is providing not enough plastic to the injection system,
• the plunger (injection or accumulator) is sizing,
• the extruder does not rotate at the expected speed.

(Cont'd)

3 - 20 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

(Cont'd)
Leakage located at the cap border
Causes:
• misalignment between internal and external tools,
• the distance between internal and external tools is too small, therefore
the ridge in the internal tool is penetrating too much into the packaging
material, damaging it,
• the ridge in the internal tool is damaged and there are sharp edges or
slavers which may damage the packaging material.
TechPub_2614345_0103 - 03_2712261_03_en.fm

Pull ring completely missing

Causes:
• the pull ring is trapped into the tools when they open because of the
wrong sequence of movements when the tools open.

(Cont'd)

Doc. No. BoC-2712261-0103 3 - 21 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

(Cont'd)
Leakage located in the membrane
Causes:
• the membrane is too thin and therefore too weak. It can break because of
the pressure of the product in the filling machine or because of any
internal load. The risk is high if the membrane is 0.10 mm. The leak in
the membrane is wide and can be located in any part of the membrane,
• the pull ring is (at least partially) trapped in the tools when the tools are
opening, creating concentrated stress in the membrane area. If this is the
reason, the leak is located in the area of pull-ring connection and the pull
ring is moulded in a way that is lifted up out from the neck,
• the ridge in the external insert that makes the membrane is damaged or
there are alien parts trapped into the tools. If this is the case the leak is a
small pin hole and can be located anywhere along the membrane.

TechPub_2614345_0103 - 03_2712261_03_en.fm

(Cont'd)

3 - 22 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

(Cont'd)
Neck pulled off, trapped into the tools
Causes:
• the paper web is not following in the right way the release movement of
the cap,
• the external tools don't open enough so that the thread of the cap is
trapped and can not be released,
• the paper index starts too early, when the cap is still in the tools.

Plastic splashes inside the cap and at the same time underfilled
pull ring
Causes:
• The distance between internal and external tools is too high and the
plastic is not kept inside the tools cavity.
• The injection starts when the tools are still not completely closed.
TechPub_2614345_0103 - 03_2712261_03_en.fm

(Cont'd)

Doc. No. BoC-2712261-0103 3 - 23 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

(Cont'd)
Deformed neck (pinched)
Causes:
• The cap is too close to the TS and it is damaged by the inductor.
• The cap is too close to the left side of the package.
• Interference of the cap with some parts of the filling machine

TechPub_2614345_0103 - 03_2712261_03_en.fm
Plastic splashes in the neck
Causes:
• Something (plastic residues) is left inside the tools mechanism and
prevents from having a complete closing of the tools.
• The cap is overfilled
• There is not enough clamping force in the toolbox to keep the plastic
pressure during the injection.

(Cont'd)

3 - 24 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

(Cont'd)
Incomplete pull ring
Causes:
• The plastic is a bit colder at the injection gate, resulting in more difficult
to inject.
• Missing plastic
TechPub_2614345_0103 - 03_2712261_03_en.fm

Packaging material inside the cap (overlap)

Causes:
• The inner ridge of the internal tools squeegees too much the packaging
material and forces it towards the inside
• Misalignment between internal and external tools
• Position cap over hole out of the maximum acceptance tolerance range.

Doc. No. BoC-2712261-0103 3 - 25 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

3.3.3 Preparation of the Samples

1
Select a suitable number of packages
according to the level of accuracy
needed.
Note! At least 1 package produced
by each moulding station must be
sampled and checked.

If the test is applied during

troubleshooting take a tray of packages in
which at least 1 appears defective.

2
Cut the packages into two halves with the

TechPub_2614345_0103 - 03_2712261_03_en.fm
scissors. Only the top parts will be used
for the test.
Rinse the package samples and let them
dry in a well ventilated area or using
compressed air.

3 - 26 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

3.3.4 Procedure
FlexiCap Integrity Check
1
Note! If the check is being carried out
after a packaging material splice
check the FlexiCap forming as
described in the FlexiCap forming

Apply red ink to the inside of the package

in the area indicated in the illustration
with a plastic pipette, covering the
FlexiCap completely.
Leave the red ink inside the package for
at approximately 5 minutes. Remove the
excess of red ink with the pipette.
Wait for the ink to completely dry.
Note! Do not pour red ink out of the
package as this could lead to false
positive reading.
TechPub_2614345_0103 - 03_2712261_03_en.fm

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

Doc. No. BoC-2712261-0103 3 - 27 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

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

TechPub_2614345_0103 - 03_2712261_03_en.fm

3 - 28 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

LightCap Integrity Check

1
Note! If the check is being carried out
after a packaging material splice
check the LightCap forming as
described in the LightCap forming

Apply red ink to the inside of the package

in the area indicated in the illustration
with a plastic pipette, covering the
LightCap completely.
Leave the red ink inside the package for
at approximately 5 minutes. Remove the
excess of red ink with the pipette.
Wait for the ink to completely dry.
Note! Do not pour red ink out of the
package as this could lead to false
positive reading.
TechPub_2614345_0103 - 03_2712261_03_en.fm

2
Carefully peel off the outer layer of PE
starting from the LS overlap. Some
paperboard will come off together with
PE.

Doc. No. BoC-2712261-0103 3 - 29 (40)

 3.3 Opening Devices - Direct Injected Moulded Openings
(MTD 1211) 3 Opening Devices

3.3.5 Evaluation of the Samples

FlexiCap evaluation
1
Check for any red spots around the
application. Absence of red spots
indicates that the FlexiCap application is
good.

Good application

TechPub_2614345_0103 - 03_2712261_03_en.fm
2
Red spots indicate that the FlexiCap
application is defective.
Note! Problems with FlexiCap
sealing may result in unsterile
packages and corrective action shall
take place.

Defective application

3 - 30 (40) Doc. No. BoC-2712261-0103

 3.3 Opening Devices - Direct Injected Moulded Openings
3 Opening Devices (MTD 1211)

LightCap evaluation
1
Check for any red spots around the
application. Absence of red spots
indicates that the FlexiCap application is
good.

Good application

2
Red spots indicate that the LightCap
TechPub_2614345_0103 - 03_2712261_03_en.fm

application is defective.
Note! Problems with LightCap
sealing may result in unsterile
packages and corrective action shall
take place.

Defective application

Doc. No. BoC-2712261-0103 3 - 31 (40)

3.4 Opening Devices - PLH 3 Opening Devices

3.4 Opening Devices - PLH

3.4.1 Introduction and description
The Pre-Laminated Hole is presently used for packages with Post-applied
Caps. The hole is punched and laminated during the converting process.
The Cap is applied after product filling and package leaving the Filling
Machine.
This guideline aims to give a reference tool to have uniformity when testing
and analysing PLH packages (also when the Cap is applied).

Pre-Laminated Hole
Post-applied cap
1 Outside plastic layer (decor layer)
2 Paperboard
3 Lamination layer
4 Al-foil
5 Inner layer 1 (adhesive)
6 Inner layer 2 (sealing)

TechPub_2614345_0103 - 03_2712261_03_en.fm
2 4 1 3

outside of package

5
6
inside of package

C B A
Depth of Conductivity Red Ink Copper Tight Corrective actions
defect Test Test Test Package needed
A X X X NO YES
B X - X YES YES
C X - X YES YES

The Conductivity Test (MTD 1203), will show ruptures of type A, B and C,
but Red Ink Evaluation (MTD 1204) will reveal package integrity fault C.
Due to the tiny defect, the Red Ink should be left to dry in the package and
not (as usually done) taken out after 5 minutes.
(Cont'd)

3 - 32 (40) Doc. No. BoC-2712261-0103

 3 Opening Devices 3.4 Opening Devices - PLH

(Cont'd)
The PLH opening is mapped with the aim to obtain the definition and
numbering of sectors in the PLH area.
This can give a consistent way to refer to them when detecting contacts and/
or leakages during evaluations.
The sectors are named 1 to 12 (see pictures enclosed), consistently kept from
the packaging material to the final package.
PLH Mapping, formed package outside view

Packaging Material Packaging Material

lamination and Filling lamination and Filling
Machine direction for Machine direction for
TBA and TPA TGA packages
packages
TechPub_2614345_0103 - 03_2712261_03_en.fm

Point 12 is the first point Point 6 is the first point that

that goes into the laminator goes into the laminator and
and the Filing Machine the Filing Machine

PLH Mapping, formed package inside view

Packaging Material Packaging Material

lamination and Filling lamination and Filling
Machine direction for Machine direction for
TBA and TPA TGA packages
packages
Point 6 is the first point that
goes into the laminator and
Point 12 is the first point the Filing Machine
that goes into the laminator
and the Filing Machine

(Cont'd)

Doc. No. BoC-2712261-0103 3 - 33 (40)

3.4 Opening Devices - PLH 3 Opening Devices

(Cont'd)
PLH Mapping, flat PM, print side view
Note!
Sectors named I, II, III and IV are the packaging material reference
sectors for Packaging Material Converting QC.

I
6
5 7
Packaging Material 4 8 Packaging Material
lamination and Filling
lamination and Filling
Machine direction for IV 3 9 II Machine direction for
TBA and TPA
TGA packages
packages
2 10
1 Point 6 is the first point that
11
12 goes into the laminator and
Point 12 is the first point the Filing Machine
that goes into the laminator
and the Filing Machine III

TechPub_2614345_0103 - 03_2712261_03_en.fm
PLH Mapping, flat PM, inside view

7 6
5
Packaging Material
lamination and
8 4 Packaging Material
Filling Machine lamination and
Filling Machine
direction for TBA
and TPA packages
IV 9 3 II direction for TGA
packages

10 2
Point 12 is the first Point 6 is the first
point that goes into the 11 1 point that goes into
laminator and the Filing
Machine
12 the laminator and the
Filing Machine

III

(Cont'd)

3 - 34 (40) Doc. No. BoC-2712261-0103

 3 Opening Devices 3.4 Opening Devices - PLH

(Cont'd)
PLH Mapping, flat PM, print side view

Packaging
Material
lamination and
Filling Machine
direction for TBA
and TPA
packages
TechPub_2614345_0103 - 03_2712261_03_en.fm

Packaging
Material
lamination and
Filling Machine
direction for
TGA packages

(Cont'd)

Doc. No. BoC-2712261-0103 3 - 35 (40)

3.4 Opening Devices - PLH 3 Opening Devices

(Cont'd)
PLH Mapping, flat PM, inside view

Packaging Material
lamination and
Filling Machine
direction for TBA
and TPA packages

TechPub_2614345_0103 - 03_2712261_03_en.fm
Packaging Material
lamination and
Filling Machine
direction for TGA
packages

3 - 36 (40) Doc. No. BoC-2712261-0103

 3 Opening Devices 3.4 Opening Devices - PLH

3.4.2 Preparation of the Samples

1
Select a suitable number of packages
according to the level of accuracy
needed.
If the test is applied during
troubleshooting take a tray of packages in
which at least 1 appears defective.

2
Cut the packages into two halves with the
TechPub_2614345_0103 - 03_2712261_03_en.fm

scissors. Only the top parts will be used

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

Doc. No. BoC-2712261-0103 3 - 37 (40)

3.4 Opening Devices - PLH 3 Opening Devices

3.4.3 Procedure
PLH Integrity Check
1
Apply red ink to the inside of the package
in the area indicated in the illustration
with a plastic pipette, covering the
FlexiCap completely.
Note! Due to the tiny defect, the red
ink should be let dry in the package
and not taken out after 5 minutes, as
usually done.

Wait for the ink to completely dry.

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

TechPub_2614345_0103 - 03_2712261_03_en.fm
2
Once dry, carefully, split the paperboard
starting from the Cap by means of a
cutter.
Remove the outer layer of PE (the hole
could open up).
Note! Make sure that the red ink is
dried into the package before peeling.

3 - 38 (40) Doc. No. BoC-2712261-0103

 3 Opening Devices 3.4 Opening Devices - PLH

Hot wire
This device can be used to cut the upper
part of the Cap in order to verify the PLH
appearance and performance.
Note! At the time of release of this
manual, this device is not fully
industrialized.
TechPub_2614345_0103 - 03_2712261_03_en.fm

Doc. No. BoC-2712261-0103 3 - 39 (40)

3.4 Opening Devices - PLH 3 Opening Devices

3.4.4 Evaluation of samples

PLH evaluation
1
Check for any red spots on the
paperboard layer around the application.
Absence of red spots indicates that the
PLH application is good.

Good application

2
Red spots indicate that the PLH
application is defective.

TechPub_2614345_0103 - 03_2712261_03_en.fm
Note! Problems with PLH sealing
may result in unsterile packages and
corrective action shall take place.

Defective application

3 - 40 (40) Doc. No. BoC-2712261-0103

 4 Integrity
TechPub_2614345_0103 - 04_2712261_03_en.fm

Doc. No. BoC-2712261-0103 4 - 1 (20)

 4 Integrity

Methods:
MTD 1203 - Integrity - Conductivity test
Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD 1203, issued by Sara Davolio, date 1996/04/20.

MTD 1207 - Integrity - Copper test

Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals

TechPub_2614345_0103 - 04_2712261_03_en.fm
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD1207, issued by Sara Davolio, date 2002/03/05.

MTD 1204 - Integrity - Red Ink test

Personnel
This method must be performed by Qualified personnel. Refer to section
Personnel Requirements, page i-5 for details.
Tools and Chemicals
Refer to section B.2 Tools and Equipment, page Appendix-6 for details on
the tools used.
Reference Documents
Previous version, MTD1204, issued by Sara Davolio, date 1996/04/20.

4 - 2 (20) Doc. No. BoC-2712261-0103

 Table of Contents
4 Integrity

4.1 Integrity - General Information . . . . . . . . . . . . . . 1 - 5

4.2 Integrity - Conductivity Test (MTD 1203) . . . . . . 1 - 6

4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
4.2.2 Preparation of the Samples. . . . . . . . . . . . . . . . . . 1 - 7
4.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
4.2.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . . 1 - 9

4.3 Integrity - Copper Test (MTD 1207) . . . . . . . . . 1 - 10

4.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
4.3.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 11
4.3.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
4.3.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 14
TechPub_2614345_0103 - 04_2712261_03_en.fm

4.4 Integrity - Red Ink Test (MTD 1204) . . . . . . . . . 1 - 15

4.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
4.4.2 Preparation of the Samples. . . . . . . . . . . . . . . . . 1 - 16
4.4.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
4.4.4 Evaluation of the Samples . . . . . . . . . . . . . . . . . 1 - 18

Doc. No. BoC-2712261-0103 4 - 3 (20)

 4 Integrity

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This page intentionally left blank

4 - 4 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.1 Integrity - General Information

4.1 Integrity - General Information

The present chapter reports test methods aimed at the microbiological barrier
of a roll fed TPP aseptic package.
The microbiological barrier consists of the inner plastic layer, the Al- foil
and the lamination layer between the Al- foil and the paper board.
All three layers have to be broken before the microbiological barrier is lost.
By definition, aseptic package integrity requires, beside sealing quality as
described in the dedicated chapters, an intact microbiological barrier.
The tests are:
• Conductivity Test (MTD 1203)
• Copper Test (MTD 1207)
• Red Ink Test (MTD 1204)

Defects are detected according to the table below.

Depth of Conductivity Red Ink Copper Tight Corrective
defect Test Test Test Package actions
needed
A X X X NO YES
TechPub_2614345_0103 - 04_2712261_03_en.fm

B X - X YES YES
C X - X YES YES
D - - - YES NO

4 3 2 1

1 Outer coating
2 Paperboard
3 PE Lamination
4 Al-foil
B C D
5 Adhesion layer
6 Inner layer (PE, m-PE) A 6 5

Doc. No. BoC-2712261-0103 4 - 5 (20)

4.2 Integrity - Conductivity Test (MTD 1203) 4 Integrity

4.2 Integrity - Conductivity Test (MTD 1203)

4.2.1 Introduction
This chapter describes how to detect ruptures of the inner PE layer, which
leave the Al-foil uncoated.
The package is immersed in an electrolytic solution (salt solution). If there is
a crack in the PE layers, an electrical contact is established between the
electrolytic solution outside the package and the package content, which is
measured by an ammeter (electrolytic tester).
This method can be used for packages containing liquid products such as
water, wine or fruit juice.
Packages filled with fat products should not be checked with this method
after storage, as the greasy components could create an insulating layer on
the inside of the package, preventing current from circulating. Adopt the Red
Ink Integrity test, instead.

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

TechPub_2614345_0103 - 04_2712261_03_en.fm
To detect where the rupture is located, the test must be followed by the 4.3
Integrity - Copper Test (MTD 1207) or by the 4.4 Integrity - Red Ink Test
(MTD 1204).

4 - 6 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.2 Integrity - Conductivity Test (MTD 1203)

4.2.2 Preparation of the Samples

1
Cut all the selected packages in two
halves with a sharp cutter or scissors.
Note! The best procedure is anyway
to keep the package in one sample
only.
TechPub_2614345_0103 - 04_2712261_03_en.fm

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

Doc. No. BoC-2712261-0103 4 - 7 (20)

4.2 Integrity - Conductivity Test (MTD 1203) 4 Integrity

4.2.3 Procedure
1
Put table salt (10 g per litre of water) into
a plastic water basin.
Fill a third of each package sample with
the NaCl solution. Make sure the solution
reaches the weak areas of the package,
such as corners and creases.
Put the sample carefully into the bowl, so
that the outside corners are fully covered.
Note! The black probe (negative) has
to be placed in the water, the red
probe (positive) in the package
sample.

Dip the positive probe (Red) of the

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

TechPub_2614345_0103 - 04_2712261_03_en.fm
CAUTION
Risk of false readings!
Keep the package cut edges dry to
prevent them from acting as a bridge
and giving false deflections.
Be careful not to scratch the inside of
the packages with the electrodes.

Note! The electrodes can be

connected to the ammeter by wires,
in order to facilitate the work.

4 - 8 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.2 Integrity - Conductivity Test (MTD 1203)

4.2.4 Evaluation of the Samples

Conductivity Test Evaluation
1
Read the deflection of the ammeter:
• If the reading is 0 µA, the sample has
no ruptures in the internal PE
coating; (negative samples).
• If the ammeter reading is unsteady
and greater than 0 µA, wipe the edge
once more and make a new reading;
if still unsteady, let the sample dry.
• If the deflection is quick and steady
and the reading is greater than 0 µA,
it means that there is contact to the
Al-foil (i.e. a hole on the inner PE
layers). Those samples shall be
submitted to further investigations,
that are Copper Test and Red Ink Test
(positive samples).
TechPub_2614345_0103 - 04_2712261_03_en.fm

Note! A reading below half scale is

almost always a wet paper edge.

Doc. No. BoC-2712261-0103 4 - 9 (20)

4.3 Integrity - Copper Test (MTD 1207) 4 Integrity

4.3 Integrity - Copper Test (MTD 1207)

4.3.1 Introduction
This document describes a method to locate ruptures in the inner layers of
the roll fed TPP aseptic packages.
Ruptures in the inner PE layers can be detected by the conductivity test
(MTD 1203). The package is immersed in an electrolytic solution (i.e. salt
solution). In case of a crack in the PE layers, which leave the Al-foil
uncovered, an electrical contact is established between the electrolytic
solution outside the package and the package content.
If some copper solution is poured into the package, the copper oxide
crystalizes in the area of the cracks when using a copper tester, allowing to
locate the fault.

TechPub_2614345_0103 - 04_2712261_03_en.fm

4 - 10 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.3 Integrity - Copper Test (MTD 1207)

4.3.2 Preparation of the Samples

1
Cut all the selected packages in two
halves with a sharp cutter or scissors.
Note! The best procedure is anyway
to keep the package in one sample
only.
TechPub_2614345_0103 - 04_2712261_03_en.fm

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

Doc. No. BoC-2712261-0103 4 - 11 (20)

4.3 Integrity - Copper Test (MTD 1207) 4 Integrity

4.3.3 Procedure
Note!
If the Red ink test (MTD 1204) is going to be performed on the
packages, do it before the copper test. The copper test can cause an
enlargement of the cracks in the packaging material, compromising
the results of the ink penetration.
1
Put some NaCl solution (approx. 10%)
into a plastic water basin.
Put some copper solution into the sample
package, to cover corners and creases,
and dip it carefully into the basin, so that
it is steady.
Put the red electrode into the sample
package and the black one in contact with
the salt solution.
Refer to Use of the Electrolyte Copper
Tester, page Appendix-12, when using

TechPub_2614345_0103 - 04_2712261_03_en.fm
the Tester.

2
Press the Push button for approximately
four seconds to turn on the tester and set
High Current reading.
Check the display. If the ammeter shows
a current deflection over 50 µA, there
might be the presence of a crack in the
inner layer up to the
Al-foil.

4 - 12 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.3 Integrity - Copper Test (MTD 1207)

3
Press the button Push once again to set
the Low Current reading.
Electrolysis starts.
TechPub_2614345_0103 - 04_2712261_03_en.fm

4
Move the red electrode around the inner
corners of the packages for
approximately 3 minutes; the copper will
deposit on the cracks, making them
visible.
Mark the areas of deposition with a
permanent marker.
Repeat the test with all the packages, on
both halves.
Note! Extremely tiny pinholes would
show crystalization in long time
interval.

Doc. No. BoC-2712261-0103 4 - 13 (20)

4.3 Integrity - Copper Test (MTD 1207) 4 Integrity

4.3.4 Evaluation of the Samples

Copper Test Evaluation
1
After the copper test has been performed,
rinse the sample packages with water.
Let them dry thoroughly; use compressed
air to speed the process.
Unfold the flaps and peel off the outer
layers.

2
Look for red ink spots on the paperboard.

TechPub_2614345_0103 - 04_2712261_03_en.fm
4 3 2 1 3
B C If no red ink is found on the packaging
material, the contact was due to a rupture
of the plastic layers up to the Al-foil (3)
(cases B, C or D).
A
If red ink spots are visible, in
correspondence of a copper deposition
area (7), a rupture of the plastic layers
D and Al-foil occurred, causing a defect
(case A).
6 5
Count the number of packages with
7 exposed Al-foil, packages with red ink
1 Outer layer failures that compromise the package
2 Paperboard integrity and the total number of tested
3 PE Lamination packages. Record the data.
4 Al-foil
5 Adhesion layer
6 Inner layer (PE, m-PE)
7 Copper deposition

4 - 14 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.4 Integrity - Red Ink Test (MTD 1204)

4.4 Integrity - Red Ink Test (MTD 1204)

4.4.1 Introduction
An aseptic package is conventionally defined as leaking when Red Ink
penetrates the coating layers and stains the paperboard. According to this
definition, a package is defective when it is positive to the Red Ink Test,
since all the microbiological barriers performed by the Al-foil and inner PE
layers are broken: integrity is therefore not guaranteed.
TechPub_2614345_0103 - 04_2712261_03_en.fm

Doc. No. BoC-2712261-0103 4 - 15 (20)

4.4 Integrity - Red Ink Test (MTD 1204) 4 Integrity

4.4.2 Preparation of the Samples

During Production or After
Production Laboratory
checks
Cut the packages in two halves using a
cutter.
Note! The best procedure is anyway
to keep the package in one sample
only.

TechPub_2614345_0103 - 04_2712261_03_en.fm
During troubleshooting
Cut out a hole in the front panel of the
package.
This allows to investigate the package as
a whole, identifying the defective areas
in an accurate way.
Note! TFA packages should be cut
into halves, making sure not to cut on
damaged spots.

4 - 16 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.4 Integrity - Red Ink Test (MTD 1204)

4.4.3 Procedure
1
Apply red ink over the critical points of
the package, such as corners, TS, crosses.
Leave the red ink inside the package for
approximately 5 minutes.
Remove the excess of red ink with the
pipette.
Note! Do not pour red ink out of the
package as this could lead to false
positive reading.

2
Clean the inside of the package with a
TechPub_2614345_0103 - 04_2712261_03_en.fm

dry paper towel or let it dry thoroughly

in a well ventilated area.

3
Once samples are dry, unfold the flaps
and carefully peel off the outer layer of
PE starting from the LS overlap. Some
paperboard will come off together with
the PE.
Note! If ink is still present in the
package, leakage can be caused by
opening the flaps and breaking the
inner PE layer.

Doc. No. BoC-2712261-0103 4 - 17 (20)

4.4 Integrity - Red Ink Test (MTD 1204) 4 Integrity

4.4.4 Evaluation of the Samples

Red Ink test evaluation
1
Check for any red ink spots on
the paperboard layer on the
corners, TS, and crosses areas.
Any red ink leakage corresponds
to a defect in the package.

Defective

Fin tearing
Fin tear can develop into integrity
defects.
TBA and TPA packages can be
affected by fin tears in the top
due to interactions between the

TechPub_2614345_0103 - 04_2712261_03_en.fm
PM and folding flaps.
TWA packages are affected by
fin tears in the bottom (since the
folding flaps act on the bottom).
Check for any red ink spots on
the fins.
Any red ink leakage corresponds
to a defect in the package.

TWA package shown

Defective

4 - 18 (20) Doc. No. BoC-2712261-0103

 4 Integrity 4.4 Integrity - Red Ink Test (MTD 1204)

2
If the red ink spot is larger on the
peeled external layer than on the
package side, it means that the
ink has leaked from the
OUTSIDE of the package to the
INSIDE.
This is NOT an integrity defect
but simply and artifact by
applying the procedure.
See diagram.

1 Larger red ink spot

2 PM external layer
1
2 3 Split paperboard
4 Smaller red ink spot
5 PM internal layers
TechPub_2614345_0103 - 04_2712261_03_en.fm

Doc. No. BoC-2712261-0103 4 - 19 (20)

4.4 Integrity - Red Ink Test (MTD 1204) 4 Integrity

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4 - 20 (20) Doc. No. BoC-2712261-0103

 5 Package Forming
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Doc. No. BoC-2712261-0103 5 - 1 (10)

 5 Package Forming

The methods reported in this section are additional checks

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

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5 - 2 (10) Doc. No. BoC-2712261-0103

 Table of Contents
5 Package Forming

5.1 Package Forming. . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Date Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Weight/Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Flap Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

LS Overlap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Crease lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
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Doc. No. BoC-2712261-0103 5 - 3 (10)

 5 Package Forming

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5 - 4 (10) Doc. No. BoC-2712261-0103

 5 Package Forming 5.1 Package Forming

5.1 Package Forming

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

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

Weight/Volume
Weigh the packages.
TechPub_2614345_0103 - 05_2712261_03_en.fm

Record their weight and weight

deviations.
After setting, pick out new packages and
check them.
Note! Weight and Volume are two
separate variables that depend on
the density of the product.

Flap Sealing
Unfold the flaps and check that they are
properly sealed.
On the bottom flaps the heat should not
be directed on the TS.
Burnt marks might impact on package
integrity.

Doc. No. BoC-2712261-0103 5 - 5 (10)

5.1 Package Forming 5 Package Forming

LS Overlap
With the aid of a vernier calliper check
B the width of the packaging material
overlap, distance B.
If the overlap is out of the range
indicated, corrective actions should be
taken.
Note! Refer to the Filling Machine
Operation Manuals for related
measures B.

1
Crease lines
1 The crease lines can be checked both at
the top and bottom of the package:
Checking the top of the package:
• easy access

TechPub_2614345_0103 - 05_2712261_03_en.fm
• the top creases are naturally less
folded than the bottom
• the evaluation can be influenced by
down-stream or distribution
equipments

Checking the bottom of the package:

• important to lift the flaps, since
closed flaps might give indication of
wrong set of crease lines due to
package folding

Lift the package top or bottom fin (1)

after having opened the flaps.
Note! Lift the flaps to check correctly
crease alignment. Closed flaps might
give false reading due to package
folding (see picture beside).

5 - 6 (10) Doc. No. BoC-2712261-0103

 5 Package Forming 5.1 Package Forming

fig.1 Top view of package

2
Check the position of the preformed
crease lines (2).
The position is good if the creases are
opposite one another and aligned
(figure 1).

good

2 2
TechPub_2614345_0103 - 05_2712261_03_en.fm

fig.2 Top view of package

3
The position is not good if the creases
are opposite one another, parallel or at an
angle, but not aligned.
Example of not good crease alignments:
• figure 2: Tube twist left
Corrective actions should be taken. After
adjustments, pick up new packages and
check them.
not good

2 2

Doc. No. BoC-2712261-0103 5 - 7 (10)

5.1 Package Forming 5 Package Forming

fig.3 Top view of package

4
Note! The following examples show
a crease alignment that can be
accepted or not depending on the
consequentely forming and problems
that may arise in the folding unit and/
or the dowstream equipments.

Figure 3: tube twist right.

2 2

TechPub_2614345_0103 - 05_2712261_03_en.fm
fig.4
Top view of package 5
Figure 4: excessive overlap.
This misalignment is mostly due to LS
overlap. A wrong overlap is also
affecting:
• volume in package
• counter pressure created from
pressure flange
• size of package for final folder
function
• print alignment
2 2

5 - 8 (10) Doc. No. BoC-2712261-0103

 5 Package Forming 5.1 Package Forming

fig.5 Top view of package 6

Figure 5: small overlap.
If there are any defects, corrective
actions should be taken.
After adjustments, pick up new packages
and check them.

2 2
TechPub_2614345_0103 - 05_2712261_03_en.fm

fig.1 1
Surfaces
Cut two opposite corners (fig.1) and
empty the content of the package (fig.2).
fig.2 Cut transversally the front panel of the
package, from the lower cut corner to the
opposite one (fig.2 and 3).
Split the TS apart and open the package
(fig.4).
Rinse and dry the package with
compressed air from the filling machine.
fig.3

fig.4

Doc. No. BoC-2712261-0103 5 - 9 (10)

5.1 Package Forming 5 Package Forming

2
Check the outside and inside surfaces of
the package for scratches.
Inside deep scratches might cause
package integrity problems.
If there are any defects, corrective
actions should be taken.

TechPub_2614345_0103 - 05_2712261_03_en.fm

5 - 10 (10) Doc. No. BoC-2712261-0103

 Appendix A:
Flowcharts and
Troubleshooting
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Doc. No. BoC-2712261-0103 Appendix A - 1 (16)

 Appendix A: Flowcharts and
Troubleshooting

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Appendix A - 2 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Table of Contents
Troubleshooting

A.1 Operator Checks . . . . . . . . . . . . . . . . Appendix A - 5

A.1.1 Checking scheme. . . . . . . . . . . . . . . . Appendix A - 5
A.1.2 Flowchart of the Production Quality
Checks . . . . . . . . . . . . . . . . . . . . . . . . Appendix A - 7

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

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

A.4 Troubleshooting . . . . . . . . . . . . . . . Appendix A - 13

A.4.1 Homogeneous (Water-based)
Products . . . . . . . . . . . . . . . . . . . . . . Appendix A - 14
A.4.2 Viscous and Fatty Products . . . . . . Appendix A - 15
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Doc. No. BoC-2712261-0103 Appendix A - 3 (16)

 Appendix A: Flowcharts and
Troubleshooting

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Appendix A - 4 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Troubleshooting A.1 Operator Checks

A.1 Operator Checks

A.1.1 Checking scheme
The Checking Scheme, present in the OM of the filling machine, describes
the recommended sequence of checks to be done on the packages.
The Checking Scheme table explains:
• the event which it is recommended that the package checks are
performed immediately after, e.g. Production Start (1).
• the number of packages needed for checks according to which event has
prompted the package checks (2).
• the number of packages on which to perform the individual checks (3).
• the check to be performed (4).
• the page number of the check instructions (5).
• to mark the check box when the check has been completed (6)

Note!
For some checks, the number of packages checked depends on the
number of jaws of the filling machine. This variable is identified as X.
TechPub_2614345_0103 - A1_2712261_03_en.fm

X is equal to the number of jaws of the FM (e.g. 2 jaws in TBA/19,

TBA/21 and TP A3/Flex, and 10 jaws in TP A3/Speed and TBA/22).
X+1 means that the number of packages to be checked are equal to
the number of jaws plus one package.
Refer to the specific machine OM for instructions on how to select and
mark the packages for quality checks.

Extract from the Checking Scheme schedule

2 1
Production
3 Start

Date Print page

1 123

3 4 5 6

(Cont'd)

Doc. No. BoC-2712261-0103 Appendix A - 5 (16)

 Appendix A: Flowcharts and
A.1 Operator Checks Troubleshooting

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

Production After a raw After a LS After a patch or

X+1 start X material splice 1 strip splice Y tab strip splice

Date print Date print

1 1

X
Weight X Weight

TS TS
X X

TS TS

TechPub_2614345_0103 - A1_2712261_03_en.fm
X (Accurate) X (Accurate)

Shape & Shape &

1 design 1 design

Tab Tab Tab

Y Y position* Y position
position

Flap Flap
1 sealing 1 sealing

Crease Crease
1 lines 1
lines

Overlap Overlap
1 1

1 Surfaces 1 Surfaces

Hole Hole
Hole Y position
Y Y
position position

Patch & Patch & Patch &

Y tab sealing Y Y tab sealing
tab sealing

1 LS/SA 1
LS/SA LS/SA
1

Appendix A - 6 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Troubleshooting A.1 Operator Checks

A.1.2 Flowchart of the Production Quality Checks

The Flowchart of Production Quality Checks displays:
• the checks to be performed in the sequence described in the checking
scheme table (1)
• the type of check (2)
• the necessary actions (if any) to be taken depending on the result of the
completed check (3).

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

Extract from Flowchart of operator quality checks

TechPub_2614345_0103 - A1_2712261_03_en.fm

2
Flap
1 Sealing

1
No
TPOP
OK?
Setting
3
Yes

TS
1 Rough 2

1 No
Stop Call a
OK? Production Technician

Yes
3 3
= Legal requirement related check

= Package integrity related check

= Package appearance and line efficiency related check

(Cont'd)

Doc. No. BoC-2712261-0103 Appendix A - 7 (16)

 Appendix A: Flowcharts and
A.1 Operator Checks Troubleshooting

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

Date Print Crease

1 1 Lines

No
No Stop Call a
Ok? Ok? TPOP
Production Technician
Setting
Yes
Yes

Weight Overlap
X 1

No No
Adjust Stop Call a
Ok? Ok?
Weight Production Technician
Yes Yes

TS

TechPub_2614345_0103 - A1_2712261_03_en.fm
X Rough Surfaces
1

No No
Stop Call a Stop Call a
Ok? Ok?
Production Technician Production Technician
Yes Yes

TS Hole
X Accurate Y Position

No No
Stop TPOP TPOP
Ok? Ok? Setting
Production Setting
Yes Yes

Shape and Patch and

1 Design Y Tab Sealing

No No
TPOP Stop Call a
Ok? Ok? Production Technician
Setting
Yes Yes

Tab LS/SA
Y Position 1

No No
Stop Call a
TPOP Ok?
Ok? Production Technician
Setting
Yes Yes

Flap Continue
1 Sealing Production

No
TPOP
Ok?
Setting
Yes

Appendix A - 8 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Troubleshooting A.2 Laboratory QC Checks

A.2 Laboratory QC Checks

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

yes
Conductivity MTD LS by red ink MTD record
test 1203 injection 1202 test ok?
X 1 results

no
no
test ok? defect corrective
found actions

yes

Alu-foil TS MTD Leakages MTD yes

record
cracks 1210 by red ink 1204 test ok? results
X ?

no
Dissolve MTD
TechPub_2614345_0103 - A1_2712261_03_en.fm

X packages 1208 defect found

corrective actions
yes urgent no
check?
record results
method 1: method 2:
dissolving in dissolving in
acid solution alkaline solution

obtain
samples

MTD
Heat pattern
X 1208

TS integrity MTD
X by red ink 1208

yes record
test ok? results

no

defect corrective record

found actions results

Doc. No. BoC-2712261-0103 Appendix A - 9 (16)

 Appendix A: Flowcharts and
A.3 Products with Fibres Checks Troubleshooting

A.3 Products with Fibres Checks

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

Non-trapped fibre

Upper
package Top seal

Lower
package Bottom seal

TechPub_2614345_0103 - A1_2712261_03_en.fm
Trapped fibre

samples of trapped fibres found on

package after dissolving procedure

(Cont'd)

Appendix A - 10 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Troubleshooting A.3 Products with Fibres Checks

(Cont'd)
By definition, the filled products should be homogenous, i.e. no particles
must be retained on a sieve 0.6 mm* span after sieving.
The only non-homogeneous products that Tetra Pak accept are the Citrus
juices with a fiber content up to 50 gr./l, i.e. 5% w/w fibers (weighed in wet
conditions in the final product). The fibers must exclusively be collapsed
vesicles, no seeds, or peels or segment walls or white wires or pieces of them
are allowed.
Both Citrus juices with fibers and juices containing stones can easily require
the use of film material (recommended) regardless the fact that juices are
generally packed by means of /jl material.
*Beware that the requirement of no particle retained over a 0.6 mm sieve
(30 meshes) corresponds to a smaller average granulometry in products
containing hard stones. For instance, products like pear, guava and
berries juices, containing a very large number of particles with a natural
size distribution, could be successfully packed when the average size is
equal or lower than 0.2 mm.
Note!
Normally the defective rate increases when switching from plain
TechPub_2614345_0103 - A1_2712261_03_en.fm

product to products containing fibers and/or particles. Packability

should be verified on forehand, by designed trial plan.
The produced packages are to be checked for defective rate both
before and after package transportation. A filling test of at least 6000
packages on the desired product is highly important.
A large-scale test would then give the final performance.

Special equipment and packaging material have been designed to reduce the
risks of defective seals when packing fibrous products, see table below. For
further information, refer to the TPCA Sealing Technology and Food
Technology Departments.
Item Description Packaging Lines
HVA (High Viscosity Aseptic) kit Helps the product run through the TBA/8
filling system avoiding valve TBA/19
clogging
Special packaging material The LLDPE film improves packing All except TBA/3
TBA/lk-25 and of hard particles
TBA/lk-36

Modified counter pressure rubber Help to free the sealing area from TBA/3
dollies in combination with modified particles TBA/8
jaw system settings TBA/9
TBA/19
TBA/21

(Cont'd)

Doc. No. BoC-2712261-0103 Appendix A - 11 (16)

 Appendix A: Flowcharts and
A.3 Products with Fibres Checks Troubleshooting

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

Conductivity MTD
test. 1203
300

no
defective
test ok?
packages

yes
no
Dissolve TS integrity fibres are a
problem
100 packages ? by red ink test ok?

TechPub_2614345_0103 - A1_2712261_03_en.fm
yes yes
no
fibres
in TS? Dissolve
packages
fibres are fibres may
not a be a
problem problem
no fibres are
fibres in not a
TS? problem

yes

fibres may
become
problem

Appendix A - 12 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Troubleshooting A.4 Troubleshooting

A.4 Troubleshooting
These checks take place during troubleshooting to investigate if the
unsterility is due to package integrity. Care in every step of the evaluation is
important since the methods are destructive and packages will not be
available for further checks afterwards.
Package forming and data printing should be analysed and recorded since
they may add relevant information to find the cause of unsterility.
The procedure is slightly different for homogeneous (water-based) products
(e.g. water, fruit juice) and viscous or fatty products (e.g. cream, tomato
sauce).
The Conductivity Test is not effective with packages filled with fat products,
as fat can create a layer which covers the defects and does not allow the flow
of current. The Red Ink Test is performed instead.
Products like cream might interact with packaging material causing a
phenomenon called Environmental Stress Cracking.
The optimal population to investigate consists of the blown package (which
most likely will show also burst spots on the TS) and the packages produced
close to it (most likely belonging to the same tray).
TechPub_2614345_0103 - A1_2712261_03_en.fm

The overall troubleshooting procedure should be performed by:

• QAM Officers
• System Specialists
• Senior Tetra Pak Field Service Engineers
• Senior Technical Support Staff.

Doc. No. BoC-2712261-0103 Appendix A - 13 (16)

 Appendix A: Flowcharts and
A.4 Troubleshooting Troubleshooting

A.4.1 Homogeneous (Water-based) Products

Weight, perform A.1
Conductivity: positive.
X date print Operator Checks
Indication of rupture in
the inner PE layer
Conductivity MTD
X test 1203
Red ink: positive.
sealing channel leakers
Leakages by MTD and hidden breakages
? red ink 1204 will be detected

record no
results and defect test
corrective found ok?
actions
yes

Alu-foil TS MTD
X cracks 1210

record

TechPub_2614345_0103 - A1_2712261_03_en.fm
no
results and defect test
corrective found ok?
actions
yes

Dissolve MTD
X packages 1208

yes no
urgent
check?

method 1: * method 2:
dissolving in dissolving in
acid solution alkaline solution

get
samples

MTD
X Heat pattern
1208

(*) Recommended TS integrity MTD

X by red ink 1208

no yes
corrective defect packages
test ok? are integer
actions found

Appendix A - 14 (16) Doc. No. BoC-2712261-0103

 Appendix A: Flowcharts and
Troubleshooting A.4 Troubleshooting

A.4.2 Viscous and Fatty Products

Wash the inside of the packages with warm water and alcohol before
performing the test, to take away as much product residue as possible, at
ambient temperature.
Date, Printing, perform A.1
X Forming Operator Checks

Leakages by MTD
X red ink 1204

Crease, Flap
X alignment

no defect corrective
test ok? actions
found

yes

Alu-foil TS MTD
X cracks 1210
TechPub_2614345_0103 - A1_2712261_03_en.fm

no defect corrective
test ok? found actions

yes

Dissolve MTD
X packages 1208

method 1: yes * method 2:

urgent no dissolving in
dissolving in
check? alkaline solution
acid solution

obtain
samples

Heat pattern MTD

X 1208

TS integrity MTD
X by red ink 1208
(*) Recommended
yes no
packages defect corrective
are integer test ok?
found actions

Doc. No. BoC-2712261-0103 Appendix A - 15 (16)

 Appendix A: Flowcharts and
A.4 Troubleshooting Troubleshooting

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Appendix A - 16 (16) Doc. No. BoC-2712261-0103

 Appendix B:
Tools and Chemicals
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Doc. No. BoC-2712261-0103 Appendix B - 1 (24)

 Appendix B:Tools and Chemicals

This chapter contains description and materials used in

Package Integrity test methods.

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Appendix B - 2 (24) Doc. No. BoC-2712261-0103

 Table of Contents
Appendix B:Tools and Chemicals

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

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

B.3 Preparation of Chemicals . . . . . . . . Appendix B - 13
B.3.1 Copper Solution. . . . . . . . . . . . . . Appendix B - 14
B.3.2 Dissolving Solutions . . . . . . . . . . Appendix B - 16
B.3.3 Leakage Detection Fluid . . . . . . . . Appendix B - 21
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 Appendix B:Tools and Chemicals

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Appendix B - 4 (24) Doc. No. BoC-2712261-0103

 Appendix B:Tools and Chemicals B.1 Area Requirement

B.1 Area Requirement

An adequately equipped area must be available to carry out integrity tests.
The area must be ventilated and with good illumination.
A fume extractor is needed for the preparation of the dissolving solutions.
Running water is needed. Compressed air can be useful.

5
3

1
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1 Conductivity
2 Water
3 Magnifying lenses
4 Compressed air
5 Microscope
6 Dissolving station

Doc. No. BoC-2712261-0103 Appendix B - 5 (24)

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

B.2 Tools and Equipment

Here you have a list of tools and equipment used in Package Integrity
Methods, with reference to the specific method in which they are needed and
item code.
Name Picture Supplier and code Used in
Rolling ball Any 2.2.4-1 Rolling ball
point pen (felt point pen test (after
tip pen (red) mechanical tear
down)

Permanent pen Any All

Scissors Fiskars All

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No. 9451-7097

Pinking Fiskars 1.3 Transversal Seal

scissors - Dissolving and Red
No. 9445-7097 Ink (MTD 1208)

1.4 Transversal Seal

- Al-Foil Cracks (MTD
1210)
Cutter Any All

Note! Snap off blades

are not used in many
food industries. Refer
to local regulation.

Paper towels Any All

Appendix B - 6 (24) Doc. No. BoC-2712261-0103

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

Name Picture Supplier and code Used in

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

Beakers Any B.3 Preparation of

Chemicals
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Pipettes Any B.3 Preparation of

Chemicals

Water tray Any 4.2 Integrity -

Conductivity Test
Note! Cat litter tray (MTD 1203)
(HDPE) can work very
well. 4.3 Integrity - Copper
Test (MTD 1207)

Disposable needle ø 0.4-0.5 mm 2.3 Longitudinal Seal

syringe - Red Ink Injection

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

Name Picture Supplier and code Used in

Gloves Any All

Safety goggles Any 1.3 Transversal Seal

- Dissolving and Red
Ink (MTD 1208)
B.3.1 Copper
Solution

Tongs Any 1.3 Transversal Seal

(wooden material is - Dissolving and Red

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preferable) Ink (MTD 1208)

Abrasive Any 1.4 Transversal Seal

sponges - Al-Foil Cracks (MTD
1210)

Magnifying Any 1.2 Transversal Seal

lamp with (this model is PEAK) - Tearing (MTD 1201)
in-built light

Appendix B - 8 (24) Doc. No. BoC-2712261-0103

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

Name Picture Supplier and code Used in

Magnifying Peak 1.2 Transversal Seal
lenses - Tearing (MTD 1201)
Scale Lupe 10X
1.3 Transversal Seal
Zoom Lupe 816 - Dissolving and Red
Ink (MTD 1208)
Scale Lupe 10X

Light Lupe 15X

Note! Please contact

PEAK directly for
above parts.

Stretch pliers Tetra Pak 1.2 Transversal Seal

- Tearing (MTD 1201)
No.78073-0101

Spare parts:
Small spring
No.566772
Big Spring
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No.566773
Zonoscope Tetra Pak 1.3 Transversal Seal
- Dissolving and Red
No.90243-0203 Ink (MTD 1208)

2.2 Longitudinal Seal

(LS/SA) - Tearing
(MTD 1202)

PullTab positioning
(OM)
Ammeter Tetra Pak 4.2 Integrity -
Conductivity Test
No.90243-0110 (MTD 1203)

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

Name Picture Supplier and code Used in

Copper tester Tetra Pak 4.3 Integrity - Copper
Test (MTD 1207)
No.90459-0095

Water bath Dinkelberg 1.3 Transversal Seal

(bain-marie) - Dissolving and Red
No.ATH232319 Ink (MTD 1208)

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Portable digital Spectrum 1.2 Transversal Seal
microscope Technologies, Inc. - Tearing (MTD 1201)

IPM Scope 1.3 Transversal Seal

[Link] - Dissolving and Red
Ink (MTD 1208)

2.2 Longitudinal Seal

(LS/SA) - Tearing
(MTD 1202)

Hot Wire Note! This tool is 3.4 Opening Devices

under - PLH, PLH Integrity
Check
development.
Supplier and/or
code is not
available.

Appendix B - 10 (24) Doc. No. BoC-2712261-0103

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

Use of the Zonoscope

The zonoscope is a polarizer which allows to better enhance and analyse the
heat pattern of the LS. It does not give any indication on the quality of the
sealing as far as distribution of pressure is concerned.
When analysing the LS through the zonoscope, a different range of colours
appear (dark blue and brown); this is due to the fact that the multilayer
plastic of which it is made filters the light reflected from the Al-foil
differently from the PE of the LS.
The zonoscope has two sides. The one marked with a double circle is
designed for TBA/K packaging material; turn this side facing upwards when
analysing TBA/K. The other, marked with two lines, is intended for all the
other packaging materials.
Either way, turning the zonoscope only changes the range of visible colours
as light is filtered differently; therefore choose the side which better
enhances the heat pattern under investigation.
The zonoscope, that was designed for zone-heater in perforation openings, is
also widely used in PT applications to locate heat distribution.
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TBA/lk

TBA/j

(Cont'd)

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

(Cont'd)
Use of the Electrolyte Copper Tester

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

Press the Push button for approximately four seconds to turn on the tester.
The tester acts as voltage generator and detects the current loss between two
liquids by the two electrodes. The display shows the value of the current
deflection.
Press the Push button once again to make the tester produce electrolysis
acting as current generator. The display shows the value of the current
circulating between the two liquids.
The tester switches Off automatically if there is no current circulating for 5
minutes.
To switch off the instrument manually, press the button Push for five
seconds.

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Appendix B - 12 (24) Doc. No. BoC-2712261-0103

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

B.3 Preparation of Chemicals

Here you have a list of the chemicals used in Package Integrity Methods.
Specific information about each chemical preparation and usage follow.
Name Picture Supplier and code Used in
Copper solution Preparation is required, 4.3 Integrity - Copper Test
see B.3.1 Copper (MTD 1207)
Solution

Dissolving Preparation is required, 1.3 Transversal Seal -

solutions see B.3.2 Dissolving Dissolving and Red Ink
(alkaline or acid) Solutions (MTD 1208)
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Leak detection Can be ordered from 1.3 Transversal Seal -

fluid Tetra Pak on TP Dissolving and Red Ink
(red ink) No.90298-26 or prepared (MTD 1208)
according to section
B.3.3 Leakage Detection 2.3 Longitudinal Seal -
Fluid Red Ink Injection

3.2 Opening Devices -

PullTab (MTD 1211)

4.4 Integrity - Red Ink

Test (MTD 1204)

Leak detection Preparation is required, Not used in Aseptic

fluid see B.3.3.2 Blue Ink Package Integrity
(blue ink) Methods

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

B.3.1 Copper Solution

Ruptures in the inner PE layers can be detected by the conductivity test
(MTD 1203). The package is immersed in an electrolytic solution (i.e. salt
solution). In case of a crack in the PE layers, which leave the Al-foil
uncovered, an electrical contact is established between the electrolytic
solution outside the package and the package content. If some copper
solution is poured into the package, the copper concentrates in the area of the
cracks when a copper tester is used, allowing to locate the fault.
Ingredients
• Cu2SO4.5H2O (CopperII Sulfate Pentahydrate)
• Emulsifying agent
• Distilled water
• HNO3 (concentrated 65%)

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

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

Add 200 cm3 distilled water.

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

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

Add 800 cm3 of distilled water while

mixing. Make sure that the
Cu2SO4.5H2O is completely dissolved.
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CAUTION
Risk of personal injury!
Use protective goggles and gloves
when handling HNO3; put the acid
into the solution, never the other way
round

Add 2.6 g of concentrated (65%) HNO3

with a syringe and mix for additional 5
minutes.
The copper solution is ready.
Store the solution in a glass bottle, filter
or decant it after usage.

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

B.3.2 Dissolving Solutions

These solutions can be used to dissolve the Al-foil and separate the internal
polyethylene bag from the remainder of packaging material layers, when the
Transversal Seal is under investigation.
1) Acid solution (very fast method), follow B.3.2.1 Acid Dissolving
Solution (very fast method).
2) Acid solution (fast method), follow B.3.2.2 Acid Dissolving Solution
(fast method).
3) Alkali solution (slow method), follow B.3.2.3 Alkaline Dissolving
Solution (slow method).

Refer to the 1.3.3-2 Dissolving of packages chart at page 1-24 for determine
which type of solution is more suitable:
Note!
Hydrofluoric Acid is used in local applications but fumes that give off
are of health concern.
(Cont'd)

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Appendix B - 16 (24) Doc. No. BoC-2712261-0103

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

(Cont'd)
B.3.2.1 Acid Dissolving Solution (very fast method)

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

Three different solutions are used, which we will call:

1) HCl 1:1 Solution,
2) HCl 1:3 Solution,
3) Neutralizing Solution.
This method is very fast, therefore it is advisable when the results of the test
are urgent. A fume extractor and a water bath are needed.
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Ingredients:
• HCl (37% - starting solution as commercially available),
• Distilled water (1:1),
• CuCl2,
• Na2CO3 in cristals.

(Cont'd)

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

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

a) Dilute the concentrated HCl in distilled water (1:1) at room temperature.

b) Add 1wgt % CuCl2 (e.g. 1 l. HCl, 1 l. distilled water, 20 g. CuCl2) at
room temperature.
c) Store the solution in a glass container with a glass lid when not in use.
The bath can be filtered at room temperature and reused.

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

a) Dilute the concentrated HCl in distilled water (1:3).

b) Add 0.5 wgt % CuCl2 (e.g. 250 cm3 HCl, 750 cm3 distilled water,
5 g.CuCl2);

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c) Store the chemical in a glass container with a glass lid. The bath can be
filtered at room temperature and reused for several TS examinations.

3) Neutralizing Solution (Sodium Carbonate at room

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

a) Prepare 10 wgt % solution of Na2CO3 in distilled water (e.g. 100 g.

Na2CO3, 1 l. distilled water) at room temperature.
b) Store the chemical in a glass container with a glass lid. The bath can be
filtered at room temperature and reused.

Appendix B - 18 (24) Doc. No. BoC-2712261-0103

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

B.3.2.2 Acid Dissolving Solution (fast method)

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

Two different solutions are used:

1) Acid Solution,
2) Neutralizing Solution.
This method is fast, but slower than the method at B.3.2.1 Acid Dissolving
Solution (very fast method). A fume extractor is needed.
Ingredients:
• HCl (37% - starting solution as commercially available),
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• Distilled water (1:1),

• Na2CO3 in cristals.

1) Acid Solution (Hydrochloric acid)

Prepare an acid solution of HCl 30% (e.g. for 3 litres solution put 600 ml of
water in a beaker and add carefully 2400 ml of HCl 37%).
2) Neutralizing solution
Prepare 10 wgt% Na2Co3 in distilled water (e.g. 100 g Na2Co3 and add water
until the solution is 1 litre.

Doc. No. BoC-2712261-0103 Appendix B - 19 (24)

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

B.3.2.3 Alkaline Dissolving Solution (slow method)

Ingredients:
• Distilled water,
• NaOH

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

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

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

B.3.3 Leakage Detection Fluid

B.3.3.1 Red Ink
Red ink is pure isopropanol based solution (99.5%), which has the
characteristic of penetrating the small cracks and pinholes which can be
present inside the package. The red colour is due to the addition of
erithrosine, and it allows to visually detect the ink leakage, which simulates
the penetration of microorganisms across the packaging material layer.
Isopropanol has a high capillary action but does not interact, at room
temperature, with the internal plastic layers of the package.
Other solvents, like turpentine, would damage PE and therefore give false
results, whereas Ethylic Alcohol (Ethanol) cannot be used worldwide due to
special local regulations.
Ingredients
• Erythrosin β, sodium salt
• Isopropyl alcohol (99.5 %, commercial purity)

1
Weight approximately 1.5 g of powder
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Erythrosin β.

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

2
Mix the Erythrosin β with 1 l. of
Isopropyl alcohol.
Shake well and leave to decant overnight.

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Filter the solution with a funnel covered
with a paper towel, into a spare container.
The red ink is ready to be used.
Store the red ink in a convenient cabinet
at room temperature, in a closed
container to reduce evaporation.

Appendix B - 22 (24) Doc. No. BoC-2712261-0103

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

B.3.3.2 Blue Ink

Blue ink is a water based solution which is used to test the tightness of the
external layer of the package (decor layer) to the penetration of water and
humidity. Its characteristic colour is due to the addition of methylene blue.
Blue ink cannot be used to assess microbiological tightness of the package at
any level. It is not used for TPCA applications, but only for TPCC. The
recipe is included here in case of interest.
Ingredients
• Methylene blue
• Emulsifying agent
• Ethanol (95%, commercial purity).
• Distilled water

1
Weight 5 g of Methylene blue.
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2
Warm up 1 l. distilled water in a heat
resistant flask at about 45 °C.
Dilute the Methylene blue into the
distilled water.
Mix the solution using a magnetic
agitator.

Doc. No. BoC-2712261-0103 Appendix B - 23 (24)

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

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

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Remove the flask from the agitator and
add 200 cm3 Ethanol.
Close tight and shake the solution well.
Blue ink is ready.
Store it at room temperature in a closed
container to reduce evaporation.

Appendix B - 24 (24) Doc. No. BoC-2712261-0103

 Appendix C:
Data Record
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Doc. No. BoC-2712261-0103 Appendix C - 1 (10)

 Appendix C:Data Record

Documenting and recording any changes related to

package integrity tests are of the utmost importance at any
stage of the product cycle, i.e. during Production and during
laboratory checks.
If unsterility problems occur and a troubleshooting
procedure is needed, it is vital to trace back past production
parameters and events to have a complete picture of the
situation.
In some countries, such as USA, Regulatory Agencies
require the documentation of the defects detected and of all
the related corrective actions.
This section includes examples of forms which can be used
as reference.

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Appendix C - 2 (10) Doc. No. BoC-2712261-0103

 Table of Contents
Appendix C:Data Record

C.1 Production Package Recording

Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C - 5

C.2 Laboratory Package Recording

Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C - 6

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

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

C.5 PLH Integrity report. . . . . . . . . . . . . . Appendix C - 9
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 Appendix C:Data Record

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Appendix C - 4 (10) Doc. No. BoC-2712261-0103

 TechPub_2614345_0103 - A3_2712261_03_en.fm

Production Package Recording Sheet

Date Packages Product PM LS legend

ID event
Machine type codes type temperature type P.O. type P.O. V = passed
Machine number KO = not passed
Operator signature X = not performed

Note: packages tested as from event scheme

on OM package checks

EXAMPLE Checks

Shape and lab. checks?

Date print Weight TS rough TS accurate Flap sealing Crease lines Overlap Surfaces LS/SA
Appendix C:Data Record

design

ID time event [Link] check box check box check setting check box setting check box check box check box check box check box check box setting yes no
taken box

EX
AM

Doc. No. BoC-2712261-0103

PL
E
C.1 Production Package Recording Sheet

[Link] Sara Davolio

last update 13/09/2004 Monica Malagoli
C.1 Production Package Recording Sheet

Appendix C - 5 (10)
 Laboratory Package Recording Sheet

Date Pack Product PM LS

ID event
Machine type Codes Type Temper. Type P.O. Type P.O. Check box legend
Machine number V = passed
Operator signature KO = NOT passed
X = not performed

Appendix C - 6 (10)
Checks
Package integrity TS quality by dissolving LS (by red ink
Sample ID Conductivity Red ink Heat pattern Red Ink injection)
C.2 Laboratory Package Recording Sheet

Top Bottom Top Bottom Top Bottom Top Bottom

ID link n. date machine check box check box check box check box check box check box check box check box check box
event
01
02
03
04
05
06 EX
07 A
08
M
09
PL

Doc. No. BoC-2712261-0103

10 E
01
02
03
04
05
06
07
08
09
10
C.2 Laboratory Package Recording Sheet

[Link] Sara Davolio

last update 13/09/2004 Monica Malagoli
Appendix C:Data Record

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 Appendix C:Data Record C.3 Sample Collection Form

C.3 Sample Collection Form

Sample Collection Sheet

Machine Type Date
Machine Number Time
Operator Name Batch No.
Link No.
TOP

E
PL
AM
EX
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BOTTOM

Comments:

monica malagoli
updated 13/09/2004 sara davolio

Doc. No. BoC-2712261-0103 Appendix C - 7 (10)

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

C.4 Troubleshooting General Data Form

Troubleshooting Sheet - General Data

Test Code (if more than one)

Date
Report Reference
Package Volume
Family
Opening
Filling Machine Type
Development Step
Serial number
Customer Filling product
Production Date
[Link]
Product temperature (C)
Packaging Material Design

E
Packaging Material

PL
Converting factory

AM

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[Link]
LS Strip
EX
Al-Foil
Thickness(µ)
Sealing Configuration Cutting Rail
End Pieces
Inductors
Dollies
Pulse Time
TS Setting
Jaw pressure (bar)
Jaw Gap (mm) if not standard
TS working window performed?
TS working window settings and location
Purpose of the Test Short description
Amount of Samples
Package Integrity Unsterility Rate
Red Ink
TS Cracks
Inner bags
heat Pattern
Numbering Progressive
Project number

Notes

Appendix C - 8 (10) Doc. No. BoC-2712261-0103

 Appendix C:Data Record C.5 PLH Integrity report

C.5 PLH Integrity report

PLH Integrity Report
Report No. (Progressive)
Project Number
Date
Name

Please follow this template for mapping leakage and/or contact found on packages with PLH:
1 Enter the data regarding machine, PM, Package and Customer
Volume
Family
Package
Opening
N. of Samples
Type

E
P-Order

PL
Packaging Material
Converting factory

AM
Lane

Type

EX
Machine Dev. Step
Serial No.

Filling Product
Production Date
Customer Exp. Date
Product Temperature
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PackMat Design

2 Select on the PLH map the area wher you found the leakage and/or contact according to the examples
provided in the guidelines (mark on the right side the type of sample you tested).

Packaging Material
lamination and Filling
Machine Direction for TGA
packages

pack mat flat

package

view from inside

view from outside

Packaging Material
and Filling Machine
Direction for TBA
and TPA packages

Example:

Contact found

Leakage found
mml 12/01/2007

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C.5 PLH Integrity report Appendix C:Data Record

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