Training Module
Monoblock
Training Module
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Module 1 – Introduction &
Objective
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Introduction –
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Monoblock Operator in a bottling plant is responsible for operating and overseeing the monoblock machine, which
is a type of equipment used in the bottling process. The monoblock machine integrates several functions into a single unit, typically
combining the processes of bottle rinsing, filling, and capping into one continuous machine.
Breakdown of the key duties:
• Operating the Monoblock Machine: The operator ensures that
the machine is running smoothly, setting up and adjusting the
equipment for different bottle sizes and types.
Monoblock
• Monitoring the Process: The operator continuously monitors the Operator
filling, capping, and rinsing stages to ensure proper machine
function and product quality. They also keep an eye on the
machine for any malfunctions or issues.
• Quality Control: The operator checks for proper fill levels, seal
integrity, and that no contamination occurs during the process.
They may also handle the inspection of finished bottles for
defects.
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Module 2 – Machine Setup and Operation
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Machine Setup and Operation – The Monoblock Operator in a
bottling plant plays a critical role in both machine maintenance and
operation. Their responsibilities ensure the efficient functioning of
the monoblock system, which combines several key processes like
rinsing, filling & capping. Machine Setup and Operations are used
in the MARKET
following phases: TECHNICAL FINANCIAL ECONOMIC
ANALYSIS ANALYSIS ANALYSIS ANALYSIS
• Startup Operation
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• Operating Operation sit amet, sit amet,
consectetur consectetur
• Changeover Operation
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• Shutdown Operation do eiusmod tempor do eiusmod tempor
incididunt ut labore incididunt ut labore
et dolore magna et dolore magna
aliqua. aliqua.
Machine Name: HEUFT SPECTRUM II
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Start-up Operations - At the start-up of a bottle manufacturing plant, the role of a Monoblock operator is
crucial to ensure smooth operations and the proper setup of equipment.
Star-up Operations
1. Ensure General checkpoints for line startup as per laid down procedure.
2. Ensure all connectors are adequately tight.
3. Be familiar with emergency shut-off procedures.
4. Report any equipment malfunction immediately.
5. Ensure machine is calibrated according to production plan & ensure rated
machine speed.
6. Ensure General Hygiene & cleaning of machine
7. Maintain air & water pressure in the machines as per optimum
requirement required for the air solenoid valve Sets filler & Sealer height.
8. Ensure covering the unused pipelines with blind flanges or nipples to
prevent deposition of dust.
9. Checks for any physical damage of Change parts and ensures correct
change part is in use as per the running SKU/ Brand.
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Ensures all the emergency switches are accessible.
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Operating Operations – Monoblock operator contribute to the safe and smooth operation of machinery, automation, and energy
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systems. They ensure proper installation, perform ongoing maintenance, troubleshoot machine components and help maintain
compliance with safety standards. Their role is essential in keeping production lines running efficiently, safely, and with minimal
downtime.
Operating Operations
1. Ensure precise filling & capping of bottles.
2. Maintain proficiency in operating and maintaining bottling machinery
and equipment.
3. Manage time effectively to meet production deadlines.
4. Use computerized systems to monitor and control bottling processes.
5. Ensure that the cam rollers are following the cam track correctly.
6. Ensure that the nozzle alignment & washer setting is checked
thoroughly.
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Be alert for any malfunctions in the inspection system.
Be familiar with emergency procedures in the event of a machine malfunction, fire, or other workplace emergencies.
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Changeover Operations - It refer to the process of switching production lines from
one type of product to another.
Steps for Changeover
1. Set the Time setting from Rinser infeed to filler outfeed.
2. Clear any bottles left in the system.
3. Perform a thorough cleaning of the machine and surrounding area.
4. Adjust the height of the filling & capper section as per SKU
5. Adjust to changing production schedules, equipment malfunctions,
or process changes.
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Perform any activity on the machine when power is off.
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Shutdown Operations – A shutdown operation typically refers to temporarily halting production to perform maintenance, repairs,
upgrades, or safety checks. Monoblock operator ensures safety, operational continuity, and compliance with industry standards.
Procedure for shutdown –
1. Conduct regular checks for defects or inconsistencies in the bottling process as per
laid down procedure.
2. Use the main control panel to stop all operations.
3. Ensure Cleaning and alignment of the system
4. Check the Lubrication level and manual Point for lubrication
5. Ensure all Safety interlocks are healthy and working fine
6. Complete the shutdown following the shutdown procedures., logs & notes down
the time, reason, and any issues encountered.
Switch Off Button
Control & Hazards
Wear the PPEs as per PPE matrix (Head cap, cut level 5 hand gloves, Goggle & Safety shoes).
Be familiar with emergency procedures in the event of a machine malfunction, fire, or other workplace emergencies.
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Module 4 – Maintenance & Troubleshooting
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Maintenance & Troubleshooting – Maintenance & Troubleshooting ensures safety, efficiency, and the smooth
functioning of all mechanical components, contributing significantly to the overall productivity and profitability of the plant
Routine Maintenance
1. Ensure the Monoblock machine is calibrated according to specifications.
2. Apply Lubrication to conveyor belts as needed.
3. Adjust processes in response to changing production demands.
4. Ensure Clean & Greased/ Lubricated Gears, pulleys & Gearboxes as per CLIT
5. Troubleshooting Common Issues
6. Quickly identify and resolve issues in the bottling line.
7. Troubleshoot and perform minor repairs on bottling machinery.
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Module 3 – Safety Protocols
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Safety Protocolsanalysis
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Health and safety in a bottling plant are critical to ensuring the well-being of employees, maintaining
product quality, and complying with industry regulations. Bottling plants, like other manufacturing environments, pose
various risks, including mechanical, chemical, ergonomic, and environmental hazards.
key steps to maintain Safety Protocols
Ensure that all safety guards and mechanisms are functioning.
Understand safety protocols and regulations in a manufacturing environment.
Safety shoes Anti cut gloves
Identify and mitigate potential hazards and follow safety protocols.
Check the surface for wear and deformation, and repair/ replace if required (Star
wheel & guides, Wheel Shaft, Worm Shaft Bearings).
Ensure use of PPEs as per PPE matrix.
Ensure all the emergency switches are accessible and area free from tripping Ear plug Safety google
hazards
Keep the knowledge & understanding of cleaning and sanitizing the bottling
equipment and the production area.
Head cap Mask
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Module 5 – Quality Control & Performance
Monitoring
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Quality Control slide
& Performance Monitoring – 5 Quality Control (QC) and Performance Monitoring are critical
components of any bottling plant operations, monoblock operator is responsible for ensuring production line is functioning
optimally and safely.
Ensuring Product Quality
• Ensure that bottling complies with quality standards such as food safety, packaging
integrity, and product consistency as defined.
• Continuously monitor the bottling process for any irregularities.
• Check the pressure at each sealing head to get proper sealing.
• Understand the quality assurance processes to ensure products meet standards.
• Identify the leakage/ blockage points and eliminate the source of contamination by arresting
leak points.
• Check visually for any leakage and inform maintenance.
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Module 6: Documentation and Reporting
Documentation & Soft Skills
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Documentation
Maintain record of team meetings, role assignments, and training sessions.
Document any incidents and resolutions for future reference.
Document and communicate production issues and maintenance needs
Accurately record production numbers, downtime, and issues encountered during
shifts
Soft Skills
Maintain an effective communication with supervisors, maintenance personnel,
and quality control teams to resolve issues and optimize production flow.
Ensure escalation of a problem to the supervisor promptly if it is not resolved
within the team.
Train co-workers on operations.
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Tools required for EBI machine ( Operation , Maintenance & Quality )
Allen key set ( 1.5 to 10 mm ) T-shaped Allen key set ( 1.5 to 10 mm ) ) Straight Nose pliers ) Bend nose pliers Universal pliers Screw driver Cross / Ball pien hammer
Tester Adjustable spanner One end Open and ring Spanner set Oil can Grease gun Measuring tape Mallet hammer
Spirit level Micro Screwdriver Screw driver Tool
Digital Multimeter Hex Tubular Box Rachet Spanner Set 90 degree Angle
Tool kit kit 65 pieces
Spanner Set (8-19 (8-19 mm)
mm)
Operational Excellence
Record production data and use software for inventory management.
Eliminate bottle falling at infeed through conveyor.
Implement Kaizens as per suggestions
Provide suggestions for improvement
Check & ensure that the vacuum pressure as per the defined parameter.
Check Nozzle alignment and the washer setting.
Identify top PI’s for the Machine and record them in SIC chart.
Understand and update OWS board elements including 20 element SOP.
Refer to the reaction Plan incase PI are out of threshold and act as per reaction plan
Update reaction plan on timely basis.
Understand the CCP’S & OPRP’s and actions to be taken to maintain CCP & OPRP
requirements.
Thank You
