SP

Safety Precautions
TetraPak® A3/Speed
648576-0500

WARNING
Read and follow all safety precaution instructions throughout this
document and on safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.

Doc. No. SP-3546893-0101

Copyright © 2018 Tetra Pak International S.A.
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.

, Tetra Pak, and all other trademarks displayed in this document are the property of the
Tetra Pak International SA. Tetra Pak Packaging Solutions together with Tetra Pak
International SA form part of ‘the Tetra Pak Group’. The content of this document is in
accordance with the design and construction of the machine or equipment at the time of
publishing. The Tetra Pak Group reserves the right to introduce design modifications without
prior notice.
The English language version of this document contains the original instructions. All other
language versions are translations of the original instructions.
This document was produced and printed by:
Tetra Pak Packaging Solutions
Via Delfini 1
41123 Modena
Italy

Doc. No. SP-3546893-0101

Issue 2018-11
This document is valid for: Safety Instructions

Serial No. / Machine No.

Year of Manufacture Sign.

SP
Safety Precautions

TetraPak® A3/Speed
648576-0500

Machine or equipment configurations that

this document is valid for are described on
the next page.

Doc. No. SP-3546893-0101

Issue 2018-11

Tetra Pak Packaging Solutions

Valid for:
Name Drawing Specification and Additional Information
Development Step

Tetra Pak® A3/Speed 648576-0500 Optional Equipment: HI -

Headspace by Injection, Stair on
RH Side
 Safety Instructions

®
Doc. No. SP-3546893-0101 5 (56)
 Safety Instructions

Description
Safety Precaution Instructions

WARNING
Read and understand this manual before using the machine.
Failure to follow safety precautions and instructions can result in death or serious
injury.

6 (56) Doc. No. SP-3546893-0101

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Safety Instructions Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Abbreviations and Terminology ............................... 9

Document Information ..........................................11
Safety Messages Description ................................ 12
Personnel Requirements...................................... 13
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Instructed Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety Signs ...................................................... 14

Protective Devices .............................................. 33
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Emergency Stop Push-Buttons . . . . . . . . . . . . . . . . . . . . . . . . 34

Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Indicating Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Safe Manual Handling.......................................... 39

Personal Protection ............................................ 40
Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Entanglement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Hazardous Substances ........................................ 41

Disposal of Chemical Substances . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydrogen Peroxide (H2O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inhalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Ingestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . 42

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Doc. No. SP-3546893-0101 7 (56)
Table of Contents Safety Instructions

Handling of Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . . 42

Storage of Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disposal of Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . . 44
Caustic Soda/Sodium Hydroxide (NaOH) . . . . . . . . . . . . . . . . . 44
Nitric Acid (HNO3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Ultraviolet Light ................................................. 45

Supply Systems ................................................. 46
Definition of Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Residual Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Valid for: All countries except USA and Canada . . . . . . . . . . . . . . . . . . . .48
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Valid for: USA and Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steam Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Working at Height ............................................... 54

8 (56) Doc. No. SP-3546893-0101

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Safety Instructions Abbreviations and Terminology

Abbreviations and Terminology*

Abbreviation/Terminology Meaning Translation
ANSI American National American National
Standards Institute Standards Institute
ASU Automatic Splicing Unit Automatic Splicing Unit
B Base (package shape) Base (package shape)
AWG American Wire Gauge American Wire Gauge
CE Conformité Conformité
Européenne/European Européenne/European
Conformity Conformity
CM Conversion Manual Conversion Manual
CSA Canadian Standards Canadian Standards
Association Association
DIMC Direct Injection Direct Injection
Moulded Concept Moulded Concept
E Edge (package shape) Edge (package shape)
EAC Eurasian Conformity Eurasian Conformity
EEA European Economic European Economic
Area Area
EM Electrical Manual Electrical Manual
EN European Norm European Norm
EU European Union European Union
HI Headspace by gas Headspace by gas
Injection Injection
ICU Integrated Cleaning Integrated Cleaning
Unit Unit
IM Installation Manual Installation Manual
ISO International Standards International Standards
Organization Organization
LH Left Hand Left Hand
LS Longitudinal Seal(ing) Longitudinal Seal(ing)
M Mid (package shape) Mid (package shape)
MM Maintenance Manual Maintenance Manual
OE Optional Equipment Optional Equipment
OM Operation Manual Operation Manual
PBB Polybrominated Polybrominated
biphenyls biphenyls
PBDE Polybrominated Polybrominated
diphenyl ethers diphenyl ethers
QuTI-P Quality and Technical Quality and Technical
Issues Platform Issues Platform
RH Right Hand Right Hand
RM Rebuilding Manual Rebuilding Manual
RoHS 2 Restriction of Restriction of
Hazardous Substances Hazardous Substances
2 2
S Slim (package shape) Slim (package shape)
SA Strip Applicator Strip Applicator
SDS Safety Data Sheet Safety Data Sheet

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Doc. No. SP-3546893-0101 9 (56)
Abbreviations and Terminology Safety Instructions

Abbreviation/Terminology Meaning Translation

SPC Spare Parts Catalogue Spare Parts Catalogue
Sq Square (package Square (package
shape) shape)
TBA Tetra Brik® Aseptic Tetra Brik® Aseptic
TeM Technical Manual Technical Manual
TPOP Tetra Pak Operator Tetra Pak Operator
Panel Panel
TPA Tetra Prisma Aseptic Tetra Prisma Aseptic
TPMS Tetra Pak Maintenance Tetra Pak Maintenance
System System
TS Transversal Sealing Transversal Sealing
UL Underwriters Underwriters
Laboratories Laboratories
UP Update Pages Update Pages

10 (56) Doc. No. SP-3546893-0101

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Safety Instructions Document Information

Document Information
Note! The information presented in this user manual shall be considered as an
integral part of all user manuals delivered with the equipment.
Prior to interacting with the equipment, carefully read the instructions in the
applicable documentation pertinent to the activity. Make sure that the delivered
documents are available to personnel who operate or maintain the equipment.
It is important to keep this document for the lifetime of the equipment and to pass the
document on to any subsequent holder or user.

Any item that is named specifically in this document is to be considered a designated

item for the equipment. Designated items are verified by the Tetra Pak Group for use
with the equipment.
The Tetra Pak Group will not be held responsible for any damage, loss, injury, or
death caused by not following the instructions in the documents delivered with this
equipment, or by a failure to use designated items specified in the documents
delivered with this equipment.

Physical buttons on the operator panel, emergency stop devices, program steps, and
program tasks are printed in CAPITAL LETTERS.
Cross-references are underlined.

The following symbols may be used in illustrations:

A pointer arrow indicates the position of an object.

A zoom arrow indicates that an object view is

enlarged. The arrow points towards the enlarged
view of the object.

®
Doc. No. SP-3546893-0101 11 (56)
Safety Messages Description Safety Instructions

Safety Messages Description

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

The safety alert symbol 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 document to
inform the user of hazards.

Danger indicates an imminently

DANGERI
DANGER hazardous situation which, if not
avoided, will result in death or serious
injury.

Warning indicates a potentially

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

Caution indicates a potentially

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

12 (56) Doc. No. SP-3546893-0101

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Safety Instructions Personnel Requirements

Personnel Requirements
Note! Personnel includes all persons working on or near this equipment.
Only skilled or instructed persons are allowed to work with this equipment.

Skilled Person
A skilled person must have relevant education and experience to enable him or her
to identify hazards, analyse risks, and avoid hazards which electricity, machinery,
chemicals, other energies, and supply systems on this equipment can create.
Skilled persons must meet local regulations, such as certifications and qualifications
for working with these energies and systems.

Instructed Person
An instructed person must be adequately advised or supervised by a skilled person.
The skilled person enables the instructed person to identify hazards, analyse risks,
and avoid hazards which electricity, machinery, chemicals, other energies, and
supply systems on this equipment can create.

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Doc. No. SP-3546893-0101 13 (56)
Safety Signs Safety Instructions

Safety Signs
WARNING
Damaged or missing safety signs.
Safety signs are used to indicate safety hazards. If the signs are missing or
damaged, they can not fulfil this function. Replace all missing or damaged safety
signs immediately.
Safety signs are attached to the equipment. The illustrations below show their
locations on the equipment. The table that follows lists the position numbers of the
signs that are used. Each position number refers to two standards of a safety sign in
the table, but only one is used on the equipment.

• Make sure that each safety sign is legible and in its correct position after
installation and maintenance.
• Replace all missing or damaged safety signs immediately.

(Cont’d)

14 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

1
1

1 1

1
1

1
1

1
1
1

1 1
.

(Cont’d)

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Doc. No. SP-3546893-0101 15 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

1
1

1 1 1

1
.

(Cont’d)

16 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

1 1

1
Valid for: Final Folder TPA packages
.

(Cont’d)

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Doc. No. SP-3546893-0101 17 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

13

2
1

2 1

1
2

(Cont’d)

18 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

2
2
2

2
3

2 2

3 17

Not valid for: High Alcohol 20-45% machines

.

(Cont’d)

®
Doc. No. SP-3546893-0101 19 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

18

18

(Cont’d)

20 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

9
9 9
Right hand conveyor
Left hand conveyor

9
Valid for TBA 1000 B, TBA 1000 S, TBA 1000 M volumes only
.

(Cont’d)

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Doc. No. SP-3546893-0101 21 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

5 5
20

20 7

5 5

5
5

5
5
.

(Cont’d)

22 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

(Cont’d)

®
Doc. No. SP-3546893-0101 23 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

5
5
5

5
5
5

5
5

(Cont’d)

24 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

(Cont’d)

®
Doc. No. SP-3546893-0101 25 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

10 20
10

10

(Cont’d)

26 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

13

16

13

(Cont’d)

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Doc. No. SP-3546893-0101 27 (56)
Safety Signs Safety Instructions

(Cont’d)

The illustration shows where the safety signs are located. The table that follows lists
the position numbers of the signs that are used.

1
5

Valid for: machines with Headspace Unit (OE)

Pos. ISO Standard ANSI Standard

1

Hot surface.
Do not touch.
Follow lockout procedure before maintenance.

(Cont’d)

28 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

Pos. ISO Standard ANSI Standard

2

Chemical burn hazard.

Wear personal protective equipment.
3

Chemical hazard.
Corrosive and oxidising chemical. Could cause death or serious injury.
Read Safety Precautions in Operation Manual (OM) before handling
hydrogen peroxide.
4

Hazardous chemicals.
Can cause eye injury.
Wear eye protection.
5

Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure before maintenance.
6
WARNING
Hazardous voltage could be
present with power supply
disconnector switched off.
Can shock, burn, or cause death.
Conductors supplied from
an external source. Follow lockout
procedure before maintenance.

Hazardous voltage could be present with power supply

disconnector switched off.
Can shock, burn, or cause death.
Orange conductors supplied from an external source.
Follow lockout procedure before maintenance.

(Cont’d)

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Doc. No. SP-3546893-0101 29 (56)
Safety Signs Safety Instructions

(Cont’d)

Pos. ISO Standard ANSI Standard

7

Hazardous residual voltage on capacitors.

Will shock, burn or cause death.
Disconnect power and wait 5 minutes before opening.
Follow instructions for safe work practices.
8

Hazardous voltage.
Can shock, burn, or cause death.
Read Maintenance Manual (MM) before using this socket outlet.
9
WARNING
Hazardous rotating
shafts and belts
-
Can crush and cut
-
Keep hands clear while
the machine is operating

Hazardous rotating shafts and belts.

Can crush and cut.
Keep hands clear while the machine is operating.
10
WARNING
Moving parts
can crush and cut.
-
Do not operate with guard
removed.
guard
-
removed.
Follow lockout procedure
before maintenance.

Moving parts can crush and cut.

Do not operate with guard removed.
Follow lockout procedure before maintenance.
11
WARNING
Magnetic field.
Interaction with metallic
objects can cause
injury.
Follow instructions for
safe work practices.

Magnetic field.
Interaction with metallic objects can cause injury.
Follow instructions for safe work practices.

(Cont’d)

30 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safety Signs

(Cont’d)

Pos. ISO Standard ANSI Standard

12
CAUTION
Laser Radiation.
Do not stare into
beam.
Class 2 laser product

Laser Radiation.
Can cause injury to eyes.
Do not stare into beam.
Follow instructions for safe work practices.
Class 2 laser product.
13

Moving part can crush and cut.

Do not operate with guard removed.
Follow lockout procedure before maintenance.
14
CAUTION
Do not reach in.
Moving parts may
cause injury.
Follow instructions for
safe work practice.

Do not reach in.

Moving parts may cause injury.
Follow instructions for safe work practice.
15

Sharp element.
Can cause cuts.
Do not touch.
16
WARNING
Do not enter

Moving parts can cause

serious injury
Follow lockout procedure
before entering

Do not enter.
Moving parts can cause serious injury
Follow lockout procedure before entering.

(Cont’d)

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Doc. No. SP-3546893-0101 31 (56)
Safety Signs Safety Instructions

(Cont’d)

Pos. ISO Standard ANSI Standard

17

Read Operation Manual (OM) before using this equipment.

Failure to do so could result in death or serious injury.
18
CAUTION

Wear Protective Gloves

Risk of injury.
Wear protective gloves.
19
CAUTION
This equipment produces
ionizing radiation when
energized
Service by authorized
personnel only.

This equipment produces ionizing radiation when energized.

Service by authorized personnel only.
20
WARNING
Hot corrosive substance
under high pressure.
Do not point nozzle at
another person or at
electrical devices.
Wear personal protective
equipment.

Hot corrosive substance under high pressure.

Do not point nozzle at another person or at electrical devices.
Wear personal protective equipment.

32 (56) Doc. No. SP-3546893-0101

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Safety Instructions Protective Devices

Protective Devices
There are different kinds of protective devices designed to ensure safe use of the
equipment. See the sections below.

WARNING
Hazardous zones.
Hazardous zones are safeguarded and provided with protective devices. Do not inch
or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.

For the locations of safeguards and/or other protective devices not mentioned in this
section, see the Maintenance Manual.

Emergency Stop
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Hazardous voltage remains ON after activating an EMERGENCY STOP.
Emergency stop devices are used to stop this equipment immediately in a hazardous
situation. Learn the positions of all emergency stop devices and how to use them.
Instructions for a normal production stop are included in the Stop chapter of the
Operation Manual.

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Doc. No. SP-3546893-0101 33 (56)
Protective Devices Safety Instructions

Emergency Stop Push-Buttons

Push one of the EMERGENCY STOP push-buttons to stop this equipment
immediately.

The location of each EMERGENCY STOP push-button is shown by an arrow.

34 (56) Doc. No. SP-3546893-0101

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Safety Instructions Protective Devices

Safeguards

WARNING
Moving machinery parts.
Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones, are
fitted with interlocking devices where required. These devices are usually electric
safety switches that are parts of the safety system and must never be defeated,
bypassed, or otherwise made inoperative.
Where movable guards (doors) are equipped with means to be locked in a nonclosed
position, any person with the intention to preside, for any reason, behind such a
guard must lock the guard in the nonclosed position by use of a padlock.
Note! For work on the electrical equipment, the electrical power must also be
disconnected.

CAUTION
Corners and edges.
Close the doors, guards, or parts of the equipment unless they must be open during
work.

CAUTION
Burn hazard.
Parts of the equipment protected by guards may be hot after operation. Allow
components to cool down or use personal protective equipment.
After installation and maintenance, and before this equipment is inched or run, check
that all safeguards are in place and that they operate correctly.
.

(Cont’d)

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Doc. No. SP-3546893-0101 35 (56)
Protective Devices Safety Instructions

(Cont’d)

CAUTION
Equipment damage.
The equipment can be damaged if it is not stopped in the correct way. Never stop
this equipment by opening a movable guard, for example, a door or cover, equipped
with an interlocking device.
The location of each interlocking device is shown by an arrow.

internal door

36 (56) Doc. No. SP-3546893-0101

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Safety Instructions Protective Devices

Indicating Tower
An indicating tower is a column of warning lights:
• A red light (1) indicates a hazardous condition. This is a situation that requires
immediate action.
• A yellow light (2) indicates an abnormal or impending critical condition. This is a
condition calling for action by the operator.
• A blue light (3) indicates that operator action is required.
• A green light (4) indicates a normal condition.

1 Red light 3 Blue light

2 Yellow light 4 Green light
.

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Doc. No. SP-3546893-0101 37 (56)
Protective Devices Safety Instructions

Audible Alarm
The audible alarm (1) produces a warning signal every time this equipment is about
to start. The warning signal sounds for approximately three seconds prior to starting
to alert personnel.

1 Audible alarm
.

38 (56) Doc. No. SP-3546893-0101

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Safety Instructions Safe Manual Handling

Safe Manual Handling

Use mechanical lifting aids whenever possible. If mechanical lifting aids are not
available, do not attempt to lift loads over 23 kg without the assistance of a
colleague. Avoid lifting below knee height and above shoulder height. If it is
necessary to lift from the floor, follow the instructions below to reduce the risk of back
and disc injuries.

• Use safety shoes and be sure that the surface of the floor is not slippery.
• Get close to the load.
• Take a wide stance and find the best positions for your feet.
• Bend your hips and knees, and use your leg muscles.
• Keep the load close to your body.
• Do not twist your body while moving the load.
• Take small steps when turning.

In order to reduce the risk of injury to discs and back muscles, be careful to not bend
or twist your back when lifting. Keep the load close to your body to reduce the strain
on your back.

To reduce the ergonomic risks to each individual operator, job rotation is

recommended, so that recovery and variety are provided.

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Doc. No. SP-3546893-0101 39 (56)
Personal Protection Safety Instructions

Personal Protection
This section applies to all personnel at all times when this equipment is in operation.
For special personal protective equipment required when handling hazardous
substances, see the Hazardous Substances section.

Noise
CAUTION
Hazardous noise.
May cause impaired hearing.
Hearing protection is recommended whenever this equipment is in operation.

Entanglement

WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this equipment.
Restrain long hair with, for example, clips or rubber bands.

Personal Protective Equipment

The personal protective equipment for hot surfaces is
• protective gloves TP No. 90600-5981, (or other protective gloves with similar
characteristics).

40 (56) Doc. No. SP-3546893-0101

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Safety Instructions Hazardous Substances

Hazardous Substances
WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by the
manufacturer or local supplier, when handling chemicals.
Make sure that
• the safety data sheet is available
• preparations have been done to ensure that the stated safety measures in the
safety data sheet can be followed
• the locations of the first aid equipment are learned in order to act immediately in
case of an accident

Disposal of Chemical Substances

Always read and follow the disposal instructions in the safety data sheet supplied by
the manufacturer or local supplier.

It is strongly recommended that used chemical containers are

• disposed of according to the instructions immediately after use
• not used as disposal containers for other chemicals in order to avoid uncontrolled
chemical reactions within the container
.

Hydrogen Peroxide (H2O2)

WARNING
Corrosive chemical.
Wear personal protective equipment.
In both liquid and gas states, hydrogen peroxide may cause irritation or damage if it
comes into contact with skin, mucous membranes, eyes, or clothes. Call for medical
attention immediately if there is an accident.
Liquid hydrogen peroxide in concentrations of less than 1% is generally considered
harmless to humans.

Consult the instructions on the label of the tank or container.

Emergency Procedures
If there is an accident involving hydrogen peroxide, rinse the affected area as soon
as possible with large amounts of water.

Eyes
If splashes or vapour from hydrogen peroxide come in contact with the eyes
• wash the eyes thoroughly with lukewarm water for 15 minutes (keep eyelids wide
apart)
• call for medical attention immediately

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Doc. No. SP-3546893-0101 41 (56)
Hazardous Substances Safety Instructions

Skin
If hydrogen peroxide comes into contact with skin or clothes
• rinse immediately with plenty of water
• call for medical attention immediately if skin burns appear
• thoroughly wash the clothes before wearing them again

Inhalation
If irritation or pain is experienced due to having inhaled hydrogen peroxide vapour
• leave the affected area and get some fresh air
• call for medical attention if the symptoms get worse

Ingestion
If hydrogen peroxide is swallowed
• do not attempt to cause vomiting
• drink large amounts of lukewarm water to dilute the peroxide
• call for medical attention immediately

Personal Protective Equipment

The personal protective equipment for hydrogen peroxide is
• protective goggles (for instance, TP No. 90303-11), tight fitting
If there is a risk of splashes, a visor is a suitable complement
• protective gloves made of neoprene (for instance, TP No. 90303-12), nitrile, or
butyl rubber
• protective apron (for instance, TP No. 90303-13), or protective suit when
handling larger amounts
• protective shoes or boots made of PVC, PE plastic, or rubber
• proper respiratory equipment, if ventilation is insufficient

Handling of Hydrogen Peroxide

WARNING
Sudden and violent chemical reaction.
Avoid any contamination of hydrogen peroxide.
Hydrogen peroxide can react very suddenly and violently in combination with many
compounds, or if it is contaminated. Never pour surplus hydrogen peroxide back into
the original container. There is a risk of a violent decomposition liberating oxygen
and heat, with a big increase in volume due to the oxygen generated by the
peroxide decomposition. This will cause a large overpressure if the contaminated
hydrogen peroxide is in a closed container. If the integrity of the container fails, this
could result in a dangerous hazard.
Ensure that equipment used for handling and diluting hydrogen peroxide is clean
before it comes in contact with hydrogen peroxide. Pumps or other equipment used
for handling hydrogen peroxide must be used for this purpose only and must be
manufactured from appropriate materials, such as stainless steel 316 L, glass,
polyethylene, or teflon. After use, make sure that all peroxide residue is rinsed away.
(Cont’d)

42 (56) Doc. No. SP-3546893-0101

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Safety Instructions Hazardous Substances

(Cont’d)

If hydrogen peroxide is spilled, dilute it with large amounts of water. Dispose of the
diluted hydrogen peroxide according to local regulations.

WARNING
Self-ignition.
Never wipe up hydrogen peroxide with materials such as rags or paper as these may
self-ignite several hours after contact. If there is a fire, spray with large quantities of
water.

Storage of Hydrogen Peroxide

WARNING
Containers may become overpressurised if they are not properly ventilated. If
the integrity of a container fails, this could result in a dangerous hazard.
Keep the container upright and fitted with its proper ventilation cap. If there is a fire,
cool all containers by spraying them with large quantities of water.
Hydrogen peroxide decomposes much faster with increasing temperature. There is a
risk of a container becoming overpressurised at high temperatures, since the
ventilation cap cannot release the gases produced quickly enough. If the integrity of
the container fails, this could result in a dangerous hazard.
(Cont’d)

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Doc. No. SP-3546893-0101 43 (56)
Hazardous Substances Safety Instructions

(Cont’d)

Hydrogen peroxide must be stored in the original container delivered by the

supplier. Keep the container upright and fitted with its proper ventilation cap, which
allows oxygen to escape. Otherwise there is a risk of overpressurisation of the
container due to violent decomposition of the peroxide. If the integrity of the
container fails, this could result in a dangerous hazard.

Make sure that the container is always properly closed.

Commercial food-grade hydrogen peroxide has been stabilized to inhibit the
catalytic decomposition effects of metals and other impurities, but it can decompose
into oxygen and water if it is exposed to heat or contaminated.

Make sure that the area used for storage of hydrogen peroxide is
• cool, clean, and well ventilated
• shielded from direct sunlight
• kept free from combustible materials

Disposal of Hydrogen Peroxide

Always read and follow the disposal instructions in the safety data sheet supplied by
the manufacturer or local supplier.

Caustic Soda/Sodium Hydroxide (NaOH)

WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by the
manufacturer or local supplier, when handling chemicals.

Nitric Acid (HNO3)

WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by the
manufacturer or local supplier, when handling chemicals.

44 (56) Doc. No. SP-3546893-0101

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Safety Instructions Ultraviolet Light

Ultraviolet Light
WARNING
Ultraviolet light.
Can cause eye or skin burns.
The ultraviolet lamp must only be operated when it is in its normal operating position
and protected by its safeguard.
An ultraviolet lamp is protected by an interlocking guard, such as a door or cover.
Ultraviolet light damage is cumulative. Extended exposure may cause illness.
Exposure to ultraviolet light should be avoided.

CAUTION
Hot surfaces.
May cause burns.
The assembly housing and components around the ultraviolet light assembly are hot.
Allow components to cool down before maintenance.
The location of each ultraviolet light is shown by an arrow.

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Doc. No. SP-3546893-0101 45 (56)
Supply Systems Safety Instructions

Supply Systems
Definition of Lockout Procedure
A lockout procedure is a procedure to put each necessary energy isolating device in
its safe position to prevent the energisation of the equipment, such as when a
maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an energy
isolating device cannot be operated.

An energy isolating device is a mechanical device that physically prevents

transmission or release of energy, such as an electrical supply disconnecting
device.
A detailed instruction for the specific lockout procedure(s) for this equipment is
found in the Maintenance Manual.

Electrical Supply
DANGERI
DANGER
Hazardous voltage and moving machinery.
The electrical supply disconnecting device must be in position O (OFF) and secured
with a lock before any work with the equipment that requires the electrical supply to
be disconnected. See the Machine Status section of the MM Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.

DANGERI
DANGER
Hazardous voltage can be present with the electrical supply disconnecting
device in position O (OFF).
Circuits identified by orange-coloured conductors are not disconnected by the main
electrical supply disconnecting device. The location of the electrical supply
disconnecting device of these circuits is described in the Maintenance Manual
procedures that include work on these types of circuit.
Certain procedures may require that the electrical supply disconnecting device is in
position I (ON). These exceptions are clearly stated in the manuals.
The illustrations show the electrical supply disconnecting device and its location.
.

Residual Voltage

DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
After the electrical supply disconnecting device is turned to position O (OFF),
residual voltage remains in the capacitor circuits. Wait five minutes before opening
the enclosure containing these circuits. Ensure that no residual voltage remains on
the capacitors before touching them.

46 (56) Doc. No. SP-3546893-0101

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Safety Instructions Supply Systems

Electrical Cabinet
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Parts behind doors to the electrical cabinet may be live. The electrical supply
disconnecting device must be turned to position O (OFF) and secured with a lock
before maintenance inside the electrical cabinet.
Note! The key to the lock must be removed by the technician and retained in his/her
possession until all work is completed.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with locks must be locked.

The location of each electrical cabinet is shown by an arrow.

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Doc. No. SP-3546893-0101 47 (56)
Supply Systems Safety Instructions

Socket Outlet
Valid for: All countries except USA and Canada

WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read the Maintenance Manual before using this socket outlet.
The socket outlet (1) is connected to a residual current device (2) to protect users
against electrical shock if there is an earth fault in the connected equipment. The
residual current device must be tested each time before the socket outlet is being
used. See the Maintenance Manual for test procedure.
The illustrations show the socket outlet, the residual current device, and their
locations.

2 1
1 Socket outlet
2 Residual current
device
.

48 (56) Doc. No. SP-3546893-0101

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Safety Instructions Supply Systems

Socket Outlet
Valid for: USA and Canada

WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read the Maintenance Manual before using this socket outlet.
The socket outlet (1) has a built-in ground fault circuit interrupter device to protect
users against electrical shock if there is a ground fault in the connected equipment.
The ground fault circuit interrupter device must be tested each time before the socket
outlet is being used. See the Maintenance Manual for test procedure.

The illustrations show the socket outlet, the residual current device, and their
locations.

1 Socket outlet
.

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Doc. No. SP-3546893-0101 49 (56)
Supply Systems Safety Instructions

Air Supply

WARNING
Compressed air and moving machinery.
Close the main air valve and lock it, and safely release compressed air from the air
system before any work with the equipment that requires the air supply to be closed.
See the Machine Status section of the Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require the air supply system to be on. These
exceptions are clearly stated in the manuals.

The illustrations show the main air valve (1), the lock (2), and their location.

1 Main air valve

2 Lock
.

(Cont’d)

50 (56) Doc. No. SP-3546893-0101

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Safety Instructions Supply Systems

(Cont’d)

Note! The air supply for the ASU pneumatic panel and the pre-applicator pneumatic
panel are connected before the main air valve (1).
The illustration shows the air valve (3) for the ASU, the air valve (4) for the pre-
applicator, the main air valve (5) on the ASU pneumatic panel and their locations on
the filling machine.

1 Main air valve

3 Air valve
4 Air valve
5 Main air valve
.

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Doc. No. SP-3546893-0101 51 (56)
Supply Systems Safety Instructions

Steam Supply

WARNING
Hot steam can cause scalds.
Pressurised steam can be discharged unexpectedly.
Close the main steam valve and lock it, and safely vent all steam pressure from the
steam system before any work on parts with steam, such as pipes and valves that
requires the steam supply to be closed. See the Machine Status section of the
Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require the steam supply system to be on.
These exceptions are clearly stated in the manuals.
The illustration show the main steam valve (1), the padlock (2) and their location.

1 Main steam valve

2 Padlock
.

52 (56) Doc. No. SP-3546893-0101

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Safety Instructions Supply Systems

Water Supply

CAUTION
Water under pressure.
Close the main water valves before any work with the equipment that requires the
water supply to be closed. See the Machine Status section of the Procedure Start
Table.
Certain maintenance procedures may require the water supply systems to be on.
These exceptions are clearly stated in the manuals.
The illustration shows the main water valve (1) and the main water valve (2), and
their location.

1
2

1 Main water valve

2 Main water valve,
external cleaning
.

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Doc. No. SP-3546893-0101 53 (56)
Working at Height Safety Instructions

Working at Height
This equipment is provided with a means of access to all locations where routine
tasks for operation and maintenance need to be carried out.

WARNING
Risk of falling.
For any kind of work at height always ensure that safe means of access is available
and used. Where additional safe means of access other than provided with the
equipment is required, follow local work at height regulations and guidelines. Use
scaffolds or a mobile work platform and a safety harness. Create a safety perimeter
around the working area and secure tools or other objects from falling.
The illustration shows the location of eye bolts for attaching a safety lanyard to the
electrical cabinet and the fastening position for the drying chamber.
Use a minimum length safety lanyard. Always replace missing eye bolts.

54 (56) Doc. No. SP-3546893-0101

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