1.0 OBJECTIVE: To lay down the procedure for the Cleaning and Operation of the Monoblock Filling and Sealing Machine.
2.0 SCOPE: This procedure is applicable for the Cleaning and Operation of the Monoblock Filling and Sealing Machine in the liquid department.
3.0 RESPONSIBILITY
Operator, Officer, Executive – Production and QA Department
Manager – Production and QA Department
4.0 PROCEDURE
4.1 Cleaning
4.1.1 Checking Status labeling: Check the status “TO BE CLEANED” on equipment with details filled in. If next product is the same as the previous product (campaign production), follow the batch-to-batch changeover procedure. If next product is different from previous product, follow the product-to-product changeover procedure and follow shift-end cleaning procedure at the end of day’s work.
4.1.2 Batch-to-Batch change over procedure (TYPE A): To maintain batch segregation-
4.1.2.1 Remove the “ TO BE CLEANED “ label and affix the “ UNDER CLEANING “ label to
the machine.
4.1.2.2 Ensure that no empty bottles from the previous batch remain in the machine.
4.1.2.3 Remove all the good and rejected bottles from the area and machine. Carry out the reconciliation. Destroy the rejected bottles.
4.1.2.4 Collect the remaining liquid of previous batch from the machine tank by opening the bottom valve and draining it. Close the bottom valve.
4.1.2.5 Collect the remaining liquid of previous batch from the transfer lines by opening the tri-clover clamps situated at lowest points and drain the liquid.
4.1.2.6 Remove the glass pieces of broken bottles if any from the machine platform
and wash the machine plate form with sufficient purified water.
4.1.2.7 Attach the purified water line to SS transfer line before the transfer pump and drain this water from machine tank’s bottom valve and pistons at a slow speed for 5 minutes.
4.1.2.8 Mop the entire machine with clean lint-free cloth.
4.1.2.9 Status labeling: Tick mark the “CLEANED” status on the equipment Fill in the details.
4.1.2.10 Records: Record the details of cleaning in equipment usage sheet.
4.1.3 Shift end cleaning procedure
4.1.3.1 Stop the bottle washing from bottle washing area.
4.1.3.2 Close the Holding tank’s bottom valve and disconnect the line by Putting a blank.
4.1.3.3 Switch “OFF” the liquid transfer pump from the machine panel.
4.1.3.4 Switch “OFF” the machine from the machine panel and check the volume of the bottle filled in the last rounds. Reject the low-volume bottles.
4.1.3.5 Collect the liquid of the batch in a closed container from the machine hopper by opening the bottom valve and transferring it to a main holding tank.
4.1.3.6 Collect the liquid of the batch in a closed container from the transfer line by opening the tri-clover clamps situated at lowest points and transfer it to a main holding tank.
4.1.3.7 Attach the purified water line to SS transfer line before the transfer pump and drain this water from machine tank’s bottom valve and pistons at a slow speed for 5 minutes.
4.1.3.8 Drain the water completely from machine tank and lines.
4.1.3.9 Mop the complete machine with a lint-free cloth.
4.1.3.10 Close the machine tank’s bottom valve and rejoin the lines opened for draining the water.
4.1.4 Product-to-product change over procedure (TYPE B): This procedure is applicable if – there is a change in product or during campaign production, 7 batches have been Processed. Equipment is taken for maintenance during processing and maintenance work continues for more than 24 hrs or maintenance work involves any part, which comes in direct contact with purified water.
4.1.4.1 Cleaning of Bottle Filling and cap sealing machine
4.1.4.2 Remove all the good and rejected bottles from the area and machine. Carry out
the reconciliation. Destroy the rejected bottles.
4.1.4.3 Switch OFF the machine from panel and collect remaining liquid of previous batch from machine tank, SS transfer line, and drain it.
4.1.4.4 Fill purified water in the hopper of the machine through SS transfer line and run the machine to drain out all the water along with traces of the product.
4.1.4.5 Clean the SS batch transfer line.
4.1.4.6 Dismantle the star wheels, bottle guide, and cap plungers of the machine as per requirement of the next product.
4.1.4.7 Dip the piston and nozzles in hot purified water at 60 to 70 °C for 30 minutes and clean them thoroughly with the help of a nylon brush and purified water.
4.1.4.8 Dry the change parts and apply little food-grade oil on piston rod to avoid rusting and store the change.
4.1.4.9 Clean the machine liquid tank with purified water and rub it with lint-free cloth till it is visually clean and drain water from bottom valve.
4.1.4.10 Rinse the machine table with purified water and drain out all the water.
4.1.4.11 Remove all the water from machine with compressed air.
4.1.4.12 Mop the machine with dry lint-free cloth.
4.1.4.13 Visual inspection: Check that all the surfaces of the parts of monoblock filling and sealing Machine are visually clean and dry.
4.1.4.14 Reassembly: Reassemble all accessories and parts dismantled for cleaning purpose.
4.1.4.15 Status labeling: Put ‘CLEANED’ status label having Unit, Department, Equipment name, Cleaned by, Checked by Production Officer, Date, and finally certified by Quality Assurance (QA).
4.1.4.16 Protection of clean equipment Protect the cleaned Bottle Filling and Capping Machine by closing the acrylic covers of the machine if the equipment is not planned for use within a day.
4.1.4.17 Records: Record the details of cleaning in equipment usage sheet as per Annexure-I.
4.2 Machine Setup and Operation
4.2.1 Machine Set Up
4.2.1.1 Ensure that Bottle filling and sealing Machine is cleaned.
4.2.1.2 Fix change parts if required as per bottle size.
4.2.1.3 Ensure that SS Transfer line is clean and dry. Do this by opening the tri-clover
clamps situated at lower level in the line.
4.2.1.4 Open the drain valve of liquid tank to ensure it is dry and close it.
4.2.1.5 Attach the transfer line to holding tank through lobe pump.
4.2.1.6 After line clearance from Q.A. put “WORK IN PROGRESS” label on the machine.
4.2.1.7 Enter start time of the batch in Equipment Usages Log Sheet.
4.2.2 Operation
4.2.2.1 Open the air valve and check that it is not less than 5 Kg/cm2.
4.2.2.2 Connect the Lobe pump with panel
4.2.2.3 Connect the PLC with main plug.
4.2.2.4 Switch ON the PLC
4.2.2.5 First Start the conveyer belt.
4.2.2.6 After 5 seconds start the machine
4.2.2.7 Start cap feeding Machine for the continuous feeding of Caps.
4.2.2.8 Start providing the washed bottles to filling machine conveyor from bottle washing area.
4.2.2.9 Set the guide rails as per the bottle so that the neck of the bottle moves below the nozzles freely and with minimum clearance.
4.2.2.10 Set the nozzles at the center of the respective bottles.
4.2.2.11 Set the diving stroke and position such that the top position is about 20 to 40 mm above the bottleneck and lower position depending on the frothing characteristics of the liquid. The diving stroke can be adjusted with the help of the wheel provided at the front, below the conveyor.
4.2.2.12 Adjust the ‘NO’ bottle sensor.
4.2.2.13 Transfer the liquid to be filled in the S.S feeding tank through SS pipelines
from storage tank.
4.2.2.14 Set the filling rate of the machine from the main panel of the machine.
4.2.2.15 Adjust the volume of the liquid-filled per stroke. For this Loosen the Ram Shaft nut and turn the adjustment screw clockwise to increase the volume and anticlockwise to decrease the volume. Tighten the Ram Shaft nut and never start the machine when ram shaft nut is loose
4.2.2.16 Check the volume of all eight nozzles with calibrated volumetric cylinder. The frequency of checking the volume should be as per the respective Batch Production Record.
4.2.2.17 Screw tight the bottles having less/More volume than the set range of volume and keep such bottles in the recovery tray.
4.2.2.18 After filling the bottles moves to sealing machine through centre star wheel.
4.2.2.19 The sealed bottle unload through second star wheel to conveyor belt.
4.2.2.20 If the machine is stopped during the shift for lunch break, then leave no bottle on the conveyor belt.
4.2.3 Shut Down
4.2.3.1 Ensure that all the filled bottles have been capped and there is no bottle remaining on the conveyor.
4.2.3.2 Ensure that there is no liquid remaining in the feed tank.
4.2.3.3 Switch OFF the main electric supply to the machine
4.2.3.4 Affix the “TO BE CLEANED” label on the machine as per the “Status Labeling” SOP.
4.2.3.5 Enter ending time of the batch in the Equipment Usages Log Sheet as per “Making entry in equipment logbook” SOP.
4.3 NOTE
4.3.1 Ensure adequate oil level by reducing gearbox.
4.3.2 Ensure air pressure in the unit is not less than 5 Kg/cm2.
4.3.3 Lubricate daily all moving parts with food-grade oil when product is coming in contact and grease for closed parts.
4.3.4 Never start the machine in reverse direction.
4.3.5 Do not drop oil on torque limitation clutch or on the very belt.
4.3.6 The speed of machine can be varied.
4.3.7 No bottle no filling arrangement is provided to avoid spillage of liquid.
5.0 ABBREVIATION (S)
SOP: Standard Operating Procedure.
No. : Number
PLC: Programmable logic controller
6.0 ANNEXURE (S)
Nil
7.0 DISTRIBUTION
Master copy: Quality Assurance
Controlled copy ( s): Production department
Reference copy (s): Production department
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