krones filler machine manual

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8/16/2019 krones filler machine manual
1 Preface
1.1 About this Operating Manual 13 1.1.1 Translation of the Original Operating Manual 13 1.1.2 Purpose of the Operating Manual 13 1.1.3 Target group 13 1.1.4 Structure of the Operating Manual 13 1.1.5 Documentation Types 14 1.1.6 Use and Storage of the Documentation 14 1.1.7 Representation of Information, References, and Warnings 14
1.2 Personnel Requirements 16 1.2.1 Personnel Selection and Qualifications 16 1.2.2 Restrictions on the Use of the Machine 16
1.3 Copyright 17
2.1.1 General Information 21 2.1.2 Information Concerning the Documentation 21
2.2 Machine Safety Concept 22 2.2.1 Protective measures 22 2.2.2 User information 23
2.3 Machine Signs 24 2.3.1 Examples of Signs 24
2.4 Residual Machine Hazards 25 2.4.1 Sample: Excerpt – risk assessment according to EN ISO
12100 25 2.5 Warnings in the Operating Manual 26
2.5.1 Warning Identification/Hazard Levels 26 2.5.2 Structure of Warnings 26 2.5.3 Warning Example - "Danger" 26
2.6 Fundamental Safety Instructions 27 2.6.1 Operating Personnel Requirements, Safety Behaviour 27 2.6.2 Laws, Regulations, Guidelines, Standards 28 2.6.3 Responsiblities of the Operating Company 29
2.6.4 Machine Application 302.6.5 Hazards Caused by Energy Systems, Processing and Operating Materials, Emissions 31
2.6.6 Technical Condition of the Machine 33 2.6.7 Safety and Protective Devices of the Machine 34 2.6.8 Stop the machine and lock it, to prevent it being turned
ON/Restart the machine 35 2.6.9 Safety Instructions for Operation, Change-Over, Trouble-
Shooting, Maintenance 36 2.6.10 Safety Instructions Concering Compehensive
Maintenance, Installation/Dismantling 38 2.6.11 Hazardous Situation and Accident Behaviour 40
2.7 Subject-Specific Safety Instructions 42 2.7.1 Handling Carbon Dioxide (CO2) 42 2.7.2 Handling Nitrogen (N2) 42

2.7.3 Handling Hydrogen Peroxide (H2O2) 43 2.7.4 Handling Acids and Caustics 44 2.7.5 Handling Radiation 46 2.7.6 Use of Pressure Vessels 49
2.7.7 KRONES Online Service 53 2.8 Machine-Specific Safety Information 54 2.9 Machine-Specific Safety Measures 55
2.9.1 Identification of Residual Hazards 55 2.9.2 Identification of Danger Zones 55 2.9.3 Sealing Off the Danger Zones 55 2.9.4 Safety Measures Against Emissions 55
2.10 Machine-Specific Protective Clothing 56
3 Machine Description
3.1 Introduction 58 3.2 Sustainability of "enviro" Machines 59
3.2.1 Ecological Sustainability 59 3.2.2 Economical Sustainability 59 3.2.3 Ergonomics 59
3.3 Application 60 3.3.1 Permissible Application 60 3.3.2 Impermissible Application 60 3.3.3 Change of owner 60
3.4 Workplaces and Operator Stations 61 3.5 Danger Zones 62 3.6 Conformity 63
3.6.1 A Sample of an EU Declaration of Conformity 63 3.7 Machine Marks/Labels 64
3.7.1 Identification Plates 64 3.8 Warranty 66 3.9 Scope of Supply 67
3.9.1 Machine and Components 67 3.9.2 Handling Parts 67 3.9.3 Accessories and Spare Parts 67 3.9.4 As-Delivered Condition 67
3.10 Manufacturer and Operating Company 68 3.10.1 Manufacturer's Address 68
3.10.2 Contacts 68
4 Technical Data 4.1 Fundamental Information 71
4.1.1 Ambient Conditions 71 4.1.2 Maximum Supply Pressures 71 4.1.3 Filler Types 71 4.1.4 Production Gases 71
4.2 Basic Data 73 4.2.1 Dimensions and Weights 73
4.2.2 Electrical Specifications 73 4.2.3 Noise Emission Value 73
4.3 Limit, Standard, and Set-Point Values for Counter-Pressure Fillers 74

4.3.1 Product (values for products with CO2) 74 4.3.2 Production Gas (values for products with CO2) 74 4.3.3 Product (values for products without CO2) 75 4.3.4 Production Gas (values for products without CO2) 75
4.4 Limit, Standard, and Set-Point Values for Gravity Fillers 78 4.4.1 Product 78 4.4.2 Production Gas 78
4.5 Limit, Standard, and Set-Point Values for Vacuum Fillers 80 4.5.1 Product 80 4.5.2 Vacuum 80
4.6 General Limit, Standard and Adjustment Values 81 4.6.1 Operating Air 81 4.6.2 Air for Sterile Air Filtration on the Machine 81 4.6.3 Water 82 4.6.4 Cleaning Agents 84 4.6.5 Lubricants 84 4.6.6 Preservatives 84 4.6.7 Produced Waste 85
4.7 Cleaning Agents, Disinfectants, and Sterilising Agents 86 4.7.1 Interior Cleaning of Machine/CIP 86 4.7.2 Exterior Cleaning of Machine (Variant – System without
Hygiene Centre) 86 4.7.3 Exterior Cleaning of Machine (Variant – System with
Hygiene Centre) 87 4.7.4 Steam for Sterilisation of Sterile Filters (optional
additional equipment) 88
5 Construction/Method of Operation 5.1 Fundamental Information 91 5.2 Construction of the machine 92 5.3 Container Handling Through the Machine 94 5.4 Media Distribution 95
5.4.1 Valve Manifold and Pipe System 95 5.5 Description of the Assemblies 99
5.5.1 Infeed and Discharge 99 5.5.2 Carrousel 102 5.5.3 Guards 106 5.5.4 Control Cabinet 107 5.5.5 Main Operator Station 108 5.5.6 Capper 108
5.6 Safety and Protective Devices 109 5.6.1 Technical Safety Precautions 109 5.6.2 Additional Safety Precautions 111 5.6.3 User information 113
5.7 Modes of Operation 115 5.7.1 Safety-Relevant Modes of Operation 115 5.7.2 Process-Relevant Modes of Operation 115
5.8 Filling Phases 117
6 Controls 6.1 Fundamental Information 121 6.2 Chapter-Related Safety Instructions 122 6.3 Machine Control Components 123
6.4 Main Operator Station 124 6.4.1 Overview 124 6.4.2 Touch-Screen 124 6.4.3 Pilot Lamp – General Malfunction/Communications 125 6.4.4 Button – General RESET 125 6.4.5 EMERGENCY STOP Switch 126 6.4.6 Button - Container Stop 127 6.4.7 Reader for Transponder 128 6.4.8 Button – JOG the Machine 128 6.4.9 Mode of Operation Selector Switch 129 6.4.10 Button – Machine ON 129
6.4.11 Button – Machine OFF 1306.5 Hand-Held Pendant 131 6.5.1 Overview 131 6.5.2 EMERGENCY STOP Switch 131 6.5.3 "Jogging in Set-Up Mode" Button 132 6.5.4 Switch – Height Adjustment System 133
6.6 Mobile Pedal 134 6.6.1 Overview 134 6.6.2 JOG/EMERGENCY STOP Pedal 134 6.6.3 Button - Release the EMERGENCY STOP 135
6.7 Control Components on the Control Cabinet 136 6.7.1 Overview 136
6.7.2 Master Switch 136 6.7.3 Switch – Uninterruptible Power Supply (UPS) (optional
additional equipment) 137 6.8 Control Components on the Guards 138
6.8.1 Overview 138 6.8.2 Button - RESET Infeed Monitoring Function 138 6.8.3 Button – Lock/Release Safety Switch 139 6.8.4 Button - RESET Guards 139 6.8.5 Escape release mechanism switch 139 6.8.6 Button - Stop Process 140 6.8.7 Signal Beacon Post 140 6.8.8 Horn (optional additional equipment) 141
6.9 Pipe System Control Components 142 6.9.1 Overview 142 6.9.2 Pressure Regulator 142 6.9.3 Shut-Off Valve 143 6.9.4 Sampling Valve 143 6.9.5 CO2 Consumption Gauge 144 6.9.6 Pressure Gauge 144 6.9.7 Pipe System Valves 145 6.9.8 Switch - Product Pre-Run 145 6.9.9 Switch – Stop Transfer Valve Manifold (optional
additional equipment) 145
6.10.1 Isolator (optional additional equipment) 147 6.11 Machine Signs 148
6.11.1 Generally Applicable Signs 148 6.11.2 Country-Specific Signs 152
6.11.3 Krones-Specific Signs 156
7.3.1 Checking Before Start-Up 177 7.3.2 Hygiene/Quality Assurance 183 7.3.3 Start-Up 184
7.4 Production 190
7.4.1 Production 190 7.4.2 Type Change-Over - Different Product 192 7.4.3 Type Change-Over - Different Containers 192 7.4.4 Production Interruptions 193 7.4.5 EMERGENCY STOP 194
7.5 Set-Up Mode 197 7.5.1 Turning OFF the Machine to Work in the Set-Up Mode 197 7.5.2 Jogging the Machine 199
7.6 Depressurise the Machine, Pressurise the Machine 202 7.6.1 Depressurisation of the Machine or Assemblies 202 7.6.2 Repressurisation of the Machine/Assemblies 204
7.7 End of Production 205 7.8 Stop the Machine 209
7.8.1 Stop the machine and lock it, to prevent it being turned ON. 209
7.9 CIP (Variant - Machines With External CIP Start) 211 7.9.1 Performing CIP 211 7.9.2 Machine Rinsing 212
7.10 CIP (Variant - Machines Without External CIP Start) 214 7.10.1 Performing CIP 214 7.10.2 Conduct Displacement/Draining 215 7.10.3 Machine Rinsing 216
7.11 Stationary disinfection/brimful 217
8 Change-Over 8.1 Fundamental Information 222
8.1.1 The Purpose of this Chapter 222 8.1.2 Work Schedule 222 8.1.3 Tools and Aids 222
8.1.4 Instructions for Change-Over 2228.1.5 Additional Manuals in the Supplement 223 8.2 Chapter-Related Safety Instructions 224

8.3 Overview 225 8.4 Overview Schedule 226 8.5 Work in the Set-Up Mode 230
8.5.1 Change-Over to Another Container 230
8.6 Work While the Machine Is Not in Operation 254 8.6.1 Change-Over to Another Container 254
9 Malfunctions 9.1 Fundamental Information 257
9.1.1 The Purpose of this Chapter 257 9.1.2 Malfunction Categories 257 9.1.3 Troubleshooting Faults and Malfunctions 258
9.2 Chapter-Related Safety Instructions 259 9.3 Malfunctions Signalled by Indicator Lamps 260
9.3.1 Indicator Lamps of the Main Operator Station 260 9.3.2 Indicator Lamps at Infeed 260 9.3.3 Signal Beacon Post 260 9.3.4 Horn (optional additional equipment) 261
9.4 Process Faults 262 9.4.1 General Malfunctions 262 9.4.2 Malfunctions During Production 264 9.4.3 The CIP system malfunctions 266 9.4.4 The fill level regulating system malfunctions 266 9.4.5 The Height Adjustment System Malfunctions 266 9.4.6 Pressure Drops Constantly (applies only to counter-
pressure fillers) 267
9.4.7 Vacuum Pump Malfunctions (depending on the machine design, provided) 267
9.4.8 The central lubrication terminal malfunctions 268 9.4.9 The machines of the Bloc malfunction 268 9.4.10 The containers are not conveyed or transferred properly 268 9.4.11 Declutchable Infeed Worm (or container stop) 269 9.4.12 Container Back-Up 269
10 Transport/Installation 10.1 Fundamental Information 271
10.2 Chapter-Related Safety Instructions 272 10.3 Requirements for Professional Installation 273
10.3.1 Transportation Equipment 273 10.3.2 Space Requirements 273 10.3.3 Installation Site 273 10.3.4 Power/Supply Connections 274 10.3.5 Pipes 274 10.3.6 Waste Disposal Facilities 274 10.3.7 Processing/Operating Materials 274
10.4 Transport of the Machine 275 10.4.1 Machine Delivery 275
10.4.2 Unloading the Machine 27710.4.3 Unpacking the Machine 279 10.4.4 Transport to the Installation Site 279

10.5 Installation 282 10.5.1 Installation of the Machine 282 10.5.2 Connection of the Machine 284
10.6 Start-Up 285
10.7 Acceptance 286
11 Dismantling/Disposal 11.1 Fundamental Information 288 11.2 Chapter-Related Safety Instructions 289 11.3 Shutdown 290
11.3.1 Shutdown without Changing the Location 290 11.3.2 Shutdown Including a Location Change 290 11.3.3 Shutdown for Disposal 290 11.3.4 Cleaning the Machine/Line 290
11.3.5 Preserving the Machine/Line 291 11.3.6 Shutting Down the Machine/Line 291
11.4 Recommissioning 292 11.5 Dismantling 293
11.5.1 Dismantling the Machine/Line 293 11.5.2 Packing the Machine/Line 293 11.5.3 Storage 293
11.6 Disposal 294
12 Maintenance
12.1 Fundamental Information 298 12.1.1 The Purpose of this Chapter 298 12.1.2 Work Schedule 298 12.1.3 Tools and Aids 299 12.1.4 Maintenance Instructions 299 12.1.5 Sustainability of "enviro" Machines 300 12.1.6 Additional Manuals in the Supplement 300
12.2 Chapter-Related Safety Instructions 301 12.3 Overview 302 12.4 Overview Schedule 303 12.5 Work During the Running-In Period 313
12.5.1 Scheduled: After 1,000 Operating Hours 313 12.6 Work During Production 316
12.6.1 Interval: Every 8 Operating Hours or at Least Once Daily 316 12.6.2 Interval: Every 500 Operating Hours or at the Latest After
a Month 320 12.6.3 Interval: Every 6,000 Operating Hours or at the Latest
after a Year 322 12.7 Work in the Set-Up Mode 325
12.7.1 Interval: Before Starting Production 325 12.7.2 Interval: Every 500 Operating Hours or at the Latest After
a Month 331 12.7.3 Interval: Every 3,000 Operating Hours or at the Latest
After 6 Months 335
12.7.4 Interval: Every 6,000 Operating Hours or at the Latest after a Year 337
12.8 Work While the Machine Is Not in Operation 339

12.8.1 Interval: Before Starting Production 339 12.8.2 Interval: Every 8 Operating Hours or at Least Once Daily 341 12.8.3 Interval: Every 120 Operating Hours or at the Latest After
a Week 342
12.8.4 Interval: Every 500 Operating Hours or at the Latest Aftera Month 354 12.8.5 Interval: Every 1,500 Operating Hours or at the Latest
After 3 Months 361 12.8.6 Interval: Every 6,000 Operating Hours or at the Latest
after a Year 363 12.8.7 Interval: Every 6,000 operating hours or at the latest after
2 year 367 12.9 Work for professionals 368
12.9.1 Parts and Components Subject to Mandatory Testing 368 12.9.2 Interval: Every 120 Operating Hours or at the Latest After
a Week 371 12.9.3 Interval: Every 3,000 Operating Hours or at the Latest
After 6 Months 37412.9.4 Interval: Every 6,000 Operating Hours or at the Latest after a Year 377
12.9.5 Interval: Every 30,000 Operating Hours or at the Latest After 5 Years 379
12.10 Work for KRONES professionals 380 12.10.1 Interval: Every 6,000 Operating Hours or at the Latest
after a Year 380
13 Cleaning 13.1 Fundamental Information 384
13.1.1 The Purpose of this Chapter 384 13.1.2 Work Schedule 384 13.1.3 Tools and Aids 384 13.1.4 Cleaning Instructions 384 13.1.5 Cleaning Agents/Disinfectants 385 13.1.6 Use of High-Pressure Washers 385 13.1.7 Filling Method and Hygienic Level 386 13.1.8 Order of Work 387 13.1.9 Sustainability of "enviro" Machines 387 13.1.10 Additional Manuals in the Supplement 387
13.2 Chapter-Related Safety Instructions 389
13.2.1 Fundamental Safety Instructions 38913.3 Overview 391 13.4 Overview Schedule 392 13.5 Preparations 401
13.5.1 Interval: Prior to each cleaning: 401 13.6 Cleaning During Production 408
13.6.1 Interval: Several Times Daily or As Required 408 13.7 Cleaning in the Set-Up Mode 410
13.7.1 Interval: Every 500 Operating Hours or at the Latest After a Month 410
13.8 Cleaning While the Machine Is Not in Operation 413 13.8.1 Interval: DAILY or as Required 413
13.8.2 Interval: Weekly or Every 50 Operating Hours 424 13.8.3 Interval: Every 120 Operating Hours or at the Latest After
a Week 429

13.8.4 Interval: Every 200 operating hours or at the latest after a month 439
13.8.5 Interval: Every 500 Operating Hours or at the Latest After a Month 444
13.8.6 Interval: Every 1,500 operating hours or at the latest after 3 months 444
13.8.7 Interval: Yearly or Every 5,000 Operating Hours 445 13.9 Cleaning in CIP 449
13.9.1 Interval: DAILY or as Required 449
14 Lubrication 14.1 Fundamental Information 457
14.1.1 The Purpose of this Chapter 457 14.1.2 Doing Work 457 14.1.3 Tools and Aids 458
14.1.4 Lubricant Identification Number 458 14.1.5 Initial Lubrication 458 14.1.6 Relubrication and Changing the Lubricant 459 14.1.7 Additional Manuals in the Supplement 460
14.2 Chapter-Related Safety Instructions 461 14.3 Overview 462 14.4 Overview Schedule 463 14.5 Work in the Set-Up Mode 468
14.5.1 Interval: Every 8 Operating Hours or at Least Once Daily 468 14.6 Work While the Machine Is Not in Operation 470
14.6.1 Interval: Every 24 hours or at the latest after 3 days 470
14.6.2 Interval: Every 120 Operating Hours or at the Latest Aftera Week 472 14.6.3 Interval: Every 500 Operating Hours or at the Latest After
a Month 480 14.6.4 Interval: Every 500 Operating Hours or at the Latest after
3 Months 484 14.6.5 Interval: Every 1,500 Operating Hours or at the Latest
after a Year 492 14.6.8 Interval: Every 12,000 Operating Hours or at the Latest
After 2 Years 49414.6.9 Interval: Every 15,000 Operating Hours or at the Latest After 5 Years 496
14.6.10 Interval: Every 30,000 Operating Hours or at the Latest After 5 Years 498
14.7 Work for professionals 500 14.7.1 Interval: Every 25,000 Operating Hours or at the Latest
After 5 Years 500
Preface
Register01
1.0 Table of Contents
1.1 About this Operating Manual 13 1.1.1 Translation of the Original Operating Manual 13 1.1.2 Purpose of the Operating Manual 13 1.1.3 Target group 13 1.1.4 Structure of the Operating Manual 13
The Main Manual 13 Additional Manuals in the Supplement 14
1.1.5 Documentation Types 14 1.1.6 Use and Storage of the Documentation 14 1.1.7 Representation of Information, References, and Warnings 14
Information 14
1.2 Personnel Requirements 16 1.2.1 Personnel Selection and Qualifications 16 1.2.2 Restrictions on the Use of the Machine 16
1.3 Copyright 17
Preface
1.1.1 Translation of the Original Operating Manual
This operating manual is a translation of the original German operating manual.
1.1.2 Purpose of the Operating Manual This operating manual is part of the technical documentation of the machine.
The operating manual contains the following: The information necessary to operate and maintain (simple maintenance work)
the machine safely, properly, and economically.
Information for the operating company. Complex tasks on the machine such as, set-up work, difficult maintenance work, repair work, or work on electrical components are not an integral part of this operating manual. Installation, commissioning, and dismantling of the machine are done by the manufacturer or a trained representative. The machine is handed over ready for operation.
1.1.3 Target group The contents of this operating manual are for the most part intended for personnel in charge of operation and maintenance of the machine. Based on their qualifications, training provided by the operating company, and the information in the operating manual, this personnel must be capable of operating the machine under normal operating conditions. Complex tasks on the machine such as, set-up work, difficult maintenance work, repair work, or work on electrical components must be done by trained set-up or maintenance personnel of the operating company or KRONES service engineers.
In order to ensure that the machine is operated properly, this operating manual also contains information for the company operating the machine. You as the company operating the machine must therefore observe the contents of this operating manual. Most of this information is contained in the "Safety" chapter.
1.1.4 Structure of the Operating Manual This operating manual is divided into: The main manual Additional manuals in the supplement
The Main Manual
The main manual was written especially for the machine type in question and contains the following information: Information relevant to safety in the "SAFETY" chapter. Fundamental information about the machine in the "Machine Description",
"Technical Data", "Construction/Method of Operation" chapters.
Information about machine operation in the "Controls", "Operation","Malfunctions" chapters.
Preface

Information about comprehensive maintenance work done by the operator on the machine in the "Maintenance“, "Cleaning" chapters.
Additional Manuals in the Supplement
Additional manuals are provided at the end of the operating manual. Read the information and follow the instructions in the operating manual as well as in the addtional manuals. This is the only way of ensuring safe operation and that the entire machine is in a functional condition.
Additional manuals: Additional manuals corresponding to independent components manufactured by
Krones or manuals concerning extensive subjects are provided in the supplement to the main manual. For example, lubricants, KRONES cappers, ...
Additional manuals for independent components not manufactured by KRONES are provided separately.
For example, third-party capper, ...
1.1.5 Documentation Types Three types of documentation are provided for this machine when it is delivered. The delivery date of the individual types of documentation may vary. Each type of documentation bindingly applies to the respective target group.
1.1.6 Use and Storage of the Documentation Before doing any work on the machine, the operator must read the operating manual, to familiarise himself with the machine. The entire manual must be read.
To prevent possible hazard when the machine is operated, the following safety instructions must be followed. The safety instructions in the "Safety" chapter The safety instructions at the beginning of individual chapters of the operating
manual Work-specific warnings immediately before doing work Always store the documentation in a safe place near the machine. The user must know where this place is and have unrestricted access to the documentation.
1.1.7 Representation of Information, References, and Warnings
Information
Information symbol This symbol is associated with additional instructions and information on a particular subject.
Documentation Types Target Group
Electrical documentation Comprehensive maintenance personnel
Preface
References
Arrow symbol This symbol is associated with references to other sections of the operating manual, additional manuals in the supplement, or separate documents.
Warnings
DANGER Safety Alert Symbol and Signal Word The safety alert symbol is associated with warnings which alert you to hazards (personal injury) that could be caused by inappropriate execution of the work described afterward. Signal words indicate the severity of a hazard. For a detailed description of how the warnings are structured, see the "Safety"
chapter.
NOTICE Signal Word "NOTICE" The signal word "NOTICE" is associated with warnings which alert you to machine damage caused by inappropriate execution of the work described afterward. For a detailed description of how the warnings are structured, see the "Safety"
chapter.
Preface
The operating company is responsible for selecting, assigning, and supervising suitablepersonnel for operation of the machine.
The operator's education, knowledge, and practical expirience must make him capable of operating the machine under normal operating conditions. This particularly includes the following requirements: The operator must be physically and mentally able. The operator's education, knowledge, experience, and training must qualify him as
suitable. The operator must be able to assess the expedience and effectiveness of the work
assigned to him and execute this work reliably and professionally. The operator must be able to detect hazards in time, and if necessary, take the
necessary precautions.
The operator must read and understand the operating manual.The assignment of unqualified personnel obligates the operating company to compensate for deficits in the personnels' qualifications by providing appropriate training and instruction. The personnel must also be informed about existing hazards and be supervised by their superior.
For further information about personnel qualifications, see the "Safety" chapter.
1.2.2 Restrictions on the Use of the Machine Use of the machine is prohibited for unauthorised and inept persons.
The following persons, for example, are unauthorised: Persons who are not authorised for operation of the machine in question. Persons who are not adequately qualified or trained.
The following persons, for example, are not suitable: Persons who cannot read or do not understand the operating manual. Persons who cannot operate the machine for health reasons, because of their slow
reaction time, or for legal reasons. Persons with implanted medical devices. Persons who tend to have epileptic attacks. Persons under the effects of alcohol, medication, or drugs.
Preface

1.3 Copyright This operating manual is protected by copyright. It contains technical descriptions and illustrations which, without written consent from Krones AG, may not be duplicated, modified, translated, and passed or made accessible to a third party.
Subject to change without notice. Errors and ommissions excepted. © Krones AG
Safety
2.0 Table of Contents
2.1 For your own Safety 21 2.1.1 General Information 21 2.1.2 Information Concerning the Documentation 21
Documentation Types 21 Use and Storage of the Documentation 21
2.2 Machine Safety Concept 22 2.2.1 Protective measures 22 2.2.2 User information 23
2.3 Machine Signs 242.3.1 Examples of Signs 24
2.4 Residual Machine Hazards 25 2.4.1 Sample: Excerpt – risk assessment according to EN ISO 12100 25
2.5 Warnings in the Operating Manual 26 2.5.1 Warning Identification/Hazard Levels 26 2.5.2 Structure of Warnings 26 2.5.3 Warning Example - "Danger" 26
2.6 Fundamental Safety Instructions 27 2.6.1 Operating Personnel Requirements, Safety Behaviour 27
Personnel Qualifications 27 Restrictions on the Use of the Machine 27 Assuming the operator and/or work position 27 Personnel Safety Behaviour 27 Wear protective clothing. 28
2.6.2 Laws, Regulations, Guidelines, Standards 28 Machine manufacturer (Krones AG) 28 Operating Company of the Machine 29
2.6.3 Responsiblities of the Operating Company 29 Selection/Qualifications of Personnel 29 Personnel Safety Instruction 29 Personnel Instruction – Workplace/Machine 29 Condition of the Work Facilities 29 Inspections by Supervisory Organisations 30 Disposal 30
2.6.4 Machine Application 30 Permissible Application 30 Impermissible application 31 Hazard caused by misuse of the control devices 31
2.6.5 Hazards Caused by Energy Systems, Processing and Operating Materials, Emissions 31
Energy Systems 31Processing and Operating Materials, Emissions 32 2.6.6 Technical Condition of the Machine 33
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2.6.7 Safety and Protective Devices of the Machine 34 2.6.8 Stop the machine and lock it, to prevent it being turned ON/
Restart the machine 35 Stop the machine and lock it to prevent it being turned ON (before doing work). 35 Turning ON the Machine 35
2.6.9 Safety Instructions for Operation, Change-Over, Trouble- Shooting, Maintenance 36 Operation 36 Change-Over 37 Troubleshooting/Malfunctions 37 Maintenance 37
2.6.10 Safety Instructions Concering Compehensive Maintenance, Installation/Dismantling 38 Comprehensive Maintenance 39 Installation/Dismantling 39
2.6.11 Hazardous Situation and Accident Behaviour 40 Instructions Concerning Hazardous Situations 40 Stopping the machine in an emergency (EMERGENCY STOP) 40 Emergency Measures 40 What to Do in Case of Fire 41 What to Do in Case of an Accident with Chemicals 41
2.7 Subject-Specific Safety Instructions 42 2.7.1 Handling Carbon Dioxide (CO2) 42
Properties of carbon dioxide (CO2) 42 2.7.2 Handling Nitrogen (N2) 42 2.7.3 Handling Hydrogen Peroxide (H2O2) 43
Properties of Hydrogen Peroxide 43 Safety Precautions and Safety Practices 43 Measures for Hazardous Situations 44 Disposal 44
2.7.4 Handling Acids and Caustics 44 Properties of Acids and Caustics 45 Safety Precautions and Safety Practices 45 Measures for Hazardous Situations 45
2.7.5 Handling Radiation 46 Generally applicable information on handling radiation 46 Residual Optical Radiation Hazards (infrared/UV radiation) 47
Residual hazards - magnetism 47 Residual hazards – X-ray radiation 48 Residual Hazards - Laser Radiation 48 Residual Hazards - Radioactive Radiation 49 Residual Hazards – X-Ray Radiation 49
2.7.6 Use of Pressure Vessels 49 Definition - Pressure Vessels 49 Transport/installation of pressure vessels 50 Starting Pressure Vessels 50 Operation of Pressure Vessels 51 Comprehensive Maintenance of Pressure Vessels 52
2.7.7 KRONES Online Service 53
2.8 Machine-Specific Safety Information 54
Safety
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2.9 Machine-Specific Safety Measures 55 2.9.1 Identification of Residual Hazards 55 2.9.2 Identification of Danger Zones 55 2.9.3 Sealing Off the Danger Zones 55
2.9.4 Safety Measures Against Emissions 55
2.10 Machine-Specific Protective Clothing 56
Safety
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2.2 Machine Safety Concept In accordance with the valid Machine Directive and other applicable standards, the safety concept of the machine consists of the following points: An inherently safe design of the machine. Protective measures if danger cannot be avoided or adequately minimised from a
design viewpoint. User information on the residual hazards if danger cannot be avoided despite a
safely engineered design and protective measures.
2.2.1 Protective measures The machine design, its method of operation and the state of technology dictate that risks and hazards cannot always be totally excluded from a engineering viewpoint. The remaining risks and hazards must be excluded or minimised by employing suitable protective measures.
Such safety measures are:
Technical safety precautions are separating and non-separating protective devices as measures for protection against hazards presented by moving parts, e.g.: Fixed separating protective devices:
guards, housings Moving separating protective devices with or without locking with automatic
monitoring: Guard doors with locking and monitoring, guard doors and protective covers to be opened with keys/tools
Sensitive protective devices, e.g.: P.E. sensors, light grids, sensing units, proximity switches
Mode of operation selector switches
Jogging and enabling devices Additional non-separating protective devices, e.g.:
Limitation and monitoring devices for pressure, temperature, emissions, speed, acceleration and torque
Safety measures for reducing emissions of noise, vibrations, dangerous substances, and radiation, e.g.: Encapsulations, silencers, vibration dampers, filters, venting units and shields
Safety precautions for the stability, e.g.: Anchor bolts, locking devices, movement limiters
Supplementary safety precautions are safety precautions which are neither inherently safe designs nor technical safety precautions nor user information, however which must be provided based on the proper use and the reasonably foreseeable incorrect use of the machine/
system, e.g.: Components and construction elements for shut-down in an emergency:
EMERGENCY-STOP switch Measures for freeing and rescuing trapped persons:
Escape devices for guard doors with locking Measures for disconnecting and dissipating energy sources:
Master switches, shut-off valves for compressed air, shut-off valves for liquids Precautions for the easy, safe use and handling of machines and heavy parts:
Lifting devices with slings, hooks, transport eyes or holes with an inside thread Measures for safe access to machines:
Steps, grab handles, stairways, transitions, working platforms, antislip corridor areas, pedestrian routes, fastening points for personal safety equipment
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For more information, see the "Construction/Method of Operation" and "Controls" chapters.
2.2.2 User information If risks and hazards cannot be eliminated through design or by implementing suitable safety precautions, the user must be informed of this.
The information is provided by: Optical and acoustic signals and warning devices, e.g.:
Signal beacon post, horn Information on the machine:
Marks and labels such as the manufacturer's name and address, designation of machine series/model
Symbols,pictograms Written warnings
For more information, see the "Construction/Method of Operation" and "Controls" chapters.
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2.3 Machine Signs Signs have been posted in certain areas on the machine, as required. For the meaning of the signs, see the operating manual. Depending on the message to be conveyed, the sign can be a prohibitive, warning,
mandatory, or an instruction sign. These signs are designed to protect the personnel and machine. For this reason, make sure that these signs are always in perfect condition, and that damaged signs are replaced. Failure to observe prohibitive, warning, mandatory, and instruction signs can result in damage to property, bodily injury, or even death.
2.3.1 Examples of Signs
Sign Meaning Sign description
Prohibitive signs
Signs which warn of risks involved when using the machine.
Wear eye protection Mandatory signs
Signs which alert you to something which is mandatory to prevent accidents in the workplace.
Follow the lubrication instructions in the operating manual
Instructions signs
machine components For operation of/work on the
machine Other signs (e.g., identification
plates)
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2.4 Residual Machine Hazards The machine is state of the art and is safe to operate. In engineering the machine, as many safety risks as possible have been eliminated. Nevertheless, due to the kind of machine this is, its power supply, the processing and
operating materials used, and the emissions produced, there are still residual hazards for the personnel.
WARNING Disregarding residual hazards! Disregarding residual hazards may be harmful to your health, cause bodily injury, or even death. For this reason, in order to prevent hazardous situations, be aware of and bear the
following residual machine hazards in mind!
For the residual machine hazards, see the "Supplement" chapter in the operating manual. Read and observe this document "Excerpt – risk assessment according to EN ISO 12100".
2.4.1 Sample: Excerpt – risk assessment according to EN ISO 12100
Sample: Excerpt – risk assessment according to EN ISO 12100
01go0212
TD12000420 EN 00 2.5 Warnings in the Operating Manual 26
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2.5 Warnings in the Operating Manual In the operating manual, warnings are provided before potentially hazardous tasks. The warnings are categorised into hazard levels. The hazard level indicates the probability and severity of harm/damage associated with not following the warning.
Follow these warnings, as they help prevent hazards which cause damage to property, bodily injury, or in the worse case, death.
2.5.1 Warning Identification/Hazard Levels Warnings are identified by a safety allert symbol, by the hazard level (degree) indicated in the left margin, and by the borderlines above and below.
2.5.2 Structure of Warnings
2.5.3 Warning Example - "Danger"
DANGER Rotating machine parts! Crush and pull-in hazards - can result in death. It is strictly prohibited to remain inside of closed guards.
Safety Alert Symbol
Hazard Level Description of Safety Level
DANGER High-risk hazard which could result in severe bodily injury or death if not avoided.
WARNING Medium-risk hazard which could result in severe bodily injury or death if not avoided.
CAUTION Low-risk hazard which could result in medium or minor bodily injury or death if not avoided.
NOTICE Warns of property damage.
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Access danger zones inside of the protective devices only through entrances designated by the manufacturer and only after having properly shut down the machine and locked it to prevent it being turned ON.
Before starting work, check the safety devices and machine for visible defects. If the defects pose an operational safety hazard, do not operate the machine or
stop it. If the machine has any defects, especially those which affect safety, inform your
superior, any co-worker who may be concerned, and when changing shifts also inform the person who takes over for you and your superior.
Never actuate or tamper with machine control components and monitoring devices, etc., if you are unauthorised or do not know how they work.
Never wear jewellery (rings, chains, etc.) which could get caught in machine parts. Long hair should be tucked under a hair net.
Never allow the machine to operate unattended.
Wear protective clothing.
For your own safety, wear protective clothing whenever the machine is used. Protectiveclothing should be tough, fit closely, and be resistant to cleaning agents. It should, for instance, protect you against noise, glass fragments, and spilled cleaning agents. When selecting protective clothing, observe the information provided on the safety data sheet.
The following items are examples of protective clothing: Ear protection Hair net Safety glasses Cut-resistant protective gloves Coverall Apron
Safety helmet Slip-resistant safety shoes
Always wear chemical-proof clothing when using machines with which chemicals (e.g., H2O2) are used: Chemical-proof safety glasses, if necessary, a protective visor (protection against
splashing) Respiratory protection if necessary Chemical-proof gloves made of PVC or rubber Coverall made of acid-proof PVC or rubber Slip-resistant chemical-proof boots made of PVC or rubber
Machines in a clean room: Wear the clean room clothing prescribed for your designated area.
Observe the instructions, information, and documentation of the clean roommanufacturer.
2.6.2 Laws, Regulations, Guidelines, Standards
Machine manufacturer (Krones AG)
European Economic Area and EFTA states: This machine satisfies the criteria stipulated in the EU Declaration of Conformity.
It has been engineered and manufactured according to the applicable guidelines, laws, regulations, and standards. For information, see the EU Declaration of Conformity.
States outside of Europe: This machine has been engineered and manufactured according to the applicable
European and international standards.
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Operating Company of the Machine
The operating company of the machine must thoroughly inform itself about the guidelines, laws, and regulations which are bindingly applicable for the operation of technical equipment in the respective country.
Among others things, the following must be observed: Regulations which prescribe that a licence be issued by the respective authority,
allowing the installation/operation of the machine/equipment. Guidelines for installation, operation, repair, and disposal of equipment. Regulations which govern the storage, use, and disposal of operating and
processing materials. Regulations specifically relevant to your plant.
2.6.3 Responsiblities of the Operating Company The main responsibility for an accident-free working process is borne, above all, by the operating company of the machine, as well as those persons authorised by the company to operate, clean, maintain, and repair it. In order to be able to achieve the level of safety required under actual operating conditions, the operating company is obligated to initiate necessary measures and monitor their implementation. When planning and implementing measures also include personnel who do not belong to the company.
Selection/Qualifications of Personnel
The operating company must ensure the following: Operation, maintenance, and repairs are restricted to appropriately qualified
professionals authorised by the operating company. The personnel must be trained for the respective machine, e.g. at special KRONES
courses.
Personnel Safety Instruction
The employer is obligated to do the following: The personnel must be trained and receive regular instruction on a all safety issues
that apply to their tasks. The employer must make sure that the required documents are always available to
the personnel and that the personnel have read and understood them. The personnel must be provided with the required personal protective equipment
and be advised as to the importance of using it. The employer must conduct a hazard analysis and alert the personnel to existing
hazards.
Personnel Instruction – Workplace/Machine
The operating company is obligated to do the following: The operating company is obligated to instruct the personnel on the machine
workplaces and to give them operating instructions. It must be made sure that it has been clearly defined which areas the personnel are
in charge of and responsible for.
Condition of the Work Facilities
The work facilities must satisfy the requirements placed on machine installation sites.
Observe the following:
substances.
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The machine’s surrounding area must be well illuminated. Provide enough space to operate, convert, maintain the machine. Store accessories in a place where they are easily accessible but do not hamper
machine operation. Maintain the machine area neat and clean.
Inspections by Supervisory Organisations
Certain line components (e.g., pressure vessels, safety valves) must be checked on a regular basis by public inspection authorities. The intervals for regular inspection of machine components subject to mandatory testing depend on the operating conditions and country-specific requirements. Find out the intervals from the registered authority responsible for your. Have the inspections conducted at the prescribed intervals by the responsible, registered public authorities. Store the corresponding documentation (e.g., TÜV - technical inspection authority - documents) in a safe place.
Disposal Make sure that processing and operating materials, machine parts, and other waste are disposed of properly, as prescribed by law.
The disposal of the following items is especially critical: Do not drain off acids or caustics into the sewage system without neutralising
them. Check whether parts which are no longer needed and refuse from repairs and
maintenance work as well as refuse from dismantling the machine contain hazardous waste, and make sure that the respective parts and/or materials are disposed of properly.
Make sure the following materials and substances are disposed of by a professional: Oils and greases as well as their containers (e.g., spray cans, lubricators) Cleaning agents, solvents, and coolants Batteries, picture tubes, fluorescent tubes, etc., Plastic materials Radioactive sources of inspection devices
Make sure that recyclable materials (e.g., metal, glass, etc.) are collected, so they can be processed and recycled afterward.
2.6.4 Machine Application
Permissible Application
The machine has been designed, set up, and equipped to meet your requirements as per order. Safe operation of the delivered machine can be guaranteed only if it is used for its permissible application. The machine must be used only for its designed purpose, or an application as per contract with KRONES AG.
For information concerning the permissible application, see the operating manual.
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Look at connection diagrams to find out which machine/system components remain live after the master switch is turned OFF (e. g., sockets, control cabinet lighting, live components up to the main machine contactor, control cabinet heating, parts of the machine’s control system).
Prior to doing any work, if necessary, also interrupt the power supply to these
components. On machines with a UPS, a separate UPS mains switch must also be turned OFF.
Hydraulic/Pneumatic Systems Hazard caused by unqualified personnel doing work on hydraulic/pneumatic
systems: Working on hydraulic/pneumatic systems requires expert knowledge. This work must be done only by specially trained, authorised professionals.
Hazard caused by doing work on pressurised hydraulic/pneumatic systems (e. g., pressure vessels, pneumatic components, pipe systems): Before doing work on theses systems, they must be depresurised. The following safety precautions must be observed: Close the pressure supply. Lock the machine, to prevent it being turned ON, thus preventing
pressurisation. Depressurise. Verify depressurisation (e. g., pressure gauge) Hydraulic systems: Drain off operating fluids if necessary.
Processing and Operating Materials, Emissions
When operating the machine/line, use only processing and operating materials of suitable quality: Processing and operating materials such as product, gas, lubricant, cleaning
agents/disinfectants.
Materials such as containers, caps, labels, etc. Processing and operating materials must be fit for use in the food sector. They must not contain anything which is prohibited in the product (e.g., microorganisms, cleaning agents/disinfectants, dirt).
When operating the machine/line, processing and operating materials and emissions can be potentially hazardous. Prevent such hazards by enforcing the appropriate safety behaviour (e.g., wear protective clothing) and taking appropriate safety precautions (e.g., adequate ventilation). Adhere to existing regulations for the use of processing and operating materials and do not exceed any specified limit values. Follow the safety instructions of the respective manufacturer of such materials.
The following are examples of processing and operating materials which are
potentially hazardous: Product (alcohol) Containers (broken bottle) Gases (CO2, N2, O2, H2O2) and vapours (product, solvent) Lubricants (oils, greases) Cleaning agents/disinfectants (chemicals, caustics, acids, liquid H2O2, steam, hot
water, waste water)
The following are examples of emissions which are potentially hazardous: Escaping processing and operating materials (e.g., gases, vapours, cleaning agents/
disinfectants), Noise Released radiation (e.g., radioactive radiation, X-ray radiation).
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Processing and operating materials/emissions can cause the following hazards: The use of operating and processing materials (e.g., cleaning agents/disinfectants)
is restricted to specially trained professionals familiar with the use of these
materials. Hazard caused by substances which are harmful to your health (e.g., lubricants, cleaning agents/disinfectants, solvents and coolants): Contact with certain substances can be harmful to your health. Therefore, wear appropriate protective clothing and exercise utmost caution with these substances. Adhere to applicable regulations (e.g., hazardous substances regulations).
Hazard caused by the reaction of fluids/substances: Fluids/substances can react with each other, creating toxic substances. Do not mix fluids/substances if this can cause hazardous reactions (e.g., H2O2 and greases, acids, caustics), or if you do not know whether theses fluids/substances can be mixed without hesitation.
Hazard caused by inadequate ventilation in work facilities/absence of extraction
system devices. Emissions from substances (e.g., from gases, vapours from critical products, solvents, chemicals) which are not removed from the work area by adequate ventilation can be potentially hazardous (e.g., explosion hazard, harmful to your health). Provide adequate ventilation in the work facilities when using such substances.
With gases heavier than air, also ventilate low-lying facilities and/or channels adequately and protect them against permeation of gas.
If necessary, the operating company of the machine/line must install extraction system devices for gases and/or vapours. If necessary, and not otherwise stipulated, these extraction systems must be installed by an authorised industrial ventilation systems company.
Check the ventilation and extraction systems regularly for proper operation. Noise hazard:
Noise emissions produced during machine/system operation can be harmful to your health.
Take required measures, to limit noise emissions during machine/line operation (e.g., optimise building acoustics). Observe the noise protection regulations applicable in your country and/or company.
In noise-prone workstations, the operators must wear the required protective equipment (noise protection).
Hazard caused by released radiation: There may be components that release harmful radiation on the machine. Warning signs are used to identify areas where radiation is released. Observe the subject-specific safety instructions concerning "Radiation".
2.6.6 Technical Condition of the Machine The safe and technically perfect condition of the machine is essential for the operational safety of the machine and the safety of personnel. For this reason, observe the following: To prevent damage, operate the machine only within the permissible operating
limits and use only permissible processing and operating materials. Never modify, manipulate, etc. the machine on your own. Do not make any
technical changes without the consent and supervision of KRONES AG. KRONES AG shall not be held liable for damage resulting from unauthorised technical changes.
Do not start any machine which is not in perfect technical condition.
The machine’s safety and protective devices must always function and be ready for operation. If not, do not operate the machine.
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The machine signs, in particular, the safety signs must be clearly recognisable and be in good condition.
If the technical condition of the machine evidently becomes worse during production (e.g., unusual noises, production faults), stop the machine immediately until the cause of the damage has been troubleshot!
Faulty products must be removed from the production batch. Repair leaky storage tanks immediately (e.g., tanks for acid and caustic). Moreover,
the required precautions must be taken in order to dispose of spilled operating and process materials.
Do maintenance and repair work regularly and thoroughly, to prevent production downtimes and damage due to inadequate maintenance and repair work. This work must be done only by appropriately qualified professionals. The following tasks are considered maintenance and comprehensive maintenance: Maintenance: Includes lubrication, cleaning/disinfection Comprehensive maintenance: Includes inspection, repairs
If machine parts must be replaced, use only original spare parts. Failing to do so will void your warranty from Krones AG.
After the effects of unusual circumstances (e.g., fire, improper use of cleaningagents and disinfectants), it may not be possible to operate the machine. In this case, have the entire machine inspected and repaired by qualified professionals afterward.
Recommendation for maintaining the machine in a safe and technically perfect condition: Have the manufacturer regularly conduct a general inspection of the machine.
2.6.7 Safety and Protective Devices of the Machine
The machine’s safety and protective devices are designed to protect the personnel andthe machine. Therefore, make sure that these devices always operate properly and are ready for operation:
The following are examples of safety and protective devices: Control components relevant to safety
Master switch EMERGENCY STOP/maintenance switch
Signalling and warning devices Indicator lamps, indicators Horn
Protective devices Guard doors, guards, covers, windows
Safety P.E. sensors Machine safety mechanisms Brake Pressure switches, safety valves Motor protector, fuses/circuit breakers
Machine signs Prohibitive, warning, and instruction signs
Tampering with the machine’s safety and protective devices can cause damage to the machine, lead to severe injuries, or even death. For this reason, observe the following: When the machine is in operation, it is strictly prohibited to remain inside of closed
guards! Operate the machine only under the following conditions:

All safety and protective devices are installed, function and are ready foroperation. All guard doors are closed, and all guards, covers and windows are in place.
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The EMERGENCY STOP switch is intended only for stopping the machine immediately in an emergency. It is not a supply disconnecting device! After the EMERGENCY STOP switch is pressed, some parts of the machine's energy systems remain active: Electrical components remain live. Pneumatic/hydraulic components may remain pressurised.
Never remove, override or disable safety and protective devices. If there is no way of avoiding that the machine's safety and protective devices are
temporarily removed, overridden or disabled during set-up, maintenance or repair work, this must be done only by specially trained professionals. After work is finished, restore the initial condition and check for proper functioning.
The control panel / control cabinet doors and protective covers must always be closed. Only professionals are allowed to open them for as long as it takes to do work, but they must take the required safety precautions.
Example of hazards caused by failing to do so: Crush/pull-in hazards caused by disabling safety and protective devices. Danger of an electric shock, e.g., with the control cabinet doors open.
Hazard caused by UV radiation when covers are missing. If air conditioners are installed on the control cabinet:
Damage when opening the control cabinet doors due to condensation, insufficient cooling and overloading of the air conditioner.
2.6.8 Stop the machine and lock it, to prevent it being turned ON/ Restart the machine
Stop the machine and lock it to prevent it being turned ON (before doing work).
Before doing work on the machine, avoid personal hazard by shutting it down and locking it to prevent it being turned ON (e.g., for change-over, troubleshooting,
maintenance). When doing so, observe the following: Shut down the machine properly.
When doing so, follow the instructions provided in the operating manual. After shutting down the machine, lock it to prevent it being turned ON.
Lock the respective switch with a padlock (master switch, EMERGENCY STOP/ maintenance switch).
Remove the key and take it with you. Observe the following: To lock the machine and prevent it being turned ON, each person working on the machine must attach his own lock.
Do not remove the padlock until work is finished.
If the machine must be briefly operated/turned ON between individual work tasks: Make sure the machine is not damaged.
Operate the machine, but only as long as absolutely necessary. For this reason, when jogging/starting the machine, it is imperative to observe the
following hazard information provided in the section on "Operation" under "Safety Instructions for Operation, Change-Over, Troubleshooting, Maintenance".
Relock the machine afterwards until the work is finished.
Turning ON the Machine
Before starting the machine, make sure the following is done: Check whether all work has been finished and all parts have been properly fitted. Make sure that there is no one inside of the guards. Restart the machine properly
When doing so, follow the instructions provided in the operating manual.
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Operation
Control components:
For machine operation, it is imperative that you are familiar with the machine’s control components and how they function. Therefore, familiarise yourself with the control components before operation. If necessary, look up their function in the operating manual.
Operation:
The machine can be operated in different modes. Bear in mind that the modes of operation have different safety levels:
To prevent hazards and accidents, adhere to the following safety instructions which apply to the respective modes of operation: Mode of operation – production:
Always follow the instructions in the operating manual when operating the machine (start-up, operation, end of operation).
Mode of operation – set-up (if provided): In the set-up mode, the machine can be jogged while the guard doors are open. This poses a high safety risk, making the highest level of precautionary measures imperative so that personal hazards/machine damage are prevented. For this reason, observe the following: Work done in the ”set-up” mode is restricted to specially trained, authorised
professionals. Do not hand over the mode of operation key to anyone other than this personnel.
Do not jog the machine unless you are sure that neither you nor anyone else is
at risk. Before doing so, make sure there is no one else working on/in the machine.
Do not reach into the machine. Stay a safe distance away from moving machine parts (e.g., from the
starwheels, carrousel, …) especially if you must stand with your back toward these machine parts.
Lock the machine as well as subordinate components and systems to prevent them being turned ON before working on them.
After finishing work, the machine's mode of operation selector switch must be set to "Production" mode. Remove the key from the mode of operation selector switch and take it with you.
If work on the machine is not finished, the machine must be shut down.
Mode of operation Safety level
Production Machine operation at the highest safety level! Low risk!
Set-up (if provided)
Jogging is possible while the guard doors are open! High risk!
Service (if provided)
Simulated production mode for work done by service engineers! High risk!
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Mode of operation – service (if provided): The machine can be operated at the nominal output in a simulated production mode by an authorised person (service engineer), without production goods entering at the infeed and independently of control commands or other machines. This poses a high safety risk, making the highest level of precautionary measures
imperative so that personal hazards/machine damage are prevented. For this reason, observe the following: Work done in the "Service" mode is restricted to specially trained, authorised
professionals.
Change-Over
Do the following change-over work, to convert the machine for handling other products, containers, packs. The following must be observed: Do the required work properly and thorougly. Always follow the instructions provided in the operating manual when converting
the machine for change-over.
Trouble-shoot in order to ensure/resume machine operation.
Observe the following: Be alerted to malfunctions indicated on the machine (e.g., malfunction warnings
on the touch-screen, lamps, horn). Stop the machine immediately in the event of a malfunction or shut it down
immediately in the event of a major malfunction. Use the malfunction table in the operating manual to troubleshoot malfunctions.
If a malfunction occurs which cannot be troubleshot using the operating manual, or for which you are not qualified to troubleshoot yourself, this must be done by a qualified professional (e.g., comprehensive maintenance personnel, KRONES service engineer).
Do the required work properly and thoroughly.
Maintenance
To prevent personal injury and damage to the machine, observe the following when doing maintenance work on it: Maintenance work must be supervised by a responsible person and be done
cautiously by trained, authorised professionals. Before doing work on the machine, take the required safety precautions.
Examples: Post the "Maintenance work" warning sign at the main operator station.
If necessary:- Stop the machine and lock it to prevent it being turned ON. - Depressurise hydraulic/pneumatic system components. - Thoroughly drain off substances such as cleaning agents/disinfectants, lubricants ...
After doing maintenance work, do not start the machine without the approval of the person in charge. Only then is maintenance work finished. Before allowing machine operation, the person in charge must make sure of the following: That all work on the machine has been completely finished. That the machine is ready for operation. That there is no one in the machine’s danger zone.
Maintenance
Do maintenance work to maintain the machine in perfect technical condition.
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Observe the following: Do the required work properly and thoroughly. Maintain the required intervals. Observe the information provided in the operating manual and the safety
instructions/warnings applying particularly to this chapter. After doing work and before eating, use water and a mild cleanser or soap to
thoroughly clean dirty skin areas. If necessary use moisturising creams to retain the natural protective layer of your skin.
Cleaning
If the machine’s hygienic level directly affects the product, interior cleaning/ disinfection (CIP) must be performed to prevent contamination of the product/ machine. For cleaning/disinfection of these machines, a separate chapter is provided in the operating manual.
Observe the following:
Do the required work properly and thoroughly. Maintain the required intervals. Observe the information provided in the operating manual and the safety
instructions/warnings applying particularly to this chapter. Avoid contact with cleaning agents/disinfectants to prevent harming your health.
Be careful when using cleaning agents/disinfectants. Work with these hazardous substances must be done only by specially trained, authorised professionals.
Wear appropriate protective clothing. After doing work and before eating, use water and a mild cleanser or soap to
thoroughly clean dirty skin areas. If necessary use moisturising creams to retain the natural protective layer of your
skin.
Lubrication
Do lubrication work to ensure that the machine operates trouble-free over a long period of time.
Observe the following: Do the required work properly and thoroughly. Maintain the required intervals. Observe the information provided in the operating manual and the safety
instructions/warnings applying particularly to this chapter. Avoid contact with lubricants to prevent harming your health.
Exercise caution when using hot lubricants, as they can cause burns. Change clothes immediately if they are soaked with oil/grease. Do not stick
oily/greasy cloths into your pockets. Wear appropriate protective clothing. Do not inhale oil mist/vapours.
After doing work and before eating, use water and a mild cleanser or soap to thoroughly clean dirty skin areas. If necessary use moisturising creams to retain the natural protective layer of your skin.
2.6.10 Safety Instructions Concering Compehensive Maintenance, Installation/Dismantling
Bear in mind that this operating manual does not concern itself with inspection and repair work and the installation/dismantling of the machine.
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To prevent personal injury and damage to the machine, observe the following when doing this type of work. This work must be done only by authorised professionals trained specifically for
this machine (e.g., KRONES service engineers). Work must be supervised by a responsible person and be done cautiously by
professionals. Before doing work on the machine, take the required safety precautions.
Examples: Post the "Repair work" warning sign at the main operator station. If necessary:
- Stop the machine and lock it to prevent it being turned ON. - Depressurise hydraulic/pneumatic system components. - Thoroughly drain off substances such as cleaning agents/disinfectants, lubricants ...
After doing work, do not start the machine without the approval of the person in charge. Only then is work finished. Before allowing machine operation, the person in charge must make sure of the
following: That all work on the machine has been completely finished. That the machine is ready for operation. That there is no one in the machine’s danger zone.
Notice: KRONES shall not be held liable for comprehensive maintenance work and installation/ dismantling work as well as any consequential damage, if this work is done by the customer and/or someone he commissions and not by KRONES professionals! Examples: When repairing, dismantling, re-assembling, and restarting components and/or
the machine. When installing/dismantling the machine.
Comprehensive Maintenance
To maintain the machine in perfect technical condition, have required comprehensive maintenance work done at regular intervals.
Observe the following for comprehensive maintenance: Before doing welding work and all types of spark-producing work:
Drain the pipe system, tanks, and fittings completely. Before doing autogenous welding work, remove solvents thoroughly.
Be careful with plastic materials on the machine: These materials could be combustible and toxic gases could develope.
When doing electric welding work, also disconnect all electrical components.
Be careful when doing welding work on pipes: You could damage electricalcables/supply lines which could be inside of the pipes. If stainless steel is not treated properly, it can rust, for instance:
Welding on stainless steel without "passivating" afterward (special treatment of the welds).
Steel parts come into contact with stainless steel, e. g., when working on steel parts close to stainless steel (flying sparks, steel chips, etc.)
Working on stainless steel with a metal brush. The machine comes into contact with sparks from cut-off grinding work.
Installation/Dismantling
Observe the following for installation/dismantling:
The machine must be transported and installed properly at the site. Before starting the machine, all inspection measures required for safe operation of
the machine (e. g., commissioning, acceptance) must be completed.
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Proper shut-down, dismantling, and storage of the machine is essential for proper functioning and safety of the machine when it is recommissioned in the future.
If the machine and the processing and operating materials used are disposed of, this must be done by properly without harming the einvironement.
2.6.11 Hazardous Situation and Accident Behaviour Observe applicable regulations and follow instructions so that you can react properly and safely in hazardous situations and emergencies, e. g.: Applicable accident prevention regulations Occupational health and safety regulations Your company’s emergency rules
Instructions Concerning Hazardous Situations
During machine operation, always be aware of potentially hazardous situations. Before doing work on the machine, inform yourself about the following:
Hazards posed by the machine. How to prevent such hazards and/or how to deal with them properly (e. g., machine EMERGENCY STOP, safety procedure for escaping substances, first aid measures).
Location of emergency equipment (e. g., first aid equipment, fire extinguisher). Existing emergency systems and their location (e. g., fire detector, escape routes).
Stopping the machine in an emergency (EMERGENCY STOP)
The machine must be stopped as quickly as possible in a hazardous situation. For this reason, observe the following: Before you do any work, familiarise yourself with the design, location, operation,
purpose of all EMERGENCY STOP devices of your machine, and the areas they affect.
In case of an emergency, immediately activate the EMERGENCY STOP device (e.g., EMERGENCY STOP/maintenance switch) closest to the area which affects the machine to be stopped. The machine is stopped, and the pipe system is switched so that it is in a safe condition.
Hazard caused by live/pressurised components after pressing the EMERGENCY STOP switch: The EMERGENCY STOP switch is intended only for stopping the machine as soon as possible in case of an emergency. It is not a supply disconnecting device! After the EMERGENCY STOP switch is pressed, some parts of the machine's energy systems remain active: Electrical components remain live.
Pneumatic/hydraulic components may remain pressurised. Hazards caused by misuse of the master switch:
If the master switch cannot be identified as an EMERGENCY STOP device (red/ yellow), then it is not an emergency disconnecting device. The machine requires power, so it can be actively stopped. For this reason, do not use the master switch to immediately stop the machine in case of an emergency. Use only the EMERGENCY STOP switch to stop the machine in case of an emergency.
Lock the machine to prevent it being turned ON. Implement necessary emergency measures.
Emergency Measures
In an emergency, proceed according to your company's emergency rules.
Make sure the following is done in an emergency: Stop the machine immediately. Rescue injured persons.
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Inform the respective emergency services about the accident (e. g., doctor, fire department).
Provide first aid. Inform your superior.
What to Do in Case of Fire
Inform yourself about the following in case of fire: Suitable firefighting methods (e.g., CO2 fire extinguisher) The location and operation of extinguishing equipment (fire extinguisher, fire
blanket, wall hydrants). What to do in case of fire:
In case of fire, also observe the following: In case of a large fire: Get out of the danger zone immediately. Use only appropriate extinguishing agents to put out fires.
If the wrong extinguishing agents are used toxic gases/vapours may develop, and the electrical system could pose a hazard.
If vapours escape: Get out of the danger zone. Access the danger zone only with a respirator equipped with an appropriate
filter. If gases escape:
Get out of the danger zone. Access the danger zone only with a respirator equipped with an appropriate
filter. If possible, stop the gas escaping by closing the main valve.
What to Do in Case of an Accident with Chemicals
Use the appropriate safety data sheets to inform yourself about the following in case of an accident with chemicals: The properties of the chemicals used. Safety precautions and rules for the use of the respective chemicals Appropriate first-aid measures (e.g., eyewash, mouthwash) What to do in a hazardous situation.
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2.7.1 Handling Carbon Dioxide (CO2)
WARNING Risk of asphyxiation or cold burns through contact with carbon dioxide (CO2) Liquid gas in high concentrations can result in asphyxiation by inhalation. Contact with the liquid can cause cold burns/frostbite. Poor ventilation and incorrect handling of gas cylinders can cause health hazards. Carbon dioxide gas/vapour is heavier than air. It can collect in closed rooms, especially on the floor or in low areas. Provide adequate ventilation in the work facilities. Rooms and ducts must be
adequately ventilated and protected against the build up of gas. Maintain the system in perfect technical condition to prevent putting personnel at
risk (e.g., due to leaks in the pipe system and tanks). Wear work gloves and safety shoes when handling gas cylinders.
Important information:
The manufacturer of the products is responsible for the use/processing of carbondioxide (CO2) as a product ingredient. KRONES shall not be held responsible for injury to persons or damage to products
which results from the use/processing of carbon dioxide (CO2). Follow the national regulations/guidelines which apply to the use/processing of
carbon dioxide (CO2). Observe the information provided in the safety data sheet for carbon dioxide (CO2)!
Properties of carbon dioxide (CO2)
Carbon dioxide (CO2): Colourless and odourless gas Non-combustible gas Moderately water soluble gas Carbon dioxide is heavier than air Risk of asphyxiation with high concentrations
2.7.2 Handling Nitrogen (N2)
DANGER Risk of asphyxiation or cold burns caused by contact with nitrogen (N2) Nitrogen in high concentrations can result in asphyxiation by inhalation. Contact with the liquid can cause cold burns/frostbite. Poor ventilation and incorrect handling of gas cylinders can cause health hazards. Provide adequate ventilation in the work facilities. Rooms and ducts must be
adequately ventilated and protected against the build up of gas. Maintain the system in perfect technical condition to prevent putting personnel at risk (e.g., due to leaks in the pipe system and vessels).
Wear work gloves and safety shoes when handling gas cylinders.
Important information: KRONES shall not be held responsible for injury to persons or damage to products
which result from the use/processing of nitrogen (N2). Observe applicable, national regulations/guidelines when using/processing
nitrogen (N2). Observe the information provided in the safety data sheet for nitrogen (N2)!
Properties of nitrogen (N2):
Colourless and odourless gas Non-combustible gas Slightly water soluble gas
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Nitrogen is lighter than air Risk of asphyxiation with high concentrations
2.7.3 Handling Hydrogen Peroxide (H2O2)
WARNING Fire and expolsion hazard caused by decomposition of hydrogen peroxide! When hydrogen peroxide decomposes, vapours can be released, which could cause a fire, or pressure vessels could explode due to catalytic decomposition or overheating. Provide adequate ventilation and protection against permeation of contaminants. Avoid the use of materials which are incompatible (e. g. certain metals, organic
substances, leather). Monitor the temperature, pH value, and check for possible contaminants.
Risk of injury due to escaping hydrogen peroxide! Hydrogen peroxide can escape through leaky areas. Exposure can cause skin burns, mucous membrane irritations, serious eye damage as well as eye, respiratory tract, and lung irritation.
Avoid exposure to hydrogen peroxide and wear appropriate protective clothing. Prevent the decomposition of hydrogen peroxide. Do inspection work regularly.
Hot Machine Components! Depending on the operating condition, individual pipe system sections and components may be hot. Burn hazard. In areas around machine components used for the flow of H2O2.
Hazardous H2O2Atmosphere inside of the guards! If the machine's guards are opened while a machine component which uses H2O2is in operation, this can cause breathlessness. End the process. Close the H2O2supply. Wait approximately 5 minutes until the H2O2concentration in the machine is no
longer hazardous. After 5 minutes the machine guards can be reopened.
Important information: Work involving the use of hydrogen peroxide (H2O2) must be done only by
authorised, specially trained professionals, instructed in the use of hydrogen peroxide (H2O2).
KRONES shall not be held responsible for personal injury/damage to the product resulting from the inappropriate use/processing of oxygen(H2O2).
Observe applicable, national regulations, guidelines when using/processing
oxygen (H2O2). Observe the information provided in the safety data sheet for hydrogen peroxide
(H2O2)!
Properties of Hydrogen Peroxide
Name of hazardous substance: Hydrogen peroxide solution 35 %, ± 2 % Aqueous solution (clear, colourless fluid) Highly concentrated H2O2 is unstable and can explode spontaneously. When it reacts with other chemicals, H2O2 can form hazardous substances.
Safety Precautions and Safety Practices
Always exercise caution with H2O2. Observe the following: Prevent H2O2 contamination/spills. In case of H2O2 contamination, dispose of the
contaminated materials and/or clean them with water.
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Adequately ventilate the H2O2 tanks and protect them against contaminant permeation.
Avoid the use of materials which are incompatible (e. g. certain metals, organic substances, leather).
Wear appropriate protective clothing (protective gloves, safety glasses). Use a skin protection ointment. Do not store/consume food, beverages, or luxury food at the workplace. Make sure there are safety showers/an adequate supply of water.
Measures for Hazardous Situations
In case of fire Extinguishing agent: water Do not use an extinguishing agent nor foam!
First Aid
Observe the additional information about measures for hazardous situations. See "Hazardous Situation and Accident Behaviour" in this chapter.
Disposal
Dispose of hydrogen peroxide waste properly, according to applicable regulations: Small quantities of hydrogen peroxide:
Dilute the solution with plenty of water and gradually pour it into the sewage system. The concentration must remain under 5 %.
Collect spills with inorganic absorbants (e. g. sand, vermiculite) and dispose of them as regular waste.
Dispose of large quantities of hydrogen peroxide as hazardous waste.
2.7.4 Handling Acids and Caustics
DANGER Risk of formation of chlorine gas! When sodium hypochloride (NaOCl) and acid (e.g., hydrochloric acid or nitric acid) are mixed or meet, chlorine gas is released. When chlorine gas is inhaled, it attacks the mucous membranes and can result in death. Be sure to avoid the occurrence of sodium hypochloride and acid consecutively in
the process sequence. Intermediate rinsing with water is required.
Exposure to H2O2 Measures
Rinse skin with plenty of water upon contact.
Eye contact Flush eyes with flowing water for at least 10 minutes upon contact - with eyelids wide open.
Inhalation Provide fresh air ventilation. Clear the respiratory tract.
Injestion Do not induce vomitting! Wash mouth out with water. Drink plenty of water. Consult a physician immediately.
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WARNING Risk of chemical burn caused by contact with acids and caustics Exposure to acids and/or caustics (e. g. by inhalation of vapours, injestion, direct contact) can be harmful to your health by causing skin burns, mucous membrane irritations, serious eye damage as well as eye and respirtory tract irritation. Observe the instructions of the acid and caustic manufacturer concerning the use
of these substances (e. g. storage, application, ventilation, disposal). Avoid contact with acids and caustics. Wear appropriate chemical-proof protective clothing.
Important information: Work involving the use of acids and caustics must be done only by authorised,
specially trained professionals, instructed in the use of these substances. Krones shall not be held responsible for personal injury/damage to the product
resulting from the inappropriate use of acids and caustics. Observe the manufacturer's information and the national regulations applicalbe to
the use of acids and caustics. Observe the information provided in the safety data sheets of the respective acids
and caustics.
Properties of Acids and Caustics
Acids and caustics: When it reacts with other chemicals, even a low concentration of acid or caustic can
form hazardous substances. Mixing acid and caustic concentrates or mixing acid and caustic concentrates with
other substances can cause an exothermic reaction (extreme temperature increase due to heat release).
Safety Precautions and Safety Practices
Always exercise caution when using acids and caustics. Observe the following: Wear appropriate chemical-proof protective clothing. Avoid using incompatible materials (e.g., base metals, leather). Make sure the workplace is well ventilated. Do not store/consume food, beverages, or luxury food at the workplace. Make sure there are safety showers/an adequate supply of water. Wash your hands and face after work. Storage of acids and caustics:
Always label acid and caustic containers properly to prevent hazardous mix- ups.
Keep containers tightly closed. Containers must be suitable for storage (no containers made of base metals).
Store containers in or over collecting pans. The collecting pans should not havea drain. They should provide a spill containment volume that is at least 1.5 times the volume of all containers.
Store in cool and dry place. Do not mix acids and caustics with other substances, unless this is necessary in
order to prepare the appropriate solution for a particular application. Make sure disposal is taken care of by professionals.
Measures for Hazardous Situations
First aid Contact with acids and caustics Measures
Skin contact Immediately rinse skin with plenty of water upon contact. With concentrated sulphuric acid: Dab off (with cotton cloth or paper tissue) until dry before rinsing. Consult a doctor.
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Observe the additional information about measures in hazardous situations. See "Hazardous Situations and Accident Behaviour" in this chapter.
2.7.5 Handling Radiation
Generally applicable information on handling radiation
There may be components that release harmful radiation on the machine. Warning signs are used to identify areas where harmful radiation is released.
The following are examples of radiation which can be harmful: Optical radiation Magnetism Microwaves Laser radiation Radioactive materials or ionising radiation
Generally applicable safety precautions when handling radiation: It is imperative that laws/regulations/guidelines (e.g., personnel instruction) on
handling radiation be observed. Warning signs must always be legible and in good condition.
Eye contact Flush eyes with flowing water for at least 10 minutes upon contact - with eyelids wide open. Consult a doctor.
Contact with clothing Remove contaminated clothing immediately.
Inhalation Provide fresh air ventilation. Clear the respiratory tract. Consult a doctor.
Swallowing Do not induce vomiting! Wash mouth out with water. Drink plenty of cold water or cold tea. Consult a doctor immediately.
Contact with acids and caustics Measures
Radiation source Examples
blow moulder). Infrared sensor (Checkmat fill level inspection unit).
UV radiation, e.g.: UV lamps (inspector, capper)
Magnetism Magnetism, e.g., Linear motors (blowing station of the blow moulder, heating
station of the microwave heating module, Ecopush rejection system).
Magnetron (heating station of the microwave heating module).
Microwaves Microwaves, e.g.: Magnetron (heating station of the microwave heating
module).
Laser radiation Laser radiation, e.g.: Monitoring devices (e.g., bar code detection, slanted cap
inspection) Thread inspection (inspector)
Radiation, e.g.: Fill level inspection unit with gamma source (Checkmat)
Laser radiation, e.g.: X-ray fill level inspection (Checkmat)
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Avoid areas with harmful radiation, and remain in these areas only as long as absolutely necessary to do work.
Stay the required minimum distance away from radiation sources. Never look directly into radiation sources (e.g., laser beam). If necessary, wear appropriate protective clothing and protective equipment (e.g.,
UV safety glasses).
For further information about measures for hazardous situations, see Safety instructions concerning the individual types of radiation Safety instructions on what to do in hazardous situations and accidents in this chapter.
Residual Optical Radiation Hazards (infrared/UV radiation)
WARNING Infrared/UV Radiation! Improper handling of infrared/UV radiation is hazardous. Looking into a beam of
infrared/UV light can damage your eyes and even blind you. Skin exposure

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