Chap 1-5

Pam Pac Machines Private Limited
Index
Company profile
Introduction
Statutory information
Safety
Machine specifications
Transport and handling
Installation
General function & working
Starting & operating the Machine
Controls
CARTOBLIS
Blister Packing Machine
Description of different stations

Attachments of the Machine
Change over procedure
Operations Manual
This document contains technical information and procedures
prepared by Pam Pac Machines Private Limited, India and are
highly confidential and proprietary in nature. This document is
provided under our scope of supply for the project referenced
above and is intended for use in conjunction with the same. The
contents of this document shall not be disclosed to third party
without prior written consent from Pam Pac Machines Private
Limited. Copies and distribution of this document (either paper
or software) shall be limited to the requirements for installing,
validating, operating, and/or maintaining the Pam Pac
equipment.
Alignments and settings

Service and maintenance
Trouble shooting - Mechanical
Trouble shooting - Electrical
Electrical data
Parts manual
After-Sales-Service
February - 2005
Revision - 01
MACHINES PRIVATE LIMITED

Gat No. 446/2, Village - Bebadohol,
Tal. Maval, Dist. Pune - 410 506. India.
Tel. : 009102114237093, 94,95,96.97
Fax : 009102114237092
E-mail : pampac@pampac.com
Dear Sir,
We take pleasure in presenting to you this Operations Manual for CARTOBLIS Blister Packing Machine.
The Machine which you have been using or which you are about to use is a State of the Art Machine. It has
been conceptualised, designed, developed and produced with a great amount of effort and research.
In view of the fast changing requirements in term of GMP operation validation and installation validation
that is now the nom de ruiguer of the Pharma Industry, we felt the need to update this Manual with updated
instructions on , installation, maintenance and troubleshooting guides.
The Manual has been simplified for easy use with sketches, figures and photographs of the related
equipment as much as possible. It also covers important topics like safety, installation, change over and
setting, operation, service and maintenance, spare parts and electrical circuits.
We are sure this Manual will be of a great help to your operational staff while handling the Machine at
different stages of use.
We would request you as well as your operating staff to go through this Manual thoroughly and give us
feedback and suggestions on the usefulness of this Manual. We highly value the suggestions and opinions
from our customers like you and your feedback shall be incorporated in improving on standards of both our
Machines and the Manuals.
With best wishes,
D. P. Saxena
(Vice President)
Chapter-1
Index
CARTOBLIS Blister Packing Machine
Chapter
No.
Subject
Page
No.
Index
1.1
Company Profile
2.1
Introduction
3.1
Manual Overview
3.1
3.2
How to read the Manual
3.1
3.3
Objectives of the Manual
3.3
3.4
Responsibility of customer
3.3
3.5
Modification in the Machine and Manual
3.3
3.6
Safe keeping of the instructions Manual
3.3
3.7
Abbreviations used in the Manual
3.4
Statutory Information
4.1
Copyright
4.1
4.2
Warranty
4.2
4.3
Liability restrictions
4.3
Safety
5.1
Basic safety instructions and warnings
5.1
5.2
Identifying danger spots
5.2
5.3
Location of the stickers on the Machine
5.5
5.4
Health and safety requirement
5.6
5.5
Personnel qualification and training
5.8
5.6
Working with process materials
5.9
5.7
Safety and protective devices
5.11
5.8
General warnings
5.12
Machine specifications
6.1
Description of models
6.1
6.2
Technical specifications
6.2
6.3
Floor space diagram
6.4
6.4
Electrical supply requirement
6.6
6.5
Compressed air requirement
6.6
1.1
Chapter-1
Index
Chapter
No.
Subject
Page
No.
6.6
Chilled water requirement
6.6
6.7
Hopper capacity
6.7
6.8
Ambient condition
6.7
6.9
Pneumatic circuit diagram
6.8
6.10
Salient features
6.9
6.11
Block diagrams
6.10
6.12
Electrical power requirement and connection details
6.14
Transport and Handling
7.1
The package
7.1
7.2
Symbols and inscriptions on the case
7.1
7.3
Packing of the Machine
7.2
7.4
Transporting the packed Machine
7.3
7.5
Storing the packed Machine
7.4
7.6
Unpacking the Machine
7.4
7.7
Disposal of the packing Material
7.6
Installation
8.1
Prerequisites for installation
8.1
8.2
Shifting to the required location
8.2
8.3
Levelling
8.3
8.4
Mounting of loose parts
8.4
8.5
Utilities connections
8.8
General Function and Working
9.1
General functions
9.1
9.2
Main functions
9.1
9.3
Operating sequence /description of Machine cycle
9.2
10
Starting and operating the Machine
10.1
Safety considerations
10.1
10.2
Risk assessment
10.4
1.2
Chapter-1
Index
Chapter
No.
Subject
Page
No.
10.3
Description of operational electrical components
10.7
10.4
Operating modes
10.9
10.5
Preparation and precautions for starting and operating of Machine
10.10
10.6
Actual starting of Machine
10.11
10.7
Running the Machine in run mode
10.12
10.8
The MMI operating instrucitons
10.13
11
Controls
11.1
Electrical controls
11.1
11.2
Pneumatic controls
11.2
12
Description of different Stations
12.1
Forming film unwinding station
12.2
12.2
Forming film cleaning unit
12.3
12.3
Heating and forming station
12.3
12.4
Web guide and infeed station
12.4
12.5
The lidding foil unwinding station
12.5
12.6
Sealing station
12.6
12.7
Indexing station
12.7
12.8
Perforation station
12.7
12.9
Punching station
12.7
13
Attachments of the Machine
13.1
Universal feeding system
13.2
13.2
Brush box feeding system
13.2
13.3
Multi feeding system
13.3
13.4
Manual feeding tray
13.4
13.5
Fill box feeding system
13.4
13.6
Over printing unit
13.5
13.7
Embossing
13.5
13.8
Scoring
13.6
1.3
Chapter-1
Index
Chapter
No.
Subject
Page
No.
13.9
Print registration system
13.7
13.10
Non filled detection system
13.8
13.11
Two in one change part
13.9
14
Change Over Procedure
14.1
Forming foil roll
14.1
14.2
Lidding foil roll
14.2
14.3
Forming drum
14.3
14.4
Guide plate
14.5
14.5
Feeding track plate
14.6
14.6
Punching unit
14.7
14.7
Change gear
14.8
14.8
Brush box feeding
14.9
14.9
14.10
14.10
14.11
15
Setting details
15.1
Forming foil
15.1
15.2
Lidding foil
15.2
15.3
Forming
15.3
15.4
Guide plate
15.4
15.5
Sealing
15.5
15.6
Indexing
15.6
15.7
15.7
15.8
15.8
15.9
Feeding
15.9
15.10
Two in one change part
15.10
1.4
Chapter-1
Index
Chapter
No.
16
Subject
Page
No.
Service and Maintenance
16.1
Regular maintenance
16.1
16.2
General warnings
16.1
16.3
Preventive maintenance
16.1
16.4
Preventive maintenance schedule
16.2
16.5
Standard operating procedure
16.4
17
Trouble Shooting
17.1
Forming of cavities
17.1
17.2
Universal feeding system
17.3
17.3
Indexing
17.4
17.4
Overprinting unit
17.4
17.5
Sealing
17.5
17.6
Blister punching
17.6
17.7
Vacuum pump
17.7
18
Trouble Shooting - Electrical
18.1
19
Electrical Data
19.1
PLC input details
19.1
19.2
PLC output details
19.2
19.3
Terminal details
19.3
19.4
Component details
19.8
19.5
Circuit diagrams
19.13
19.6
NFD connector details
19.27
19.7
Ladder diagrams
19.28
20
Parts Manual
20.1
Parts List
20.1
20.2
Recommended spare parts list
20.57
20.3
Spare parts ordering
20.59
20.4
Request for quotation
20.60
1.5
Chapter-1
Index
Chapter
No.
20.5
21
Subject
Statement of CE conformity
Page
No.
20.53
After - Sales - Service
21.1
After-sales-service
21.1
21.1
Contact Addresses for After -Sales-Service in India
21.2
21.2
Contact Addresses for overseas After-Sales-Service
21.3
1.6
Chapter - 2
Company Profile
Company Profile
of
Pam Pac Machines Private Limited has been manufacturing Hi-tech Blister Packaging and Carton
Packaging Machines for the last several years. Pam Pac is a Group company of ACG Worldwide
which is one of the few Groups in the world offering end-to-end solutions for solid dosage delivery
system. The Group comprises of ten companies, including subsidiary companies in the USA,
Indonesia and the Philippines. ACG worldwide is one of the largest manufacturer of hard gelatin
capsules in the world and has been serving the pharmaceutical industry for the last four decades.
Through its ten companies, ACG Worldwide is involved in a range of related activities such as
manufacture of empty gelatin capsule shells, packaging films, Machines for Encapsulation, Blister
Packing and Carton Packing and Formulation Processing.
ACG has established an unparalleled value chain in order to serve its worldwide customer base with
complete solutions to encapsulation. Pam Pac, a member of ACG Worldwide is the flagship
engineering company of the group. It is one of the largest Pharmaceutical Packaging Machinery
Companies in Asia. The considerable synergy of Pam Pac with other Group Companies enables it to
offer its customers a comprehensive solution for manufacture of solid dosage forms.
Pam Pac has a long experience in the field of blister packing and carton packing Machines, and has a
wide range of products in its stable. The rotary forming Machines with automatic feeding system
used for various purposes in the pharmaceutical industry in India and abroad give negligible
rejections and ensure better return on investment. These Machines are suitable for packing tablets,
and hard / soft gelatin capsules. Special versions of these Machines are suitable for packing multi
products i.e. different sizes of capsules and tablets in one blister, ampoules, vials, battery cells, spark
plugs, disposable syringes, tooth brushes, etc. High speed, Flat compressed air forming and flat
sealing / rotary sealing continuous motion Machines provide high degree of sophistication and are
suitable for blister packing of tablets/ hard gelatin capsules, soft gelatin capsules etc. Fully
automatic continuous motion horizontal cartoning Machines with rotary pick up unit and quick
changeover are highly user friendly Machines. These Machines are suitable for cartoning of blisters,
tubes, vials+ampoules, bottles, droppers, soaps, photo film rolls, bearings, spark plugs, etc. The
semiautomatic vertical cartoning Machines incorporating advanced features, which provide a
high degree of sophistication and are suitable for cartoning of bottles, pouches, physician samples,
blisters, strips and combination packs of bottles+dropper, Pouch+spoons etc.
Pam Pac also provides complete Blister packing and Cartoning Lines, which provide an automated
and integrated blister cartoning operation. These complete lines give highest levels of reliability,
need lesser maintenance and provide ease in operation.
2.1
Chapter - 2
Company Profile
Pam Pac has an obsession for innovative technology and the quest for the new product
development gives it an opportunity to deliver value added products to the customer.
Understanding market demands and requirements have always been a part of the business process
of Pam Pac.
The high degree of precision and ergonomics built into the Pam Pac range of products, make them
world class and cGMP compliant products.
Pam Pac operates in 40 countries around the globe and is a market leader in many countries. Most
Pam Pac customers are repeat buyers. Pam Pac partners the success and the growth of its customers
by giving them the best value for money and ensuring high standards of customer support. Pam Pac
gives the sense of partnership to it's customers and its partners perceive Pam Pac, not only as a
pharmaceutical Machinery manufacturer, but also as a total solution provider in the field of solid
dosage encapsulation.
2.2
Chapter-3
Introduction
3.1
Manual Overview
This 'Operations Manual' comprises instructions for operation, maintenance, trouble shooting (both
mechanical and electrical) and requirements of spare parts for the Blister Packing Machine Models
CARTOBLIS manufactured by Pam Pac Machines Private Limited.
In all the subsequent pages henceforth in this Manual:
3.1.1 This 'Operations Manual' will be referred to as the 'Manual'.
3.1.2 The Blister Packing Machine Model CARTOBLIS for which this 'Manual' is meant for will be referred to as
'Machine'.
3.1.3 The manufacturer of this Machine M/s. Pam Pac Machines Private Limited will be referred to as Pam
Pac.
This Machine is a quality product from Pam Pac. It demands utmost care and caution during its operation and
maintenance.
Correct operation and maintenance of the Machine is indispensable to retain the quality of the Machine. To
help you to ensure this, every CARTOBLIS Blister Packing Machine comes to you with a complimentary copy
of this Manual.
The Manual contains very important information enabling the user a safe, correct and trouble free operation
of the Machine. It explains in details with vivid illustrations, various Machine functions, details pertaining to
transport, unpacking, installation, commissioning, operation, cleaning, repairs and maintenance, trouble
shooting and spare parts requirements. Accidents, failures, costly downtimes and repairs can be avoided by
strictly following the guidelines and instructions in this Manual.This will also ensure economic operation and
prolonged Machine life.
All the personnel connected with the handling of the Machine including the Manager and the shop floor
Supervisor should first study this Manual thoroughly and get familiar with the Machine prior to operation.
3.2
How to read the Manual
The Manual starts with giving a brief introduction to the profile of the company and its products.
The important subjects covered in the Manual are given in their operational sequence. Different subjects and
related topics against that subject are grouped under one chapter. Thus, there are different chapters for
different subjects and under each chapter, there are different topics related to that subject.
The Manual starts with introduction to the Manual and the Machine and emphasizes the need for every
person connected with the operation of the Machine to read and understand the Manual and the Machine.
The Manual is full of vivid illustrations, on every topic covered by it so that even a person who has never seen
or operated the Machine earlier will get a clear perception of the construction and operation of the Machine.
Major attention and importance is given to the safety of the personnel using the Machine, safety of the
Machine itself and the environment. To highlight the dangers involved in operating the Machine in unsafe
condition, different symbols are given specifying instruction for observance of safety precautions.
3.1
Chapter-3
Introduction
Special chapters are given for Trouble shooting and Spare Parts. Each possible problem is solved in the
Manual by giving probable cause of the problem and its solution.
In the Spare Parts Section, photos are given for each spare to facilitate finding the required part
number for each component.
A specimen page layout in the Manual gives following information.
Subject
Chapter-7
Transport and Handling
Machine Model
Topic
Photograph
CARTOBLIS
Chapter related
Number
Photo No. 7/1
Figure
Fig. No. 7/1
Symbols
Page
Number
41
3.2
Chapter-3
Introduction
3.3
Objectives of the Manual
This 'Operations Manual' will help you achieve trouble free performance and desired output of acceptable
quality from the Machine.
3.4
Responsibility of customer
3.4.1
Managers or the shop Supervisors should study the Manual beforehand.
3.4.2
Impart necessary training to the Machine operators.
3.4.3
Ensure that the Manual is easily accessible and available to the operators whenever it is needed.
Note : The time spent in studying this Manual will be largely compensated by saving valuable time and
money, if the Machine is operated and maintained exactly as per the instructions given in this Manual .
However, the Manual should not be seen as a substitute for intensive hands-on training of the operating and
maintenance personnel.
The Manual presupposes that the prevailing health and safety norms, as per the laws of the land are observed
in the establishments where the Machine is installed and operated.
3.5
Modifications in the Machine and Manual
Pam Pac reserves the right to make any technical changes or modifications for making improvements in the
Machine. Such modifications will be communicated to our customers as and when necessary and the
customers will be responsible to ensure that only the updated version of the Manual is kept in proximity with
the Machine.
3.6
Safe keeping of the Operations Manual
Keep the Operation Manual with care and in proximity with the Machine . It must accompany the Machine
wherever and whenever the Machine is shifted to a new location of installation.
Handle the Manual with care, with clean and dry hands and the Manual must not be placed on wet and dirty
surfaces. It must be stored in a place free from humidity and heat.
Do not fold, tear or modify pages. No pages or a part there of must be removed from the whole volume.
Further copies of the Manual can be supplied by Pam Pac at a reasonable price on written request from the
customer.
3.3
Chapter-3
Introduction
3.7
Abbreviations used in the Manual
Abbreviation
Full Form
Abbreviation
Full Form
AC
Alternate Current
M/C
Machine
ACPL
Associated Capsules Private Limited
Mins
Minutes
Adj.
Adjustment
mm
Milimeter
Amp
Ampere
MMI
Man Machine Interface
Alu.
Aluminium
Mtr.
Meter
BP
Blister Packing
Neutral
Degree Celsius
NFD
Non Filled Detection
cc
Cubic Centimeter
No.
Number
cGMP
Current Good Manufacturing

Practice
Pam Pac
PLC
Programmable Logic Controller
Per Square Centimeter
PVC
Poly Vinyl Cloride
DC
Direct Current
PVDC
Poly Vinyl Die Cloride
db(A)
Decibels in Scale A
Qty.
Quantity
FDA
Food and Drug Administration
RH
Relative Humidity
Fig.
Figure
Sr. No.
Serial Number
FMCG
Fast Moving Consumer Goods
S.S.
Stainless Steel
FR
Ferrule
TR
Terminal
FRL
Filter, Regulator and Lubricator
UCPL
Universal Capsule Private Limited
High
Volts
Hg
Mercury
VCP
Vertical Carton Packing
Hz
Hertz
V/V
Volume/volume
Illus.
Illustration
Width
IR Sensor
Infra Red Sensor
Percentage
KCal.
Kilo Calory
Kgs.
Kilograms
cm
Kg/sq.cm. Kilogram per square centimeter

Kw
Kilowatt
Low
LED
Light Emitting Diode
Lts.
Litres
Machine
Blister Packing Machine
Manual
Manual for Blister Packing Machine
MCB
Miniature Circuit Breaker
3.4
Chapter-4
4.1
Copyright
The instructions, drawings, illustrations, photographs and documents contained in this Manual are strictly
the property of M/s. Pam Pac Machines Private Limited. No part of this Manual may be copied, reproduced,
sold or transmitted in any form or by any means, electronic or mechanical including photocopying, recording
by any information storage and retrieval system without written permission from the Machine Manufacturer,
Pam Pac.
The Manual may also be used for its approved purpose by the customer who has purchased and installed our
Machine directly from us.
Legal proceedings will be initiated against anyone who violates this copyright.
4.1
Chapter-4
4.2
Warranty
The Machine is under a warranty for a period of 12 months from the date of receipt by the client for any
premature failure of a component/ assembly.
This Manual contains all the instructions necessary for observance of the warranty condition. The Manual
should be carefully studied by all concerned before installation and commissioning the Machine for regular
use.
Expendable components are not covered by the warranty after their useful life. The warranty will lapse in the
event of damage arising out of usage of non-genuine spare parts and / or accessories as well as unauthorised
alteration or modifications to the Machine or any of the accessories.
The warranty will also lapse in the event of:
l
Wrong or negligent handling.
l
Improper or inappropriate use of the Machine.
l
Operating by an untrained or unauthorised person.
l
Incorrect installation.
l
Incorrect
or negligent connections of cables and electrical or mechanical controls between the

Machine and it's accessories.
l
Non-compliance of the instructions contained in this Manual by the customer or any of their personnel
handling the Machine at any stage.

l
Damage resulting as a consequence of error in operation, maintenance and repairs.
l
Protective devices removed or modified without permission from Pam Pac.
4.2
Chapter-4
4.3
Liability restrictions
We assume no liability for damages, breakdowns or stoppages consequent to non-compliance of

instructions in this Manual.
All technical data, information and instructions for the operation and maintenance of the Machine,
contained in this Manual are provided to the best of our knowledge and experience at the time of printing of
this Manual. We reserve the right to make any technical changes in the Manual and / or the Machine with a
view to improve the performance of the Machine from time to time and will not entertain any claims arising
out of the contents and illustrations in this Manual.
The illustrations provided in this Manual project only a general profile of the given component or assembly
to facilitate easy identification and understanding of the function of the given component / assembly and do
not necessarily give exact specifications, size or shapes as they are not drawn to scale in relation to the whole
Machine or to other assemblies or components.
The original text of this Manual is drafted in English language and this original English language Manual will
remain decisive for the handling, operation and maintenance of the Machine. In case of translations in any
other language, we assume no liability consequent to any errors, additions, deletions, omissions and
misunderstandings in such translations carried out by the client or any other agency.
Pam Pac also does not accept any liability arising out of:
l
Damage to Machine, injuries to person or other accidents if safety instructions are ignored.
l
Damage to Machine due to faulty transportation, installation, operation, maintenance or repairs.
l
Contact with or inhalation of harmful fluids, gases, mists, fumes, and dusts by the operating personnel.
l
Exposure of operating personnel to any biological or microbiological hazards.
l
Fire or explosion arising out of materials and substances used during the operation.
4.3
Chapter-5
Safety
5.1
Basic Safety instructions and warnings
5.1.1
Maintain the Machine in perfect working order. It should always be handled by authorised and trained
personnel and should be used only for its intended purpose strictly in accordance with the instructions
contained in this Manual.
5.1.2
Always keep the Manual in proximity with the Machine for easy reference whenever required.
5.1.3
It is the responsibility of the Management and the Supervisor to study the Manual thoroughly and then
impart proper training to the operating and maintenance staff in respect of all the vital functions of the
Machine, emphasizing the necessity of strictly observing the safety precautions and following the
instructions laid down in the Manual. This has to be done well before installation, commission and
starting the operation. Besides the Manager and Supervisor, it is imperative for all the operating and
maintenance personnel to read and understand the Manual thoroughly.
5.1.4
Only competent, trained and reliable persons who have reached the legal adult age should be allowed to
handle the Machine.
5.1.5
The operator should be authorised to take instructions only from an accredited Supervisor or Manager
and not from anybody or everybody so as to ensure that the Machine remains always in good and safe
condition.
5.1.6
While working on the Machine, the operating and maintenance staff should not keep their hair open,
wear loose clothing, tie, jewellery or ornaments including necklace, bracelet, ring and chain.There is a risk
of injury as any of these articles may get caught or pulled into the Machine and cause an accident or
injury.
5.1.7
All safety and warning signs on or about the Machine should be clearly visible and legible at all times.
5.1.8
The operators should be familiar with the location and working of fire extinguishers kept in the vicinity of
the Machine.
5.1.9
Do not carry out any additions, deletions, conversions or modifications to the Machine without written
consent from Pam Pac.This can adversely affect its safety and cause accidents, injuries to the operators or
damage the Machine.
5.1.10
Switch off the main switch of the Machine during the process of installation, assembly, disassemble,
maintenance and cleaning. The Machine must be protected against unintended operation by
disconnecting it from the main source of power, vacuum or compressed air.
5.1.11
Never deactivate the safety devices installed on the Machine.
5.1.12
Never run the Machine in automatic mode with the safety guards removed.
5.1.13
The operations carried out under reduced safety conditions must be strictly carried out as per indications
provided in the relevant instructions.
5.1.14
After carrying out operations under reduced safety conditions, the state of the Machine with active safety
devices must be re-established as soon as possible.
5.1.15
Carry out the cleaning operations only after disengaging the Machine from its electric and pneumatic
power supply.
5.1.16
Clean the surface, panels and controls of the Machine with soft, dry cloth or cloth slightly dampened in a
mild detergent solution. Do not use any type of solvent such as alcohol or petrol as it could damage the
surface and cause fire or explosion.
5.1
Chapter-5
Safety
5.2
Identifying danger spots
The following symbols have been used at different places in this Manual relating to work safety whereever
there is a risk to the life, limb and health of persons, risk of damaging the Machine or danger to the
environment.
Symbol
Symbol Indicates
Warning of a
danger spot
CAUTION
Note carefully
F
NOTE
The text given against this symbol must be read carefully

and special attention must be given to ensure that
directives, regulations, instructions and correct sequence
of work are observed. Failure to do so may result in
damage and destruction of the Machine or parts thereof.
Live hazardous voltage and dangerous electric current
can cause severe injury or death. Always switch off electric
current and disconnect or unplug power supply cable
before performing any repairs or maintenance work.
Always connect power supply cord to a grounded
electrical circuit with the specified voltage and fuse
protection. Never use any equipment which is powered
by electricity in rain, wet area or near an explosive
environment.
Danger of
environmental
pollution
Failure to follow the instructions against this symbol may

cause environmental pollution.
Danger from fire
Inflammable vapours can cause a fire or an explosion and

result in severe injury or death and destruction.
Hazardous vapours
Can cause severe nausea, fainting or death. Use a respirator

or mask whenever there is a risk or chance of inhaling
hazardous mists or vapours emanating out of formulations,
solvents or lubricants.
Compressed air
Never point an air nozzle or sprayer towards any part of the

body or towards any person.
Danger to limb
Moving parts can cause severe injury.

Before commencing any maintenance or repair work,
ensure the following :
Switch off the electric power supply and disconnect the
power supply cord and compressed air system.
Disconnect the air compressor from the Machine.
FIRE HAZARD
HAZARDOUS FUMES
COMPRESSED AIR
DANGER TO LIMB
The instructions given against this symbol must be read

carefully. They relate to a dangerous spot on the Machine
and/or to a procedure, if not followed strictly may result in
danger to life, limb, the Machine and the environment.
Danger
ELECTRIC
CURRENT
ENVIRONMENT
POLLUTION
Consequence of violation
Whenever any of these symbols are found in the Manual, instructions against these symbols should be read
very carefully and followed strictly. Also each of such safety instructions should be communicated to all
those concerned with the Machine.
5.2
Chapter-5
Safety
Warning through symbols affixes directly on the Machine, such as,

Symbol
Symbol indicates
Consequence of violation
The symbol indicates power supply area and the risk of electrical
shock in this area.
While doing any work electrical power should be switched off by
putting off the isolator switch.
This symbol cautions about the danger of hand being caught in
moving parts.
WARNING
KEEP
GUARDS IN
PLACE
Earthing point
Pit earthing point
PE
Hot surfaces
Arrows showing direction of rotation
WARNING
Warning
Failure to comply may result in severe injury to the operator.

Keep hands away from the moving parts as Machine operates
automatically.
Do not remove this sign from it's place.
WARNING
WARNING
DANGER
Warning
Operating the machine with doors open can cause serious injury.
Keep emergency switch pressed when working on the Machine
with doors open.
Warning
Contact with moving parts can lead to entrapment of body

parts and serious injury. Do not put your hands into the conveyor
during operation.
Warning

High voltage is used in this Machine.
Only qualified persons should attempt installation or repair.
Do not remove this sign from its place.
WARNING
Warning

Close door before / during operation.
Do not remove this sign from its place.
5.3
Chapter-5
Safety
In addition to the high attention safety symbols already mentioned, the symbols indicative of the flow of
electricity and flow of compressed air or vacuum are also used in the Manual.
Different types of functional symbols for effective communication:
lMain electrical supply ON
lMain electrical supply
OFF
lElectrical control panel switch ON

lElectrical control panel switch OFF
lRelease emergency stop push button
lFlow of air
Special attention should also be given to instructions given against these symbols as they are indicative of
the flow of electric and pneumatic power which may result in life threatening injury and damage, both to
persons and the Machine, if not operated strictly as per the instructions.
5.4
Chapter-5
Safety
5.3 Location of the stickers on the Machine.
5.5
Chapter-5
Safety
5.4
Health and safety requirements
5.4.1. Health
5.4.1.1
Cleanliness
The place where the Machine is installed and is in operation must always be kept clean.
Accumulation of dirt and refuse must be removed daily by sweeping or by any other
effective methods. The floor must also by cleaned at least once every week by washing,
using disinfectant.
5.4.1.2
Disposal of wastes and effluents

Effective arrangements should be made for the disposal of wastes and effluents generated
during the process, so as to render them innocuous before their ultimate disposal.
5.4.1.3
Dust and fumes

If dust, fumes, formulations or any other offensive substance is given off during the
operation of the Machine to such an extent as likely to be injurious or offensive to the
workers, effective measures should be taken to prevent its inhalation and accumulation
around the Machine. If any exhaust system is felt necessary for this purpose, it should be
installed as near as possible to the point of origin of such offensive substance and such
point should be enclosed to the extent possible.
5.4.1.4
Lighting
The workplace should be provided with sufficient and suitable lighting either natural or
artificial or both.
All glazed windows and skylights used for lighting the workplace should be kept clean on
both the inner and outer surfaces and should be such as to prevent any glare, either directly
from a source of light or by reflection from the smooth or polished surface and also as to
prevent the formation of shadows to such an extent as to cause eye-strain or the risk of
accident to the workers.
5.4.2
Safety
5.4.2.1
Fencing of Machine
The machine should be securely fenced by safeguards. These safeguards should be kept in
position while the parts of the Machine which they are fencing are in motion or in use.
5.4.2.2
Work on Machine while in operation

No person should be allowed to clean, lubricate, repair or adjust any part of the Machine
while it is in motion/operation.
5.4.2.3
Employment of persons on the Machine

No person should be allowed to work on the Machine unless the person has been fully
explained and instructed about the dangers involved, precautions to be observed, has
received adequate training in operating and handling the Machine and is under adequate
supervision by a person who has a thorough knowledge and experience of the Machine.
5.4.2.4
Cutting off the power supply in emergency

Suitable devices for cutting off power from the running machinery should be provided and
maintained in case of emergencies.
5.6
Chapter-5
Safety
5.4.2.5
Lifting devices, chains, straps, ropes and tackles

All parts including working gear, whether fixed or movable of every lifting device and every
chain, strap, rope or tackle should be of good construction, sound material and adequate
strength and free from defects, properly maintained and thoroughly examined
periodically by a competent person.
It should be ensured that a crane does not approach close to the place where a person is
working on the Machine.
5.4.2.6
Manual lifting of excessive weights

No person should be allowed to carry or move any such heavy loads which may result in an
injury.
5.4.2.7
Protection of eyes
Effective screens or suitable goggles must be provided for the protection of the operators
working on processes involving risk of injury to the eyes from the particles, fragments or
process material being thrown off during the process or which involve risk of injury to the
eyes due to exposure to excessive light.
5.4.2.8
Use of portable electric light

No portable electric light or any other electric appliance of voltage exceeding 24 volts
should be permitted for use inside any chamber, tank, pit, pipe, flue or any other confined
space unless adequate safety devices are provided. If any inflammable gas, fume or dust is
likely to be present in such chamber, tank, pit, pipe, flue or other confined space, no lamp or
light other than that of flame-proof construction should be permitted to be used therein.
5.4.2.9
Explosive or inflammable dust and gas

Where the process produces dust, gas, fumes or vapours which are likely to explode on
ignition, all practical measures should be taken to prevent such explosion by :
a.
Effective enclosure of the plant or machinery used in the process.
b.
Removal or prevention of accumulation of such dust, gas, fume or vapour.
c.
Exclusion or effective enclosure of all possible sources of ignition.
5.4.2.10 Precautions against fire

All practicable measures must be taken to prevent outbreak of fire and it's spread, both
internally and externally.
Provide and maintain :
a.
Necessary fire fighting equipment and facilities for extinguishing fire.
b.
Safe route and means of escape for all, in the event of fire.
Effective measures should also be taken to ensure that all the workers are familiar with the
route and means of escape in case of fire and are adequately trained in the routine to be
followed.
5.4.3. First -aid

First-aid boxes or cabinets should be made available and accessible to all workers during all working
hours. These first-aid boxes or cabinets should be equipped with prescribed contents. These should
be kept under the charge of a responsible person who is trained in first-aid treatment and who shall
always be available during all working hours.
5.7
Chapter-5
Safety
5.4.4. Employment of young persons

No person below 18 years of age should be required or allowed to work on the Machine.
5.5
Personnel qualifications and training
The persons entrusted with the job of installation, commissioning, operation, maintenance and servicing of
the Machine must be adequately qualified and competent in their respective fields while handling the
Machine. It is imperative that the following requirements are met with, before a person is allowed to handle
the Machine.
5.5.1
The Manager or the Supervisor himself should first study and understand the Operations Manual
and the Machine.
5.5.2
The management must ensure that everybody who is entrusted with handling the Machine at
any stage should have read and understood the contents of the Manual.
5.5.3
All those handling the Machine should be educated enough to read and understand the text, signs,
symbols, diagrams, drawings and illustrations in the Manual and on the Machine.
5.5.4
They should have adequate knowledge, experience and training in handling products like foods and
drugs.
5.5.5
They should have adequate knowledge and experience in Statutory Safety and Accident Prevention
Regulations in the country.
5.5.6
They should be able to understand generally accepted guidelines and technical codes so that they
can judge the safe condition of foods and drugs filling and packaging Machines.
5.5.7
They should be familiar and knowledgeable with the pro-active equipments, relevant tools, first aid
measures, fire fighting and other emergency equipment and services.
5.5.8
If the persons handling the Machine do not have adequate competence, knowledge or experience,
they should be first provided necessary training in their respective field of responsibility, before
allowing them to handle the Machine in anyway, whatsoever.
5.5.9
Even if they have in general previous experience and knowledge of all the above mentioned aspects
the specific training of the particular Blister Packing machine Model BP-102 / BP-105 MF / BP 450 AD
is a must before allowing anybody to handle the Machine.
5.5.10 If necessary, the customers can request Pam Pac to organize necessary training of their personnel.
5.8
Chapter-5
Safety
5.6
Working with process materials
The mineral oils, lubricants and coolants used in the Machine may contain additives which, even in
howsoever small quantities, may have detrimental effects on health.
Skin damage may occur following contact with such oils, lubricants and coolants.
Pulmonary illness may be caused by inhaling oil mists and vapours from these substances.
5.6.1
Health and skin protection
Take following precautions to avoid adverse effect to your health.

5.6.1.1 Avoid prolonged, extensive and repetitive skin contact with either fresh or used oils, lubricants and
coolants.
5.6.1.2 Use suitable skin protection and gloves while working with oils, lubricants and coolants.
5.6.1.3 Change your clothing before it becomes saturated with these materials.
5.6.1.4 Do not keep any web cleaning rags in the pockets of your clothes, coats or aprons.
5.6.1.5 Wash your skin immediately with soap and water if it has been soiled with oils and lubricants.
5.6.1.6 Never wash your hands with coolants or solvents.
5.6.1.7 If skin damage takes place while working with these substances, consult a doctor as soon as possible.
5.6.1.8 If any of these materials get into your eyes, rinse your eyes immediately with clean water and consult
a doctor as soon as possible.
5.6.1.9 Ensure that no oil is spilled on the floor. In case of a oil spill, scatter sawdust or an oil absorbent over
the spilled oil and clean the area.
5.6.1.10Never pour oils or liquids containing oils into a drain or open waters.
5.6.1.11Waste oil should be collected and disposed off at the collection points specified for such wastes.
5.6.2 Cleaning agents

Cleaning agents and solvents contain substances which are a health hazard. Quite a number of them are also
combustible and explosive.
Take following precautions while handling such cleaning agents.
5.6.2.1 Carefully read and follow safety instructions on the container or the package.
5.6.2.2 Ensure adequate ventilation while working with solvents.
5.6.2.3 Smoking and naked flames should be strictly prohibited while working with combustible cleaning
agents and solvents.
5.6.2.4 Use available skin protection and skin care products before and after using the cleansing agents.
5.6.2.5 Do not pour any solvent in the drains or open waters.
5.6.2.6 Ensure that all cleaning agents and solvents are removed from the machine before starting the
Machine.
5.9
Chapter-5
Safety
Provision of Emergency Stops

l
Before turning on the power switch, make sure of the locations of Emergency Stop buttons so that
you can press one of them to stop the Machine immediately, in case of emergency.
l
Emergency switches are provided at 3 places, which can be the most common working places of
the Machine operation.

l
One switch is provided on the MMI, the second switch is provided near the conveyor & punch tool
assembly and the third switch is provided at the rear side of machine. ( as shown in photo)
l
The emergency stop is for stopping all the machine movements and drive transmission. This also
stops the vacuum pump and feeder motor.

Note :
Even if emergency stop is pressed the heaters are not disconnected from the supply. For
switching off the heaters the power off push button on the main control panel has to be
pressed.
5.10
Chapter-5
Safety
5.7
Safety and protective devices
Operational safety of the Machine is ensured by the following safety devices.

5.7.1
Safety interlocks have been incorporated for

l
All polycarbonate guards
l
Control cabinet doors.
l
Safety
switches are provided for protection from moving parts. In case the guards or
control cabinet etc. are opened in run mode, the Machine will stop immediately.
5.7.2
All high voltage electrical components have proper covers.
5.7.3
All the components have proper earthing.
5.7.4
Operator accessible area i.e. MMI, safety interlocks switches and sensors etc. are given 24 Volts
DC supply. This 24 V DC is derived from switch mode power supply connected through a
transformer.
5.7.5
All major moving parts are housed in an enclosed polycarbonate cabinet having three doors with
locking arrangement and safety interlocks.
5.7.6
It is strictly prohibited to run the machine in the RUN mode by, bypassing any one of the safety
interlocks.
5.7.7
Machine setting should be done only by trained, authorised person.
5.7.8
It is presumed that no part is used / changed on the machine other than supplied by Pam Pac.
Pam Pac may not be responsible for malfunctioning of such device.
5.7.9
The safety and operating precautions are mentioned in various sections of the Machine Manual. It
is presumed that the operator and the maintenance and servicing personnel take all the
necessary precautions while working on the Machine.
5.7.10
In 'Inch' mode, if the inching function fails due to the component failure or some other reason,
emergency stop is provided to disconnect the power from the actuators.
5.7.11
Whenever the power is not essential during mechanical settings, ensure that the power is isolated
by the isolator switch.
5.7.12
Provision of Emergency Stops

l
Before switching
on the power, make sure the location of 'Emergency Stop' buttons so that you
can press one of them immediately in case of emergency.
l
Emergency switch is provided at MMI, which is the most common working place of the machine
operation.
5.11
Chapter-5
Safety
5.8
General warnings
Non-observance of specific safety instructions and warnings contained in this chapter and the Safety
Instructions and Cautions indicated through words and/or symbols at other places in the Manual and/or the
Machine or General Safety Practices required to be followed while handling the Machine can lead to
accidents and risk to health and life of persons and/or damage to property, environment and the Machine.
Non-observance of Safety Precautions and Practice will also forfeit all claims for compensation and cessation
of the warranty.
Some of the examples of dangers consequent to non-observance of safety instructions are:
l
Risk to life and health of persons through either electrical or mechanical mishaps.
l
Failure of important and vital functions of the system and the Machine.
l
Failure of prescribed methods for repairs and maintenance.
l
Risk to environment through process materials and effluents.
Pam Pac assumes no responsibility and liability whatsoever for risk of life and health of persons and damage
to Machine, property and environment consequent to non-observance of any of the General or Specific
Safety Instructions or Precautions.
5.12

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Pam Pac Machines Private Limited

Description of different stations

Alignments and settings

MACHINES PRIVATE LIMITED

How to read the Manual

Objectives of the Manual

Modification in the Machine and Manual

Safe keeping of the instructions Manual

Abbreviations used in the Manual

Basic safety instructions and warnings

Identifying danger spots

Location of the stickers on the Machine

Health and safety requirement

Personnel qualification and training

Working with process materials

Safety and protective devices

Floor space diagram

Electrical supply requirement

Compressed air requirement

Chilled water requirement

Pneumatic circuit diagram

Electrical power requirement and connection details

Transport and Handling

Symbols and inscriptions on the case

Packing of the Machine

Transporting the packed Machine

Storing the packed Machine

Unpacking the Machine

Disposal of the packing Material

Prerequisites for installation

Shifting to the required location

Mounting of loose parts

General Function and Working

Operating sequence /description of Machine cycle

Starting and operating the Machine

Description of operational electrical components

Preparation and precautions for starting and operating of Machine

Actual starting of Machine

Running the Machine in run mode

The MMI operating instrucitons

Description of different Stations

Forming film unwinding station

Forming film cleaning unit

Heating and forming station

Web guide and infeed station

The lidding foil unwinding station

Attachments of the Machine

Universal feeding system

Brush box feeding system

Multi feeding system

Manual feeding tray

Fill box feeding system

Over printing unit

Print registration system

Non filled detection system

Two in one change part

Change Over Procedure

Forming foil roll

Lidding foil roll

Feeding track plate

Brush box feeding

Non filled detection system

Print registration system

Non filled detection system