Carton Check Up - CB1 - EN - Released PDF

Tests
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9 Tests
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9.1 General information on tests
In order to aseptically fill and pack foodstuffs, the production process must fulfil specific quality
criteria. The following of these criteria must be controlled through the following test
procedures.
All tests must be documented. Use respective forms for that purpose, see chapter
“Checklists/Forms”.
This section describes the individual procedures to test the quality characteristics.
Production controls
The proper condition of the equipment used (combibloc filling machine, UHT system) and of all
materials required is the essential condition for a trouble-free production process.
For this reason, it is recommended to carry out the necessary tests and control measures
before production start-up and during production.
The following chart is a summary of all measures to be taken and time intervals of tests to be
carried out.
Summary of test- and control measures
Measures Check-up intervals Who?

upon
delivery / Start of when
daily
when production required
refilling
Machine operator,
Cleaning control
plant laboratory
Plant laboratory /
Sterilisation control
machine operator
Machine operator,
H2O2test
plant laboratory
Controls of packaging Machine operator,
material quality assurance
Package test,
Machine operator,
including blue/red dye
plant laboratory
test
Final packaging
Machine operator
checks
Bacteriological
Plant laboratory
controls
Follow protection mark Stand 15.11.2013 9-1

ISO 16016. cb 1 / cf 1
Tests
Documentation
INFO
For reasons of product liability and production safety, it is necessary to have available a
detailed production documentation. This is the only way to prove that the foodstuff has been
treated/processed correctly. The manufacturer of the foodstuff is liable for the consequential
damages incurred by the consumer through the consumption of a foodstuff treated incorrectly.
Important elements of the documentation:

 General production data, such as date, production time (time: start-end)
 Product and carton package (format)
 Responsible staff members (machine operator, division manager, shift supervisor)
 Quantity produced
 Plant and equipment used
 Additional resources used (possibly recipes)
 Results of chemical-physical analyses
 Microbiological results
 Production Checklist
 Protocols from the filling machine
 Acquisition of production- and machine faults, including time, duration and reason for fault
 Data on cleaning, disinfection and other sanitary measures
INFO
The filling machine operating company must make available forms for that purpose.
The weight control of the cartons including a statistical analysis of the results and an
extensive micro-biological test of the products are stipulated by law. The products must
be tested in accordance with the respectively valid guidelines. The results of the tests must be
kept for certain periods of time to enable control measures through legal departments.
In general, such safekeeping periods also apply to the printouts of the protocols of the plants
used (such as heating plant and filling machine) on which important process parameters such
as heating temperature, flow volume etc.) are recorded during the complete production time.
The Protocols, Forms and Checklists must be identified (together with date, product
filled and signatures of responsible person) and must be kept at a safe custody
together with the other product documentation.
See Chapter "Checklists/Forms".
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9-2 Stand 15.11.2013 Follow protection mark

cb 1 / cf 1 ISO 16016.
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9.2 Packaging material
All packaging materials used for the filling on combibloc filling machines have been produced
in accordance with the valid combibloc specifications in our production facilities Linnich,
Wittenberg (Germany), Saalfelden (Austria), Rayong (Thailand), Suzhou (China), Curitiba
(Brazil) or Riad (Saudi Arabia). In order to match a large variety of products to be filled, the
packaging material does not consist of one single material but is a compound material made
of different laminations. Thus, the packaging material is also called a compound packaging
material, since the properties of the individual components as a "compound" add up to an
overall property.
The composite packaging material consists of 70 % of paper-board.
Schematic structure of a carton package
1 Polyethylene
2 Polyethylene
Aluminium foil (for

3 aseptic composite
material only)
1
2
4 Polyethylene 3
4
5
5 Paper board 6
7
6 Polyethylene
bi bloc ®
m
SI G Co
7 Colour
00005201
Ill. 9-1

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Significance of individual layers

Printing ink – used to print onto the carton package.
Outside PE (polyethylene) – is designed to protect outside of compound material
against moisture and water vapor.
Paper board – used as a stability agent, provides the shape to the final
carton package, provides the required stability of shape
and rigidity and makes the carton package transportable.
Laminating PE (polyethylene) – is designed as a laminate agent between the board and
the aluminium.
Aluminium film – serves, in particular, as a light protection, gas-, diffusion-
and aromatic barrier.
Adhesive (PE) – used to increase the adhesive between aluminium and
inner coating to prevent a delamination of the layers.
Inside PE – necessary as a protection against moisture penetration of
the board, as welding material for top, bottom and
longitudinal seam and as a protection against re-infection.
The base material for the carton package is the paper board. The board provides rigidity, grip
stability and stability under load to the carton package and provides the condition for a folding
of the carton packages through creasability. The specific requirements towards the paper
board are manifold and not easy to combine.

cb 1 / cf 1 ISO 16016.
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9.2.1 Production process of a sleeve
From the paper board roll to the sleeve
1 2 3 4 5 6 7 8
2 9 2
00005002
Ill. 9-2
1 Board roll 6 Sealing of longitudinal seam

2 Polyethylene (PE) 7 Finished sleeve
3 Coated compound 8 Shipping box
4 Printing 9 Aluminium
5 Creasing/Cutting of blanks
Usually printing is done onto the outer PE layer after the coating (see Ill. 9-2). The printed roll
is creased and cut into individual blanks on the cutter in two separate operating stages.
An identification number is printed onto each blank, which informs the specialist about the
position of the blan on the web see section 9.2.4.
At the outfeed of the cutter, the sleeves are stacked and transported to the automatic folding
and sealing machine.
The production of a sleeve is completed with the sealing of the longitudinal seam (see Ill. 9-3).

ISO 16016. cb 1 / cf 1
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The finished sleeves are taken up by a conveyor belt and fed to a boxing machine via a
counting unit. Boxes containing the same type of sleeves are automatically palletised, shrink-
foiled and made ready for delivery.
During all of the production cycle, the manufacturing is continuously controlled. Sampling is
effected at specific steps of the processing and tests are carried out according to specified
quality criteria pursuant to ISO 9001. The test results are archived, in order to enable
assessments of the respective production at a later stage. In addition, sample sleeves are
stored documenting production by way of finished products.
Cross section of longitudinal seam of combibloc carton package
00005102
Ill. 9-3
1 Aluminum foil
2 Board
3 Polyethylene (PE)

cb 1 / cf 1 ISO 16016.
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9.2.2 Incoming controls of packaging material and storage
It is essential for aseptic packaging that the packaging materials to be used are in an
undamaged condition, because otherwise a contamination of the foodstuff with germs (through
leaks, for example) may happen and this would result in a perishing of the foodstuff or even in
a health hazard.
In order to avoid a processing of defective sleeves, always check goods delivered for
completeness and damages. Claims must be immediately notified to the respective carrier or
supplier, respectively (do not forget to state delivery data).
NOTE
Board moisture
Unusable sleeves
An optimum processing of sleeves is only guaranteed with a specific board humidity. For this
reason, each pallet is shrink-wrapped before leaving the processing plant. This should prevent
a drying-off or wetting of the sleeves. If this plastic film is missing or defective upon delivery,
this may lead to problems when processing the sleeves and during production.
 Only use sleeves, which had been wrapped into a film before.
The system is designed for a specific process temperature and relative air humidity.
Deviations from that can lead to faults (leaks for example). Follow the following storage
conditions to allow a problem-free processing of the material:
Temperature: + 15 °C to + 35 °C
Relative humidity in the air: 50% to 70%
NOTE
Temperature
Unusable sleeves
The optimal functioning of sleeves is only guaranteed only at a certain temperature. Failure to
observe this temperature may lead to processing and production problems
 Only use sleeves that were stored above + 5 °C.
 Do not store sleeves outdoors. Do not store in the open!

ISO 16016. cb 1 / cf 1
Tests
Are the sleeves delivered or sored within the above mentioned conditions the sleeves can be
used directly for filling processing.
In case the delivery or a storage at temperatures of 15 - 35 °C is not possible, the pallet must
be placed into the filling area or into a room with operating temperature two days before
processing to achieve a climatic adaptation. If the sleeves have been stored below 15°C
remove immediately shrink wrapping to allow an adaptation to the room climate. If the sleeves
have been stored over 35 °C the shrink wrapping should only be removed just before the
processing to maintain the inner climate of the pallet
In order to avoid damages to the sleeves, the pallets shall not be stacked on top of each other
without a rigid intermediate layer. In order to avoid any soiling, it is recommended to close
open boxes and to cover open pallets.
Avoid any long-term storage of sleeves (more than 24 months). Thus, use the sleeves in the
sequence of the delivery. Under local specific environmental conditions the maximum period
of storage can be shorter.

cb 1 / cf 1 ISO 16016.
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9.2.3 Longitudinal seam default values/Tolerances of packaging materials
D
00005502
Ill. 9-4
Format D E
cb1 11.8 ± 0.8 mm 8.7 ± 1 mm
If the dimensions of the longitudinal seams are outside the tolerances specified for the
packaging material, please inform SIG Combibloc Service, see chapter "General
Information/Addresses of Service Agencies".

ISO 16016. cb 1 / cf 1
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9.2.4 Packaging material identification
In case of any possible claims, the respective production may be tracked and checked by
using the box inscription and the blank identification number. This way, it is possible to check
at a later stage, whether any irregularities occurred during this production. This enables a
faster analysis of problems during the filling process caused from the side of the packaging
material.
Box inscription
Each box is coded during production. The coding includes all important data on the product
and on production and differs for each type of carton package.
The wording is made up of several components:
Example for an inscription on a shipping box

a b c d
240 PC091500 FRUIT RED BERRY MIX 10030/9
e f g h i j k l
715456500 SWIFT 0004 2588 31.12.12 23:59 20216558 3114
Identification print Amount of digits available

a Number of sleeves in a shipping box 3 digits
b* Product hierarchy 8 digits
c Short ID of material 20 digits
d* Technical Information Code 7 digits
e Material number 9 digits
f Customer text 11 digits (field e + f max. 20 digits)
g* Production plant 4 digits
0004 = Linnich / Germany
0044 = Wittenberg / Germany
0100 = Saalfelden / Austria
0070 = Rayong / Thailand
0170 = Suzhou / China
0800 = Riad / Saudi Arabia (Obeikan)
0354 = Curitiba / Brazil
h* Production line 4 digits

i, j * Date, time of production 14 digits
DD.MM.YY_HH:MM
k Order number of production 8 digits
l Continuous number of shipping box 4 digits
This is a clear identification of each shipping box.

cb 1 / cf 1 ISO 16016.
Tests
Blank Identification number

The blank identification number is printed
next to the print design number. It informs
about the position of the blank on the web.
3 329 140 combibloc

SIG
00005204
III. 9-5

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9.3 Carton check-up
WARNING
Non-sterile conditions
Health risk through non-sterile conditions
The aseptic filling is at hazard in case of defective cartons. Unsterile cartons present a health
risk for the consumer.
 Strictly follow test instructions and thus make sure that only defect-free products will reach
the customer!
The carton check-up is designed to determine whether the carton package is sufficiently leak-
proof. This is a condition for the reliable and permanent protection of the product.
In addition, it is tested
 whether the carton package has the required weight,
 whether the head space corresponds to the specifications and
 whether the product is below specified residual H2O2 limits.
At the same time it is ensured that the opening system works properly.
The test and check procedures listed up in this section must be carried out by the operating
staff at the intervals specified. This ensures a production under uniform, optimum conditions.
Enter actual settings at the beginning of production and changes during production into
Production Checklist, see section 12.1.2.
INFO
The figures show the sleeve or carton package, respectively, prepared for the application of a
fitment. This preparation is waived when operating the filling machine without downstream
applicator for opening features.
In case of any faults you cannot eliminate, please inform SIG Combibloc Service, see chapter
General Information/Addresses of Customer Service Agencies".

cb 1 / cf 1 ISO 16016.
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9.3.1 Short overview of the test procedures
The following pictures show a short overview of the test and check procedures, which must be
carried out in the course of the carton check-up. The individual testing methods will then be
briefly presented.
The testing process defined in this manual must be strictly followed for final confirmation.
9.3.1.1 Short overview of the test procedures combibloc-carton package
30 29
5. 3.
1. 21 22 20 19 21
6. 8.
2.
243,00
4.
3.
4.
5.
6.
7.
8.
9. 1
1
² ² - T est
1. 7. 8.
H O
10.
3.
00180100
III. 9-6

ISO 16016. cb 1 / cf 1
Tests
9.3.1.2 Tests
Test 1: Sleeve activation pattern

Purpose of testing:
The check of the activation pattern of the
sleeve’s bottom section enables a check of
the bottom heating function and an
evaluation of the adjusted temperature.
For this purpose, the borderlines of the
activation and the heating-up of the 00180107
activated areas are tested.
Corrective and preventive measures can be III. 9-7
taken by using the activation patterns in
order to avoid or prevent possible leakers at
the bottom section.
Test process: See section 9.3.5.3
Test 2: Filling volume (weight)
Purpose of testing:
The weight check is necessary to ensure a
constant filling volume in the carton
package.
Testing process: See section 9.3.6
c ®
biblo
Com
SIG
243,00
00180171
III. 9-8

cb 1 / cf 1 ISO 16016.
Tests
Test 3: Visual check of outer appearance

in terms of bottom and top forming
2
Purpose of testing:
The check of the package forming enables a
fast identification of irregularities with regard
to the sealing of bottom, top and top flaps as
well as the overall appearance of the
package. 000AI001
Particular attention is given to: III. 9-9

- bottom and top forming
- overlap of bottom and top section
- position and accuracy of the date
- possible damages and scratch marks
on the package
- sealing and alignment of top flaps.
Test 4: Head space
Purpose of testing:
In order to obtain a well shaped package, it
is essential to keep the head space as small
as possible. The head space will be mainly
influenced by foam formationof the product
and the steam injection.
00005224
III. 9-10

ISO 16016. cb 1 / cf 1
Tests
Test 5: Top sealing
Purpose of testing:
The testing of top sealing enables a quick
evaluation of the sealing quality as well as a
check of the alignment of the sealing tools /
package pockets.
Testing is carried out on the following items :
- the complete area of the weld
- the light gap in the weld,
- the appearance of the weld,
- any burning marks and any signs of 000AI002
channel forming beside the III. 9-11

longitudinal seam,
- the dimension of the longitudinal
seam, if necessary (e.g. in case of
any previous irregularities).
Testing process: See sections 9.3.9 and
9.3.10
40 38 37
2
2
000AI012
III. 9-12

cb 1 / cf 1 ISO 16016.
Tests
Test 6: Activation of top flaps
Purpose of testing:
Causes for badly sealed top flaps and
leaking tops can be reliably determined with
the aid of activation patterns. 000AI004
For this purpose, the activated area of the III. 9-13

top flaps, temperature, pressing force and
top forming are checked.

ISO 16016. cb 1 / cf 1
Tests
Test 7: Activation pattern and forming at

the bottom section, as well as heating up
through drying station
Purpose of testing:
A check of the activation pattern of the
package bottom enables once more an
evaluation of the bottom heater function and
an evaluation of the temperature setting, see
test 1 on page 9-14.
Again, the pattern of the activation
borderlines and the heating-up of the 000AI005
activated areas are checked.

III. 9-14
In the course of this inspection further
attention is given to
- bottom forming,
- any possible channel forming at the
transition area to the longitudinal seal
and beside the triangle tips,
- possible loads on the folding edges,
- heating-up through drying air.
Any channel forming in the sealing area can
only be detected by visual check.
00180151
III. 9-15

cb 1 / cf 1 ISO 16016.
Tests
Test 8: Bottom sealing
Purpose of testing:
A check of the bottom seal enables a fast
evaluation of the quality of the package
bottom. The forming of any channels can
thus be safely detected.
00180106
III. 9-16
Testing process: See sections 9.3.9 and

9.3.13
000AI003
III. 9-17
Test 9: H2O2 residue check
Purpose of testing:
The H2O2 test strips indicate whether the
filled package has left the filling machine
below residual H2O2 limits.
Testing process: See section 9.3.15 H O -Test
² ²
SIG
Com
b ibloc
®
00005266
III. 9-18

ISO 16016. cb 1 / cf 1
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Test 10: Blue/red dye test
Purpose of testing:
After all other inspection tests have been
successfully completed, the blue/red dye
test is the final and conclusive test for
package tightness.
00005267
III. 9-19
INFO
As long as the blue/red dye test does not fulfill the requirements stated in the test manual,
production must be interrupted until the cause has been found and repaired.

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9.3.2 Check-up works and intervals (Summary)
INFO
Ensure correct function of steam injection before control works!
Check-up intervals
After all repair and maintenance

When changing production date
When changing product or print
At the beginning of production
Procedure: see section

When changing pallet
Each 4 hours
Every hour
design
works
c®
biblo
Com
SIG
Check-up works
1. Activation pattern at
sleeve * * 9.3.5.3
2. Filling volume (weight)

9.3.6
243,00
00180119
3. Visual check / forming

(date print, damages 9.3.7
etc.)
4. Head space
9.3.8
5. Top sealing 9.3.10
6. Activation of top flaps 9.3.11
7. Activation pattern at
bottom section 9.3.12
8. Bottom sealing 9.3.13

9. H2O2 residual check
9.3.15
10. Blue/red dye test

- Reaction time: 30 min * 9.3.16
* Only if required, if the other tests do not result in a reliable evaluation, e.g. with a simultaneous
change of print design, of the date of manufacturing, or if the storage conditions of the pallet
considerably deviate from the standard conditions specified:

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9.3.3 Identification points at packages
In order to improve the communication with regard to the location of package leakers,
activation faults etc., certain ID points are specified for the packages.
III. 9-20 combibloc carton package

cb 1 / cf 1 ISO 16016.
Tests
000AI009
III. 9-21 combibloc carton package

ISO 16016. cb 1 / cf 1
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ID Identification Position
6 Creased cross top Opposite to longitudinal seam
7 Creased cross top Longitudinal seam side
8 Longitudinal seam Edge of longitudinal seam - top web
9 Creased cross top Opposite to longitudinal seam
10 Creased cross top Longitudinal seam side
11 Top corner
12 Creased cross top Top triangle – right to the longitudinal seam
13 Top corner
14 Top corner
15 Creased cross top Top triangle - opposite to longitudinal seam
16 Top corner
17 Longitudinal seam Longitudinal seam - top edge
18 Longitudinal seam Longitudinal seam sealing top / bottom
19 Bottom corner
20 Bottom corner
21 Bottom corner
22 Bottom corner
23 Bottom Bottom edge broad side - longitudinal seam side
24 Bottom Bottom edge narrow side - longitudinal seam side
25 Bottom Bottom edge narrow side - opposite to longitudinal seam
26 Bottom Bottom sealing - longitudinal seam
27 Bottom Folding edge between ID 29 +30
28 Longitudinal seam Longitudinal seam - bottom edge
29 Bottom Triangle tip - longitudinal seam side
30 Bottom Triangle tip - opposite to longitudinal seam
31 Bottom Bottom edge broad side opposite to longitudinal seam side
32 Bottom Channel next to triangle tip ID 30 - opposite to longitudinal seam side
33 Bottom Channel next to triangle tip ID 29
34 Bottom Channel next to longitudinal seam
35 Longitudinal seam Channel next to longitudinal seam - top
36 Top seam Sealing point - top triangle opposite to longitudinal seam
37 Top seam Sealing point - top web crease opposite to longitudinal seam
38 Top seam Sealing point next to inner edge of longitudinal seam
39 Top seam Sealing point next to outer edge of longitudinal seam
40 Top seam Sealing point – top web crease right to the longitudinal seam
41 Top seam Sealing point – top triangle right to the longitudinal seam
42 Longitudinal seam Channel in the area of the web crease line - top
43 Bottom Diagonal - transition web - longitudinal seam side
44 Bottom Diagonal - transition web - opposite to longitudinal seam side
80 Opening Coated straw opening

cb 1 / cf 1 ISO 16016.
Tests
Detailed view to fault ID points:
X1. of III. 9-21 combibloc carton package
000AI011
III. 9-22
Carton package bottom in the area of the triangle tip / longitudinal seam.
29: Triangle tip – longitudinal seam side

30: Triangle tip – opposite to longitudinal seam side
32 + 33 Channel next to the triangle tip
34: Channel next to longitudinal seam

ISO 16016. cb 1 / cf 1
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9.3.4 Use of polarisation filter
The polarisation filter is used to check the activation (heating-up) of the sleeve. The
polyethylene (PE) activated at the inner surfaces can be made visible through the polarisation
filter.
The use of the filter is only possible for aluminium coated sleeves. The filter is attached to this
Chapter. If necessary, the polarisation filter is available through SIG Combibloc (Item no.
8889.80201).
00180107
III. 9-23
1. Place polarisation filter onto areas to be checked.

2. Turn filter so that the activated areas (heated up to welding temperature) are shown
coloured and that the boundary sections of the activation pattern (/arrows) can be reliably
assessed.
III. 9-24

cb 1 / cf 1 ISO 16016.
Tests
9.3.4.1 Explanation of the activation border
At the activated area usually a border line

and then an activation gleam can be seen.
The border line is shown in Ill. 9-25 and Ill.
9-26 (see arrows) and is called activation
border on the activation pattern.
Ill. 9-25
INFO
The activated areas are shown with deviating colours under the polarisation filter;
however, the colour or colour shade does not allow any conclusion regarding the
activation temperature.
In case of an uneven distribution of temperature within an activation area, this may, however,
be indicated by different colour shades depending on the temperature.
Ill. 9-26

ISO 16016. cb 1 / cf 1
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9.3.4.2 Example for different coloured activation pattern
The colour of activation pattern depends on the used packaging material and can also differ
on production lots.
When using further carton package structures in the future, the colour can be different from
the shown examples as well.
III. 9-27

cb 1 / cf 1 ISO 16016.
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9.3.5 Bottom activation

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9.3.5.1 Activation pattern at sleeve
WARNING
Hot surfaces
Risk of injuries through hot machine components
The machine components in the area of the bottom heating may be hot and may cause burns
in contact.
 Wear protective gloves and long-sleeved work clothes.
 Do not touch hot components.
 Allow filling machine to cool down.
The check-up of the activation of the sleeve at the bottom section allows a control of the
function of the bottom heater and an assessment of the temperature set. For this purpose, the
borderlines of the activation and the heating-up of the activated areas are tested.
INFO
A faulty activation may be the reason for a poor sealing and may lead to bottom leakers.
Good activation patterns do not necessarily mean tight bottom sections. Requirements see
section 9.3.17.
Test intervals:
 at the beginning of production.
 when changing product, print design or pallet with a change of the day of manufacturing in
the shipping box inscription.
 when changing pallet without a change of the day of manufacturing in the shipping box
inscription, as necessary *.
 after all repair and maintenance works.
* The check when required means that the activation pattern at the sleeve may give hints to
the reason of a welding problem. The activation patterns do not substitute the visual
checks of the bottom sealing and the blue/red dye test.
Take into account the following points when producing activation patterns:
 Air pressure within tolerance range.
 Only use sleeves of the same date of production.
 Production of activation patterns at the same time for all tracks.
 Only sleeves from the pallet intended for processing may be taken for the production of
activation patterns, which should have adapted to the room temperature of the filling room,
see section 9.2.2.
 Activation heads and hoods free from soiling and properly installed.

ISO 16016. cb 1 / cf 1
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1. Allow filling machine to "warm up".
NOTE
Faulty production of activation patterns
Incorrect setting of filling machine through unusable activation patterns
Activation patterns, which will correctly and reliably allow conclusions about the bottom sealing
can only be produced on a filling machine properly warmed up ready for production. A
specifically installed sensor is used to measure the ambient temperature in the area of the
bottom heating.
 When producing the activation patterns, the required ambient temperature in the area of
the bottom heating must have been reached.
 Do not produce activation patterns, if the ambient temperature in the area of the bottom
heating has not been reached.
INFO
The sleeves to be tested shall not be inside the magazine during the warming-up of the
machine.
2. The sleeves placed into the sleeve magazine for the production of activation patterns must
be pushed onto the mandrels within two minutes in order to avoid any excessive heating-
up of the sleeves before the infeed.
6 sleeves of each filling machine track are sucked off. The last sleeve of each track is
used as a test sample.
Procedure see following page.
NOTE
Improper handling of sleeves
Incorrect setting of filling machine through unusable activation patterns
If the sleeves to be tested are touched in the activation areas, the results of the analysis will
be incorrect.
 Do not touch activated section of sleeves.
 Be careful when removing the sleeves from the mandrels.
 Do not touch mandrel surface in order to avoid contamination.

cb 1 / cf 1 ISO 16016.
Tests
3. Pull off activated sleeves from mandrels:
- Pull off activated sleeves cautiously

and immediately.
00180075
III. 9-28
4. In case of a re-adjustment of the temperature, repeat activation test from item 1.
Test samples
The test samples must be kept at least until the results of the bacteriological tests are
available. The samples will serve as a proof for the correct setting of the filling machine in
case of complaints; thus, keep the reserve samples as long as possible.
For this purpose, each test sample must show the following data:
 Production line or manufacturing no. of filling machine
 Track no.
 Temperature of bottom heating
 Air pressure of bottom heating
 Date and time of test
 Shift, day of manufacturing or production and time of sleeve and number of shipping box
(see sample).

715456500 SWIFT 0004 2588 31.12.12 23:59 202016558 3114
Date, time of Shipping box no.
production

ISO 16016. cb 1 / cf 1
Tests
Pos: 46 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Auswertung von Aktivierbildern "Bodenaktivierung" 004 cb 1 @ 25\mod_1357658772450_28.docx @ 185025 @ 4 @ 1
9.3.5.2 Analysis of activation patterns
1. Cut open activated sleeves opposite to longitudinal seam along the line through point 21.
2. Place polarisation filter onto aluminium-coated side of opened-up sleeve.
The activated section shows a deviating colour under the polarisation filter.
30 29
21 22 20 19 21
00180165
III. 9-29
= Activated PE
= Groove (crease lines)
The points 19 - 30 correspond to the identification points at the package, see section 9.3.3.
The proper temperature has been set, if
 the activated sections are conjoin.
 the activation limits are within the admissible range (details are described on the following
pages).
 no channel generation is visible.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 48 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Beurteilung der Aktiviertemperatur 003 (Bodenaktivierung) cb1 @ 53\mod_1380267897679_28.docx @ 2609349 @ 44 @ 1
9.3.5.3 Evaluation of activation temperature
Correct activation
Example:
30 29
21 22 20 19 21
00180109
III. 9-30
= Activated PE
III. 9-31
INFO
The coloured pictures in this carton check-up are shown for a better understanding, decisions
have to be made on the basis of the imaged schematic drawings within this document!

ISO 16016. cb 1 / cf 1
Tests
Characteristics for a correct activation:

 Folding edge
The activated border area goes close to
the groove (crease line) and, within the
still tolerable upper temperature, may
protrude into the groove (crease line),
see arrows in III. 9-32.
19 21
00180110
III. 9-32
 ID points: 19, 20, 21, 22

The activated areas stop immediately before the circles around the ID points 19, 20, 21
and 22 shown in the in III. 9-30 and in III. 9-33. The activation may slightly extend into this
area in the upper, still admissible temperature range.
 ID points: 29, 30
The activation reaches as far as the ID points 29 and 30 within the circular line, but must
not protrude beyond downwards in the direction of the triangle, see arrows in III. 9-33.
MAX MIN
29 30
20 19 21 22
00180111
III. 9-33

cb 1 / cf 1 ISO 16016.
Tests
Explanation of the circular line:

The circular area in the groove (crease line) cross area corresponds with the area X within the
circular line which goes as far as the grooves (crease lines), see III. 9-34.
x x
00180023
III. 9-34

ISO 16016. cb 1 / cf 1
Tests
Examples for a correct activation pattern of the machine type CFA 112:
Min – Max
Min.
30 29
21 22 20 19 21
00180112
III. 9-35
Opti
30 29
21 22 20 19 21
00180167
III. 9-36
x
Max.
30 29
21 22 20 19 21
00180166
III. 9-37
= Activated PE
= Wrinkle generation
X = Blister generation

cb 1 / cf 1 ISO 16016.
Tests
Min – Max
Min
III. 9-38
Opti
III. 9-39
Max
III. 9-40

ISO 16016. cb 1 / cf 1
Tests
Min – Max
Min
00180156
III. 9-41
Opti
00180157
III. 9-42
Max
00180158
III. 9-43
= Activated PE

cb 1 / cf 1 ISO 16016.
Tests
Min – Max
Min
III. 9-44
Opti
III. 9-45
Max
III. 9-46

ISO 16016. cb 1 / cf 1
Tests
Over-activation
Examples for inadmissible over-activation due to incorrect setting of machine components.
30 29
21 22 20 19 21
00180115
III. 9-47
= Activated PE
III. 9-48

cb 1 / cf 1 ISO 16016.
Tests
Over-activation
Examples for inadmissible over-activation due to excessive activation temperature.
30 29
21 22 20 19 21
00180116
III. 9-49
= Activated PE
A blister generation usually indicates an excessive activation.
Activation blisters are not allowed to reach the crease line.
III. 9-50
 The activated sections exceed the allowable borderlines over the whole area.
 The activated areas inadmissibly extend over points 19, 20, 21, 22, 29 and 30.

ISO 16016. cb 1 / cf 1
Tests
Under-activation
Examples for inadmissible under-activation due to incorrect setting of machine components:
30 29
21 22 20 19 21
00180117
III. 9-51
= Activated PE
III. 9-52

cb 1 / cf 1 ISO 16016.
Tests
Under-activation
Examples for inadmissible under-activation due to insufficient activation temperature:
Severe breaks (see arrows) in the activation profile are not allowed.
30 29
21 22 20 19 21
00180118
III. 9-53
= Activated PE
III. 9-54
An insufficient activation may result in a poor sealing quality and in faulty foldings.

ISO 16016. cb 1 / cf 1
Tests
Pos: 50 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Über- und Unteraktivierung durch die Bodenheizung" BuPP cb1+cb7 @ 53\mod_1380184964671_28.docx @ 2605205 @ 44 @ 1
9.3.5.4 Fault elimination in case of over- and under-activation through bottom heating
WARNING
Hot surfaces
in contact.
 Allow filling machine to cool down.
INFO
Enter changes of settings into Production Checklist.
1. Check temperature values for bottom heating and correct in accordance with the activation
patterns produced before.
Check temperature reading at operating unit.
The temperature should be nearly constant, i.e. should only show slight variations. Major
variations of the temperature readings indicate a defect of the temperature controller.
2. Check air pressure for bottom heating and have setting corrected through qualified staff, if
necessary.
In case of deviation, check sterile air pressure and set correctly, if necessary. See section
7.25.
Higher air pressure = stronger activation
Lower air pressure = weaker activation
3. Check air piping system for leaks.
4. Check activation heads and hoods for packaging material residue and deposits and clean,
if necessary. See section 8.11.4.3.
NOTE
Incorrect installation of activation heads and hoods
Damaging of filling machine
If the activation heads and hoods are installed incorrectly, machine components may be
damaged.
 Make sure when installing the activation heads and hoods that these are properly
installed.
5. Check temperature sensor of bottom heating for fixed position and for visible damages.
Have temperature sensor replaced by qualified staff, if required.
6. Check heating elements and have replaced by qualified staff, if required.
7. Check feeding of sleeves onto mandrels.
8. Check activation heads of bottom heating for correct installation position.
9. Check distance of activation heads to mandrels by qualified staff.
If the measures described above do not result in correct activation patterns, inform SIG
Combibloc Service, see chapter "General information/Addresses of customer service
agencies".

cb 1 / cf 1 ISO 16016.
Tests
Pos: 52 /gds-BA/Prüfungen/Packungsprüfung/1.1.1.1 Einfluss einer Fehlfaltung neben der Rilllinie (Bodenheizung) cb1 @ 53\mod_1380268052351_28.docx @ 2609378 @ 44 @ 1
9.3.5.5 Impact of faulty folding beside the groove (crease line) on the bottom forming
In the course of the activation

pattern test an inspection of the
triangular folding is advisable.
The folding procedure was correct if

the folding was carried out along
both diagonal grooves (crease
lines).
III. 9-55
Faulty folding beside the groove

(crease line) acc. to III. 9-56 can
indicate
- incorrect pusher setting
- wrong bottom heater setting
or wrong activation nozzle
setting
- wrong position of bottom
heater heads
- incorrect lateral folder
setting
III. 9-56
For the evaluation of any faulty
folding an examination of the bottom
forming (inside and outside) is
necessary.
INFO
For such an evaluation only samples which have been pulled off the mandrel without any
damage may be used!

ISO 16016. cb 1 / cf 1
Tests
Examination and evaluation of

bottom forming „inside“ see section
9.3.12.7
III. 9-57
If, in case of faulty foldings, unusual

package bottoms with a significantly
inconsistent alignment acc. to III.
9-58 are detected, proceed acc. to
chapter 9.3.5.6.
If, in case of faulty folding acc. to III.
9-56 no unusual bottom forms are
detected, production can be started
or continued.
III. 9-58
Pos: 53 /gds-BA/Prüfungen/Packungsprüfung/1.1.1.1 Fehlerbehebung bei Fehlfaltung (Rilllinie Bodenheizung) @ 24\mod_1344333895905_28.docx @ 182003 @ 4 @ 1
9.3.5.6 Fault elimination in case of faulty foldings

2. Check temperature values for bottom heating and correct in accordance with the activation
patterns produced before.
3. Have setting of lateral and longitudinal folder checked by qualified staff.
4. Check activation heads of bottom heating for correct installation position as well as for
package residue and deposits and clean, if necessary.
5. Have setting of mandrels to bottom press checked by qualified staff acc. to MI.
If the measures described above do not result in a correct package forming or bottom forming,
inform SIG Combibloc Service, see chapter “General information/Addresses of customer
service agencies”.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 55 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1 Füllvolumen (Gewicht) 003 cb1 @ 53\mod_1380268339079_28.docx @ 2609407 @ 33 @ 1
9.3.6 Filling volume (weight)
INFO
Set fill volume (weight), so that the respective state regulations or statutory provisions are
fulfilled.
Test intervals:
 at the beginning of production
 each hour during production
 after change of product
 after all repair and maintenance work
1. Take off two packages of each track at
off-conveyor.
2. Check weight of package removed by
using scale. Com
biblo
c®
SIG
243,00
00180171
III. 9-59
INFO
Use test sample afterwards to carry out visual test of bottom or top forming or to check head
space.
Pos: 56 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Volumenkorrektur" @ 27\mod_1371557947362_28.docx @ 206460 @ 44 @ 1
9.3.6.1 Elimination of fault
Volume correction
The setting of the filling volume is done at the operating unit.
INFO
If the measures described above do not result in correct filling volume, inform SIG Combibloc
Service, see Chapter “General information/Addresses of customer service agencies”.

ISO 16016. cb 1 / cf 1
Tests
Pos: 58 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1 Visuelle Kontrolle / Boden-, Giebelformung 004 cb1 @ 53\mod_1380268687338_28.docx @ 2609436 @ 33 @ 1
9.3.7 Visual check: outer appearance of bottom and top forming
Test intervals:
 when changing product, print design or pallet
 after all repair and maintenance works
INFO
Use test samples used to check fill weight before.
1. Check overall appearance of package.

a
Particularly check the following points:
- Mechanical damages and
deformations
- Check of top folding
- The overlap of the top section is
slightly positive to ensure a quick test.
A positive overlap of the top section
"a" of 0-2 mm is admissible, III. 9-60.
In individual cases, these dimensions
may deviate slightly.
- The top flaps are correct and properly
bonded (details of top flap activation -
see section 9.3.11)
- Position and correctness of date
c®
biblo
Com
SIG
00180175
III. 9-60

cb 1 / cf 1 ISO 16016.
Tests
2. Check of bottom folding along the

bottom edge.
The bottom folding was carried out along
the groove (crease line).
00180169
III. 9-61
- The groove (crease line) is visible

exactly along the bottom edge
according to (see III. 9-63) or slightly
above the bottom edge according to
III. 9-62.
000AI006
III. 9-62
- The folded bottom web X1

according to III. 9-63 runs flush with
the bottom flap X2 and may have a
slightly negative or positive overlap
to the bottom flap edge X2 at the
outer bottom edges.
- Extreme wrinkles on the bottom
edge are not permitted.
X2 X1 000AI007
III. 9-63

ISO 16016. cb 1 / cf 1
Tests
- The overlap of the bottom section

shall not be negative! A positive
overlap of the bottom section "b" of
0-2 mm is necessary, see III. 9-64
(measuring range = package
centre).
00180120
III. 9-64
III. 9-65
III. 9-66
INFO
Use test sample afterwards to check head space or to check top sealing.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 60 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Giebel/Boden" 002 @ 53\mod_1380185951977_28.docx @ 2605321 @ 44 @ 1
INFO
Top section
1. Check function and folding position of top prefolding tools.
2. Check correct installation position of top sealing tools.
3. Check function and temperature of steam injection.
4. Check top flap folder and heads for soiling as well as for deposits and proper function, see
section 9.3.11.1.
Bottom
2. Have lateral and longitudinal folder settings checked through qualified staff.
3. Check temperature and air pressure of bottom heating, see section 9.3.5.4.
4. Check activation heads of bottom heating for correct installation position as well as for
package residue and deposits and clean, if necessary.
5. Have setting of mandrels to bottom press checked by qualified staff acc. to MI.
If the measures described above do not result in a correct package forming, inform SIG
Combibloc Service, see chapter “General information/Addresses of customer service
agencies”.

ISO 16016. cb 1 / cf 1
Tests
Pos: 62 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1 Kopfraumvolumen 005 cb1 @ 53\mod_1380269403331_28.docx @ 2609465 @ 33 @ 1
9.3.8 Head space
INFO 1
The head space achievable with the steam
injection depends on the generation of foam
of the product and on the steam supply.
Only use package with correctly set filling
volume to check head space.
Test intervals:
 when changing product
 after all repair and maintenance work
00005224
 when required, f.ex. when changing the
package forming appearance III. 9-67
INFO
Use the test samples used to check the fill weight or for the visual control / forming before.
Equipment required:
 Graduated cylinder, volume = 50 ml
 Water-filled container
 Scissors
The following head space volumes (1) may be achieved with a properly working steam
injection:
Format range non-foaming heavily foaming

CFA112 ~ 5 ml ~ 15 ml
CFA124 ~ 5 ml ~ 15 ml
INFO
When using packages with underfilling, the head space can be different.

cb 1 / cf 1 ISO 16016.
Tests
Measuring of head space

1. Undo top flaps of test package and
1
raise top web (1).
®
bi bloc
Com
SI G
00005225
III. 9-68
2. Immerse test package, with top web

pointing downwards, into container filled
with water.
3. Cut open top flap section as shown and
hold package in this position.
000AI014
III. 9-69

ISO 16016. cb 1 / cf 1
Tests
4. Completely fill up graduated cylinder

inside container.
000AI015
III. 9-70
5. Position graduated cylinder as shown

on, so that no air can penetrate into
cylinder.
6. Bring test package (top web is still
pointing downwards) to opening of the
immersed graduated cylinder.
000AI016
III. 9-71
7. Now turn test package and slightly

squeeze, until all of the air inside the
package is fully forced into the
graduated cylinder
00005229
III. 9-72

cb 1 / cf 1 ISO 16016.
Tests
8. The water volume displaced in the

graduated cylinder corresponds to the
head space volume of the test package,
A
see dimension "A“ in III. 9-73.
10
20
30
40
50
00180121
III. 9-73
Pos: 63 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Kopfraumvolumen" @ 27\mod_1371557500248_28.docx @ 206364 @ 44 @ 1
INFO
1. Check accuracy of filling and adjust, if necessary,

2. Check product for foam generation,
3. Check steam supply and function of steam injection (function of cycle valve of steam
injection, set steam temperature, function of condensate trap).
INFO
The steam temperature has an impact on the top sealing. After changing the steam
temperature, it is thus necessary to check the top seam.
If the measures described above do not result in the reduction of the head space intended,
inform SIG Combibloc Service, see Chapter “General information/Addresses of customer
service agencies”.

ISO 16016. cb 1 / cf 1
Tests
Pos: 65 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1 Packungsdichtigkeit allgemein 002 cb1 @ 53\mod_1380269707106_28.docx @ 2609584 @ 334444 @ 1
9.3.9 General leak test for carton package
A faulty top or bottom sealing leads to top / bottom leakers.

The squeezing of the package and the check of the top and bottom seal enables a quick
assessment of the quality of the package top / bottom section.
Test intervals:
the shipping box inscription
NOTE
Incorrect steam injection
Incorrect top sealing
If steam injection is incorrect, top sealing will be carried out incorrectly.
 Check function of steam injection before test works.
9.3.9.1 Test for top leakers by squeezing of the carton package
1. Check one package of each track of the

test packages used for the prior testing
of the top and bottom forming.
2. The package is taken as shown on
picture III. 9-74, turn away longitudinal
seam of package from body.
3. Both forefingers are placed onto top
triangles (2) and pressed slightly.
4. While slightly pressing the top triangles,
exert medium pressure onto package by
1
the other fingers until top web starts
bulging (1) (squeezing time approx 5
seconds).
2
00180122
III. 9-74
INFO
No product shall penetrate.
Do not return squeezed packages to the converting process.

cb 1 / cf 1 ISO 16016.
Tests
9.3.9.2 Test for bottom leakers by squeezing of the carton package
1. Check one package of each track of the

test packages used for the prior
2
squeezing test of the top seal.
2. The package is taken as shown on
picture III. 9-75, turn away longitudinal
seam of package from body.
3. Both forefingers are placed onto top
triangles (2) and pressed slightly.
4. While slightly pressing the top triangles,
exert medium pressure onto package by
the other fingers until bottom web starts 1 00180106
bulging (1) (squeezing time approx 5
seconds ). III. 9-75
INFO
No product shall penetrate.
Do not return squeezed packages to the converting process.
Pos: 66 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1 Giebelverschweißung 004 cb1 @ 53\mod_1380269880068_28.docx @ 2609933 @ 334444 @ 1
9.3.10 Top sealing
A faulty top sealing leads to top leakers.

The complete test for top leakers includes the following test procedures:
 Squeezing of the carton package.
 Visual check.
 Check-up of weld position on top and check of the top seal.
 “Blue/red dye test" as a final and conclusive check for top leakers.
The check of the top seal enables a quick assessment of the quality of the package top
section.
Test intervals:
INFO
Use the test samples used to check the general leak test for package.

ISO 16016. cb 1 / cf 1
Tests
9.3.10.1 Check-up of weld position
1. Undo top flaps from finished

package top or fold up and 2
check impression of sealing
tools (1).
With a correct setting of welding

tools, mark of welding tools (1) is
1
parallel to upper edge (2) of top
web, see III. 9-76.
00005232
III. 9-76
If welding tools are not set parallel, 2

the impression of the welding tools
(1) runs off angle to the upper edge
(2) of the top web, see III. 9-77.
00180124
III. 9-77
A strong angular impression of the

welding tools (1) up to the upper
edge (2) is not permitted, as shown 2
in III. 9-78.
Detail measure for the valid working
range, see in chapter 9.3.10.4
below III. 9-84.
00180105
III. 9-78

cb 1 / cf 1 ISO 16016.
Tests
9.3.10.2 Overlap of top section
The overlap of the top section is slightly

positive to ensure a quick test.
A positive overlap "A" of 0 to 2 mm is
admissible, see III. 9-79.
A
In individual cases, these dimensions may
deviate slightly.
00180125
III. 9-79
INFO
In order to carry out further tests, one package of each track is cut open and drained.

ISO 16016. cb 1 / cf 1
Tests
Pos: 68 /gds-BA/Prüfungen/Packungsprüfung/1.1.1.1 Prüfung der Schweißnaht 003 cb1 @ 25\mod_1357736044216_28.docx @ 185225 @ 4 @ 1
9.3.10.3 Check up of weld
1. Cut open package slightly on top of

package bottom section at the 3 sides
next to or opposite to the longitudinal
9
seam side and drain product.
2. Now push down top section and open 14
package at right edge opposite to
longitudinal seam through point 14 up to
point 9 up to weld.
The points marked correspond to the
identification points at the package, see
section 9.3.3.
00005235
III. 9-80
3. Slowly open up weld on complete length

of package top from inside towards
outside.
00005236
III. 9-81

cb 1 / cf 1 ISO 16016.
Tests
4. For checking the light gap in weld, hold

the sample (welding seam) against
sufficient light source, as shown in III.
9-82.
00180154
III. 9-82
5. For checking the PE-wedge on weld

seam edge, ensure the present PE-
wedge by touch with the finger.
00180155
III. 9-83

ISO 16016. cb 1 / cf 1
Tests
Pos: 70 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Auswertung der Schweißnaht 005 cb1 @ 54\mod_1380285023565_28.docx @ 2610252 @ 44 @ 1
9.3.10.4 Analysis of weld
Example 1: Correct top welding.
37 40 41 40 38 37 36 37
1
40 38 37
A A
B
X
C
B
A
2
2
00180126
III. 9-84
= Interwoven sections with two layers of aluminium

= Open board
A = Optimum light gap in weld: 1 to 1,5 mm
allowed: 1.5 ± 0.5 mm (dimensions are not applicable to longitudinal seam
section)
B = Total width of weld 3 + 1 mm
C = Distance from upper edge top web approx. 2 - 1 mm
X = Cross section through weld
1 = Opposite sections board / structure containing the seam
2 = Weld seam edge / PE wedge
The sealing parameters or the settings of the sealing tools are correct if
 the complete area of the weld (III. 9-84, Item. 1) is interwoven. On one side, the aluminium
is still visible in the weld.
 a clearly noticeable PE wedge / weld edge (III. 9-84, Item 2) towards the product which
mainly guarantees that there are no package leakers.
 the translucent weld has the same width of (dimension A) on the complete length.
 the aluminium layer of the translucent weld (III. 9-84, dimension A) is mostly destroyed or
if only a few aluminium parts can be detected.

cb 1 / cf 1 ISO 16016.
Tests
Example 2: Allowed top welding at transitional section to longitudinal seam.
35 35 x
B
A
39 38 39 38 39 38 39 38
D 2
00180170
allowed, optimum allowed,

when PE wedge is detectably when discolouring towards the
present bottom is blocked by PE wedge
III. 9-85
= Open board
= Unwelded sections
= Interwoven sections with two aluminium layers
X = Discolouring
A = Light gap in weld
B = Total width of weld
D = Allowed: less than 1 mm
2 = Weld seam edge / PE wedge is present

ISO 16016. cb 1 / cf 1
Tests
35 35 x
A
B
40 39 38 40 39 38 40 39 38 40 39 38
00180128
allowed limit, optimum allowed limit,

when PE wedge is detectably when discolouring towards the
present bottom is blocked by PE wedge
III. 9-86
As slight constriction of the PE wedge is allowed with a non-translucent weld if the PE wedge
is detectably present.
A weak pointed discolouring at the transitional area to the longitudinal seam "Point 38" or
"Point 39" is allowed.
to X:
The point-shaped discolouring
- must be completely inside the interwoven area,
- and must be blocked by a PE wedge against the product and,
- must not be larger than the light gap in the discoloured area.

cb 1 / cf 1 ISO 16016.
Tests
Example 3: Faulty top welding at transitional section to longitudinal seam.
III. 9-87
= Open board
= Unwelded sections
= Discolouring
35 35
B
A
40 39 38 40 39 38 40 39 38 40 39 38
00180130
III. 9-88

ISO 16016. cb 1 / cf 1
Tests
At transitional area to longitudinal seam the weld is, as described, not allowed acc. to III. 9-87
and III. 9-88 if:
- no detectable PE wedge with a weak sealing is present,
- the interwoven section of the weld seam becomes smaller than the light gap "A",
- a continuous unwelded section is present,
- the point-shaped discolouring is larger than the light gap in the discoloured area.
Possible reasons:
 Anvil is positioned laterally to direction of movement
 Package pockets are displaced laterally to the running direction or bent (since usually only
individual pockets are displaced or damaged, all pockets must be checked for their correct
positions and intactness).
 Longitudinal seam deviating from default dimension. see section 9.2.3.
 Pressure too low (risk of channel).
 Pressure too high (risk of discolouring points).
Visible coloured point from the outside is not allowed.
In case of the occurrence of a large-scale discolouring at the transitional section to the

longitudinal seam not blocked with a PE wedge towards the product or if a continuous channel
is detected in the area (ID point 35) proceed according to section 9.3.10.5.

cb 1 / cf 1 ISO 16016.
Tests
Example 4: Faulty welding with energy output too low.
37 40 41 40 38 37 36 37
B
A
00180131
III. 9-89
= Open board
III. 9-90
In case of an excessively low welding energy, the light gap A in the middle of the seam is too
small or does not exist at all. The width of the weld B becomes smaller with a reduced welding
energy resulting from:
 a pressing force of welding tools which is too low
 the influence of the steam injection
 the influence of drying temperature
 the influence of the packaging material

ISO 16016. cb 1 / cf 1
Tests
Example 5: Inadmissible discolouring in centre of weld.
37 40 41 40 38 37 36 37
B
A
A
B
00180132
III. 9-91
= Open board
= Discolouring
III. 9-92
Inadmissible colouring in the translucent welding seam A-A caused by:

 excessive pressing force of welding tools
 the influence of the steam injection
 the influence of the packaging material

cb 1 / cf 1 ISO 16016.
Tests
Example 6: Faulty setting of welding tools.

Use of welding tools not parallel.
41 40 38 37 36
A
A
B
B
A
00180133
III. 9-93
= Open board
= Discolouring
III. 9-94
Example 7: faulty welding with worn-out welding tools.
III. 9-95

ISO 16016. cb 1 / cf 1
Tests
Example 8: Faulty welding tool setting with energy output too low.
Use of welding tools not parallel.
41 40 38 37 36
A
B
A
A
B
00180134
III. 9-96
= Open board
III. 9-97
A variation in the width of the light gap in the weld "A" is caused by:
 a setting of the welding tools which is not parallel

cb 1 / cf 1 ISO 16016.
Tests
Example 9: Faulty position of weld.

The distance between weld and groove (crease line) is too small.
A
B
00180102
III. 9-98
= Open board
C = Distance from upper edge top web
Detail measure for the valid working range, see section 9.3.10.4, III. 9-84.
III. 9-99
Possible reasons for a faulty position of weld:

 faulty setting of welding tools
 incorrect position of package pockets in relation to welding tools.

ISO 16016. cb 1 / cf 1
Tests
Example 10: Faulty position of weld.

The distance between weld and package edge is too small.
A
B
00180101
III. 9-100
= Open board
C = Distance from upper edge top web
Detail measure for the valid working range, see section 9.3.10.4, III. 9-84.
III. 9-101
Possible reasons for a faulty position of weld:

 faulty setting of welding tools
 incorrect position of package pockets in relation to welding tools.
INFO
Afterwards use test samples to check activation of top flaps.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 72 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/generell/1.1.1.1 Fehlerbehebung "Giebelverschweißung" 005 cb1 @ 54\mod_1380522965051_28.docx @ 2610403 @ 44 @ 1
INFO
1. Check the actual longitudinal seam dimensions ”D” and ”E” at respective packages and at
randomly selected sleeves from the batch involved.
Longitudinal seam default values/Tolerances

of packaging materials: E
Format D E
Cb 1 11;8 ± 0,8 mm 8,7 ± 1 mm
00005244
III. 9-102
2. If the dimensions of the longitudinal seams are outside the tolerances specified for the
packaging material, please inform SIG Combibloc Service, see chapter "General
Information/Addresses of Service Agencies".
3. Have parameter setting of ultrasonic generators checked by qualified staff and adjusted, if
necessary.
4. In order to obtain the correct surface pressure of the welding tools, check air pressure
setting for pressure cylinders and correct setting, if necessary (depending on packaging
material, temperature of steam injection and drying temperature).
5. Check function of steam injection and have repaired by qualified staff, if necessary.
6. Have setting of anvils and welding horns checked or corrected by qualified staff.
7. Have setting and condition of package pockets checked, or corrected, if necessary, by
qualified staff.
8. Check temperature setting of drying zone, check product data, check function of the
heater unit and temperature sensor or have fault eliminated by qualified staff.
If the measures described above do not result in correct top sealing, inform SIG Combibloc
Service, see Chapter “General information/Addresses of customer service agencies”.

ISO 16016. cb 1 / cf 1
Tests
Pos: 74 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1 Aktivierung der Giebellaschen 004 cb1 @ 54\mod_1380523100592_28.docx @ 2610432 @ 33 @ 1
9.3.11 Activation of top flaps
Impact of activation of top flaps on top leakers

An excessive activation of the top flaps at the topforming station can cause a sealing inside of
the package and may cause top leakers during loading and transport.
Test intervals:
INFO
Use test samples used to check top welding before.
1. In order to evaluate the activation, place polarisation filter onto aluminium-coated side of
opened-up section of top.
Analysis
Admissible activation
Example:
1 1
00180135
III. 9-103
= Open board
= Activated PE
With a correct activation of the top flaps, insides of the package show no or only slightly
discoloured areas (1). The activated sections are located in the centre of the top flaps.
An activation exceeding the groove (crease lines), as well as a blister generation are
inadmissible.
In case of a faulty sealing of the top flaps proceed according to chapter 9.3.11.1. Before
increasing the activation temperatur, other parameters as position of the activation heads,
soiling, etc. have to be checked as well.

cb 1 / cf 1 ISO 16016.
Tests
Inadmissible activation
Example:
2 1
00180136
III. 9-104
= Open board
= Activated PE
= Blister
An excessive activation (2) exceeding the groove (crease lines) is not allowed.
The reason for an excessive activation on one side may, for example, be a clogging of the
opposite activation head (see Item 1) or an incorrect position of the activation heads.
INFO
If the reason was not detected and the temperature of the top forming station had been raised
as a wrong measure, this will result in an excessive activation in point (2).
III. 9-105

ISO 16016. cb 1 / cf 1
Tests
Wrong setting of activation head

Example:
1 2
00180137
III. 9-106
= Open board
= Activated PE
= Blister
III. 9-107
Abb. 9-108
A misaligned position of activation (1) or an excessive activation on both sides ((1) and (2))
exceeding the groove (crease lines), as well as a blister generation are not allowable.
The reason for an offset position of the activated area (1) is the incorrect position of the
activation head.
INFO
If the reason was not detected and the temperature of the top forming station had been raised
as a wrong measure, this will result in an excessive activation on both sides.
INFO
Afterwards use test samples to check the activation of bottom section of carton package.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 76 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Giebellaschen" cb1/7 @ 53\mod_1380189210102_28.docx @ 2605524 @ 44 @ 1
WARNING
Hot surfaces
in contact.
 Allow hot machine parts to cool down.
INFO
Enter changes of settings into Production Checklist!
1. Check temperature setting for top-forming station and adjust, if necessary.

2. Check temperature reading at operating unit.
The temperature should be nearly constant, i.e. should only show slight variations.
Large deviations of the temperature readings indicate a defect.
3. Check air piping system for leaks.

4. Check activation heads for soiling and
clean, if necessary. See illustration.
5. Check position of activation heads (1)
and adjust, if necessary. See illustration.
6. Check temperature sensor at heaters of
top forming station for fixed installation
and check for visible damages. If
necessary, have temperature sensor
replaced by qualified staff.
7. Check heating tube and hot-air
distributor for soiling and damages,
clean and have repaired by qualified
staff, if necessary.
1
00005050
Ill. 9-109
If the measures described above do not result in correctly sealed top flaps, inform SIG
Combibloc Service, see chapter “General information/Addresses of customer service
agencies”.
Pos: 77 /gds-BA/____ Seitenumbruch ____ @ 15\mod_1315315453688_0.docx @ 90840 @ 4 @ 1

ISO 16016. cb 1 / cf 1
Tests
Pos: 78 /gds-BA/Überschriften/1.1.1 Aktivierbild am Packungsboden @ 8\mod_1313391534724_28.docx @ 17391 @ 3 @ 1
9.3.12 Activation pattern at bottom section

Pos: 79 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Prüfung der verschweißten Bereiche "Aktivierbild Packungsboden" 003 @ 53\mod_1380190305122_28.docx @ 2606227 @ 443 @ 1
9.3.12.1 Check of welded sections
Test intervals:
INFO
Use the test samples that were used to
check the top seam and the top flap
activation before.
00005248
III. 9-110
1. Tear open package at all four edges

down to bottom and fold down sides of
package.
00005061
III. 9-111

cb 1 / cf 1 ISO 16016.
Tests
Pos: 81 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Auswertung von Aktivierbildern "Packungsboden" 004 cb1 @ 54\mod_1380523466935_28.docx @ 2610461 @ 44 @ 1
9.3.12.2 Analysis of activation patterns
Activation with correct activation temperature

1. Place polarisation filter onto upper half of package.
Example for a correct activation of packages bottom without visible heating up through drying
station:
= Activated PE
= Still admissible
21 19
activation exceeding
groove (crease line)
X = Longitudinal seam 30 29
activation
22 X 20
00180172
III. 9-112
 The points 19, 20, 21, 22, 29 and 30 identified correspond to the identification points at the
package, see section 9.3.3.
 Between points 29 and 30, activation shall only be visible at the side of the longitudinal
seam.
III. 9-113
INFO
The corresponding sleeve activation, see III. 9-30 in chapter see section 9.3.5.3.
For an explanation regarding the activation border see chapter 9.3.4.1.

ISO 16016. cb 1 / cf 1
Tests
Examples for a correct activation pattern of bottom section of package: Min – Max
Min
= Activated PE
21 19
= Still admissible
activation exceeding
crease line
30 29
= groove (crease line)
X = Longitudinal seam
activation
22 X 20
00180173
III. 9-114
Opti
21 19
30 29
22 X 20
00180174
III. 9-115
Max
21 19
30 29
X
22 20
00180141
III. 9-116

cb 1 / cf 1 ISO 16016.
Tests
Over-activation
Examples for inadmissible over-activation due to incorrect setting of machine components.
 The activated sections

excessively extend over the
complete area.
21 19
 The bottom edges are activated.
 The activation considerably
protrudes over the groove 30 29
(crease line) in the folded
areas..
X
22 20
00180142
III. 9-117
= Activated PE
= Inadmissible activation exceeding groove (crease line)
X = Longitudinal seam activation
III. 9-118

ISO 16016. cb 1 / cf 1
Tests
Over-activation
Examples for inadmissible over-activation due to excessive activation temperature.
 The activated sections

excessively extend over the
complete area.
21 19
 The bottom edges are activated.
 The activation considerably
protrudes over the groove 30 29
(crease line) in the folded areas.
X
22 20
00180143
III. 9-119
= Activated PE
=Inadmissible activation exceeding groove (crease line)
III. 9-120

cb 1 / cf 1 ISO 16016.
Tests
Under-activation
Example for inadmissible under-activation due to incorrect setting of machine components:
The small activated areas at the

lower side of the triangles indicated
by the arrows (III. 9-121) show a
noncontinuous activation pattern
which is not permitted.
III. 9-121
= Activated PE
= Longitudinal seam activation
X = Still admissible activation exceeding groove (crease line)
III. 9-122

ISO 16016. cb 1 / cf 1
Tests
Under-activation
Example for inadmissible under-activation due to insufficient activation temperature:
21 19
30 29
X
22 20
00180144
III. 9-123
= Activated PE
III. 9-124
Pos: 82 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Aktivierbild Packungsboden" BuPP @ 53\mod_1380190622016_28.docx @ 2606755 @ 444 @ 1
INFO
For the fault elimination please follow to the fault elimination of the activation pattern at the
sleeve, see section 9.3.5.4.
If the measures described above do not result in correct activation patterns, inform SIG
Combibloc Service, see section "General information/Addresses of customer service
agencies".

cb 1 / cf 1 ISO 16016.
Tests
Pos: 84 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Optische Prüfung der Bodenverschweißung 002 cb1 @ 25\mod_1357742160817_28.docx @ 185363 @ 4 @ 1
9.3.12.4 Visual check of bottom seal
III. 9-125
X = PE protrusion is not necessary at these points.
Pos: 85 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Einfluss von Aluminiumbrüchen an der Umlegekante auf die Bodendichtheit 002 cb1 @ 54\mod_1380523852042_28.docx @ 2610490 @ 444 @ 1
9.3.12.5 Influence of aluminium breakage at the folding edge on bottom seal
Aluminium breakage in the area of the folding edge can, under certain circumstances, lead to
leaking bottoms. In case of strong over-activation of the bottom the folding edge is overheated
which can result in cracks at the folding edge after the longitudinal folding / bottom pressing,
see III. 9-126 and III. 9-127.
III. 9-126
INFO
Leaking package bottoms can be a result of this; however, they most frequently are caused by
incorrect adjustment of other mechanical components such as pusher, lateral or longitudinal
folder position, pressure and incorrect mandrel position in relation to bottom press.
If over activation is not the problem and if the blue/red dye test is ok, production can be started
or continued.

ISO 16016. cb 1 / cf 1
Tests
III. 9-127

cb 1 / cf 1 ISO 16016.
Tests
Pos: 87 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung Bodenformung @ 53\mod_1380191304614_28.docx @ 2607851 @ 44 @ 1
9.3.12.6 Fault elimination
1. Check activation pattern and temperature values of the bottom heating and, if necessary,
correct in accordance with the activation patterns produced before.
INFO
Generating activation patterns – see section 9.3.5.1.

3. Have setting of lateral and longitudinal folders checked by qualified staff.
4. Have setting of positioning of mandrels to bottom press checked by qualified staff.
5. Check overlap of the bottom section.
6. Blue/red dye test, see section 9.3.16.1.
If the measures described above do not lead to a correct result, inform SIG Combibloc
Service, see chapter “General information/Addresses of customer service agencies”.

ISO 16016. cb 1 / cf 1
Tests
Pos: 89 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Prüfung der Bodenformung (Innen) 002 cb1 @ 25\mod_1357742853134_28.docx @ 185409 @ 4 @ 1
9.3.12.7 Check of bottom forming (inside)
Bottom offset - inside
If correctly set, both triangle tips (2)

are positioned directly beside the
folding edge (1), see III. 9-128.
III. 9-128
III. 9-129
Max. tolerable offset:
“A“ = 2 mm
III. 9-130

cb 1 / cf 1 ISO 16016.
Tests
An excessive distance (A) between the folding edge (1) and the triangle tip (2) according to III.
9-131 is a sign of a possible incorrect bottom folding.
INFO
In case of a distance (A) larger than 2mm stop the machine and proceed according to chapter
9.3.12.8. If the measures according to this chapter do not lead to a correct result, have the
basic setting checked by Combibloc Service.
A distance smaller than 2 mm does not necessarily mean that the bottom seal is leakproof,
especially if there are other misadjustments, such as wrong bottom temperature, wrong
pressure etc.
In case of doubt, a check according to chapter 9.3.12.8 respectively the examination of the
basic setting acc. MI is advisable.
Once the examinations have been carried out, the blue/red dye test is obligatory and decisive
for a production start or continuation.
Examples of incorrect „bottom offset – inside and outside”
III. 9-131

ISO 16016. cb 1 / cf 1
Tests
The reason for an excessive distance between the triangle tip and the folding edge is mostly a
consequence of a faulty folding in the bottom area and may be caused by:
- incorrect bottom temperature setting
- incorrect activating nozzle setting
- incorrect pusher setting
- incorrect setting of lateral and longitudinal folders,
- incorrect mandrel position in relation to bottom press
In case of any excessive distance (A) acc. to III. 9-131 proceed acc. to chapter 9.3.12.8.

cb 1 / cf 1 ISO 16016.
Tests
Position of triangular flaps

With correctly folded triangular flaps
the tip of the triangle (2) is
positioned in alignment with the
notch in the mandrel (3) or slightly
behind – see III. 9-132.
III. 9-132
Any excessive distance acc. to III.
9-133 can lead to a channel at ID
point 29 or 30 respectively to
leaking bottoms, especially if,
- the activation temperature
is too low in this area, or
- the bottom contact pressure
is too low.
In this case proceed acc. to chapter
9.3.12.8.
See also III. 9-151 in chapter
9.3.13.2.
III. 9-133

ISO 16016. cb 1 / cf 1
Tests
Pos: 91 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung Bodenformung @ 53\mod_1380191304614_28.docx @ 2607851 @ 44 @ 1
9.3.12.8 Fault elimination
1. Check activation pattern and temperature values of the bottom heating and, if necessary,
correct in accordance with the activation patterns produced before.
INFO
Generating activation patterns – see section 9.3.5.1.

3. Have setting of lateral and longitudinal folders checked by qualified staff.
4. Have setting of positioning of mandrels to bottom press checked by qualified staff.
5. Check overlap of the bottom section.
6. Blue/red dye test, see section 9.3.16.1.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 93 /gds-BA/Prüfungen/Packungsprüfung/1.1.1.1 Einfluss der Trockenstation auf die Bodendichtheit 003 cb1 @ 25\mod_1357743213921_28.docx @ 185432 @ 4 @ 1
9.3.12.9 Influence of drying station on bottom leakers
Allowable heating-up through drying station

The hot air of the drying station flowing towards the bottom section of the package heats up
this section, particularly for small package heights. This generates a bright or coloured section
with visible border zones. The areas activated through the bottom heating remain fully visible.
Example for a correct bottom activation with a visible, but still admissible heating-up through
the drying station.
= Activation through
bottom heating
= Heating up through 21 19
drying station
30 29
22 20
00180152
III. 9-134
III. 9-135

ISO 16016. cb 1 / cf 1
Tests
Inadmissible activation through drying station

An excessive heating-up through drying air leads, in particular at the groove (crease lines), to
an inadmissible activation of the polyethylene. This may lead to damages to the inner coating.
The sections activated by the bottom heater are not fully visible anymore.
Example of an "Over-activation" through the drying station..
= Activation through
bottom heating
= Heating up through 21 19
drying station
= Discoloured border
areas 30 29
22 20
00180153
III. 9-136
III. 9-137

cb 1 / cf 1 ISO 16016.
Tests
Pos: 95 /gds-BA/Prüfungen/Packungsprüfung/Fehlerbehebung/1.1.1.1 Fehlerbehebung "Unzulässige Aktivierung durch die Trockenstation" @ 27\mod_1371555745331_28.docx @ 206172 @ 44 @ 1
9.3.12.10 Elimination of fault in case of inadmissible activation through drying station
1. Have temperature setting of all heads of drying zone checked or adjusted by qualified
staff.
Check temperature reading at operating unit.
The temperature should be nearly constant, i.e. should only show slight variations. Large
deviations of the temperature readings indicate a defect.
2. Have sterile air pressure checked by qualified staff, .

If inadmissible activation areas at the bottom section of the carton cannot be eliminated to a
sufficient extent by way of the measures described, inform SIG Combibloc-Service,see
Section "General Information/Addresses of Customer Services".
INFO
Use test samples afterwards to check the welded bottom sections.

ISO 16016. cb 1 / cf 1
Tests
Pos: 97 /gds-BA/Überschriften/1.1.1 Bodenverschweißung @ 2\mod_1312788584904_28.docx @ 7161 @ 3 @ 1
9.3.13 Bottom sealing

Pos: 98 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Prüfung der verschweißten Bereiche "Bodenverschweißung" 004 cb1 @ 54\mod_1380525270088_28.docx @ 2610519 @ 434 @ 1
9.3.13.1 Check of welded sections
The check of the bottom sealing enables a quick assessment of the quality of the package
bottom section. Any channel generation can be reliably detected this way.
Test intervals:
The complete test for bottom leakers includes the following test procedures:
 Squeezing of the carton package
 Use the same test sample used for the “top seal squeezing test” (description and
implementation, see section 9.3.9).
 Visual check
 Check of bottom sealing
 “Blue/red dye test" as a conclusive check for bottom leakers
The squeezing of the carton package and the check of the bottom seal enables a quick
assessment of the quality of the carton package bottom section.
INFO
For further testing, use test samples used for the prior check of the activation pattern of the
bottom section of the package.

cb 1 / cf 1 ISO 16016.
Tests
INFO
In order to check the bottom section of the package, tear open according to instructions given.
See following pages.
Tear off bottom section of package

1. Loosen web and lift up.
III. 9-138
2. Separate web at both sides and fold

over diagonal folding edges.
III. 9-139

ISO 16016. cb 1 / cf 1
Tests
3. Carefully and slowly tear open package

bottom from the inside along the four
diagonal folding edges and web.
III. 9-140
4. Cut open bottom section opposite to

edge seam.
00005258
Abb. 9-141

cb 1 / cf 1 ISO 16016.
Tests
5. Open up package bottom for test

purposes.
00005259
III. 9-142

ISO 16016. cb 1 / cf 1
Tests
Pos: 100 /gds-BA/Prüfungen/Packungsprüfung/generell/1.1.1.1 Auswertung der verschweißten Bereiche 004 cb1 @ 54\mod_1380525384567_28.docx @ 2610548 @ 44 @ 1
9.3.13.2 Analysis of welded sections
Correct welding of bottom section

Example 1:
30 29
21 22 20 19 21
00180145
III. 9-143
= Activated PE
= Open board
III. 9-144
The points 19 - 30 correspond to the identification points at the package, see section 9.3.3.
Total area torn open only shows paper board.

cb 1 / cf 1 ISO 16016.
Tests
Example 2:
30 29
21 22 20 19 21
00180146
III. 9-145
= Activated PE
= Open board
Small-scale, unwelded sections (see arrows) next to longitudinal seam, which are enclosed,
are admissible.
INFO
If large-scale unwelded sections will occur next to the longitudinal seam that extend up to the
end of the package edge or that stop shortly before, see section 9.3.14.1.

ISO 16016. cb 1 / cf 1
Tests
Example 3:
30 29
21 22 20 19 21
A A C C
00180147
III. 9-146
= Activated PE
= Open board
= Open aluminium
The torn section shows board as well as aluminium. In this case, the polarisation filter should
be placed onto the bottom torn open to enable a reliable evaluation.
If aluminium sections are coloured under the polarisation filter, such sections are coated with
PE. If no discolouring is visible on the respective, opposite sections A-A, the welding is
correct.
In this case, the PE layer was separated from the aluminium and is located on one side.
Unwelded (closed) island sections in the C-C area are insignificant.

cb 1 / cf 1 ISO 16016.
Tests
Example 4:
A B
30 29
21 22 20 19 21
00180103
III. 9-147
= Activated PE
= Open board
A = Overall length of welding seam 8mm (tolerance = - 2 mm)
A
B = Permitted channel length = <
2
Smaller unwelded areas beside the

triangle tips as far as half of the
overall welded area are permitted,
see arrow in III. 9-147 and III. 9-148.
III. 9-148
INFO
For these examinations only the tear-open methods described in these instructions are
permitted.
INFO
In case of unwelded areas beside the triangle tips larger than half of the possible welded area
or in case of unwelded areas that reach as far as the package edge proceed acc. to section
9.3.14.1.

ISO 16016. cb 1 / cf 1
Tests
Faulty welding
Example 1:
30 29
21 22 20 19 21
B B
00180148
III. 9-149
= Activated PE
= Open board
The opposite aluminium areas B-B in the sample both are coloured under the polarisation
filter. In this case, there is a polyethylene layer on both sides, i.e. there has been no welding.
A channel B-B results in leakers at the bottom section.

cb 1 / cf 1 ISO 16016.
Tests
Example 2:
30
29
21 22 20 19 21
00180104
III. 9-150
= activated PE
= open board
In III. 9-150 and III. 9-151 an end-to-

end channel reaching as far as the
package edge is shown in the area
of ID 29. An end-to-end channel at
ID 29 or 30 leads to leaking bottoms.
III. 9-151
INFO
For these examinations only the tear-open methods described in these instructions are
permitted.

ISO 16016. cb 1 / cf 1
Tests
Possible causes and measures:

- Bottom temperature and the activation pattern deviates from the requirements
according to chapter 9.3.5.3.
- Sleeve feed position onto the mandrels deviates from MI setting (have checked by
qualified staff).
- Lateral and longitudinal folder setting deviates from MI setting (have checked by
qualified staff).
- Mandrel end position to bottom press deviates from MI setting (have checked by
qualified staff).
Further necessary measures:

- Check bottom forming (inside and outside) for irregularities.
- Check bottom overlap for irregularities.
- Blue/red dye test according chapter 9.3.16.1.

cb 1 / cf 1 ISO 16016.
Tests
Pos: 102 /gds-BA/Prüfungen/Packungsprüfung/1.1.1 Prüfung der Bodendichtheit 003 cb1 @ 25\mod_1357744532975_28.docx @ 185501 @ 3 @ 1
9.3.14 Check of bottom tightness
A faulty bottom sealing leads to bottom leakers.

The complete test for bottom leakers includes the following procedures:
 Check of bottom activation
- Activation pattern at sleeve (1)
- Activation at completely sealed bottom section of package (7)
- Heating-up through drying air (7)
 Visual control
- Outer appearance of carton package, bottom folding (3)
 Squeezing of the carton package
 Check of welded sections (8)
3
2
00180149
III. 9-152
Only if the above mentioned points have shown a correct result, the subsequent check for
bottom leakers shall be ensured by way of the " blue/red dye test".

ISO 16016. cb 1 / cf 1
Tests
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INFO
Procedure:
 Check activation at sleeve and at bottom: see sections 9.3.5.1 and 9.3.12.2.
 Check temperature values for bottom heating and drying zone: see section 9.3.5.4.
 Check sterile air pressure and air pressure for bottom heater: see section 9.3.5.4 or see
section 7.24.
 Check function of water cooling (temperature and flow volume) for mandrels and bottom
press.
 Check activation heads and die profile of mandrels and of bottom press for soiling and
damages.
In case of any channels beside the triangle tips the further measures are necessary:
 Check sleeve feed onto the mandrels.
 Have lateral and longitudinal folders checked by qualified staff.
 Have mandrel position to bottom press checked by qualified staff.
 Check bottom formation (inside and outside) for irregularities.
 Check bottom overlap.
 Squeezing test: see sections 9.3.9 and 9.3.13.1.
 Blue/red dye test: see section 9.3.16.1.

cb 1 / cf 1 ISO 16016.
Tests
Test samples
The test samples must be kept at least until the results of the bacteriological tests are
available. The samples will serve as a proof for the correct setting of the filling machine in
case of complaints; thus, keep the reserve samples as long as possible.
For this purpose, each test sample must show the following data:
 Production line or manufacturing no. of filling machine
 Track no.
 Temperature of bottom heating
 Welding pressure ultrasonics (top welding pressure)
 Date and time of test
 Shift, day of manufacturing or production and time of sleeve and number of shipping box
(see sample).

715456500 SWIFT 0004 2588 31.12.12 23:59 20216558 3114
Date, time of Shipping box no.
production

ISO 16016. cb 1 / cf 1
Tests
It is recommended to jointly store the test samples of each track as follows:

S1. Activation pattern,
S2. Sample with bottom and top torn open,
S3. Welded bottom section of package (if required),
S4. Welded top section of package (if required)
30 29
S1.
21 22 20 19 21
S2.
S3.
S4.
00180150
III. 9-153

cb 1 / cf 1 ISO 16016.
Tests
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9.3.15 H2O2 residual test
WARNING
Hydrogen peroxide (H2O2)
Risk of injuries through H2O2
Use H2O2 test to control, whether residues are inside the product. H2O2 causes caustic burns,
irritates eyes, skin and respiratory organs.
Since the check-up in a carton filled with product only gives results for milk products, water
and apple juice, run empty cartons for all other products () and fill afterwards with
demineralised and chlorine-free water.
 Run empty cartons only under exceptional circumstances under the supervision of the
machine operator to ensure, that the filling machine is not damaged through the empty
cartons.
 Strictly follow safety instructions given by manufacturer.
 Wear eye protection and protective clothing.
 Dilute any spilled H2O2 immediately with plenty of water and rinse into sewage system.
The H2O2 test strips (source of supply, see section 13.7) indicate whether the filled package
has left the filling machine free from H2O2.
Test intervals:
Test procedure:
1. Take off one package per track, clean outside with water and dry off to remove H2O2
residue from the outside.
2. Open up or cut open packages taken out.
3. When carrying out the H2O2 residue test with empty packages, fill up packages with de-
mineralised water (or chlorine-free water) to nominal volume.

ISO 16016. cb 1 / cf 1
Tests
NOTE
Improper storage of H2O2 test strips
H2O2 test strips become unusable
H2O2 test strips may become unusable through improper storage. This results in unusable or
false measuring results.
 The containers for the H2O2 test strips must be stored in a closed condition.
 Immediately close container again after you took out a test strip.
4. Take out test strips from container (1).
H O -Test
² ²
SIG
Com
b ibloc
®
00005266
Ill. 9-154
5. Dip test strips into liquid for 5 seconds.

The control mark of the test strips shall not touch the outer walls of the package.
6. Check control mark for colour change.
There shall be no discolouring of the control mark; any later discolouring in the air is of no
importance.
7. Check de-mineralised water that is used to fill empty packages by using a second strip.
Such counter-check shall not show any discolouring of the control mark.
8. Check proper function of strip by getting control mark into contact with H2O2.
Result: blue colouring through H2O2 residue.

cb 1 / cf 1 ISO 16016.
Tests
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INFO
WARNING
Hydrogen peroxide (H2O2)
Risk of injuries through H2O2
H2O2 causes caustic burns, irritates eyes, skin and respiratory organs.
 Strictly follow safety instructions given by manufacturer.
 Dilute any spilled H2O2 immediately with plenty of water and rinse into sewage system.
1. Clean H2O2 vaporizers.

2. Check H2O2 spray quantity, adjust if required or have fault eliminated through qualified
SIG staff.
3. Check H2O2 transporting air pressure and adjust, if necessary.
4. Have temperature setting for H2O2 vaporisers and drying zone checked or set by qualified
staff.
Check the relevant parameters at the operating unit.
The temperatures may only vary within the alarm limits specified.
5. Check sterile air pressure, .
6. Have H2O2 dosing, H2O2 vaporisers and temperature sensors checked or repaired by
qualified staff.
7. Have heaters, air infeed and temperature sensors of drying zone checked or repaired by
qualified staff, if necessary.
Service, see Section "General information/Addresses of customer service agencies".

ISO 16016. cb 1 / cf 1
Tests
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9.3.16 Check of carton package for leakers with “blue/red dye test”
WARNING
Non-sterile conditions
Health risk through non-sterile conditions
If the weld is not completely sealed, this may result in faulty and unsterile cartons. Unsterile
cartons present a health risk for the consumer.
 A channel formation in the weld area can only be reliably detected through a visual
control, see section 9.3.13.2 unter "Faulty welding - bottom section" and in section
9.3.10.4 under "Analysis weld - top section".
WARNING
Solvent naphtha
Risk of injuries through white spirit
Blue/Red dye test liquid contains white spirit. White spirit is easily inflammable. White spirit
may irritate eyes, skin and respiratory organs.
 Strictly follow safety instructions of manufacturer and general safety instructions given in
Chapter "Safety".
NOTE
Wrong white spirit
Unusable or incorrect blue test results
When using white spirit not approved by SIG Combibloc, the results cannot be compared.
 In order to get comparable results when carrying out a blue/red dye test of combibloc
packaging material, only use the de-aromatised white spirit (such as Shellsol D60 or Exxol
D60 (LAWS)* approved by SIG Combibloc.
The final and conclusive test for package leakers is the "blue/red dye test".
After all other inspection tests have been successfully completed the “blue/red dye test" is
carried out. It rounds up the quality check-up and provides hints for fault points at filling
machine and packaging material.
Test liquid:
 Solvent naphtha (de-aromatized), with a boiling range of 180 - 220°C.
 Adding of ink 1 tip of knife on 1 litre of test liquid; solvent blue B01 (CAS No. 7354-14-2;
C.I.Solvent blue 35 – Anthrachinone ink), respectively oil red 5B02 (Sudanred) is used as
the ink for the test liquid .
 The using of ink must be conform with the local law.

cb 1 / cf 1 ISO 16016.
Tests
INFO
The blue/red dye test liquid can be used again, after separating the residual water.
Test intervals:
 each four hours during production
 when changing product, print design and pallet*
* When changing the day of manufacturing or if the storage conditions of the new pallet
deviate from the standard conditions specified.
INFO
Before filling in agent, make sure that the top flaps remain sealed. Blue/red dye test liquid
penetrations with top flaps not sealed to the package or after tearing off top flaps are
insignificant to the tightness of the package.

ISO 16016. cb 1 / cf 1
Tests
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9.3.16.1 Procedure of tests
One package of each mandrel in succession

is tested for leakers using the blue/red dye
test liquid.
1. Cut open packages in the middle without
damaging bottom or top section.
2. Drain package halves, rinse them with
water and carefully remove all product
residue and grease.
3. Dry package halves by carefully
knocking them against packages or by
blowing them out with oil-free
compressed air.
4. Fill test liquid into both halves so bottom 00005267
is covered.
III. 9-155
INFO
The above-mentioned steps point 1 to point 4 are to be carried out uninterrupted and in
sequence.
The blue/red dye test liquid must be filled into both halves immediately after point 1-3.
5. Allow test liquid to react for 30 minutes.

6. Test packages in all sections for
penetrations.
INFO
Within the 30 min residence time no mechanical load is permitted!
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9.3.16.2 Analysis
NOTE
Incorrect blue test analysis
Faulty top sealing through wrong performance of blue test
The blue/red dye test must be carried out correctly, in order to early detect a poor top sealing
and to prevent faulty productions.
 After 30 min. of reaction time, no penetrations shall show.
 If penetrations occur during the reaction time of the blue test, the test must be repeated. If
penetrations are detected again after a repeated blue test procedure, the fault must be
immediately eliminated. Only then production may be continued.
 If during an 8-hour production more than altogether three faulty cartons are detected with
a correct blue/red dye test procedure, immediately eliminate fault. Only then production
may be continued.

cb 1 / cf 1 ISO 16016.
Tests
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9.3.16.3 Penetrations
If the testing agent will penetrate at the possible penetration points according to III. 9-156 and
III. 9-157 it becomes visible at the points marked with arrows.
Points of penetration: ○
Examples:
 Possible paths of penetration of
blue/red dye test agent through
damages in the bottom section. 20 22
28
26
29 30
27
25
24
43 44
19 21
00005268
III. 9-156
 Possible paths of penetration of

blue/red dye test agent through
channels in the bottom section.
34 33 32
00005269
III. 9-157

ISO 16016. cb 1 / cf 1
Tests
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WARNING
Blue/Red dye test liquid
Risk of injuries through blue/red dye test liquid
The blue/red dye test liquid contains chemical substances, which may be a hazard to the
environment.
 Strictly follow safety data sheet and instructions for disposal of respective countries.
 Blue/Red dye test liquid must be disposed of as hazardous waste.
 The disposal of drained cartons used for "Blue/Red dye test" is not allowed on class 3
household waste dumps unless the filling company has received a confirmation from an
independent, recognised institute (such as the Chemical Test Institute) that the country-
specific regulations have been followed.
 In order to receive this proof of disposal, the test result must be attached to the application
for disposal on a deposit.
 In case this proof for disposal is not granted, cartons must be disposed of as hazardous
waste.
INFO
1. Check bottom activation and bottom weld, see sections 9.3.5.3 and 9.3.13.2.
2. Check top welding, see section 9.3.10.4.

cb 1 / cf 1 ISO 16016.
Tests
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9.4 Handling of claims
In case of deviation, the related forms needs to be filled out containing the following contents.
Important contents/components of a claim:
Information required:
 Customer designation
 Type of production line
 Fault/Problem description stating the ID points
 Inscription on shipping box (material identification, format, manufacturer, date of
manufacturing etc.), see section 9.2.4.
 Track code (can be seen on bottom section), see III. 9-5.
 Quantity (product claimed, quantity produced, quantity still available from faulty
production)
 Measures taken and impacts.
Test samples:
 At least 20 faulty samples
 In case the fault has been detected at the packaging material or at the fitment only after
the filling, also keep some faulty filled packages.
 Test samples acc. to III. 9-153 from the claimed production day, together with the required
data such as:
- Filling machine no.
- Track no.
- Temperature of bottom heating
- Air pressure of bottom heating
- Welding pressure ultrasonics (top welding pressure)
- Date and time of test
- Date/Time of production or manufacturing of sleeve
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ISO 16016. cb 1 / cf 1

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Tests

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9.1 General information on tests

Summary of test- and control measures

Measures Check-up intervals Who?

Follow protection mark Stand 15.11.2013 9-1

Important elements of the documentation:

9-2 Stand 15.11.2013 Follow protection mark

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9.2 Packaging material

Schematic structure of a carton package

Aluminium foil (for

Follow protection mark Stand 15.11.2013 9-3

Significance of individual layers

9-4 Stand 15.11.2013 Follow protection mark

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9.2.1 Production process of a sleeve

From the paper board roll to the sleeve

1 Board roll 6 Sealing of longitudinal seam

Follow protection mark Stand 15.11.2013 9-5

Cross section of longitudinal seam of combibloc carton package

9-6 Stand 06.12.2013 Follow protection mark

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9.2.2 Incoming controls of packaging material and storage

Follow protection mark Stand 15.11.2013 9-7

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9-8 Stand 15.11.2013 Follow protection mark

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9.2.3 Longitudinal seam default values/Tolerances of packaging materials

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Follow protection mark Stand 15.11.2013 9-9

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9.2.4 Packaging material identification

Example for an inscription on a shipping box

Identification print Amount of digits available

h* Production line 4 digits

l Continuous number of shipping box 4 digits

This is a clear identification of each shipping box.

9-10 Stand 15.11.2013 Follow protection mark

Blank Identification number

3 329 140 combibloc

Follow protection mark Stand 15.11.2013 9-11

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9.3 Carton check-up

9-12 Stand 15.11.2013 Follow protection mark

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9.3.1 Short overview of the test procedures

9.3.1.1 Short overview of the test procedures combibloc-carton package

Follow protection mark Stand 15.11.2013 9-13

Test 1: Sleeve activation pattern

Test 2: Filling volume (weight)

9-14 Stand 15.11.2013 Follow protection mark

Test 3: Visual check of outer appearance

Particular attention is given to: III. 9-9

Test 4: Head space

Follow protection mark Stand 15.11.2013 9-15

Test 5: Top sealing

channel forming beside the III. 9-11

9-16 Stand 15.11.2013 Follow protection mark

Test 6: Activation of top flaps

For this purpose, the activated area of the III. 9-13

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Test 7: Activation pattern and forming at

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