The document provides instructions for a packaging operator to prepare packaging equipment for startup. It details pre-start check procedures, including obtaining necessary materials, checking equipment functions, and verifying settings. The operator must fill glue pots, check operator interface terminals for the correct recipes, inspect photoelectric eyes and belts, and run test product through the packaging line to ensure proper operation before notifying supervisors that the line is ready for production.

1. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
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Revision 0 ABC’S GROUP A, TX 3-2-1
Introduction This Lesson explains the duties and responsibilities of a Packaging
Operator during Start-Up. It details how to prepare the Packaging Area
for Production, check Packaging Equipment before a Product Run, and
how to start Packaging Equipment.
Correct Start-Up Procedures are essential to a successful Product Run
and help to prevent accidents and emergencies on the Packaging Line.
Learning
Objectives
At the end of this Lesson you will be able to:
1. Start glue pots.
2. Verify the Case Erector, Case Packer, Case Sealer Recipes, and
verify that Shift Specifications are correct on the OIT’s
(Operator Interface Terminals).
3. Verify and check Case Codes.
4. Check belts and eyes for Tracking and Positioning.
5. Load case blanks into the Case Erector.
6. Perform Pre-Start Checks on the Case Erector and start the
Equipment.
7. Perform Pre-Start Checks on the Case Packer and start the
Equipment.
8. Perform Pre-Start Checks on the Case Sealer and start the
Equipment.
9. Check High Conveyor and Diverter Functions.
10. Explain how preparing the Packaging Area for Start-Up is
different after a fog.
Finished Cases of
Product at the End
of the Palletizing
Belt

2. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
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Revision 0 ABC’S GROUP A, TX 3-2-2
Start-Up Second shift Packing Operator begin a Product Run at the beginning of
the week with a Start-Up shift. The ABC’s Group Z shuts down for
Sanitation between Product Runs. The first responsibilities of Packing
Operator beginning a Start-Up shift are to:
Make sure the Packaging Area has been properly cleaned.
Obtain the necessary Materials for Starting-Up the Packaging
Equipment.
Obtain shift paperwork.
After these items are finished, the Packaging Operator must conduct
Pre-Start Checks and prepare the Line to Start.
Sanitary Materials It is necessary for the Packaging Operator to obtain Sanitary Materials
before beginning Pre-Start Checks. All Sanitation items are kept on a
cart in the QA (Quality Assurance) office. These items include hand
sanitizer, dry cloths for cleaning photo electric eyes, and gloves. The
cart should be brought into the Packaging Area by the Packaging
Operator at the beginning of the Start-Up shift.
Gloves must be worn by Packaging Operators at all times. Hand
sanitizer is to be used on the gloves before touching Product on the
Packaging Line. Also sanitize gloves before loading case blanks and
adjusting any Equipment.
CAUTION: Do not use hand sanitizer before refilling the glue pots. The heat
and blue can potentially react with the sanitizer and cause fires,
explosions, or Hazardous Chemical Reactions.
Packaging
Operator Putting
on Gloves

3. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-3
Building Fog If the building was fogged while the Line was down, the plastic that
was used to protect the Equipment needs to be removed before the
Foreign Material Check can be conducted.
Any uncovered conveying belts will have been exposed to the
insecticide and will need to be wiped down with hand wipes and water.
OIT screens may need to be wiped clean as well.
Visual Inspection A quick visual inspection of the Packaging Area should be conducted
by the Packaging Operator at the beginning of a Start-Up shift. There
should be no evidence of previous Product, for example: empty
cartons, bars, or half-built cases. Glue pellets should not be on the
floor and there should be no evidence of glue spills. The floor must be
free of debris. If there is previous Product evidence, or the Floor Area
is not clean, the Packaging Operator must clean and sweep the
Packaging Area before obtaining Materials to begin the Start-Up shift.
Broom and Dust
Pan
Review Question When does a Packaging Operator have to wear gloves?
A. Only for cleaning after a building fog.
B. Only when handling Product.
C. A Packaging Operator does not need gloves.
D. Packaging Operators must wear gloves at all times.

4. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-4
Answer The answer is D.
A Packaging Operator must wear gloves at all times.
Obtaining
Materials
Process Materials for a Product Run must be gathered before Pre-Start
Checks are conducted on the Equipment.
Case blanks for the Case Erector are requested from the Shipping
Warehouse Backroom by the Packaging Operator. Case blanks are
delivered on shrink-wrapped wooden skids. Usually two or three skids
are brought to the Packaging Area at a time. During a Product Run, a
Utility Person can be used to request more case blanks from Shipping.
Utility Personnel on the Packaging Line assist with Housekeeping and
any responsibility the Packaging Operator requires help with
completing. Packaging Operators should never leave the Packaging
Line unless they have been relieved for a break by the Line Supervisor
or another Packaging Operator.
Old Product for Pre-Start Checks is obtained from QA. The old
Product must be the exact same type of Product currently running.
Keep it separate from current Product. Old Product is thrown away or
returned to QA once Pre-Start Checks are finished.
Taking Case
Blanks from the
Top of a Skid

5. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-6
Answer The answer is False.
Utility Personnel on the Packaging Line assist with Housekeeping and
any responsibility the Packaging Operator requires help with
completing. Packaging Operators should never leave the Packaging
Line unless they have been relieved for a break by the Line Supervisor
or another Packaging Operator.
Obtaining
Materials (cont.)
Green and blue handled knives are also kept sheathed in the toolbox.
Knives are issued by the ABC’s Group Z to every Packaging Operator.
Green knives are for use with Product suitable for Human
Consumption including Product that may be returned to the Line. Blue
knives are only for use with Product no longer suitable for Human
Consumption and that cannot be returned to the Line.
Glue pellets must also be obtained from the Storage Area before
Pre-Start Checks. A Utility Person is usually sent to retrieve the glue
pellets while the Packaging Operator is Visually Checking the
Packaging Area. A blue labeled container of glue pellets is placed near
each glue pot. Glue pots are located next to the six pack Case Erector
and the Case Sealers.
CAUTION: Glue pellets must not be placed too close to the glue pots. Heat
from the glue pots will melt the pellets before they can be used.
Glue Pellets in Blue
Container Next to
Glue Pot
A hand scoop for the glue pellets is kept on the bottom of the Work
Station Table. If there is not a hand scoop available, notify the
Packaging Lead before Pre-Start Checks begin.

6. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-7
Glue Pots Once the glue pellets have been obtained the glue pots can be filled.
A Wrapper Operator begins the Sunday night Pre-Start-Up Procedures
by turning ON the glue pot and, while in the Area, checking the glue
level. The Packaging Lead sometimes turns the glue pots on during the
initial Check of the Areas.
The glue pots will have been off since the Line was Shutdown. It will
take approximately 30 minutes for the glue pot to heat the glue to its
liquid state. The glue pots must be checked regularly throughout the
shift. A glue pot should never be allowed to run out.
The Procedure for filling a glue pot includes the following steps and is
repeated to fill each glue pot:
1. Visually Check the status of the glue pot.
a. If OFF, Press the ON button to power the Unit.
b. Otherwise continue.
2. Open the lid and Visually Check glue level.
a. If low, add more glue pellets from the pellet container
using the scoop kept at the Work Station Table.
b. If full, continue.
3. Close the container lid securely and return the scoop.
CAUTION: Heating an empty glue pot will burn out the heating element.
Make sure glue pots are full before plugging them into the power
source. glue pots should not be allowed to run dry.
Open Glue Pot
Filled with Glue
Pellets

7. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-10
OIT’s Once the Packaging Area has been properly cleaned, necessary
Materials for Starting-Up the Packaging Line have been obtained, and
shift paperwork has been retrieved, the OIT’s must be Checked to
make sure they are running the correct Recipes and Shift
Specifications.
OIT’s-Case Erector Start with the six pack Case Erector OIT. It is located on the six pack
Case Erector on the West side of the Machine. Select the F2 to choose
the Recipe button. Select Enter (the Long Arrow Key on the bottom
right of the OIT).
The Recipe is programmed by the Line Supervisor. It should already
be entered into the OIT. Compare the Recipe on the six pack Case
Erector OIT with the Recipe on the Product Specification Sheet. They
should be the same.
If the Recipe is incorrect notify the Packaging Lead and Production
Manager. If it is correct, press F1 for the Main Menu screen. Then
select Enter (the Long Arrow Key). The display should return the six
pack Case Erector OIT to the Main screen. No other input is required
by the Packaging Operator on the six pack Case Erector OIT unless the
Packaging Operator is required to clear an Alarm.
West Side of Case
Erector
Review Question Name two pieces of paperwork obtained from the Production Manager
or Packaging Lead.
______________________________________________________
______________________________________________________
Case
Erector
OIT

8. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-17
Answer The answer is False.
Belts on the Line that stutter or are loose may be threaded incorrectly
or may be stuck on the idlers. Minor adjustments to the idlers are made
by the Packaging Operator. Major Threading Problems require calling
Maintenance.
Photo Electric Eyes
(cont.)
First check the screws that hold the eye and the reflector in place are
tight. A slot head screwdriver is used to tighten the screws
Once the eye and reflector are securely held in Position, clean the
photo electric eye and reflector using a clean, dry hand-wipe. The wipe
may be dampened with a small amount of hand sanitizer to clean the
lens of the photo electric eye. Do not use sanitizer on the reflector.
CAUTION: Neverlook into a photo electric eye or allow the infra red light
from a photo electric eye to shine into your eyes.
If a spot of red light still cannot be seen on the reflector, use the slot
head screw driver to loosen (do not remove) the screws and adjust the
position of the reflector to orient it to the photo electric eye. Rotate the
reflector slightly to the left or the right until the light from the photo
electric eye can be seen on the reflector. If the red light cannot be seen
on the reflector after adjusting the reflector’s Position, return the
reflector to its original Position (oriented to the photo electric eye) and
retighten the screws to hold it in place.
Photo Electric Eye
Reflector Reading
Infra-Red Beam

9. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-30
Answer The answer is C.
The Top Flap Holds inside the Fallas Case Packer should span the
width of the sides of the empty case and fit completely inside the case
without tearing the case.
Pre-Start Checks-
Case Sealer
Once the Case Packer Pre-Start Checks are finished, the six pack Case
Sealer Pre-Start Checks must be conducted. Cases of old Product from
the Case Packer are used for six pack Case Sealer Pre-Start Checks.
On the six pack Case Sealer OIT:
1. Select the Main screen icon using the Function Keys. Press the
Enter Key (Arrow).
2. Select the RUN/JOG button on the OIT using the Function
Keys. Press the Enter Key.
3. Select Manual Mode button on the OIT screen using the
Function Keys and press the Enter Key.
4. Press the green Start pushbutton on the six pack Case Sealer to
start the six pack Case Sealer.
5. Check the right and left top flaps of the cases of old Product
once they pass through the six pack Case Sealer to make sure
they are tightly glued. Tug the flaps. If either flap comes up,
stop the six pack Case Sealer by opening the Guard doors.
Then check the glue nozzles to see if they are blocked.
Case Sealer OIT
Screen
Function
Keys
Enter Key

10. ABC’s Group Z Packaging Operations Module 3
Lesson2- Start-Up
______________________________________________________________________________
Revision 0 ABC’S GROUP A, TX 3-2-35
Answer The answer is False.
Any internal Mechanical Problems with the six pack Case Sealer need
to be reported to the Packaging Lead and Production Manager.
Alpine and
Diverter (cont.)
Old Product is fed through the Diverter to make sure that the Diverter
is Functioning correctly. Stand beside the Diverter Belt and put cartons
quickly onto the lanes. The cartons should be fed randomly into all
four lanes coming from the Alpine. The Diverter should switch
smoothly between lanes of Product. If the Diverter is not alternating
between lanes, notify the Packaging Lead and Production Manager.
Lanes Coming
from Alpine into
the Diverter
Conclusion Communicate to the Packaging Lead and Production Manager that
Pre-Start Checks have been done, the Equipment is in Automatic
Mode, and the Packaging Area is ready for a Product Run. The
Packaging Lead will co-ordinate with Processing to begin the Product
Run.
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