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1. OPERATION

General Procedure

The smoke is generated by glowing wood-chips on a heated device at temperatures of

700 - 1200 F with a lack of combustion air. The heating is affected by an electrical

heating rod supplying the necessary energy to start the process.

The Way of Procedure

The wood-chips are poured into the wood-chip funnel (2) and are fed to the burning

plate (15) by way of a stirring arm, a chute (17) and a geared motor (1) that is

controlled by an interval circuit. The height of the chute is adjustable to obtain an

optimal setting for the supply of woodchips and to produce the smoke in the required

quality. During the stirring period the spent smoldered wood-chips fall through the

burning plate (15) into the ash box (6). The electrical heating rod (18) which causes the

wood-chips to glow is integrated into a groove in the burning plate.

A fan (1.2) blows air through an air divider (7) into the smoke generator. Combustion

air is directed underneath the burning plate, while transport air is added at the top. The

ratio between the two partial streams of air are adjusted by retaining baffles.

The smoke and transport air are mixed together and conducted through the smoke exit

(8) and smoke duct into the smoking chamber. A temperature sensor (1.16) in the

smoke exit activates the extinguishing equipment should a limiting temperature of 210

F be exceeded. A water trap container (9) located underneath the smoke exit ensures

that no secondary air can be drawn into the plant.

A regulating valve (10) in the smoke duct is used to produce the necessary vacuum

within the smoke generator, thereby preventing the formation of a strong suction force

inside the smoke generator.

Smoking Phase

Smoke is admitted at times during the smoking phase. Smoke is generated by glow-

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heating woodchips inside the generator (1).

The smoke (1.1.4) is directed through a pipeline via the climatisor (2) and into the

process chamber.

While smoking is in progress, the fresh air supply (2.1.1) is shut off by way of a

motorized or pneumatically operated flap. The volume admitted into the system as

smoke is pushed out of it via the exhaust channel.

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2. START UP and SHUT DOWN SEQUENCE OF ACTIONS

Generator is turned on 20 min before the Natural Smoke Process step begin. To shut

down:

Start Up

Check the generator to be clean of the tar build up and the seals are functional.

Inspect the door gaskets and other potential point of entry for the air.

Assure that dripping bucket is full of water.

Lower ash container, need to be filled with water.

Check to assure that water and air supply are on and their control valves are

working properly.

Check the half moon plates.

i. Assure they are matched properly.

ii. Assure they seat properly. The surface underneath need to be

clean

Fill the generator with chips before it is ignited.

Check the functionality of fire extinguishing system before you start.

Report any problems immediately

Shut Down

If a clean up will follow the shut down, it needs to be performed 30-45 minutes after

the generator is shut down and the element is not hot. Cold water will damage the

heating element.

Turn off master switch. Never turn the generator off using the E-stop button.

Extinguish all material in smoke generator thoroughly, remove sawdust and ash.

Clean smoke generator thoroughly and remove tar deposits.

Report any problems immediately

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3. MECHANICAL ADJUSTMENTS

Adjusting the Chute

The chute directs the wood-chips falling from the funnel onto the burning plate. The

chute is fastened by tightening a T-screw. The height of the chute and the size of the

gap between the top edge of the burning plate rim and the bottom edge of the pipe

have an influence on the quantity of wood-chips available for glow-burning. The interior

of the burning plate should be full to the rim with wood-chips.

The following adjustment should be made in conjunction with the agitator pause:

If too many wood-chips fall over the rim onto the outer surface of the burning

plate, then chute should be lowered in 5 mm increments.

If the wood-chips do not come up to the edge, the chute should be raised in 10

mm increments.

The standard setting is a gap height of 30 mm.

Setting the Partial Vacuum of the System Exerted on the Smoke Generator

The suction acting on the smoke generator is adjusted by way of a dam flap or with a

slide plate in the smoke outlet. These adjustment mechanisms should never be more

than 50 % closed, in order to avoid increased soiling.

The suction on the smoke generator can be judged as ideal when, with the door

(top door) opened by about the width of a hand, a swirl of smoke emerges

approx 5 cm from the housing and is sucked at the edge of the opening back

into the combustion chamber.

Setting:

Open the flap / sliding plate = suction is greater = greater volume of smoke goes into

the system.

Close the flap / sliding plate = suction is less = smaller volume of smoke goes into the

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system.

Fan for Supplying the Smoke Generator with Transport- and Combustion Air

This fan supplies the smoke generator with predefined quantities of air for combustion

(through the distributor below) and transport (entry through the distributor above).

The ratio of air quantities is relevant to safety, and may therefore not be changed!

Ratio = combustion air 1 part : top air 20 parts.

The total quantity of air that is fed in can be adjusted by changing the gap using a

throttle screw on the ventilator (induction side). Too much air turns the glow-burn

process into combustion, creating smoke that is not suitable for treating foodstuffs.

Adjustment:

Gap greater = more smoke; gap smaller = less smoke

The standard setting is a gap width of 3 mm. Adjustments in 1 mm increments.

Safety information:

Smoke fumes are explosive in certain compounds. Safety features are built into the

smoke generator in order to prevent any possibility of explosiveness. Any alteration to

components or certain assemblies is forbidden and must not be attempted!

Adjusting the Fresh Air Flap in the Smoke Generator Door

The fresh air flap opens parallel to the pneumatic flap at the rear of the smoke

generator. Locking is actuated by a limit switch so that that the smoking process cannot

run with closed flap. In case of malfunctions, e.g. the flap remains closed during the

smoking process; still a diminution takes place due to the transport air delivered by the

ventilation.

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4. CLEANING

Instructions for Cleaning

The wood tar created in generating smoke spreads throughout the system and clings

stubbornly to its surfaces.

The cleaning frequency should depend on the amount the system is used and the

number of smoking operations carried out per day (or week). Certain parts of the

smoke generator must be cleaned daily!

The soiling on the smoke generator consists mainly of wood tar deposits and residue

sawdust. The smoke generator is normally cleaned by hand. This means that all

components that come into contact with glow-heated wood-chips must be taken out of

the smoke generator and cleaned externally.

The walls of the housing inside the generator can then also be cleaned with detergents.

The agent used to clean the generator is a smoke resin removal powder (or solution)

dissolved in tap water (ready-mixed solutions or concentrates may need to be diluted

with water or according to the maker's instructions).

The concentration generally used is a 2 - 3% solution. The percentage can be varied

slightly according to the degree of soiling (2 - 5%).

The cleansing agent must be allowed 10 - 15 min to take effect, depending on the

degree of soiling.

Stubborn stains should be worked off with a spatula, is necessary.

Wear safety clothing, especially gloves and goggles!

The inner components that have been removed can be placed in a bath of detergent for

softening (time approx. 10 - 15 min).

The components may also be sprayed and cleaned while on the ground.

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After the detergent has taken effect, all parts and surfaces must be rinsed thoroughly in

clear water (especially metallic surfaces, burning plate and frame).

The cleaning nozzles installed in the smoke pipe system are connected to the cleaning

device through a distributor and appropriate piping. These areas are reached together

smoke generator when the system is cleaned.

Daily

1) Clean the Generator Temperature sensor

2) Clean the Ignition plate attachments and the chip drop chute

3) Clean the Smoke generator mating surface to the above burner plates

4) Empty ash box and half fill it with water

5) Top up the chip bin and close the lid

6) Make sure the tar separating bucket is filled to overflow with water

Weekly:

1) Clean entire smoke generator. This includes the entire above plus entire

inside cabinet. (The CIP only cleans the smoke duct).

2) Remove and clean the lower pipe bend of the air divider (The pipes now have

different air orifices installed; make sure these are replaced back into the

pipes).

3) Check to make sure the extinguishing equipment is functioning properly

Environmental Impact if procedure is not followed: Failure to follow the procedures above may result in excess smoke going into the smokehouse and out of the exhaust stack to the outside air. Pollution will increase as a result of producing too much smoke because the meat inside the smokehouse will only absorb a certain amount of smoke.

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5. FIRE SAFETY - Extinguishing Equipment

The smoke generator is fitted with a self-actuating extinguisher, enabling

excessive temperatures or a fire to be combated rapidly.

The current smoke-gas temperature is measured by a temperature probe

extending from the side to the drop pipe.

If the temperature at this probe exceeds a preset limit, extinguishing water

is sprayed through an automatic valve onto the sawdust bed and into the

smoke pipe via the outlet.

The standard setting of this temperature limit is 210 F.

The valve is designed to allow continuous extinguishing even if the power

fails, i.e., the valve is opened without power!

This emergency cut-out is disabled (unlocked) by switching the smoke

generator off and then switching it back on. (S1 switch On - Off).

It is essential to ensure that the water supply and the supply of compressed

air to the smoke generator are never cut off!

Servicing the Extinguishing Equipment

Daily and /or after each cleaning

Each time before use, the extinguishing equipment must be checked.

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6. SAFE OPERATION GUIDELINES AND TROUBLESHOOTING

1. KEEP ASH CONTAINER INSIDE THE BOTTOM COMPARTMENT OF

SMOKE GENERATOR AT LEAST FULL OF WATER. (THIS WILL PREVENT THE

DOOR GASKETS FROM MELTING DUE TO OVERHEATING).

2. CLEAN SMOKE GENERATOR AS OFTEN AS NECESSARY IN ORDER TO

PREVENT THE EXCESSIVE BUILDUP OF CREOSOTE INSIDE THE UNIT.

3. DO NOT OPEN THE FRONT DOOR WHILE THE SMOKE GENERATOR IS

IN THE OFF MODE WITH THE DAMPER CLOSED TO THE SMOKE HOUSE.

(VOLATILE GASES ARE FORMING INSIDE THE HEATING PLATE CHAMBER-

OPENING OF THE FRONT DOOR MAY CAUSE AN EXPLOSION).

4. THE FRONT DOOR CAN BE OPENED WHILE THE SMOKE

GENERATOR IS IN THE ON MODE AND THE DAMPER IS OPEN TO THE

SMOKE HOUSE. (EMPTY THE ASHES FROM THE ASH CONTAINER AND FILL

WITH WATER DURING THIS PERIOD).

5. WHEN THE SMOKE HOUSE CYCLE IS FINISHED, WAIT

APPROXIMATELY 45-MINUTES OR UNTIL THE TEMPERATURE IS BELOW

130 F. BEFORE OPENING THE FRONT DOOR OF THE SMOKE

GENERATOR.

6. KEEP THE TEMPERATURE PROBE CLEAN AT ALL TIMES IN ORDER

FOR THE PROBE TO ACCURATELY RECORD THE HEATING CHAMBER

TEMPERATURE.

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Chamber of smoke generator

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Half Moon Plates

They are manufactures in batched pairs. A distinct letter is assigned for each pair. They can be placed in any generator, provided they are a properly paired match

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Air diverter damper adjustment

Once this damper is set, no more adjustments need to be made. Occasionally, it will loosen up, and then you need to make sure it is tightened. inch opening is typical. Its adjustment will depend on the environmental temperature in order to maintain a temperature 120-130 F in the smoking cabinet compartment

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Diverter Tube Cleaning

This air tube must be cleaned every time the generator is cleaned. There is an orifice inside the tube that must stay intact. Ratio = combustion air 1 part : top air 20 parts

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Damper control

The damper will open when the generator is on in your program natural smoke There is a damper inside this compartment.

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Creosote bucket

This bucket must be filled with water every time the generator is running.

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Water pressure sensor

If water pressure is shut off to unit, the generator will not turn on. If power is shut off to the unit, the water will open and spray water in your chamber.

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Extinguish temperature sensor

This sensor records the temperature on the Extinguish temp controller at your control panel, if it goes above 212 degrees, the water will extinguish the fire in the chamber

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7. QUIZ TEST

T F To be able to get more smoke