USER’S GUIDE ENROBING INSTALLATION

USER’S GUIDE ENROBING INSTALLATION

Bakon USA Bakon bv food equipment Stanleyweg 1 4462 GN GOES The Netherlands Tel. : +31 (0)113-244330 Tel. (service) : +31 (0)113-244331 Fax. : +31 (0)113-244361 E-mail : [email protected] E-mail (service): [email protected]

Serial number: 302752 With order or questions refer to this serial number.

Date: 28-02-2011 User’s guide enrobing installation


FOREWORD

This manual has been written to use and maintain the machine in a safe way. The manual is intended for users of the machine. The manual is divided into chapters and concluded with appendices. Table of contents Includes a numbered list of all components in this manual. Chapter 1 Introduction Gives general information about the machine, its operation and the requirements with which the conditions of use as well as the operator have to comply. Chapter 2 Safety Describes the most important safety risks, the applied safety precautions, the safety regulations to be observed and the meaning of the used symbols on the machine. Chapter 3 Transport and storage Indicates how the machine can be transported and stored. Chapter 4 Installation and putting the machine into operation Describes the basis actions for putting the machine into operation. Chapter 5 Operation Describes how the machine is operated. Chapter 6 Inspection and maintenance Describes the inspection and maintenance of the machine. Chapter 7 Scrapping Describes how the machine can be scrapped in an environment friendly way at the end of its life. Appendices © Bakon bv food equipment No part of this publication may be reproduced and/or transmitted in any form or by any means, including printing, photocopying or microfilm, without a prior written permission of Bakon bv food equipment.


TABLE OF CONTENTS 1. INTRODUCTION 1.1. Supplier page 1 1.2. Product description page 1 1.3. Practical use page 1 1.4. Conditions of use page 1 1.5. Requirements concerning the operator page 1 1.6. Control units page 2 2. SAFETY 2.1. Introduction page 5 2.2. Safety and health risks page 5 2.3. Safety precautions page 5 2.4. Safety measures to be observed page 6 2.5. Symbols and general warnings page 7 3. TRANSPORT AND STORAGE 3.1. Transport page 8 3.2. Storage page 8 4. INSTALLATION AND OPERATION 4.1. Introduction page 9 4.2. Unpacking page 9 4.3. Installation page 9 4.4. Preparation for use page 9 4.5. Start up page 11 5. OPERATION 5.1. Using the enrobing installation page 12 5.2. The decoration pattern page 12 5.3. Shutting down page 13 6. INSPECTION AND MAINTENANCE 6.1. Inspection page 14 6.2. Maintenance page 14 7. SCRAPPING page 17 APPENDIX A : Specifications APPENDIX B : Components APPENDIX C : Electric circuit diagram APPENDIX D : Pump APPENDIX E : Similarity statement NOTES


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1. INTRODUCTION 1.1. SUPPLIER Bakon bv food equipment Stanleyweg 1 4462 GN Goes The Netherlands Tel. : +31 (0)113-244330 Tel (service) : +31 (0)113-244331 Fax : +31 (0)113-244361 E-mail : [email protected] E-mail : [email protected] 1.2. PRODUCT DESCRIPTION The enrobing installation exists of a conveyor belt with above a enrobing unit. Underneath the conveyor you will find the receiving bin. The receiving bin will be filled with product. The pump will pump the product to the enrobing unit. The wasted product, which arises, will go to the receiving bin. 1.3. PRACTICAL USE The machine is only intended for the described process in § 1.2. 1.4. CONDITIONS OF USE The machine may solely be used under the following conditions of use. - Place the machine on a hard, flat underground. - Place the machine as accessible as possible. 1.5. REQUIREMENTS CONCERNING THE OPERATOR The machine may solely be operated by persons who have been instructed and are familiar with the operating instructions off the machine.


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1.6. CONTROL UNITS The location of the various control buttons and other control units are shown in figure 1.6.1 - 1.6.6. Control unit (receiving bin) Function 1 Main switch Switch on / off voltage

I = machine On O = machine Off

2 Emergency stop In emergency cases you can switch the machine off by pressing this button.

3 Control lamp (white) Lamp will burn when the kettle is placed under the conveyor.

4 Push switch Switching the kettle ON/OFF. 5 Push switch Switching the agitator ON/OFF. 6 Push switch Switching the pump ON/OFF. 7 Push switch / control lamp After an emergency stop you can reset the

machine with this switch. 8 Control lamp (red) Lamp will burn at a mailfunction. 9 Push switch Switching the conveyor ON/OFF. 10 Control lamp (white) Lamp will burn when there is control current. 11 Turn switch Adjusting the conveyor speed. 12 Temperature controller Adjust the wanted product temperature. 13 Speed regulation valve Adjust the pump speed. 14 Pressure reducing valve Adjust the pump pressure (3 bar). 15 Pressure reducing valve Adjust the main pressure (6 bar). 16 Air link Connecting air. 17 Cup Lubrication of the pump-rod.

The cup around the pump rod should always be filled with water. Check this every hour during production.

Figure 1.6.1: Main switch Figure 1.6.2: Emergency stop


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Figure 1.6.3: Control panel Figure 1.6.4: Pump


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Control unit (receiving bin) Function 18 Gauge glass Indicates water level. 19 Tap Filling/ draw off water jacket. 20 Ball valve Open/ close the kettle. 21 Coupling Product out to the pump. 22 Fastener Adjust the angle of the enrobing container. 23 Star knob Adjust the height of the enrobing container. fixation Figure 1.6.5: Kettle Figure 1.6.6: Height adjustment enrobing container


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2. SAFETY

2.1. INTRODUCTION This chapter examines all safety aspects of the machine. It is therefore of great importance that everybody who works with the machine knows about the contents of this chapter. The prevailing safety regulations are therefore important. Apart from what has been stated in this chapter, the regulations of the competent (government) bodies should also be taken into account. The manual should always be present at the machine or installation. 2.2. SAFETY AND HEALTH RISKS The use of the machine may be dangerous, if: - the machine is used by non-professional staff. - the machine is used in an improper way. - the machine is operated in a wrong way. Remark: All safety precautions introduced to the machine by the manufacturer and the instructions in the manual are conditions to operate the machine in a safe way. The owner as well as the competent staff are ultimately responsible for working safely with the machine. The owner should see to it that: - the competent staff has been trained for its task, with due observance to the

safety regulations; - the safety regulations are followed up. 2.3. SAFETY PRECAUTIONS In order to use the machine as safely as possible, the following safety measures are necessary: - The machine has an emergency stop button. In emergency situations it is

possible to stop the machine by pressing this button. - Several covers


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2.4. SAFETY MEASURES TO BE OBSERVED In order to use the machine in a safe way, it is necessary to observe a number of safety measures. They will be summed up for each category below. Preparation for a safe use - Take care that operational activities, maintenance activities and activities for

erecting, building up and moving the machine may only be carried out by qualified staff. This means that the staff must be professional and familiar with the contents of this manual.

- See to it that the machine is erected correctly and in a stable way. - Connect the machine to a 3 x 220 VAC + PE, 60 Hz. wall socket. - See to it that all the screenings have been placed. Safety measures during use - A safe operation of the supplied machine can only be guaranteed if it is used as

intended and outlined. This machine has been designed on the basis of the specified operational conditions. The mentioned specifications should be considered as maximum values and it is therefore never allowed to exceed them.

- Never work with the machine when there are no screenings. - Keep the environment of the machine free from materials and other obstacles. Safety measures during inspection, cleaning and maintenance - The business management should take care that all inspection, cleaning and

maintenance work is carried out by competent and qualified staff, which must be adequately informed about the machine/installation after having read the user’s manual.

- Work may only take place on a dead machine (without voltage). The procedure for stopping the machine is described in this user’s manual and must always be observed.

- If adjustments have to be made on an operational machine, this should happen by qualified staff that is aware of all possible dangers.

- All provisions for safety and screenings should be placed again and made ready for use as soon as the work has been completed.

- If the machine has to be put into operation again, the points that are mentioned in this manual all have to be observed.

Measures to keep the machine in a good condition - Take care that the condition of the machine is always good. In the event of

repairs, only use reliable materials and suitable work methods. - Modifications and changes to the machine are only allowed after the

manufacturer has given his permission. Original spare parts and accessories approved by the manufacturer can all contribute to the safety. If other components are used, this relieves the manufacture / supplier from every form of liability with regard to any resultant consequences.


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2.5. SYMBOLS AND GENERAL WARNINGS GENERAL WARNINGS:

WARNINGS:

Warning for high current

General warning

Warning for hot surfaces

Warning for high current. The current in the machine is dangerous when connected to the mains.

The machine does not contain parts which can be repaired by the client. Maintenance to the machine should be done by qualified personnel.

Warning for hot surfaces. Hot surfaces can cause burn injuries.


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3. TRANSPORT AND STORAGE 3.1 TRANSPORT Transport over the public road The machine is packed in foil ex factory. The machine can be loaded in and unloaded from a lorry by means of a forklift truck. Transport in the bakery Disconnect the machines electrically before moving the installation. 3.2. STORAGE Carry out the following actions before you store the machine: - Disconnect the machine electrically and pneumatically. - Clean the machine (also see chapter 6).


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Caution: Never subject the machine to the full water pressure as this can result in serious damage to the machine.

4. INSTALLATION AND OPERATION 4.1. INTRODUCTION In this chapter it is described in which way the machine has to be made ready for use. 4.2. UNPACKING Remove the foil. 4.3. INSTALLATION - Check the machine information on the type plate. - Place the machine on the correct place. 4.4. PREPARATIONS FOR USE Receiving bin: See figure 1.6.1 through 1.6.6. - Check on presence / damage of:

- Hoses / cords - Coverings

- Check the liquid level in the cup around the pump rod (17). - Check the water level of the warm water system (water gauge 18). Refill the system, if necessary, with the filling / draw off tap (19) (see fig. 4.4.1). Enrobing machine: See figure 1.6.1 through 1.6.6. - Check on presence / damages of:

- cords - hoses /cords

- Coverings - Connect the machine electrical.


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Figure 4.4.1: Filling hot water system receiving bin

Receiving bin

Receiving bin

Receiving bin

Receiving bin

Filling valve

Water gauge


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4.5. START UP See figure 1.6.1 through 1.6.6. - Switch on main switch (1). - Pull out emergency stops (2). - Push RESET EMERGENCY (7). - Push KETTLE START (4). - Adjust the product temperature with the temperature controller (12)

(see fig.4.5.1). - As soon as the receiving bin has the right temperature, you can fill the receiving

bin with product. - Push STIRRER START (5). - Switch on the conveyor belt (9) and the conveyor speed (11). - Switch on the PUMP (6) and the pump speed (13). Now the machine is ready for use. Figure 4.5.1: Temperature regulator

1. press on Mode

2. press on ▲ or ▼

3. press on Mode


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5. OPERATION 5.1. USING THE ENROBING INSTALLATION - Make sure the machine can not suck in air. - The cup around the pump rod (17) must always be filled with clean water.

Check this every hour during production. - Adjust the speed of the pump with the turning knob PUMP SPEED (13). - Adjust the speed of the transport with the turning switch CONVEYOR SPEED

(11). 5.2. THE DECORATION PATTERN The enrobing pattern is fixed by the following factors: Height enrobing unit above the product Adjust the height so that a nice decoration pattern will rise. The liquid delivery The liquid delivery will be adjusted with the pump speed. The temperature The temperature determines the viscosity of the product. Warm product is thinner than a colder product and so this product will give more delivery per minute. When the decoration pattern is rough or exists of thick drops and an orange-kind of surface on the product exists, that means that the temperature is to low (or to thick, dilute with water). A to high temperature can influence the dry time of the product harmful. The transport speed The transport speed determines the speed with which the product goes under the enrobing unit. With a higher speed lesser product will go on the cakes.

Never let the pump run dry! Run dry will cause serious damage to the pump.


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5.3. SHUTTING DOWN Enrobing installation: - Switch the pump off with push switch PUMP STOP (6). - Switch the conveyor belt off with the push switch CONVEYOR STOP (9). - Release the product hose from the enrobing unit and hang the hose in a bin. - Switch the pump on with PUMP START (6). The receiving bin will be pumped

empty. - Switch the pump off with push switch PUMP STOP (6), as soon as the receiving

bin is empty. - Empty the enrobing container. The enrobing container can be kipped for

cleaning (fig. 1.6.6).

- Place the enrobing unit back in position. - Fill the receiving bin with warm water (±50°C). - Connect the product hose again on the enrobing unit. - Switch the pump on with the switch PUMP START (6). - Keep the system pumping for a while. - Switch the pump off with the push switch PUMP STOP (6). - Let the flushing water run out the receiving bin through the draw-off tap (20). Repeat above-mentioned until the flushing water stays clean. - Switch the receiving bin off with push switch KETTLE STOP (4). - Switch the main switch OFF (1).

Never let the pump run dry! Run dry will cause serious damage to the pump.


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Caution: Never subject the enrobing machine to the full water pressure as this can result in serious damage to the machine.

6. INSPECTION AND MAINTENANCE 6.1. INSPECTION Visual inspection should be carried out every day with regard to: - adequate operation. - lack of hoses and connections. - leaks. - damage to feeder cables and connections. - Water level in the cup around the pump rod (17). - water level of the water jacket (receiving bin) (18).

6.2. MAINTENANCE In order to guarantee an adequate operation of the machine it is important that it is maintained well. It is important that all parts that are subject to wear are regularly checked with regard to their operation and replaced on time if wear is established. - Grease the bearings of the conveyor belt regular. - Grease the bearings after every clean-up. - Use grease that is approved for the food industry. - The motor reductor of the conveyor belt is free of maintenance. - Maintain the pump according to appendix D.


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Greasing points: Figure 6.2.1: Greasing points

Do not use to much grease. 2 pumps each bearing is enough.


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The machine should be cleaned regularly. The machine should not be powered (main switch). Machine parts can be disinfected by means of disinfectants. Attention: - Soap residuals and/or residuals of disinfectants must be washed away well. - Cleansing agents should not cause any mutual chemical reactions. - Use the cleansing agents according to the described procedures and guidelines

of the manufacturer.

WHEN USING WATER HOSE, NEVER AIM AT SEALINGS AND OPERATING PANELS.

DO NOT USE A HIGH-PRESSURE SPRAY. DO NOT USE A STEAM CLEANER.


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7. SCRAPPING The machine can be taken to Bakon bv food equipment, where it can be disassembled in an environment friendly way. If you would like to remove the machine yourself, the following points should be observed: - Remove all plastic parts from the machine. - Stainless steel should be removed as scrap material.


APPENDIX A. SPECIFICATIONS Enrobing installation: Dimensions : 900 x 300 x 1500 mm Connecting voltage : 3 x 220VAC + PE, 60 Hz. Power : 4,5 kW Air pressure : 6 bar


APPENDIX B. COMPONENTS

RECEIVING BIN 70L Amount Description Article number

2 Swivel caster WLZ19108 2 Rigid caster WLB19158 1 Ball bearing LGK2R357227 1 Ball bearing LGK1R357217 1 PS Seal SPS55X72X10 1 Motor MSA57N=8.60.37KW 1 Heating element 250mm EI3000W 1 valve FWAFA1/2“M 1 2-way valve FWKK2WN 1.1/2“BI 1 Temperature sensor PT1006MM/95

ENROBING MACHINE WB 300 MM D

Amount Description Article number 2 Swivel caster + Brake WLZ19208HCDR 2 Swivel caster WLZ19208HC

11 Cord L=2868mm SR6MMGLADBL 1 Motor M0.37KWSA37/25A 4 Bearing Block 25mm LGBKLT25 4 Sealing ring NW25 MKDRNW25P 3 Sealing ring NW15 MKDRNW15P 1 Pump WIWA WWPS150.05R KORT 1 Speed regulation valve VTOGRE1/8B 1 Pressure reducing valve + filter VTRMS4LFR1/4D6CRM 1 Pressure reducing valve VTRMS4LRB1/4D6AS 1 Air connection FWKRT14 Electro 1 Temperature controller KT2 RTKT2211100J 1 Frequence controller 0.37KW FRSG110_0.37 2 Proximity switchIIT205 INSIIT205 1 Power supply IFM 24 VDC 2.1A V24VDC2.1A IFM


APPENDIX C. ELECTRIC CIRCUIT DIAGRAM

3-012-00-03-0158


APPENDIX D. PUMP

Points of attention: - The cup around the pump rod (see figure D.1) always has to be filled with

clean water. With intensive use it is necessary to check this several times a day.

- When the water in the cup is soiled by the product which needs to be pumped, it is necessary to tighten the cup until the leaking stops. Do not turn the cup too tight, this will give an excessive wastage to the seals. Replace the dirty water with clean water.

Figure D.1: pump

Cup


APPENDIX E. SIMILARITY STATEMENT

Declaration of conformity BAKON BV FOOD EQUIPMENT Stanleyweg 1, P.O. Box 166, 4460 AD Goes; The Netherlands; Declaration of conformity Client : Bakon USA Order number : 302752 Date order : 11-2010 Date delivery : 02-2011 We, BAKON BV FOOD EQUIPMENT, Declare, under own responsibility, that the product

ENROBING INSTALLATION

Serial number : 302752 about which this declaration concerns, (if used) is in conformity with the standards or other standardised documents: and in conformity is with the machine guideline 2006/42/EG Goes, The Netherlands, 28-02-2011

__________________________ R. Gijssel, General Manager

NEN-EN-ISO 12100-1 NEN-EN-ISO 12100-2 NEN-EN-ISO 13857 NEN-EN 349 NEN-EN-IEC 60204-1


NOTES

USER’S GUIDE ENROBING INSTALLATION

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