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Tetra Pak Frigus SF 300-C1 Operation Manual

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OM
Operation Manual
Frigus SF 300-C1
Z1320313-01en
WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.
Doc. No. OM-Z1320313-01en.book

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Summary of Contents for Tetra Pak Frigus SF 300-C1

  • Page 1 Operation Manual Frigus SF 300-C1 Z1320313-01en WARNING Read and follow all safety precautions before working on or near this equipment. Read all safety precautions throughout this manual and on safety signs attached to this equipment. Failure to follow all safety precautions could result in death or serious injury.
  • Page 2 100125 Shanghai P.R.China Additional copies can be ordered from Tetra Pak Parts or the nearest Tetra Pak office. When ordering additional copies, always provide the document number. This can be found in the machine specification document. It is also printed on the front cover and in the footer on each page of the manual.
  • Page 3 Doc. No. OM-Z1320313-01en.book Issue 2006-10 Shanghai Tetra Pak Hoyer Ice Cream...
  • Page 4 Valid for:...
  • Page 5 Update Log for Doc. No. OM-Z1320313-01en.book This table shows all changes made to this manual, such as kits installed and pages added or removed. Date Installed Kit Added Pages Removed Pages Signature (Doc. No.)
  • Page 6 Date Installed Kit Added Pages Removed Pages Signature (Doc. No.)
  • Page 7 i Introduction 1 - 1 (16)
  • Page 8 Introduction General informations about Introduction section This chapter contains basic information about this manual and related Tetra Pak equipment. 1 - 2 (16)

  • Page 9: Table Of Contents

    Table of Contents i Introduction i.1 About the introduction chapter ... . . 1 - 6 Abbreviations and Terminology ... . 1 - 7 Manual information .
  • Page 10 i Introduction This page intentionally left blank 1 - 4 (16)
  • Page 11 i Introduction 1 - 5 (16)

  • Page 12: About The Introduction Chapter

    i.1 About the introduction chapter i Introduction i.1 About the introduction chapter Risk of serious personal injury. To ensure maximum safety, always read the chapter “Safety precautions” before operating or servicing the machine or equipment. This chapter contains basic information about this manual and related Tetra Pak equipment.

  • Page 13: Abbreviations And Terminology

    i Introduction i.2 Abbreviations and Terminology i.2 Abbreviations and Terminology Abbreviation/ Meaning Translation Terminology Cleaning In Place Spare parts catalogue 1 - 7 (16)

  • Page 14: Manual Information

    It is important to keep the manual for the life of the machine or equipment and pass the manual on to any subsequent holder or user. Tetra Pak will not be held responsible for any damage to the machine or equipment caused by not following the instructions given in this manual.

  • Page 15: Page Layout

    i Introduction i.3 Manual information i.3.2 Page Layout Every main page in a manual contains a header and a footer. The page header contains the section name (2) and the chapter name (1). The page footer contains the manual’s document number (3), and the page number(4).

  • Page 16: Page Numering

    i.3 Manual information i Introduction i.3.3 Page Numering A page number has three parts: • chapter number (1) • consecutive page number (2) within the chapter • total number of pages (3) in the chapter. 1 Chapter number 2 Consecutive page number 3 Total number of pages i.3.4 Typographical Conventions...

  • Page 17: Machine Introduction

    Machine Introduction i.4 Machine Introduction i.4.1 Intended use of the machine or equipment The intended use of this Tetra Pak machine or equipment is to inject fruit pieces, nuts, candies and other free flowing granulates into ice cream or similar products.

  • Page 18: Identification

    The below illustration shows an example of the machine plate and its location on the machine or equipment. The machine plate carries data needed when contacting Tetra Pak concerning this specific machine or equipment. 1 Machine type 2 Machine serial number...

  • Page 19: Orientation

    i Introduction i.6 Orientation i.6 Orientation The illustration below shows the orientation of the equipment. This orientation information will be used throughout this manual. A Front B Right-hand side C Left-hand side D Back 1 - 13 (16)

  • Page 20: Hygiene

    i.7 Hygiene i Introduction i.7 Hygiene Ice cream production, like other foodstuffs, requires high sanitary standards. That is why the strictest demands should be made on cleaning of devices and tools getting in touch with the ice cream, ingredients coating and packaging materials.

  • Page 21: How To Use This Operation Manual

    i Introduction i.8 How to Use This Operation Manual i.8 How to Use This Operation Manual Purpose of the operation manual The operation manual provides operators with information on handling and operating the equipment before, during, and after production. Operator workflow Beginning with Chapter 1, the content is structured to follow the operator workflow, as described below.
  • Page 22 i.8 How to Use This Operation Manual i Introduction This page intentionally left blank 1 - 16 (16)
  • Page 23 ii Safety Precautions 1 - 1 (20)
  • Page 24 ii Safety Precautions 1 - 2 (20)
  • Page 25 Table of Contents ii Safety Precautions ii.1Read the safety precautions 2 - 9 ii.1 Read the safety precautions....1 - 5 ii.2 Safety Messages Description....1 - 6 ii.3 Personnel requirements .
  • Page 26 ii Safety Precautions This page intentionally left blank 1 - 4 (20)

  • Page 27: Ii.1 Read The Safety Precautions

    ii Safety Precautions ii.1 Read the safety precautions ii.1 Read the safety precautions All persons operating, servicing, adjusting or otherwise working with or near this machine or equipment must carefully read and follow all safety instructions in this manual and warning signs on the machine or equipment itself.

  • Page 28: Ii.2 Safety Messages Description

    ii.2 Safety Messages Description ii Safety Precautions ii.2 Safety Messages Description A safety message is always accompanied by a safety alert symbol and a signal word. This is the “safety alert” symbol. It is used to alert about poten- tial personal injury hazards. Obey all safety messages that follow this symbol to avoid death or injury.

  • Page 29: Ii.3 Personnel Requirements

    ii Safety Precautions ii.3 Personnel requirements ii.3 Personnel requirements Note! Personnel includes all persons performing work on or near the machine or equipment. Only skilled or instructed persons are allowed to work with the machine or equipment. ii.3.1 Skilled person A skilled person must have relevant education and experience to enable him or her to identify hazards, analyze risks, and avoid hazards which electricity, mechanics, chemicals, and supply systems can create.

  • Page 30: Ii.4 Safety Signs

    ii.4 Safety signs ii Safety Precautions ii.4 Safety signs ii.4.1 Safety Signs WARNING Hazards without safety signs drastically increase the risk of death or serious injury. Replace all missing or damaged safety signs immediately. There are two types of safety sign •...

  • Page 31: Ii.4.2 Location Of Safety Signs

    ii Safety Precautions ii.4 Safety signs ii.4.2 Location of safety signs Note! Always ensure that all safety signs on the machine or equipment are undamaged and in their correct position after installation and maintenance. The illustration below indicates where the safety signs are located. 1 - 9 (20)

  • Page 32: Ii.5 Protective Devices

    ii.5 Protective devices ii Safety Precautions ii.5 Protective devices DANGER Unshielded hazards. Never inch or run the machine or equipment if any component of the safety system is inoperative. All inoperative components of the safety system must be changed immediately. Note! Activating a safety device, such as an EMERGENCY STOP, or opening an interlocked safeguard does not switch off the power supply to the machine or equipment.

  • Page 33: Ii.6 Personal Protection

    ii Safety Precautions ii.6 Personal protection ii.6 Personal protection Note! Personal protection required when handling hazardous materials is specified for each substance, see the section “Hazardous materials”. ii.6.1 Hearing Protection WARNING Hazardous noise level. Risk of impaired hearing. Wear hearing protection.

  • Page 34: Ii.7 Hazardous Materials

    ii.7 Hazardous materials ii Safety Precautions ii.7 Hazardous materials WARNING Contact with chemicals can cause injury and illnesses. Always follow the manufacturer’s instructions when handling chemical products. Always make sure that • the showers work • an eyewash device, movable or wall-mounted, is available and operational •...

  • Page 35: Ii.7.1 Products For Cleaning And Sterilization

    ii Safety Precautions ii.7 Hazardous materials ii.7.1 Products for cleaning and sterilization The cleaning of the machine and its components previews to use of chemical products. The following table indicates the various type of recommended products. Detergent Descaler Disinfectant SU928 (Diversey Lever) P3-topax 99 (60°„C) (Henkel Ecolab) P3-topax 99 (60°„C) (Henkel Ecolab) SU616 (Diversey Lever)

  • Page 36: Ii.7.2 Personal Protective Equipment

    ii.7 Hazardous materials ii Safety Precautions ii.7.2 Personal Protective Equipment The personal protective equipment for products for cleaning and sterilization • safety goggles. • protective gloves made of neoprene. • apron • shoes made of PVC, PE plastic, or rubber. 1 - 14 (20)

  • Page 37: Handling

    ii Safety Precautions ii.7 Hazardous materials Handling WARNING Sudden and violent chemical reaction.Avoid any contamination of products for cleaning and sterilization. The products for cleaning and sterilization they can react suddenly and violently with many compounds or if it is contaminated. Ensure that equipment used for handling and diluting the products is clean before it comes in contact with the products.
  • Page 38 ii.7 Hazardous materials ii Safety Precautions Storage The products for cleaning and sterilization must be stored in the original container delivered by the supplier. Keep the container upright and fitted with its proper cap. Make sure that the area used for storage of products for cleaning and sterilization is: •...

  • Page 39: Ii.8 Supply Systems

    ii Safety Precautions ii.8 Supply systems ii.8 Supply systems ii.8.1 Electrical cabinet DANGER Hazardous voltage. Electric shock will cause death or serious injury. The power supply disconnecting device must be turned OFF and secured with a lock before any service is carried out inside the electrical cabinet Note! The key to the lock must be removed by the service technician or the electrician, and retained in his/her possession until all work is...

  • Page 40: Ii.8.2 Power Supply

    ii.8 Supply systems ii Safety Precautions ii.8.2 Power supply DANGER Hazardous voltage and moving machinery. The power supply disconnecting device must be turned OFF and secured with a lock before any service is carried out. Note! The key to the lock must be removed by the service technician or the electrician, and retained in his/her possession until all work is completed.

  • Page 41: Ii.8.3 Air Supply

    ii Safety Precautions ii.8 Supply systems ii.8.3 Air Supply WARNING Compressed air. Close the main air valve before any maintenance. Certain maintenance procedures may require the air supply systems to be on. These exceptions are clearly stated in the Maintenance Manual. 1 - 19 (20)
  • Page 42 ii.8 Supply systems ii Safety Precautions This page intentionally left blank 1 - 20 (20)
  • Page 43 1 Operation 1 - 1 (24)
  • Page 44 1 OM Description Frigus 300 is a simple and robust continuous ice cream freezer, designed and built according to the latest guidelines for hygienic food processing machinery. 1 - 2 (24)
  • Page 45 Table of Contents 1 Operation 1.1 General Description ....1 - 5 1.1.1Design ....... 1 - 5 1.1.1.1 The refrigeration system.
  • Page 46 1 OM This page intentionally left blank 1 - 4 (24)

  • Page 47: General Description

    1 Operation 1.1 General Description 1.1 General Description 1.1.1Design All parts of the freezer are produced from high quality materials and engineered to meet strict standards of hygiene, reliability and durability. All parts of the freezer in contact with mix and ice cream are manufactured from stainless materials.

  • Page 48: The Refrigeration System

    1.1 General Description 1 OM 1.1.1.1 The refrigeration system The refrigeration system is equipped with a built-in semi-hermetic freon compressor. The operating conditions of the refrigeration system can be monitored on a manometer on the front of the freezer cabinet. Defrosting of the freezing cylinder and adjustment of the ice cream viscosity can take place by means of a freon hot gas valve, operated from the front of the freezer cabinet.

  • Page 49: Operating Principles

    1 Operation 1.1 General Description 1.1.2 Operating Principles The ice cream mix is supplied to the freezer direct or via a mix balancing tank placed on top of the freezer cabinet. The ice cream mix is led to the mix pump which is fitted with an adjustable air intake valve, and pumps a mixture of mix and air into the freezing cylinder.

  • Page 50: Before Starting Up

    1.1 General Description 1 OM 1.1.3 Before starting up Perform the following checks before starting production: 1) Check that the machine is stable and has been levelled, and adjust the feet if necessary. 2) Clean and disinfect the machine carefully. 3) Check that the main switch is on.

  • Page 51: Control Panel

    1 Operation 1.2 Control Panel 1.2 Control Panel 1. Instrument indicating load on dasher. 2. Lamp indicating control current. 3. Switch for hot gas open/close / lamp for indication. 4.Switch for stop/start of refrigeration / lamp for indication. 5. Switch for stop/start of dasher and lamp for indication. 6.Switch for stop/start of air/mix pump / lamp for indication.

  • Page 52: Frontview Of The Machine

    1.2 Control Panel 1 OM Frontview of the machine 11. Manometer indicating suction temperature and suction pressure. 12. Hand wheel for adjustment of refrigeration capacity. 13. Control of overrun by using knurled finger screw. 1 - 10 (24)

  • Page 53: Troubleshooting

    1 Operation 1.2 Control Panel 1.2.1 Troubleshooting Fault: The refrigerating compressor does not start when the refrigeration starts. Pressostat Reset high/low pressostat, Pos. 72, and start again. If this attempt fails: Ensure that the solenoid valve, Pos. 82, on the liquid pipe opens when refrigeration is activated.
  • Page 54 1.2 Control Panel 1 OM Dasher overloaded Call for service to reset thermal relay 10Q5 in the high-voltage cabinet, and check the power consumption. Start dasher Start pump Start hot gas Adjust the viscosity of the ice cream by means of the hand wheel to avoid overload of the dasher.
  • Page 55 1 Operation 1.2 Control Panel Fault: Ice cream too soft. Hot gas. Stop the hot gas. If the ice cream is still soft after a few minutes, reduce the pump speed. The mix temperature. Check the mix temperature. It must be lower than 5°...
  • Page 56 1.2 Control Panel 1 OM Fault: Refrigerating compressor does not stop automatically when refrigeration is switched off. Closed valves Valve for liquid, Pos. 82, or hot gas valve, Pos. 84, does not close, and the suction pressure, Pos. 11, does not drop to approx. - 45°C.

  • Page 57: Start

    1 Operation 1.3 Start 1.3 Start Procedure for starting production: 1) Start pump. 2) Stop pump when the mix leaves the outlet pipe. 3) Start dasher. 4) Start refrigeration. 5) The mix will start to freeze in th freezing barrel. When the instrument indicated a dasher load which produces a suitable ice cream viscosity, proceed as follows: 6) Start Pump...
  • Page 58 1.3 Start 1 OM Procedure for operation: Once the freezer has been started, it is usually required to fine-tune the settings: 1) Adjust the pump speed to the required production capacity by adjusting the potentiometer. 2) Adjust overrun by means of the knurled screw on the air valve. A few minutes may pass after each adjustment until the result shows in the ice cream at the end of the cream outlet pipe.

  • Page 59: Stop

    1 Operation 1.4 Stop 1.4 Stop 1.4.1 Temporary Stop and Start 1.4.1.1 Temporary Stop 1) Stop refrigeration. 2) Stop pump. 3) Stop hot gas. The hot gas is stopped. 4) Stop dasher when the instrument indicates dropping dasher load. Note! The refrigerating compressor stops automatically when the high/low pressostat reaches the pre-set minimum pressure.

  • Page 60: Emergency Stop

    1.4 Stop 1 OM 1.4.2 Emergency Stop If a dangerous situation should occur push the emergency stop immediately. The emergency stop is placed at the control panel, pos. 8. To reset after emergency stop, release the emergency stop buttom and press the reset buttom which is located at the control panel, pos.

  • Page 61: Care And Cleaning

    1 Operation 1.5 Care and Cleaning 1.5 Care and Cleaning Cleaning of the freezer can be carried out by connection to a central CIP system to ensure maximum hygiene at minimum operational cost. The freezer is equipped with clamp type pipe connections. The following recommended cleaning instruction should be followed after stopping production.
  • Page 62 1.5 Care and Cleaning 1 OM This cleaning instruction is only meant as a guideline and must be adapted to local legislation and customers’ own cleaning procedures. WARNING The scraper blades are very sharp and loosely fitted on the dasher. Handle scraper blades with care. Note! Treat all the parts of the machine care as damage may reduce service life.

  • Page 63: Refrigeration System

    1 Operation 1.6 Refrigeration System 1.6 Refrigeration System Suction side “A” of the refrigerating compressor, Pos. 71, is connected to the top of the freezing barrel, Pos. 86. Pressure side “B” of the compressor is connected to the condenser, Pos. 77. The condensing heat from the condenser is conducted from the condenser to the cooling water.
  • Page 64 1.6 Refrigeration System 1 OM (Cont'd) A pressure controlled water valve, Pos. 78, is fitted on the water line to the condenser in order to keep water consumption to a minimum. The pressure controlled water valve is factory-set to maintain a condensing temperature of between 30°C and 40°C.

  • Page 65: Freezing Barrel

    1 Operation 1.7 Freezing barrel 1.7 Freezing barrel The freezing barrel interior is a nickel pipe plated with hard chromium on its inside; on the exterior it features a steel pipe and two flanges. The freezing barrel cannot be disassembled, and the risk of leakage of the refrigerating system is thus minimized.

  • Page 66: Checking Scraper Blades

    1.8 Checking scraper blades 1 OM 1.8 Checking scraper blades The drawing illustrates a single scraper blade, pos. 1, in operating position in the freezing barrel, pos. 2. It is necessary to sharpen a blade when its cutting edge, pos. 3, is broader than 0.5 mm.

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