Medana Operational&M..
Contents
1. 3 Tight the four screw to fix the fill pump Insert the lubrication pipe with the quick connection device red arrow Equipment SN GK72101005 Data 06 Sep 2010 6 Put the fill hopper cover and the air filter if Fi i igh h i 5 Fix the fill hopper by tighten the screw necessary see fill line preparation section Department Technical Department Page 21 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 5 Die roll coupling housing 1 Die roll coupling housing on trolley 2 Unlock the the fixing knob s Kd 7 t gt 7 E a ag a eM d a gt 5 io 5 r a T q i g ee 7 3 a en lt a a A gt URE amp f v i i piz j 4 _ iee a N S L A tg Tea hoe ae s s oe x s iu b i N Ya i nrt ro 4 i E fa ay 7 re D 3 Slide the housing on the mobile lift 4 Put the mobile lift in position in front of the machine _ B bd a e aT nium F 5 Slide it in position 6 Fix the die roll housing with the knob positioned in the middle of the two die rolls P N E THI i eal a ws FA _ Department Technical Department Page 23 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 6 Dierolls assembly Department Technical Depar2. gam After removing the capsules trapped wash the residual oil with hot water and 10 Uppercut solution Rinse with de mineralised water and dry with industrial paper moistened with alcohol 5 3 Wedge 1 unplug the heating element Remove the heatin oe 5 Unscrew the nut and remove the flexible pipes element and 3 Pull the wedge from the seat along its guide 4 Place the wedge on its trolley Disassemble the distributor from the wedge Wash with water and 10 Uppercut solution Rinse with de mineralised water and dry with paper soaked with alcohol Remove all the gaskets and replace them with new ones for a new production Department Technical Department Page 48 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 4 Die Rolls 1 Unscrew the two knobs securing the yoke assembly to the die roll assembly then unscrew the 2 Remove the Yoke Assembly from the seat two die shaft knobs securing the two die rolls 4 Pull and push the central knobs to release the die 3 Remove the 2 bracket beside the chute conveyor rolls from the yoke Pull the die roll yoke and let it slide on its guide Department Technical Department Machine preparation start up and Maintenance MANUAL Document N 2144_2009_M_09_10 Author M Lambri 5 Yoke released 6 Remove the right roll and then the left Do not bump the dies against metal surfac
3. Check the pressure set in the ee coe ee o o asevice S Underweight capsule Segment not perfectly Put the segment in centre again centred po Damaged segment Replace the segment re Blocked cavities Dismantle and clean Fill leakage on gasket Check plungers gasket and shut off valve gasket S Fill leakage on spider tube Check piepes and connections Air bubbles Try to increase the injection pump stroke Fill leakage in the net Segment not perfectly Put the segment in centre again centred po Damaged segment Replace the segment aE Eee a proper segment ne ena onsale the segment Leakage capsule or bad welding Die rolls not aligned Check alignment and adjust Low segment temperature Increase temperature a Gelatine residual glued to Clean the segment surface with E a aa P Too high production speed Lower the speed high D Fiaba aaa coating roll cavities Air bubbles in the hopper fill Check the gasket between fill tank and fill pump and the fill pump seal Air bubbles in the capsule fill Segment not perfectly ooo Damagedsegment Replace segment Shut off valve in wrong
4. Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 Dismantling the equipment and cleaning procedures 5 1 Spreader boxes and gelatine pipeline After each production run remove the two spreader boxes from the machine see pictures below and place them onthe appropriate trolley Wash the spreader boxes in the washing room by immersion in hot water or in the washing machine use hot water and rinse with demineralised water Dry with industrial paper soaked with alcohol 1 Remove the level sensor from the box 2 Remove the whole heating element and temperature probe wirings CAUTION do not hit the cooling drum while removing the spreader box the drums can be permanently damaged Department Technical Department Page 44 of 82 Machine preparation start up and Maintenance MANUAL Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 After the spreader box disassembly it is possible to proceed with the gelatine pipe washing connect the gelatine piping as shown in photo Department Technical Department Page 45 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 2 Capsule conveyor Data 06 Sep 2010 5 Lay it down on a trolley and remove the capsules gt
5. Lambri Data 06 Sep 2010 10 Troubleshooting Problem Reason Adjustment po Electrical panel malfunction Callservice po Damaged electrical panel ___ Call service wrong Hard blocks of gelatine in the Clean way the blocks with hot spreader box opening water Spreader boxes do not fill up Gelatine viscosity too high Check gelatine temperature Gelatine pipe is blocked Check the pipeline heating is on Stop the machine and clean the pipeline with hot water Only one spreader box fills up Gelatine pipe is blocked Check the pipeline heating is on Stop the machine and clean the pipeline with hot water Floating unit malfunction Dismantle the spreader box clean up and set the floating unit Gelatine pour out of spreader box Gelatine too much liquid Lower the heating temperature Air bubbles in the ribbon Air bubbles in the gelatine Substitute the gelatine tank tank Floating unit not properly set Set the unit and wait for spreader box reaction Set floating unit eS ee and let the level come up again cooling drum yy Spreader box temperature Check the probe possible too high malfunction Department Technical Department Page 82 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 The ribbons do not slide well between Oil roller lubrication Check the oil level in the back tank aaa eee O Check the elastoflex fast
6. M Lambri Data 06 Sep 2010 3 Machine Set up 3 1 Fill Block Pump assembling procedure Refer to the following scheme in order to proceed with disassembling action 1 BANKS assembling 2 BANKS assembling trought SOCKET HEAD SCREW 3 assembling INSIDE amp OUTSIDE WASHER PLUNGER SEAL 4 Tight the screw with appropriate key Equipment Name GK 72 Encapsulation Line Equipment SN GK72101005 Data 06 Sep 2010 5 PLUNGERS insertion 6 SIDE PLATE assembling 7 SLIDE VALVE assembling 8 TOP PLATE assembling Department Technical Department Machine preparation start up and Maintenance MANUAL Document N 2144 2009 M_09 10 Author M Lambri 9 Fix the screw on TOP PLATE 10 gasket positioned Department Technical Department Page 14 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 2 Fill pump housing assembly 1 Pump housing completely dismantled 2 Fix the pump housing block ref 2 and tight 4 Fix the cam ref 43 with the special compass key 5 Top view of the pump housing assembled a ee aa some raii a 6 Install the two slide ref 6 and 7 and the two 7 Install the two pump block support left and right yoke bracket left and right ref 8 and tight ref 15 and tight Department Technical Department Page 17 of 82 Equipment Name GK 72 Encapsulation Line Document N 21
7. by sliding it on the support Department Technical Department Page 33 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09_10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 Position the frontal part of the machine in front of the encapsulation machine 3 e an Ce io l A E F Now follow the instruction on the GK72 HMI manual in order to operate on the touch screen and close the machine Place the spreader boxes in position over each casting drum Secure the spreader boxes to the machine frame housing by pivot screws in the pivot brackets The spreader box body must rest on the drums Department Technical Department Page 34 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 Lower the gate completely until it rests on the drums check that the 0 05 mm thickness gauge do not pass through along the contact line between the box and the drum Put the graduated scale on the adjusting gate at zero unscrewing the dowel on the knob and rotating it until it reaches the zero Then block it During the adjustment of the ribbon thickness the two adjusting studs of each spreader box must be screwed at the same time The adjustment must be done rotating each of them gt clockwise to increase the thickness gt anticlockwise to reduce it Insert the cartridge heaters in the spreader boxe
8. designed for them It s forbidden to modify in any way the equipment it s own functions and the technical documentation attached unless given authorization from the machine builder please take care of this maintenance and usage manual as it will match all the machine lifetime Do not remove any avalanche protector It s forbidden to put anything inside the motor s cover and to shut the power OFF bypassing the main switch The workers must remark to their people in charge any malfunction and or any possible dangerous situation avoiding any operation out of their knowledge The workers must inform the machine builder about any fault in the accident prevention procedures or in any estimated dangerous situations All the maintenance operations must be performer at atmospheric pressure and the machine must be isolated from the main power Department Technical Department Page 9 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 It s forbidden to put any load on the equipment The equipment must not be exposed to a possible hydraulic ram 2 6 Unavoidable dangers The worker must pay attention to the risk of possible leakage current in the main switch in the operational panel Department Technical Department Page 10 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author
9. detergent water and 10 Uppercut solution from the top of the die roll housing Run slowly the machine at minimum speed for 5 minutes Stop and suck all the dirty water Rinse accurately with hot de mineralised water and again run at minimum speed Rinse with alcohol to remove all the water residual Dry with industrial paper soaked with alcohol be sure not to leave paper residual inside the die roll housing gt Spray some oil on the gears and the shafts of the die roll housing VVV V While washing the die roll housing check accurately the movement of the coupling shaft Clean accurately the coupling frame front flange the coupling flange and the coupling slider Clean also the die shaft sliding block Department Technical Department Page 53 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 6 Chute assembly and mangle rolls 1 Unfasten the pin under the chute conveyor 2 Pull the conveyor along its seat to remove 4 Unscrew as in picture to put the brushes in safe position Equipment Name GK 72 Encapsulation Line Equipment SN GK72101005 Data 06 Sep 2010 5 Assembly is ready to be removed 6 Store on the proper trolley disassemble to clean The Chute Assembly is removed from the machine and partially disassembled Completely dismount the conveyor belt and the capsule chute All the parts are washed with 10 Uppercut solution
10. icre ict lt 00 9 heen eee ene ene nt ee rn er Oe ee eee ee 60 5 9 Medicine pump block CISASSEMDIY csesecccesseccccesececcesececeusececeeeeceeseeecessusecesseeceeseeeceesenaeeetes 66 S0 OUP OGD ctscnres seas conte tatirn ep atencanecaaisentcosentin luussumasednselacuceals havavatia E ei uesennteceneseameavents 70 opel Md G2 qo a0 0a eee enn er cn nee ee eee eee reece eee ene le et eee ete eee en rere 72 6 Tumble dryer cleaning and disassembly cccccccssseccccsseccccessccecausececeeececeeesecessueceseenceeseuseeetsugecessees 74 T TUNDE ENNE gerne ee error ee nee eer eee eee er ee re 77 Be RCH an E NE NEO E EA E E 77 8 1 1 Manualcleanine solutio Noreen A 77 8 1 2 Automatic cleaning SoOlUtION erer E aendeneseaaeegusateruostseteuene 77 ANAS E n E E E E E 80 9 1 Die roll housing assembly e column assembly sssssssseseseseesrrnsesrenssrrrsssrrresrrressreresrrereserresereesrrressne 80 9 2 FUR Ee T AS OD y e E 80 9 3 Chute assembly 7 mangle rollere EEEE 80 9 4 PUMP housing ASSEMDIY cccccesseccccesscccceesececcesecceceecceseusececeusececseecesseeeecessusecessenecesseneceeteneeeetas 80 9 5 COGN GIONS aa S A E 80 9 6 CIEE 7 COOLING YAN a AE 80 9 7 TOENE ae E E A 80 9 8 SE e E ee E E E E AE E E EA E E a T 80 10 Troubl shooting ccosciacu dence qeecadoontesncpedexeacwnacecisune EEEE EEE EEEE 81 Every effort has been made to ensure the accuracy of this document However the information contained herein
11. the degreasing power to the environmental safety it can be in fact also used for cleanings inside establishments in the food industry UPPERCUT is one of the most versatile and effective available detergents on the market today Component alkaline silicate polypropylene glycol ethers non ionic surface actives water Chemical physical property Aspect liquid Colour pink Odour unscented pH 12 9 Boiling point around 100 C Point of inflammability not inflammable Relative density 1 05 Solubility in water complete Biodegradability The contained surface actives in the product are biodegradable in superior measure to 90 To use according to the good working practices avoiding to disperse the product in the environment Department Technical Department Page 79 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 PULYGEN Product for the daily cleaning of mechanical parts stainless steel tiles washable walls and crystals cleanser for hard surfaces Composition it mixes the synergy of non ionic surface active emulsifying agents Exempted by foam it is not corrosive and it doesn t absolutely irritate the skin Biodegradability 90 It doesn t contain phosphorus Aspect liquid clear of yellow colour Dosing pour the product on the surface to clean passing a rag or wet sponge it isn t necessary to rinse D SOLO
12. 44 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 3 Fill pump housing synchronization Check the fill pump housing alignment as shown The photo shows a correct installation Please verify in your pump housing that The crank shaft A must be parallel to the guide on the right handside at the same time the guide pin on the cam must be aligned with the zero point sensor C and the hole in the front If the zero point sensor is then aligned correctly with the guide pin please push the relevant button on the machine and the led will light up to confirm Department Technical Department Page 18 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 To synchronize the medicine pump housing please proceed as follows 1 The crank shaft must be parallel and horizontal as 2 Unscrew the cam central pivot with a compass the guide on the right Align the cam guide pin to the hole on the housing and relevant sensor then screw the cam central pivot with a compass key Department Technical Department Page 19 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 4 Fill pump and pump housing coupling 1 Lift the fill pump using the support frame supplied 2 Install the fill pump on the pump housing
13. Description alkaline detergent with strong binding action for recycle washings Physical state liquid clear colourless unscented pH sol 1 12 7 Alkalinity Na O 17 NaOH 22 Specific weight at 15 C 1 27 Middle life 12 months Biodegradability 90 Contained in P exempt Method of titration collect 10ml titrant HCI 0 25 Ns indicator metilorange conc 0 5 ml consumed HCI Concentration of use 1 5 in water to 55 C Department Technical Department Page 80 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 9 Maintenance ALL THE MAINTENANCE OPERATIONS MUST BE DONE IN SAFE CONDITIONS AT ATMOSPHERIC PRESSURE AND WITH THE MAIN POWER SHUT OFF DURING THE MAINTENANCE OPERATIONS THE WORKERS MUST COMPLY WITH THE ACCIDENT PREVENTION RULES IN ORDER TO BE IN SAFE CONDITION 9 1 Die roll housing assembly e column assembly gt Daily or production end check that the change gear surface is clean check for oil leakage from the pump housing shaft gt Monthly check the internal die roll housing clean and lubricate with Teflon spray if necessary gt Put teflon grease on idle gear gt Half yearly lubricate with Teflon spray the internal parts of column assembly and die roll housing 9 2 Oil Roller assembly gt Daily or production end empty the excess oil tank gt Weekly dismantle the oil rollers and cl
14. INE SOU Ds essas E EE E i 37 Sy OIMPOIIGI IONIC O eee E E E A A 38 316 Pump housing lUDrICatO M sessie pecasaenoceasens sseeneneeeaeats 38 24A7 Synchronize he machine serseri eer E 38 3 18 Capsule conveyor assembling on the machine ccccccccccccccecceceeceeceecececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 39 d Production starteri E AE E AE E A 41 4 1 CHERE LITE ill E E E E 41 4 2 DIVINE an E T dances etnee unas ceseecanniecoateouecas 41 4 3 SLOPPE TNE ME E ere E E E 42 4 4 T mble dryer programming serseri aA EN 42 Department Technical Department Page 3 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 Dismantling the equipment and Cleaning procedures ceecccccsseccccessececeusececeeeceeeeeseceseeecessuneeeeseges 43 5 1 Spreader DOXES and gelatine DIDCIING scccsatcarsedxvesscncdseossidwenctencadanswateudchoweienesesdaeecsavaalendadaadaranaideacste 43 5 2 Cap Ule 818 ah EVO a nee ee nee nee ner ne nO 45 5 3 WO eee ee E eee ee ee ee ee ee 46 5 4 PS TRONS crease cosine a E vec tine eatin E E A E E E A E E A E E 48 5 5 DeROSIER E E E 50 5 6 Chute ass mbpiy and mangle VOUS scsesvccscesecenaacassceecsdveasesdneeatevcoveudusduydasereasnanestevesteweedaidadaucenoreines eens 53 5 7 Medicine PUMP housing GISASSEMDIY ccccccsseccccseccccensececeusececeenecceeeesecesauecesseneceeeeneceeseneeeetas 55 5 8 Medicine eo 0 an age
15. Lock the medicine pump housing on the trolley with the same safety bracket Department Technical Department Page 60 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 8 Medicine pump disassembly 2 Open the trolley wing leave the safety bracket in 1 Medicine pump on trolley ready for dismantle place 3 Remove the hopper cover 4 Remove 8 nuts and the hopper 5 Use the trolley wings to manage the dismantled 6 Unscrew the nuts and then remove the medicine pieces flexible pipes 7 Remove the four screws to dismantle the assembly remove also the fill pump lubrication Department Technical Department Page 62 of 82 Machine preparation start up and Maintenance MANUAL Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 8 Unfasten all the plunger retaining nut 9 Plunger free from frame NY W ilig 4 Y 4 10 Remove the medicine pump from the housing 12 Medicine pump without pump block 13 Remove the 4 screws and remove the two plates 14 Remove the plates and store them on trolley 15 Remove the 6 screws to pull out the inner yoke wings bracket 16 Inner yoke bracket removed and placed on 17 Dismantle the cam with a compass key trolley wing 19 Remove the four screws holding the pump 18 Cam dismantled i housing 20 Pump hous
16. TP Blow compressed air not higher than 3 bar toward the PVC tubes in the Special filter Inject alcohol through the PVC tubes in the Special filter MTP and blow with compressed air Oil Roller Special filters MTP 1 Remove the plate in front of on the MTP filter 2 Pull the filter out of the support 3 Store the filters on the proper trolley ready for washing 2 Department Technical Department Page 72 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 11 Casting drums 1 Remove manually the knobs to remove the 2 Pull out with the sucker tools the carter carter 3 Open the lateral door 4 Unlock the knob 5 slide the cover 6 clean the drums Department Technical Department Page 74 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 6 Tumble dryer cleaning and disassembly Each section can be disassembled independently please follow the photographic procedure to disassemble the tumble dryer 1 Tumble Dryer general view 2 Open the frontal cover SS 3 Remove the two mini basket Department Technical Department Page 75 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 4 Unscrew and rotate the filter holder 5 Remove the
17. _ _ a ERA PHARMAGEL ENGINEERING SPA GK 72 ENCAPSULATION LINE SUPPLIED TO 2 medana Machine preparation start up and Maintenance MANUAL Document No 2144 2009 M 09 10 CURRENT ISSUE Issue No 0 Date Reason for Issue For comments Sign Off Issued by Reviewed by Approved by Print Name M Lambri Incardona E Peviani Signature fj J d l l Aher fA Date PREVIOUS ISSUES Type Names Issue Date Issued by Reviewed by Approved by Reason for Issue No 0 1 2 3 Department Technical Department Page 2 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 Index E NS E O ce ee een ene N eee ee eee 4 1 1 POC Cal SS CIC AE ONS igs sserscstes sae ce ceeaccise tec ssaensecins savas Gnnee cseaness nai 4 1 2 NOOR IVE CONTAGION secin en raeo T 5 1 3 SEIER OCS A TE AS EEA E E tesa sents E E E shar E E 5 2 e l E a A E A A I EE AEE E T E O E E N OE A E 6 2 1 Moving method and conditions sesesessssesssrsessrrreserersrrrressrersssrressreressrerssreressreessreresereeserereseeeesseeee 6 2 2 installation toom COMGITIONS sarrere unpenn EEE E R E E 7 2 3 Installation and first CHECK cceesssccccccccceeesseeccccccsaueesseeeccceessaeeseeececeessueessseeseeeessueessseceeseessagganses 7 2 4 Preca 9 eee eee are nr nn eee ener er Faraone E cree ey E eer 8 2 5 Cor
18. alignment Department Technical Department Page 27 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 8 Pump housing assembling on the machine 1 Fill pump on trolley 2 Slide the fill pump on the mobile lift Department Technical Department Machine preparation start up and Maintenance MANUAL Document N 2144_2009_M_09_10 Author M Lambri 4 Lift the pump 5 Slide the pump on the encapsulation machine pay attention to the coupling of the two shaft 6 Rear view of the two shaft 7 Screw the two block to fix pump 10 Insert the fill flexible pipe inside their position 11 Install the level sensor on the top of the hopper and close Department Technical Department Page 31 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 9 Chute assembly and mangle roll assembling on the machine 1 Chute assembly on trolley 2 Remove the chute assembly and install it on the correct position below the die roll housing by sliding it on the two shelves m N Department Technical Department Page 32 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 10 Wedge assembling on the machine 1 Wedge on the trolley 2 Insert the wedge
19. cable install only cables of section appropriate to the power installed The power cable must not be handled to pull out the plug from the socket Protect the cables from high temperature oil and sharp edges Use power cable extension only if approved and marked c All the instruments and equipment must be protected from stray currents electrostatic differential and or potential by adequate protection instruments and or ground connections and electrical coupling connections d The user is obliged to verify all the safety devices for each installation and for any used fluid 2 5 Correct operations and not allowed operations All the equipment must be installed and used in respect of the rules in force in the installation country the user must be aware and apply all of them The machine builder do not take upon himself any responsibility for any damage that may occur to people object or installations due to inappropriate use of the equipment The user must not put inside the machine any raw material at a temperature different from the minimum and maximum design temperature It is forbidden to put inside the machine any raw material and or mixture that will eat into rust and or corrode the contact surfaces It s forbidden to use compressed air and any diesel oil and or solvent spray The constructor is not responsible for any damage produced by inflammable and or explosive materials introduced or used in the equipment if it was not
20. e the die rolls could be permanently damaged and perform badly in ribbon cutting 7 Store the die rolls on a proper trolley Die rolls are washed with water and 10 UPPERCUT solution or similar They are rinsed with water and dried with industrial paper soaked with alcohol Department Technical Department Page 50 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 5 Die Rolls housing 1 unscrew the plug connecting Siemens encoder on 2 Unplug compressed air from the front and the back of the die roll housing back pneumatic cylinders 3 Put ht e mobile service lift in front of the machine and lift at die roll housing height push the tray until it fits in the guides on the machine frame 4 Lock the tray with pin now you can pull the die roll housing on the tray Unlock th Il i il lock i 5 pull the housing until lays completely on the tray a ia and pull it until you can lock it 8 Put the mobile service lift in front of the trolley for housing move the tray for connection then move the housing on trolley 7 Move the tray to the lower position housing is ready to be transferred to trolley cong the housing on trolley with the proper fixing 10 Dieroll housing stored on trolley Washing Procedure Follow this procedure in order to wash the die roll housing gt Suck by vacuum all the residual gt Pour hot water and
21. ean the filters 9 3 Chute assembly mangle roll gt Production end disassemble the chute assembly and the mangle rolls and wash all the pieces gt Weekly remove die rolls chute assembly front cover plate and clean 9 4 Pump housing assembly gt Production end remove the pump from the pump housing wash and replace the gaskets gt Check the Pump Yoke cross bar Replace if worn out 9 5 Cooling drums gt Production end check the overall conditions check the revolution it must be regular without any vibrations Remove any gelatine residual without any metallic tool Do not scratch 9 6 Chiller cooling system gt Half yearly check for possible leakage in the case Check the functions of the valves 9 7 Tumble dryer gt Production end start a general cleaning of the system 9 8 Service The user is allowed to execute all the operations described with details in the chapter of the Standard Maintenance Any other kind of operation on the machine must be asked for approval from the Technical Department of Pharmagel Egineering describing any possible fault operations or overhaul requested In certain circumstances Pharmagel Engineering can agree for a direct service or can give authorization and detailed repair instructions at the user maintenance service Department Technical Department Page 81 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M
22. ent Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 Fill tank 3 14 Gelatine line setup Connect the pipeline as per diagram below 7 AEN i ON ei mi a DA i 3 E Tea a aN p Ay 11 2 TC a L o amp o a Tto At L Gelatin tank gt gt f Mons J S A o i _ Sr a SSaS al a dle r N w eae E pee Capsule Dase T 1 1 2 TC i Department Technical Department Page 38 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 15 Oil roller lubrication The encapsulating machine has a gelatine ribbon lubrication system which allows an extremely precise dosage of the lubricant oil It depends on the type of capsules and on the type of product to encapsulate Fill the oil roller tanks located on the right side of control board through the two different tank gates using gt Middle Chain Triglycerides Oil 100 gt Middle Chain Triglycerides Oil mixed with Lecithin Oil 0 1 of Soya bean oil in Middle Chain Triglycerides Oil For the oil filter cleaning see the maintenance section Oil level is controlled and visible on HMI at minimum level an alarm will turn on the control panel The excess oil is guided towards two small tanks aside the machine u
23. es are fixed on the box bottom by crossed wood sticks and completely enveloped in plastic foils The outfit accessories and spare parts are packed in carton boxes If the equipment needs to be packed all the machines must be fitted in their wooden box in the same way as previously specified see packing list in VTOP package During the unpacking operation please check the supply carefully all the components must be verified in the shipment documents If any piece of equipment is missing or damaged please immediately contact Pharmagel Engineering Spa and emit the reserve in the forwarder documents The equipment is provided with directional wheels so that it can be moved without any additional device Lift the equipment with a system suitable and adequate to its weight and size It must be moved with caution and placed to avoid any damage and or crash Department Technical Department Page 7 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 2 2 Installation room conditions The equipment must be installed at atmospheric pressure the air must not include aggressive particles and maximum humidity must not damage any instrument The installation room must be provided of fire safety equipment the user must install all the adequate safety and controls systems preventing also external accidents Please consider the following place cond
24. f the adjusting gauge stud Allow spreader boxes to heat up Switch on the Gelatine Pipeline heaters on the control panel and let it heat up for 10 minutes 3 Connect the gelatine tank conical valve to the Gelatine Pipeline with the silicone tube provided by us Connect the air feeding open the valve and after one minute switch on the machine Start to fill the soreader boxes from the control panel by spreader boxes level control 5 Add one litre of vegetable oil in the medicine hopper Switch on the cooling fan and adjust the temperature to 15 C and the speed of the air Start up the machine at 2 5 r p m 7 The gelatin will become ribbon in a couple of minutes Start the oil rollers lubrication from the control panel and as the ribbons emerge from the drums feed them through the oil rollers die rolls and mangle rolls 9 Lower the segment and start the segment heating element at requested setpoint temperature 10 As soon as the segment reach the desired temperature put the die rolls in the CUTTING position and immediately operate on the shut off valve 4 1 Checking the fill Check the capsules shape fill weight and shell thickness and make necessary adjustments The fill weight varies by altering the pump dosing stroke As soon as satisfactory capsules are produced drain the vegetable oil from the hopper Connect the hopper to the main supply by the Cleanline Medicine Pump line The first few hundred capsules contain a mixtu
25. filter lt _ lt P 9 First basket conveyor details Oo Department Technical Department Page 77 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 7 Tumble dryer cleaning The baskets are removed from the tumble dryer and carried on a special trolley to the equipment washing room where the operator removes the remaining capsules and then starts to clean The baskets are cleaned with water at 60 C and then washed with 10 Uppercut solution After that they are rinsed with de mineralised water and dried with industrial paper soaked with alcohol 8 Utilities and cleaning media 8 1 1 Manual cleaning solution Uppercut 10 solution Puligen D Solo Ethilic alcohol Industrial paper conforms to law for product in contact with food VVVV YV 8 1 2 Automatic cleaning solution gt Diverflow VC26 gt Diverflow VC2 Department Technical Department Page 78 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 UPPERCUT Description Ecological degreasing soluble in water It doesn t contain phosphates Pourpose and use Uppercut thanks to the special agent DRK 55 also penetrates through the fat substances breaking up the more difficulty dirty Fat and residues will easily be removed with a simple throw of water Uniting
26. ial inspection reach a tumble dryer for the first stage of drying Department Technical Department Page 42 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 After being in the tumble dryer for approximately 2 to 3 hours the capsules are placed on trays Later they are transferred in the drying tunnel until they reach the required hardness in approximately 37 to 72 hours When this process is completed the capsule are ready for inspection 4 3 Stopping the machine Stop injection of fill material switch off the segment heaters release pressure on the die rolls and raise the pump housing assembly to the idling position Switch off the Gelatine Feeding System Close the gelatine tank valve Switch off the Cleanline Fill Pump Keep the pipeline in place for washing cycle 4 4 Tumble dryer programming The tumble dryer programming is set from the control panel please refer to chapter 6 to program the baskets work in the proper way It is possible to modify charge and discharge time and rotational speed For a proper discharge time program proceed as follows Maximum discharge time CT first basket charge time N basket number The stop time during the rotation change is fixed in 12 seconds so the basket maximum discharge time MTS willbe Example N 3 baskets CT 600 seconds Department Technical Department Page 43 of 82
27. in hot water After rinsing with demineralised water they are dried with industrial paper soaked with alcohol Department Technical Department Page 55 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 7 Medicine Pump housing disassembly 2 Remove completely the flexible pipes fastening 3 Fastenig guide removed put the flexible pipes in guide pulling the handle the pump housing be careful with oil spraying 5 Put the mobile service lift in front of the pump housing lift at correct height oush the tray until it locks in front of the pump housing base Sh 4 Unplug the fill pump lubrication pipes on the right side 7 h k h 6 Lock the tray with the pump housing base Unscrew the two knobs under the pump base to release the pump free 9 Pull the pump housing on the mobile service lift 8 Lift the upper pump block tray 10 Put the safety bracket in place on the back of medicine pump housing then pull the tray onto the mobile service lift and 11 Safety bracket in place on the back of the medicine pump housing 13 Lift down the medicine pump housing until low 12 Medicine pump housing on mobile service lift w position 14 Put the mobile service lift in front of the trolley for medicine pump housing and lock them on place then remove the safety bracket 15 Transfer the medicine pump housing onto the trolley 16
28. ing completely dismantled and ready for washing Department Technical Department Page 66 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 9 Medicine pump block disassembly Refer to the following scheme in order to proceed with disassembling action 1 Move the block pump to a clean table with appropriate tools 2 Remove the TOP PLATE gasket nia a 4 Remove TOP PLATE 5 Remove SLIDE VALVE 6 Remove SIDE PLATE 7 Remove PLUNGERS 9 Remove BANKS 10 Remove GLAND NUT 11 Remove INSIDE amp OUTSIDE WASHER PLUNGER SEAL Department Technical Department Page 70 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 5 10 Oil roller The Oil roller lubrication system needs to be cleaned if the ribbon lubrication is not uniform This is carried out in three stages gt Tank cleaning gt Pump cleaning gt Special filter MTP Tank cleaning Remove the cover from the mygliol oil tank situated on the rear of machine Clean with water and Uppercut 50 50 solution blow with compressed air and rinse with alcohol Tank filters cleaning Check and clean the filters on the lubrication tank outlet Pipeline cleaning Disconnect the PVC tubes and blow compressed air not higher than 3 bar toward the oil roller Special filter M
29. is subject to change without notice Pharmagel Engineering spa reserves the right for such change without prior notice Department Technical Department Page 4 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 1 General specifications 1 1 Technical specifications GK 72 Encapsulation machine Tumble Dryer Overall dimensions N 2 unit 2090x1399x1317 h mm Tumble speed 0 24 rpm Electrical panel Line voltage requested 400 V 50 Hz 3 phases N G 27 KVA Safety device IP 55 Department Technical Department Page 5 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 1 2 Working conditions Installation room specifications 22 24 C Relative humidity 15 20 Product specifications 9000 14000 cps at 60 C 1 3 Safety devices The safety switches are in the machine side panel turn the motor power off when the electrical panel is open leaving the auxiliary tensions on IT S DANGEROUS TO REMOVE OR CHANGE THE SAFETY DEVICES Department Technical Department Page 6 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 2 Installation 2 1 Moving method and conditions All the equipment is forwarded in wooden boxes All the machin
30. itions gt Donot expose the equipment to rain gt Donot use equipment in humid or wet rooms o Humidity max 85 o Room temperature 15 40 C gt Installation room must have a good lighting gt Keep the floor dry clean without oil or dirt spots 2 3 Installation and first check The power line must be placed in room before the equipment installation in order to be ready for connection at the equipment installation Procedures at the first start up Please verify and remove all the safety packing system then carefully clean all the equipment Place the equipment in the chosen position Connect the equipments to all the Utility as in the drawings and P amp ID attached oP Connect the electrical wires as in the drawings attached and check them again start the motors for a rotational test The cables connections must comply with the RST polarization standard Attention the machine can be seriously damaged by an incorrect phase connection DO NOT APPLY POWER AND DO NOT MOVE ANY PIECE WITHOUT OUR TECNICIANS CONSENT Department Technical Department Page 8 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 2 4 Precautions a The power supply must comply with specifications set in the functional design specifications data and the must not be different of more than 5 of the nominal voltage b Avoid any wrong usage of the electrical
31. nder the cooling drums 3 16 Pump housing lubrication Fill the Medicine Pump Housing with Middle Chain Triglycerides Oil A gear pump installed in the pump housing and speed controlled by panel feed the pump with lubrication oil it will pass through and fall in the pump housing 3 17 Synchronizing the machine The movement of the medicine pump must be synchronised with the die rolls rotation The timing mark on the face of the injection segment corresponds to the upper edge of the injection holes The timing mark on the die rolls corresponds to the trailing edge of the cavities When the machine is synchronised the fill will be fully injected immediately before these two lines meet However tolerance must be made for the thickness of the gelatine ribbon Please refer to HMI for pumps homing The machine is now ready for production 1 Conveyor on trolley 2 lift the conveyor and slide it on the machine side to pull it out Data 06 Sep 2010 5 Conveyor installed Department Technical Department Page 41 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 4 Production start Read HMI user manual before production start to get acquainted to machine functions To start the production proceed as follows 1 Switch on the spreader box cartridge heaters on the control panel and adjust the spreader box opening gates to 030 with the help o
32. re of vegetable oil as fill material and must be rejected As soon as production starts check the capsules fill and shell weights Counting from the timing mark take the first and the last capsules from the dies Wash them in a beaker full of ether to remove the external traces of lubricant Weight on the balance and record the weights Partially dissect the sample capsules at the seam and wash again in order to remove all traces of fill and allow ether to evaporate Place the shell on the balance and record the net weight The difference between the two weights is the true weight of the fill Repeat these sampling tests as frequently as the precision of the order requests Then take the capsules from the second and from the last but one cavity of the dies Take them progressively inwards After sampling make any necessary adjustments to the pump travel and spreader box openings until desired fill and shell weights are obtained After half an hour it should not be necessary to make many adjustments to the spreader boxes and pump travel although adjustments to the cartridge heaters and conditioned air may be required from time to time 4 2 Drying Newly formed capsules drop from the machine onto a conveyor which is arranged so that the rejected can be sent in one direction and the perfect capsules in the other It is important to see that the conveyor is running to reject capsules at all time during the machine set up Capsules that pass the init
33. rect Operations and not allowed operations cceeccccssscccceesecccceseccceeesececseseceeseeceeseuseeesseaeess 8 2 6 Unavoidable dangers eisien ea e e A E T 9 Be PVCS Se I o E E A E AAE E A tawarnnnnctconneulamiantnts 10 3 1 Fill Block Pump assembling procedure ssssessssesserssrressrreresrrrrssrersrrerssrrresrrressrrressrereserresereresrrressne 10 3 2 PIL p mp housing assemDly senene EET 14 3 3 Fill pump housing synchronization ccecesssccecccccccceeeeeeeseeeeeeeennneeeeeeeeceeeeeeseeeeeeeeesaaaeeeeeeeeeeees 17 3 4 Fill pump and pump housing COUPLING ececccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees es 19 3 5 Die rol COMPHNE NOUSI NE eis aa EEEE EEEa 21 3 6 Perol a a1 e ncn ee ee eee 23 3 7 Dero GN ON ascceeerser cence vaste reer cena eee eaeaeecee sea dinnnacaa ener sreeunesetacenearidetbensiceesavuiecemsissiconesiees 25 3 8 Pump housing assembling on the Machine ccccssssssceecceeeececeeeeeeeeeeeeeeeennnaeeeeeeeeeeeeeeeeeeeeens 27 3 9 Chute assembly and mangle roll assembling on the Machine ecceccccccececceeeeeeeeeeeeeeeeeeeees 31 3 10 Wedge assembling on the Machine 2 0 0 ecccceecessesesennnneeeeeeeeeeeeeeeeeeeeeeeeeeeenneeeeeeeeeeeeeeeeeeeeeens 32 311 FRO MUa Dale Connection sasen 33 3 12 Spreader boxes assembling on the Machine cccssesssecceccececcceeeeeeseeeeeeeeennnneeeeeeeeeeeeeeeeeseeees 33 sA FULE 08 nee ene ee ee eee ee 36 314 Geldtine W
34. s 2 Install the spreader box and fix it with 1 Spreader box on the proper trolley canine ee ha s 4 oF es oF aes F gt Vi a i Page 35 of 82 Equipment Name GK 72 Encapsulation Line Equipment SN GK72101005 Data 06 Sep 2010 3 Insert heating element and probe 4 Install the level sensor from the box Department Technical Department Page 36 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 13 Fill line setup The fill can be transferred from the tank to the fill pump in two different modalities prepare the fill line according to the schematics below With recirculation for paste The product is continuously keep in recirculation between the tank TKO01 and the hopper POSO01 installed on the fill pump POS002 by a transfer pump POSOO8 a filter of 0 2 um FLOO1 installed on the top of the tank TK001 assure the integrity of the product Fill tank With level sensor for oil A level sensor FLOO1 installed on the hopper POSO01 of the fill pump POS002 control the transfer pump on off POSO08 in order to maintain a stable level inside the hopper POSO01 in this case two filter FLOO1 and FLOO2 of 0 2 um installed on the top of the hopper and the tank guarantees the integrity of the product Department Technical Department Page 37 of 82 Equipm
35. tment Page 24 of 82 Machine preparation start up and Maintenance MANUAL Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 4 Closed manually the chute conveyor 5 Fix manually the Yoke Department Technical Department Page 25 of 82 Equipment Name GK 72 Encapsulation Line Document N 2144 2009 M_09 10 Equipment SN GK72101005 Author M Lambri Data 06 Sep 2010 3 7 Die rolls alignment The cavities in the right die roll must be aligned with the cavities in the left one The machine supplied is already mounted and tested with the correct die roll alignment In this situation the worker don t need to align the die rolls any further To check the alignment place the telecamera Leica near the die roll housing put and fix the camera with the knob and proceed to focus on the die rolls front tag you will see also the cavities alignment with a proper illumination 1 Assemble the telecamera support frame 2 Fix the camera with the bottom knob 1 r i Item available as an option Page 26 of 82 Equipment Name GK 72 Encapsulation Line Equipment SN GK72101005 Data 06 Sep 2010 3 Adjust the camera at maximum distance with the rear knob 4 Correct camera installation 5 Put the die rolls in place connect the camera wiring and proceed to focus on the die rolls front tag Please follow instruction of the Telecamera Leica on software and
Download Pdf Manuals
Related Search