Catalogue
- General theory
- Main use and characteristics
- Technical performance and basic parameters
- Main construction and technological process
- Product system explanation
- Transportation and storage
- Installation and testing
- Test running,sterilization and cleaning
- Production operation program
- Maintenance
- Technical file
AGeneral theory
Suggestion:If you want to get the out of the machine, we strongly urge that you adhere to the guidelines and procedures as set out in this catalogue
Disclaimer:In the situation of that you neglect the instructions in this book,damage and accident may result.No responsibility will be taken on our behalf in such cases.
IMPORTANT ATTENTION:Equipment failures due to the following reasons are not guaranteed.
First:Natural disasters
Second:Operational errors
Third:Lack of maintenance
Fourth:Short-circuit because of electrical apparatus accident
When replacing parts please use only new parts as supplied by the manufacturer.
1. Main use and characteristic
The machine is mainly used in carbonating and mixing of carbonated beverage,such as lemonade,coke,juice etc carbonated drinks.
Characteristic:
a)Advanced chemical and industial technology is applied in the machine,the transmission medium area is large, low resistance loss,high efficiency,simple construction,and the multistage centrifugal pump which has reliable performance and low noise is applied.
b)High precision needle valve's and pneumatically actuated angle valve's are separately set up in the pipe of the syrup and water,the mixing rate can be adjusted accurately by the valve, syrup and water cannot counter flow.
c)Gas content can be adjusted conveniently according with theneed of beverage gas containing.
d)Auto-control system is set up in the machine,it has characteristic of coordinate action,simple construction,production continuum,high automatic degree.
e)Home position cleaning technological process is set up in this machine. Chemical sterilization,hot sterilization and cleaning with clean water can be conveniently carried out.It meets the requirement of food sanitation law.
2. Technical performance and basic parameter
1)Production capacity:1500-1000kg/h
2)Range of syrup and water ratio:1:3-1:10
3)Gas containing:CO2：H2O>2.5
4)Mixing precision:<=2%
5)Inlet temperature of chilled water:0~4℃
6)Inlet pressure of chilled water:0.01Mpa～0.08Mpa
7)Inlet temperature of syrup:2~8℃
8)Inlet pressure of syrup:0.01Mpa~0.08Mpa
9)Inlet pressure of CO2:0.7Mpa～0.8Mpa
10)Purity of carbon dioxide:>99.9%
11)Working pressure of water storage pot and syrup pot:0.05～0.09Mpa
12)Working pressure of storage pot:0.2Mpa～0.5Mpa
13)Motor power:2～10Kw
14)Overall dimension:LWH 2000*1700*2100
15)Weight:1800 Kg
16)
3. Main construction and technical process
1)The machine comprises a pedestal,water storage pot,syrup pot,liquidmeter,static mixer,storage pot,electric appliances controls system,gas-provide box and necessary production technology pipeline and cleaning technology pipeline ,the machine are set up with globe valve, ratio needle valve,angle valve,electromagnetically operated valve,check valve.(attachment one:main structure sketch map)
2)main technology process
无菌水
4. Production system instruction
Water entry phase:Aseptic water entry into water storage pot through filter,water pump,angle valve,put CO2 gas in the water storage pot,making aseptic water and CO2 gas mixed principium. Thus,not only the gas containing is increased,but also the shelf life of beverage is extended.
Syrup entry phase:The cooled syrup enter'sthe syrup pot through a filter,syrup pump andangle valve,the liquid level of the syrup is controlled by floating ball liquid level controller. There are high and low positions in the controller. They separately control the on and off of the syrup pump.
Inlet phase of carbonize pump:Aseptic water entry into the inlet of the carbonize pump through angle valve and water ration needle valve. Syrup enters into the inlet of the carbonize pump through an angle valve and syrup ratio needle valve.Adjust the open ratio of the water ration needle valve and syrup ration needle valve to make a fix ratio of the water and syrup, and mixed equality through the pump.
Outlet of the carbonize pump:The pressure of the mixed water and syrup will rise. They will enter into the packet storage machine through metering valve,flowmeter,check valve and static mixer. The corrugated plate in the static mixer increases the uptake area. When the beverage enters into the inlet of the static mixer,CO2 gas at 0.6Mpa also enters into the static mixer. The gas and liquid will then be mixed. Then,this will reach the gas containing of the beverage .Lastlythe beverage will enter into storage pot to keep the pressure,CO2 gas completely dissolve in the beverage.
5. An advanced electronic control systemcontrol's the function of the unit, using normal relay's contactors and machine control circuitry. They direct the work of parts of the machine automatically. Such as water entry,syrup entry,mixing the carbonize gas,discharge gas at exceed pressure etc.
Thermal relay are applied to the electromotor in the electric appliance system’s major loop. This increases the reliability and safety of the machine.
Spare pressure switch turn to “I”position,then,spare pressure electromagnetism YC2 open,spare pressure is done.When the pressure in the tank reach the lower limit of pressure gauge SP2,KC4 is off power,spare pressure is over,turn off YC2.When the pressure in the pot is over upper limit of SP4, KC4 is in on power,close YC2,turn the spare pressure switch to “0”position,spare pressure is stop.
Turn switch of syrup pump to “I” position,syrup pump starts,liquid level is controlled by the floating ball liquid level controller automatically.Turn switch to “0”position, pump-stopping.
Turn the button of water pump and carbonize pump to manual position,the pump running,the liquid level in the pot is controled manually.Turn to “off” position,pump stop working,turn to “auto”position,then,the floating ball liquid level controller will control the pump on or off to coordinate with the level height in the pot.
Start carbonize pump,carbonize electromagnetism contacts,angle valve contacts,syrup water pipeline contacts with pump.
5. Transportation and adjustment
Vibration of the unit is strictly prohibit.The following components may fail due to vibration, pipeline's,meter's and liquid level meter's,gas leak and damaged may result.The machine should be stored reasonably,insolating out of doors is prohibit.
6.Installation and Adjustment
1)The machine can be installed on the formed cement ground.
2)Adjust stabilizer to make pedestal level,fasten tightly with nut.
3)Connect syrup pipeline(diameter 20mm),finished goods outlet pipeline(diameter 32mm) using stainless steel pipeline,connect CO2 gas inlet pipeline(diameter: φ8-φ10mm)with pressure hose.
4)Each electric appliance connection must be done according with the operating instruction.
7.Testing machine,Sterilization and Cleaning
1)Try machine:try machine can be operate after syrup,bacteria-free waterpipe,CO2 gas source,power supply installed. The time of try machine can be last for a quarter around. To save syrup,syrup can be steadied by bacteria-free waterpipe.
2)Sterilization:fill the sanitisers into the entrance of bacteria-free waterpipe and syrup. Meanwhile,turn the ratio needle valve on the syrup and water pipe to a large position. See produce operation program to sterilize .the order of sterilization is as below:
Syrup pot:open or close related valves and discharge waste water.
Static mixer: open or close related valves and discharge waste water.
Storage pot: open or close related valves and discharge waste water.
Note:each related valves, please see technological process chart. Sterilize time should be controlled suitably according with the sanitation requirement.
3. After the sterilization is finished, clean the machine using fresh water. The order is same as the sterilization order. Time of cleaning can be controlled suitably according with the need of sanitation. Finally,discharge wash-down water completely,cleaning work is over. Close CO2 gas container and gas inlet valves of CO2.disconnect the power supply.
8. Produce and operate program
Inspection before production:
1)Check whether the sterilization and cleaning have met with sanitary requirements. If necessary,cleaning can be done a second time to the whole machine,it is also do a cooling to the machine.
2)Check whether pipelines are leaking, water or gas. All valves are on the correct position or not?
3)Whether the preparation work is perfect.
Produce and operate program:
1)Adjust the show of electrical contact vacuum manometer on the syrup pot to 0.09～0.12Mpa. The reading should be between the lower limit needle and upper limit needle. Adjust to show 0.03～0.33Mpa of the electrical contact vacuum manometer on the storage pot according with the product need.
Note:the value shown is only an indication. Specific value is determined by beverage type,filling machine need and temperature etc.
2)Connect power supply,power light should illuminate
3)Open CO2 gas bottle,adjust the output pressure to 0.7Mpa, and keep the pressure stable. Turn prepare pressure switch to “I”position,open CO2 inlet gas valve slowly.adjust prepare pressure to 0.4~0.5Mpa using filter and pressure reducing valve to prepare pressure to the machine,at this time,the surplus of CO2 gas coming into storage pot. Carbonization adjusted to 0.4Mpa and 0.6Mpa.
4)Switch the water pump on-off to manual position. Water pump running while indicator light of water pump running comes on. When the water level of liquid level indicator shows raise to set height,turn switch of water pump button,water pump stop work while water pump running go out.
5)Turn syrup pump work button to “I” position,syrup pump running while syrup pump running indicator light come on.when liquid level in the syrup pot raise to set position,syrup pump stop work automatically while syrup pump running go out.
6)When the pressure gauge on the storage pot shows 0.3Mpa,turn carbonization pump to manual position,carbonization pump running while carbonization pump running indicator light come on,carbonization pump should be adjusted in order when running.
a)Check against the filter reducing valve used for carbonization at 0.6 Mpa,filter reducing valve used for prepare pressure at 0.4-0.5Mpa.
b)Adjust the show value of carbonization flowmeter to 2.5-3.5m3/h.
c)Adjust productivity,namely,adjust the metering valve shows on LZB-40 flowmeter.
d)Adjust the ratio between syrup and water according with different need of product. It can be carried out by adjusting ration needle valve on the syrup pipeline and prepare carbonization pipeline. And sugar degree containing should be examined through sampling valve below LZB-40 flowmeter.
When liquid level shows on storage pot level indicator raise to set height,turn carbonization pump button to stop position,carbonization pump stop work while carbonization pump running indicator light goes out.
Note:this step should be operated consult “4”’s steps supplying water into water storage pot. Watch gas containingcondition form sampling valve below storage pot. Meanwhile, electromagnetic valve on syrup storage pot should disgorge gas timing,prepare pressure indicator light of regulator cubicle come on.
Produce starts:if step above is correct and prepare pressure is done,the machine can start running, namely,turn the button of water pump and carbonization pump to “auto”position,then,open product exit ball valve below the storage pot. Thus,product can be sent into filling machine.
When filling machine moves about two cycles,examine the beverage in the bottle for first time. Ifqualified,examine for a second time after ten minutes.If also qualified,the machine can be in auto production state.
During produce program,if feeding of aseptic water,syrup,co2 gas etc are in stable state,examine can be done after an interval of some time.
If examine to beverage in the bottle are not suitable with product,do some related adjustment according with detail condition until product is qualified.
Something must be state as below”
a)Pressure of CO2 runoff is the show value at production state,the maximum of carbonization runoff is 2.4m3h.
b)The maximum of productivity is 35T/h.
c)When using the machine for the first time or produce new beverage .ratio between syrup and water and mixing pressure between gas and liquid should be examined,sampled to make a decision and ensure product quality.
d)All the data in the instruction are direct to general condition,the detail data should be determined according with beverage kink and filling condition and temperature.
e)When pressure gauge on the storage pot shows 0.6Mpa,safe valve should be open right now to discharge gas. Or else,turn off the machine and do a examination.
7).production finished:before finishing production,turn “syrup pump work”button to “0”position,stop feed into syrup, watch window opening in front of syrup pot. When liquid level reach lowest position,press down the total stop button as well as total product inlet ball valve in the storage pot. after all product are sent into filling machine,close CO2 gas bottle,close CO2 gas inlet valve and turn power off. Thus,production is finished.
8).cleaning after production finished:cleaning should be done after each production is finished. Detail operation see operation program and try machine,sterilization and cleaning instruction. After finish cleaning the machine,you can clean filling machine also. After cleaning,close gas bottle,close CO2 gas inlet valve and turn power off. Thus,machine work is over.
9. Maintenance of the machine.
1)The machine should work according with operation program strictly.
2)Pump work without water or syrup is prohibiting.
3)Outsourcing parts in the machine should be examined and maintenance according with related operating instruction.
4)If the machine will be stop work for a long time,the residue in all filter,pot,pipeline,carbonization machine,pump should be discharge completely. Then,close related valves as well as do a cleaning to the surface of the machine. Water is prohibited to spatter onto motor of pump and related electrical apparatus.
Note:the machine should be operated and maintenance by professional staff who has some professional technique.
The operator should operate the machine according with operating instruction. If unusual phenomenon happens, turn off switch and carry out some measure to solve it.
10. Technique document enclosed with the machine:
1)Operating instruction
2)Conformity certificate
3)Electric apparatus principle chart
Contact: Rebecca