9250A 14777 FLI Venezuela 12.2007-Tke1 PDF

Schaaf Technologie GmbH
OPERATING INSTRUCTION
Buffer silo with stirrer,
type 039
Continuous Moisturiser
type 035
Switch board with built-in

cooling unit № 14777-1
(90447-02, state 0004) Main Dosing unit
(location independent KT35
from Extruder)
Additional Dosing unit T20

with hopper
Processing section
Type 9250
Main switch
Special plug socket(s) /
connection for additional
machines/ aggregates:
Heating ring and Sleeve Extruder plant 9250A Operator panel
injection pumps etc. (location variable)
SN: 14777/9250A.2007
depending on order
EXTRUDER PEPSICO STANDARD 9250A

CONTINUOUS MOISTURISER TYPE B-MAIZE
INCLUDING MAIN AND ADDITIONAL DOSING UNITS & DIE SYSTEMS
COMPLETE WITH CONTROL SYSTEM № 14777-1 (A14777/90447-02)
200A - 3~/PE - 460V - 60Hz
ORDER-№*A14777*
FLI/SNACKS AMERICA LATINA/VENEZUELA
OPERATING INSTRUCTIONS
EXTRUDER PLANT
PEPSICO STANDARD 9250A
These operating instructions include all information for the operation and maintenance of
the Extruder plant.
Service:
If you need help, please do not hesitate to contact us:
Schaaf Technologie GmbH Telephone: +49 (0) 6434/91 72 0

Otto-Hahn-Straße 36 Telefax: +49 (0) 6434/91 72 30
65520 Bad Camberg www.Schaaf-Technologie.de
GERMANY
Before you will contact us ...
 Have you alarm signals ?

Could you eliminate the reasons for the fault ?
 Did you change anything at the plant (e.g. raw materials,

art of operation etc.) ?
 Have you tried to repair the fault according to the operating instructions ?
 Please state:
Serial-No.: 14777/9250A.2007
M/c nos. Type 9250A/Extruder
Buffer silo 039
Main dosing unit T35
Additional dosing unit T20
Continuous Moisturiser 035
Special toolset for “GPS Curls”
Wiring diagram-No.: 90447-02, sate 0004 (14777-1)
Copyright by
D-65520 Bad Camberg Germany
Prepared and written

by Technical Documentation
No responsibility accepted for Technical modifications and misprints !
[T:\technischeDoku ALT\0096 FLI Standard 9250A\9250A 14777 FLI Venezuela 12.2007-tke .doc{Erstelldatum 14.12.2007 10:03:00} ©2007 Schaaf Technologie GmbH
EXTRUDER PLANT
TABLE OF CONTENTS
EQUIPMENT/ACCESSORIES / TOOLS ........................................................................................................................... 1

1. SAFETY INSTRUCTIONS .................................................................................................................................... 10
1.1 DUTIES OF THE USER ................................................................................................................................................ 10
1.2 PURPOSEFUL USAGE................................................................................................................................................. 10
1.3 ORGANISATIONAL MEASURES....................................................................................................................................... 2
1.4 SAFETY-CONSCIOUS WORKING ..................................................................................................................................... 2
1.5 SAFETY FITTINGS........................................................................................................................................................ 3
ATTENTION AFTER END OF PRODUCTION: ................................................................................................................................. 4
1.6 ADDITIONAL FITTINGS................................................................................................................................................. 5
1.7 HIGH VOLTAGE.......................................................................................................................................................... 5
1.8 CUSTOMER SERVICE AND REPAIR................................................................................................................................... 5
2. CONSTRUCTION AND FUNCTION ....................................................................................................................... 6
2.1 SPECIAL FEATURES ..................................................................................................................................................... 6
2.2 PROVISIONS / CONNECTIONS FROM PRODUCTION HALL..................................................................................................... 7
2.3 TECHNICAL DIMENSIONS ............................................................................................................................................. 8
2.4 TECHNICAL SPECIFICATIONS ......................................................................................................................................... 9
2.5 EXTRUDER & PERIPHERY EQUIPMENT........................................................................................................................... 15
Extruder front views ................................................................................................................................................ 15
Special design of hopper for discharging of waste products (no standard fitting) ................................................. 16
Cutter protection & vapour exhaust hoods ............................................................................................................. 18
Detail of vapour exhaust hood: ............................................................................................................................... 19
Additional fitting for vapour exhaust hood / guiding device................................................................................... 20
Safety Switches: ...................................................................................................................................................... 21
Additional EL-fitting / front base frame: ................................................................................................................. 22
Additional fitting / Connection block for high pressure hoses from sleeve injection pump unit ............................. 23
Water cooling system of processing part: ............................................................................................................... 24
Main drive ............................................................................................................................................................... 27
Main drive / External Cooler: .................................................................................................................................. 29
Main drive / External Cooler: .................................................................................................................................. 29
Extruder flange ........................................................................................................................................................ 30
Temperature sensors:.............................................................................................................................................. 31
Inlet hopper: ............................................................................................................................................................ 31
Cutter drive / die face cutting: ................................................................................................................................ 32
Central Oil Circulation System ................................................................................................................................. 33
Extruder outlet for face cut products /feeding via pneumatic transport: ............................................................... 36
Special design / main dosing unit with buffer silo ................................................................................................... 40
Additional dosing unit T20: ..................................................................................................................................... 40
Buffer silo with stirrer:............................................................................................................................................. 41
Continuous Moisturiser ........................................................................................................................................... 51
3. OPERATING DESCRIPTION................................................................................................................................ 56
3.1 CONTINUOUS MOISTURISER ....................................................................................................................................... 56
[9250A 14777 FLI Venezuela 12.2007-tke .doc ©2007 Schaaf Technologie GmbH
EXTRUDER PLANT
4. OPERATING INSTRUCTION - EXTRUDER ........................................................................................................... 63

4.1.) DESCRIPTION OF THE MACHINE .................................................................................................................. 63
4.1.A.) EXTRUDER DRIVE ...................................................................................................................................... 63
4.1.B.) V-BELT DRIVE ............................................................................................................................................ 63
4.1.C.) EXTRUDER BODY ....................................................................................................................................... 64
4.1.D.) LUBRICATING-OIL CIRCULATION SYSTEM ................................................................................................. 64
4.1.E.) COOLING ........................................................................................................................................................ 65
CUTTING UNIT ART.- NO. C 16770, ADJUSTABLE DURING OPERATION: ....................................................................................... 69
4.1.G.) BLADE SHARPENING.................................................................................................................................. 74
4.2.) PREPARATIONS FOR PRODUCTION ............................................................................................................. 75
4.3.) END OF PRODUCTION ...................................................................................................................................... 84
4.4.) ASSEMBLY INSTRUCTIONS FOR DIE SYSTEMS .................................................................................................... 86
4.5.) CHANGING OF BEARINGS ............................................................................................................................ 88
4.6.) JAMMING OF THE EXTRUDER PROCESSING SECTION .................................................................................. 97
A. ATTEMPT TO FREELY ROTATE THE SCREW WITH THE HELP OF THE DRIVE. ............................................................................. 97
B. DISASSEMBLY ......................................................................................................................................................... 99
4.7.) TURBO EXTRUDER / SHORT OPERATING MANUAL .................................................................................... 101
Cover the extruder entry port ................................................................................................................................105
Switch on the cutter drive .....................................................................................................................................110
Remove the coarse dirt on the process parts with a brush or a broom ................................................................114
Remove the balance material from the TURBO as far as possible ........................................................................116
Clean the screw and the die-elements by using the accessories and tools specially provided for this purpose
Please use lint-free clothes. ...................................................................................................................................119
4.8.) WHITE PAPER ON RESTART OF A SCHAAF TURBO EXTRUDER .................................................................... 120
4.9.) EXCHANGE OF A DEFECTIVE TURBO-ADAPTOR.......................................................................................... 123
4.10.) ILLUSTRATIONS ........................................................................................................................................ 133
4.11.) GENERAL INSTRUCTIONS FOR MAINTENANCE AND CLEANING ................................................................. 134
4.10.3.) SPECIFIC DISASSEMBLING AND CLEANING/MAINTENANCE INSTRUCTIONS FOR .........................................................136
EXTRUDER-PROCESSING SECTION AND CONTINUOUS MOISTURISER ...........................................................................................136
4.12.) MAINTENACE & CLEANING........................................................................................................................... 146
4.13. OIL SPECIFICATION .................................................................................................................................... 150
4.13.1 OIL SPECIFICATION OF CENTRAL LUBRICATION & JAMMING OIL PRESSURE ...............................................................150
FAULT OF THE EXTRUDER OIL CIRCULATION SYSTEM ..............................................................................................................151
4. 13.2 OIL-SPECIFICATION MINERAL OIL & ROLLER BEARING GREASE (GENERAL) ..............................................................154
4.13.3 APPLICATION AREAS - OIL SPECIFICATIONS .......................................................................................................155
4.14.) VARIOUS DOCUMENTATION ..................................................................................................................... 157
EXTRUDER PLANT
EQUIPMENT/ACCESSORIES / TOOLS
PLANT PART/
serial-№/Art. № remarks
fitting/design
Extruder Special design / right hand operation flap

60-B-925-DC(BL) at Extruder top frame
Special outlet chute for connection of
pneumatic transport (0244 027c)
Switch board / location independent
from Extruder
Operator panel / location variable
Double Screw Dosing Unit main dosing of raw material / controlling
K2 MV KT35 automatic through main-switch board /
operator’s panel,
1 pc. level sensor "mangle" function is
installed at transfer pipe from buffer silo,
switches off (delayed) the water dosing
14777/9250A.2007 into continuous moisturiser when no raw
material is available
(level sensor is adjustable)
Double screw dosing unit With hopper, prepared for manual
K2 MV KT20 charging
Level sensor: lack signal
With inspection window at hopper,
protection grate and cover
Continuous Moisturiser mounted at top frame of Extruder onto a
Type 035 pivotable frame
Buffer Silo with stirrer Mounted at top frame of Extruder
Type 039 Level sensor “MIN” installed below
Level sensor “MAX” installed above
Die parts (provided with plant):
Cutting device, adjustable C 16770 Extruder accessory
(without cutter head)
Cutter head 1-blade ∅108mm D 13016 Extruder accessory
Die forming plate (special) D 04596 Extruder accessory
∅2,8mm / 12-fold to be in accordance with standard GPS-
Curls
Processing parts (provided with plant):
1. Extruder basic fitting = TURBO 2-stage (Order № A15710):
Extruder Inlet-Sleeve C 15530 molded /L=100
Extruder accessory
Extruder-Sleeve C 15006 Standard Sleeve
Extruder accessory
Extruder-Screw 4-outlet C 17071 Screw 4-outlet (new type)
(double adaptor (C 14062) is screwed
and glued)
Extruder accessory
Pressure plates 1 D 00982 bore holes ∅3mm
(at screw) Extruder accessory
1
9250A 14777 FLI Venezuela 12.2007-tke .doc ©2007 Schaaf Technologie GmbH
EXTRUDER PLANT
PLANT PART/
fitting/design
Pressure plate “M” (middle) D 00984 bore holes ∅3,0mm.
Extruder accessory
Pressure plates 2 D 00995 bore holes ∅3,0m
(at die) Extruder accessory
Screw adaptor C 14062 for double TURBO (glued into screw)
Extruder accessory
Rotor A C 14071 Extruder accessory
(using for 1- and 2-stage TURBO)
Rotor Z C 14072 Extruder accessory
(using for 2-stage TURBO)
Processing parts special (provided with plant):
Sleeve special C 15072 for liquid injection system
Pressure plate 1, special D 01370 bore holes ∅3,0mm
(at screw) for liquid injection system
Various accessories, included in delivery:
Guiding bolts D=30 D 11258 Extruder flange fixation
∅30x 430mm lang 1 Satz = 2 Stück
Built-in at processing part für alle Düsenkonfigurationen
Gewindestäbe M30x 305 mm lg. D 11259 Extruder flange fixation
incl. Muttern M30 und U-Scheibe 1 set = 6 pcs.
eingebaut am Verfahrensteil All die configurations
Die flange adaptor for D 11833 Extruder accessory, necessary for
“Head”-die systems“ different die systems
flange safety screw D 11703 Extruder accessory assembled

(star handle/ M10 with chain)
Clamping holder/ D 11088 Holder for cutter and vapour exhaust
Klemmhalter hoods (2 pcs.) assembled
Plug for Extruder inlet opening W 84965 Extruder accessory
Stopfen für Extrudereinlauf 9250
2
EXTRUDER PLANT
PLANT PART/
fitting/design
V-belt/Keilriemen XPZ 1012 (2 Stück) K 12287 Accessory / spare cutting device
Zubehör/Ersatz Schneidvorrichtung
O-Ring Dm 122,0x3,0 mm K 40000 Accessory/spare for sleeve /water cooling
Werkstoff: Viton Zubehör Stator/Wasserkühlung (10 x
Ersatz/spare)
Special tools / acceccories / Werkzeuge / Zubehör:
Sleeve draw out device C 12008
Stator-Ausziehvorrichtung
Screw cleaning rollers device C 00230

Schnecken-Reinigungsrollen
Pressure plates cleaning ring C 00200

Stauplatte Reinigungsring
Sleeve centering ring / screw D 11501

extractor ring
Stator-Zentrierring /
Schneckenausdrückring
Draw out device for inlet sleeve C 12004

Einlaufring-Auszieher
screw the
push-out (D 11829) weight in the central
hole M10
Push out weight / Ausschlaggewicht D 11829
auxiliary tool for dismantling of
guiding bolts, draw out the inlet
sleeve, centering ring etc.
3
EXTRUDER PLANT
PLANT PART/
fitting/design
Draw out device for die heads D 00200
screw
threaded bolts into the windings for
cutting device holder
Sleeve cleaning hook C 00220
Stator - Reinigungshaken einfach
Drawing-in device for screw C 51004

Schneckeneinziehvorrichtung
Ejection device for screw C 50004

Schneckenausdrückvorrichtung
Sleeve cleaning brush C 12076

Stator-Reinigungsbürste
Cleaning tool for screw W 84955

Reingungswerkzeug Schnecke
4
EXTRUDER PLANT
PLANT PART/
fitting/design
Tool set for TURBO mounting C 14096
Werkzeugsatz für Turbosatz D16
wrench for TURBO (D16) D 14092

Mounting lever C 14091
Distance ring 0,2mm K 10079/2x
Distance ring 0,5mm K 10080/2x
Out draw flat bar for sleeve centre D 11851
ring
Ausziehflachstahl für
Statorzentrierring screw the
push-out weight (D 11829) into the
central winding M10
Poke device, for inlet hopper to avoid W 84968
raw material bridges
Stopfer, für Extruder-Einlauftrichter 500mm lg.
zur Vermeidung von Rohstoffbrücken
Ratched with square wrench ¾“ and W 80160
insert SW46
Zahnradknarre m. Umsteckvierkant
3/4" und Steckschlüsseleinsatz SW 46
freewheel ratchet with ring KR16-30 W 80152

Freilauf-Knarre mit Ring KR 16-30
Flat wrench SW46 W 85750

Gabelschlüssel 46
Socket wrench W 85307

Inbusschlüssel m.T-Griff SW 5
200mm lg.
Wrench W 85852
Schlagringschlüssel SW 46
Dismantling of TURBOS
Lösen von TURBO-Rotoren
Hook spanner W 85885
Gelenk-Hakenschlüssel 35-60 mit
Zapfen
(Nachstellen der Stopfdichtung/ fixed at
Hochdruckpumpen) injection pumps unit
Befestigt am Injektionspumpenwagen
5
EXTRUDER PLANT
PLANT PART/
fitting/design
Tool set for mounting the sleeve W 84972 As picture below/
injection processing parts / Montage Siehe Abb. unten
der Statorinjektions-Werkzeuge
4x V 50065 5x V 51189
C 12223 DIN912 M8x35 DIN6912 M4x8
W 85299
2x V 50760 R 16041 + R 16073

DIN933 M8x65
W 84961
5x K 40060
W 84960
W 30100
C 12223 = auxiliary tool for mounting the inlet sleeve / Hilfswerkzeug zum Einsetzen des Einlaufstators
W 85299 hexagon socket screw key with pilot SW3, fixing of screws M4x8, closure of injection line
Sechskant-Winkelschraubendreher SW3/ Montage der Schrauben M4x8, Verschluss der Injektionsleitung
V 51189 Screws DIN6912 M4x8 / Schrauben DIN 6912 M4x8
V 50065 Screws M8x35, mounting of injection sleeve / Schrauben M8x35, Montage des Injektionsstators
V 50760 Screws M8x65 / dismantling of injection sleeve/
Schrauben M8x65, Abdrückschraube, Demontage des Injektionsstators
K 40060 O-rings, spared for injection sleeve / O-Ringe, Ersatz für Injektionsstator, Abdichtung der Wasserkühlung
W 30100 Mounting lever, dismantling of injection pressure plate/
Montierhebel, zur Demontage der Injektionsstauplatte 1
W 84960 Cleaning tool for injection line 150mm lg. / Reinigungsbohrer für Injektionsleitung 150mm lg.
W 84961 Cleaning tool for injection line 20mm lg. / Reinigungsbohrer für Injektionsleitung 20mm lg.
R 16041 Sealing for high pressure connection /spare) / Dichtring für Hochdruckanschluss / Ersatz
R 16073 Pipe fitting 1/8“ x 6, spare / Einschraubverschraubung 1/8“ x 6 / Ersatz
PLANT PART/
fitting/design
Special tools for dies, pressure plates and cutting device
Spezial-Werkzeuge für Düsen, Stauplatten und Messervorrichtung (im Lieferumfang enthalten)
Precision cotter pin driver ∅ 2,9mm W 85005 1x
Präzisions-Splinttreiber mit
Führungshülse ∅ 2,9mm
6
EXTRUDER PLANT
PLANT PART/
fitting/design
Precision cotter pin driver ∅ 3,9mm W 85007 1x

Präzisions-Splinttreiber mit
Führungshülse ∅ 3,9mm
Standard cotter pin driver ∅ 2,9mm W 85011 1x
Standard-Splinttreiber 249.3
∅2.9mm
∅3.9mm
∅4,9mm
cotter pin driver with handle ∅2,9mm W 85016 1x
Splinttreiber mit Handgriff ∅2.9mm
Splinttreiber mit Handgriff ∅3.9mm
Splintentreiber mit Handgriff
∅4.9mm
Reingungswerkzeug "Flach"für Düse W 84952 5x
Reingungswerkzeug "pick-Set“ W 84940
auxiliary tool for adjusting the cutting D 13367

device
Hilfwerkzeug für Einstellung der
Schneidvorrichtung
7
EXTRUDER PLANT
PLANT PART/
fitting/design
Tool box with standard tools according to figure / Werkzeugkiste mit Standard-Werkzeug lt. Abb.:
Tool box/Werkzeugkiste 600 x 200 x 200 W 80991

Socket wrench/ Inbusschüssel Bund SW 2,5 – 10 W 85280 1x
Socket wrench/ Inbusschlüssel Satz SW 2 - 14 W 85291 1x
Socket wrench/ Imbusschlüssel 10K SW 4 W 85300 2x
Fork spanner set /Doppelmaulschlüssel Satz 12 teilig W 85745 1x
Flat spanner / Gabelschlüssel 10-13 W 85746 1x
Screw driver set / Schraubendreher Sortiment 6 teilig W 85501 1x
polariscope / Spannungsprüfer mit Rautenlinse Nr3 W 85502 1x
Gripper/ Zange Wasserpumpe 240mm (9 1/2") W 87029 1x
File / Feile, flach H3 200mm lang W 86005 1x
File / Feile rund H3 D= 8mm 200mm lang W 86255 1x
File / Feile Messer 200 lang , Hieb3 W 86221 1x
Work gloves / Arbeitshandschuhe W 00700 2x
Wire brush / Drahtbürste VA 2-rillig W 86950 2x
Wire brush / Drahtbürste VA 3-rillig W 86951 2x
spatula / Spachtel B = 20 mm W 86960 2x
spatula / Spachtel B = 30 mm W 86961 2x
Grease gun / Fettpresse Handhebelfettpresse W 81000 1x
Grinding pin / Schleifstift Kugel ∅= 13mm rosa W 03005 5x
File handle / Feilen-Heft Kunststoff PN 11 W 86945 1x
Ring spanner / Ringschlüssel doppel 10 - 13 W 85800 1x
Ring spanner / Ringschlüssel doppel 17 - 19 W 85805 1x
Hammer /Hammer Schlosserhammer 200g W 84000 1x
Syphon gripper / Syphonzange 230 (Rohrgreifzange) W 87041 1x
Heat resitance gloves / Wärmeschutzhandschuhe W 00704 2x
lang
Hammer plastic /Schon-Hammer , Kunststoff ∅=50 W 84002 1x
Hammer plastic / Schon-Hammer , Kunststoff D = 25 W 84003 1x
Face spanner adjustable / Stirnlochschlüssel W 85962 1x
verstellbar D4
8
EXTRUDER PLANT
PLANT PART/
fitting/design
Set raw materials initial equipment / Satz Rohstoffe / Start-Ausrüstung
Dimodan HP N 01149 Start-/Stop mixtures/
1 Sack = 25 kg Start- und Stoppmischungen Extruder
Maize grit / Maisgrieß N 01000 deutsch CII
1 Sack = 25 kg
Maize grit / Maisgrieß N 01001 deutsch B
50kg
Trennwax fest /Dose 2 kg N 02404 Einfetten von Düsenteilen und

Stauplatten (aus N 02400)
Lubricants initial equipment / Schmierstoffe /Start-Ausrüstung
Klübersynth U H1 64 -62, Ka rtusche W 00171 Cutting device etc.

400g
LUBCON ALN2502, Kartusche 400g W 00190
Interflon HT1200, Tube 150ml W 00164 TURBO winding / TURBO-Gewinde
Interflon HT1200, Dose 500ml W 00163 TURBO winding / TURBO-Gewinde
Molykote P40, Dose 1kg W 00181 Screw shaft / Schneckenschaft
Molykote D, Tube 50g W 00166
LUBRIPLATE SFGO220 W 00176 Central oi l c irculation system / E xtruder
Kanister 19L bearing housing
LUBCON Turmogear oil 460 W 00113 Gear oil / high pressure pumps
Teflonspray 70-87 W 00014
OKS 260, Tube 100g W 00169
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EXTRUDER PLANT
1. SAFETY INSTRUCTIONS
1.1 DUTIES OF THE USER
 Make s ure, th at o nly trained a nd pr operly i nstructed pe rsonnel w ork o n t he pl ant.

Persons under 16 years of age may not work on the Extruder.
 The responsibility of the personnel for the operation, repair and maintenance should
be laid-down.
 Ensure, t hat t he p ersonnel h ave r ead an d u nderstood t he o perating in structions f or

all the plant components, specially the chapter "Safety instructions".
IT CONCERNS YOUR SAFETY!
 The user must arrange for immediate replacement of damaged or missing portions
 The u ser is r esponsible f or t he o bservation o f t he l aid-down an d v alid ac cident

prevention and safety regulations.
1.2 PURPOSEFUL USAGE
 The ex truder m ust b e o perated o nly w ith the c orresponding c ontrols p rovided №
90447-02, state 0004 (14777-1)
 Ensure, that only suitable raw-materials are allowed to enter the process
 Ensure, that no foreign bodies are able to enter the process
 In cas e o f p rocessing of dan gerous m aterials, al so f ollow addi tionally t he s afety in -

structions for the handling of these materials
 Operate t he e xtruder only as p er t he s pecified t echnical dat a. A ll m anipulations f or

capacity i ncrease ar e prohibited. E xcluded i s a cap acity increase b y t he e xchange o f
the original Schaaf extruder tools (Dies, Turbo etc.)
ATTENTION Proper o bservation o f the o perating in structions a nd t he m aintenance

instructions must be ensured.
10
EXTRUDER PLANT
It is absolutely forbidden to switch on the continuous moisturiser

DANGER
and the main dosing, if the moisturiser frame is not correctly mounted at the
extruder base frame and if the moisturiser is not mounted at the dosing unit!
Without the mechanical safety units (screw connections) an unhindered
access in the moisturiser as well as in the dosing tools is possible.
Very bad injuries might be a consequence and even fingers might be severed!
1.3 ORGANISATIONAL MEASURES
 Always ha ve t he o perating in structions a vailable a t t he p roduction s ite. E nsure t hat

this is always complete and readable.
 Follow special safety instructions regarding electrical fittings
In addition to the Operating instructions also follow the generally applicable legal
ATTENTION
and other binding regulations for accident prevention and environmental protection.
1.4 SAFETY-CONSCIOUS WORKING
 To t his a lso b elongs t he r eading a nd p roper u nderstanding of the O perating

instructions, sp ecially t his sa fety i nstruction, a nd th e p roper o bservations o f th e
issued instructions.
 Ensure that only authorised personnel are present in the area of the extruder.
 All activities are to be carried out with the highest possible awareness for safety.
 Before every intervention in the machines or for repair or maintenance, switch off the
plant at the main switch.
ATTENTION AT EXTRUDER MAIN OPERATING PANEL!

Before each production start, the proper functioning of the emergency-OFF switch as well
as t he S top s witch is t o b e ex amined. The plant must switch off immediately on
activation of the same.
2
EXTRUDER PLANT
1.5 SAFETY FITTINGS
 There is danger during the operation of the extruder without the safety fittings:
 physical and mortal for the user or for third parties.
 of damage to the extruder or other things of material value
 Do not alter the mechanical safety fittings or their electrical controls. Increased
accident risk.
 Check the function and seating of the safety fittings daily or as per requirement e.g.
the cutter protection hood.
 Do not open or remove any covers or safety lids during operation.
Rotating tools and drive elements in and on the extruder process section can
crush hands or fingers. Never work without safety fittings on the entry hopper, on the
motor and the cutter safety hood.
 Rotating tools in the dosing units can crush hands or fingers. Never grab in the
stirring and anti-bridging elements, while in operation.
Cutting tools can cut fingers. Never work without the cutter safety hood.
Falling tools and machine parts during the assembly and disassembly can
cause bruises, fractures or crushing of body parts. Never work without suitable safety
precautions and safety clothing.
High temperatures in the process zone can cause burns. Never work without
suitable protection during production, as well as during maintenance, assembly and
also disassembly.
3
EXTRUDER PLANT
Do not alter the electrical safety fittings e.g., Fuses. Increased accident risk.
 During exchange use only the specified fuse types.
 Check damaged cables and cable connections regularly for breakage or insulation
failure and in case of defects replace immediately.
 Check the clamp connections regularly. Loose clamp connections, especially in the
clamp boxes of the DC motors can cause arcing and therefore a fire or a total
destruction of the drive unit.
ATTENTION AFTER END OF PRODUCTION:
High Temperatures and high pressure still continue to be in existence in the

machine, even after it has been shut down.
You should proceed with the dismounting very carefully to avoid all dangers
associated with the presence of Pressure, Steam & heat.
Use only suitable tools to proceed with the dismounting.
Loosen successively and carefully Nuts of the Die system and Flange connection.
Please wear suitable protective clothing, especially Gloves with heat insulation.
Please be careful of the Steam (Danger of burns) and the residual force which
are created by the expansion of dough and the remaining steam (Danger of nuts and dough
pieces being thrown out)
Loosen completely t he N uts o f t he D ie s ystem and t he F lange co nnection o nly w hen you
are very certain that the Pressure in the process section has gone down completely.
4
EXTRUDER PLANT
Be careful of the Tools which are heavy (Danger of getting hurt from the
heavy tools which could fall down).
1.6 ADDITIONAL FITTINGS
 Introduction of changes is prohibited
ACHTUNG The user is responsible for the maintenance of the safety regulations, arising by
interaction of the SCHAAF plant with the additional fittings, introduced by the user.
1.7 HIGH VOLTAGE
 Activities in the electrical f ittings o f t he E xtruder a re t o be u ndertaken

only by qualified electricians.
 Activities in t he el ectrical f ittings m ust b e undertaken ex clusively u nder

voltage-free condition.
 The electrical control systems must be protected from moisture and water.
1.8 CUSTOMER SERVICE AND REPAIR
 Repairs to be carried out only by:
▪ responsible SCHAAF customer service

or
▪ by qualified personnel deputed by Schaaf Technologie
 You will find our address on the file cover and also the index of this document.
 Use only original spare parts for replacement.
5
EXTRUDER PLANT
2. CONSTRUCTION AND FUNCTION
2.1 SPECIAL FEATURES
The Schaaf extruder is the key element of all Schaaf plants and is universally usable for
the production of e.g.
Snacks  Capacity depending on raw material and die system

Cereals  Capacity depending on raw material and die system
Bread Chips 
Salami Chips 
Flat-bread 
Muesli components 
Instant flours 
Dry baby-cereals 
with corresponding additional fittings also usable for the production of :
pipes 
U-profiles 
filled pillow products  250 kg with auxiliary equipment / no standard
Nominal production capacity: 200 - 500 kgs/hr raw-extrudate.

Capacity would vary, depending on the raw materials used and the form to be produced.
Advantages of the Schaaf extruder in food production
 A p rocess f or m aintaining a nd in creasing n utritional v alue f or the p rocessing o f

natural materials.
• Inclusion of unused nutrition sources

• Physiologically problem-free preservation
• Minimal energy consumption
Introducible for capacity increase :

Schaaf Turbo fitting
Schaaf Die fitting(s)
6
EXTRUDER PLANT
Schaaf e xtruders ar e m anufactured f rom m aterials an d f inished p art co mponents, w hich

correspond to today's demands in terms of hygiene for the parts coming in contact with the
product. Long life of the used tools as well as low repair and maintenance requirements are
achieved by optimisation of all production components.
2.2 PROVISIONS / CONNECTIONS FROM PRODUCTION HALL
• Electrical Supply and Control through Extruder Main Switch Board

Electrical supply to be provided from customer’s side: 200A - 3~/PE - 460V - 60Hz
Wiring between Extruder – switch board/control panel is done from
customer ! Please pay attention to the maximum cable length of 25 m!
Please p ay a ttention t o d escription “ Caution” a t t he b eginning o f t his t echnical

documentation an d t he electric documentation – at e ach c onnection p oint ( motors,
sensors a.s.o.) you will find a cable mark pertaining to the cable type and length, please pay
attention to the cable plan and the electric documentations:
In t he p ast t here h ave b een p roblems w ith t he c abling b etween the ex truder
itself a nd th e switchboard c abinet. T o p revent t hese m istakes, please carefully
read this information.
Please r efer t o t he c able p lan, w hich is p art o f the w iring d iagram (Electric
documentations). T he ty pes o f c able m ust be exactly t he s ame o r s ame t ype.
Types with the “CY” are shielded cable! Please only use shielded cable types for
the specific cables, otherwise the function of the machine might be unreliable.
• At base frames Extruder, Operating panel and switchboard: screwed bolts M8 at each
unit for f ixing gr ounding s trands b y customer - potential c ompensation  to be
desperate to connect
• Drinking w ater 3 /8" 4 b ar ( max. 100 l/h) / co nnection at reservoir for c ontinuous
moisturiser (mechanical float valve)
Cooling w ater connection 1/2" 4 b ar ( max. 500 l /h) f or

Extruder 15°C (minimum 5°C, max 20°C)
The cooling water system at the extruder

ATTENTION
processing part is never allowed to be operated

at a closed water circuit!
Cooling W ater d rain connection 1 /2" f or c onnecting a

drain hose from customer's side.
7
EXTRUDER PLANT
• Vapour exhaust is done from customer side
• Condensate r eturn a t v apour-exhaust h ood 1/2"- coupling & hose clip for v apour-
exhaust at the hood = NW 100mm
• Alternative: F resh air supply f or m ain drive cooling, connection N W150 (in p lace o f
mounted filter unit)
• One water connection and drain point, for the cleaning the moisturiser and Extruder
should be located at a convenient point nearby.
• One p lug s ocket f or co nnecting a v acuum cl eaner s hould b e l ocated at a co nvenient

point nearby.
2.3 TECHNICAL DIMENSIONS
part / width (mm) Length (mm) Height (mm) Weight (kg)

Extruder & Continuous ca.2040 ca. 2900 ca. 2800 1480
moisturiser & Dosing units (ca. 3000
incl. space occu-
pied, depending
on pivotable
frame of
continuous moi-
sturiser)
Main switch board 2800 1100 2250 904

(with operator panel)
8
EXTRUDER PLANT
2.4 TECHNICAL SPECIFICATIONS
№ Bezeichnung/ Bauform Typ-Nr. Serien-Nr./serial Leistung/ Spannung Spannung Strom Eintrieb Abtrieb Untersetz Bemerkung Lieferant/Hersteller
type voltage voltage current input output ung remarks supplier/
name type number number power V V A UPM UPM reduction manufacturer
(Artikel-Nr./ Art.-№) Watt AC DC rpm rpm i=
RAW MATERIAL HANDLING / Buffer Silo with Stirrer on top of Extruder – 9250A
1 VORRATSBEHÄLTER MIT RÜHRWERK 039 14777/9250A.2007 Zwischenpuffer für aufbereitete Rohstoff-Mischungen Elektrische Versorgung und Schaaf Technolo-
Steuerung über Extruder-
BUFFER SILO WITH STIRRER Fassungsvermögen 600 Liter Schaltschrank № 13770-1 gie GmbH
Übergaberohr in die Hauptdosierung Electrical supply and
Buffering of raw material mixtures / capacity 600 l controlling through Extruder
switch board № 13770-1
Outlet pipe system transparency for visual monitoring with level
(0039 121a) sensor
2 DREHSTROM-GETRIEBE-MOTOR H5 SK 12080AF- 7/1007369676.00 IP55 / 60 Hz Getriebebau
Hohlwelle Ø 40H7
SPUR GEAR 3-PHASE MOTOR 80L/4 33711500/0713 254/ 3,46 Flansch Ø 250mm Nord
860 1650 5,9 234,6
(special design 480 2,0
460V/60Hz) (G 10065)
3 NÄHERUNGSSCHALTER / KN5101 (nicht bündiger Einbau) IFM
eingebaut an Übergabe in
EFFECTOR CAPACITIVE Hauptdosierung
Switches off the water dosing into moisturizer when shortage of
installed at transfer pipe into
material main dosing unit
(E 16019)
4 NÄHERUNGSSCHALTER / KN5101 (nicht bündiger Einbau) IFM
Eingebaut in Behälterwand
EFFECTOR CAPACITIVE unten / einstellbar
„MIN.“ Signal, for customer’s controlling height adjustable
installed at silo wall below
“MIN” sensor for customer’s
(E 16019) controlling
5 FÜLLSTANDGRENZSCHALTER Soliswitch FTE 30 94037C040E3 Eingebaut in Behälterwand Endress+ Hauser

oben
LEVEL LIMIT SWITCH Installed at silo wall above
250 20…28 10
signal “MAX”
(E 16107) for customer’s controlling
6 SICHERHEITSSCHALTER 1032248103 Magnet einmal montiert am SCHMERSAL

Deckel und einmal montiert
SAFETY SWITCH BNS 250-11ZG- am Auslaufrohr zur
Installiert am Inspektions-/ Entleerungsstutzen
10m + (E 23203 + Entleerung
Installed at inspection / emptying piece 150 Entleerungsrohr NW (
1032226000 E 23202)
Z 0097 006)
BPS 250 (2x)
9
EXTRUDER PLANT
Signals “MIN / MAX” are provided for customer’s control
CONTINUOUS MOISTURIZER– 9250A

1 KONTINUIERLICHER BEFEUCHTER B 035 14777/9250A.2007 Befeuchten und Mischen des Rohstoffes im kontinuierlichen elektrisch versorgt und Schaaf
geregelt über Extruder-
CONTINUOUS MOISTURISING UNIT Durchlauf mit automatischer Wasserdosierung, 1 Anschluss zur Hauptschaltschrank & Technologie
Flüssigkeitsdosierung, Befeuchter auf schwenkbarem Gestell, Bedientableau (separat) GmbH
integriert am Extruder-Obergestell electric supply and control
through Extruder main
moisturising and mixing of raw materials continuously with automatic switch board and operating
water dosing system/ 1 Connection for liquid dosing system panel (separately)
(0035 027) The continuous moisturiser is mounted on a frame (pivoted),
integrated at extruder top frame
2 DREHSTROM-MOTOR V1 100L/4a-spez 7040249 60Hz/IP54 EMOD
Spezialausführung:
3-PHASE MOTOR 250 50/60 Hz Wellendichtring
220/ 11,1
3000 1720 mit vorgesetztem Radial-
480 6,4 Labyrinth
Wellenwerkstoff 1.4021
3 MEMBRAN-DOSIERPUMPE P EH-E45VC (45 l) M0370117 0-20,4l/h-10 bar mit LDT Level

Bogenadapter 3/8“ montiert
MEMBRANE DOSING PUMP VA 20EPE5 230 auf Extruder-Obergestell
48 0,8 connection: nominal width
50 Hz
(P 14690) 8mm/ silicon hose
(regelbar/ajustable)
4 WASSERTANK VA approx. 50 Liter Zuleitung: Trinkwasseranschluss 1/2", Füllstandsreglung über ein montiert auf Extruder- Schaaf
Obergestell
WATER TANK Schwimmerventil/ Anschluss zur Pumpe NW 8mm mounted onto Extruder top Technologie
supply: drinking water connection 1/2", level control through frame GmbH
(096c 027a) mechanical float valve / pump connection: hose nominal width 8mm
DOUBLE-SCREW DOSING SYSTEM FOR MAIN COMPONETS T35 volumetric– 9250A

1 HAUPT-DOSIERSYSTEM 089 14777/9250A.2007 Automatische Dosierung der Rohstoff-Mischungen in den elektrisch versorgt und Schaaf
MAIN DOSING UNIT kontinuierlichen Befeuchter Hauptschaltschrank/ Technologie
Rohstoffversorgung über Vorratsbehälter durch Übergaberohr electrical supply and GmbH
transparent /Füllstandssensor schaltet bei Rohstoffmangel die controlling through Extruder
Main Switch board
Wasserdosierung von kont. Befeuchter ab
automatic dosing of raw material mixtures continuous moisturiser
Charging from buffer silo / through transparent transfer pipe/level
sensor switches off the water dosing of continuous moisturiser
10
EXTRUDER PLANT
2 DOPPELWELLEN-DOSIERGERÄT K2 MV KT35 0704828/MO- Antrieb über Drehstrom- K - tron

Motor, FU geregelt / Drive
TWIN SCREW DOSING UNIT T35 A-Getriebe 494360 through 3-phase Motor, Deutschland
3,23:1 Frequency converter
controlled
Theor. Dosierleistung 400 kg/h bei DK, fein Ausrüstung/ equipment:
Theoretic dosing capacity approx. 400kg/h (DK,fine) Schneckenrohr horizontal
(F 10285) (F 10293)
Schneckenpaar DK, fein
(F 10289)
Faltenbalg/bellows (F
10056)
3 DREHSTROM-MOTOR B5 80 L/4T 7040250 IP 55-50 Hz EMOD

Welle ι 14x30
3-PHASE MOTOR Fl. 230/ 3,5/ 700-
750 3x155°
Ø160 400 2,0 2600 Antrieb Dosiergerät / Drive
(M 11921) Dosing unit
DOUBLE-SCREW DOSING SYSTEM FOR ADDITIONAL COMPONENTS T20 volumetric– 9250A

1 DOSIERSYSTEM T20 090 14777/9250A.2007 Dosierung von Start- und Stoppmischungen und Zusatzstoffen in elektrisch versorgt und Schaaf
DOSING UNIT T20 den Einlauftrichter am Extruder, montiert auf einem schwenkbaren Hauptschaltschrank/ Technologie
Gestell electrical supply and GmbH
Mit Vorratstrichter 50 l/ Ø500/500mm hoch mit Schutzgitter und controlling through Extruder
Main Switch board
Deckel, vorgerichtet zur manuellen Befüllung, mit Sichtfenster und
Füllstandssensor (Mangelmelder)
Dosing of Start-/Stop mixtures and additives into inlet hopper of
Extruder, mounted at a pivotable frame
with buffer hopper 50 l/ Ø500/ height 500mm, with protection grate
and cover, designated for manual charging, with inspection window
and level sensor (mangle signal)
2 DOPPELWELLEN-DOSIERGERÄT K2 MV KT20 0704828/MO- Antrieb über Drehstrom- K - tron
Motor, FU geregelt / Drive
TWIN SCREW DOSING UNIT A-Getriebe 493390 through 3-phase Motor, Deutschland
2,683:1 Frequency converter
controlled
Theor. Dosierleistung 170kg/h bei ∅20 Doppelvollblatt, grob Ausrüstung/ equipment:
Schneckenrohr vertikal,
Theoretic dosing capacity 170kg/h (Screws ∅20, coarse) 50mm verlängert (F 10287)
Schneckenpaar
Vollblatt,grob
(F 10286) 50mm verlängert (F 10288)
Faltenbalg/bellows (F
10056)
11
EXTRUDER PLANT
3 DREHSTROM-MOTOR B5 80 L/4T 7040251 IP 55-50 Hz EMOD

Welle ι 14x30
3-PHASE MOTOR Fl.
3,5/ 700- 3x155°
∅160 750 230/400
2,0 2600 Antrieb Dosiergerät / Drive
Dosing unit
(M 11921)
4 NÄHERUNGSSCHALTER B IFM KN5100 Kap Eingebaut in der IFM
Trichterwand /
FÜR BÜNDIGEN EINBAU b. Installed at hopper wall /
„Mangle“ – signal
(für bündigen Einbau)
(E 16023)
EXTRUDER Type 60-B-9250 (BL) Type 080 (096)

1 EXTRUDER 9250A PEPSICO 14777/9250A.2007 Herstellung von extrudierten Produkten elektrisch versorgt und Schaaf
Standard 9250A Leistung 200 - 400 kg/h kg/h Rohextrudat, abhängig von Hauptschaltschrank Technologie
verwendeten Rohstoffen und eingesetzten Düsen-Werkzeugen und electrical supply and GmbH
TURBO-Ausrüstung, 3-Temperaturzonen controlling through Main
Switch Board with
Producing of extruded products integrated operating panel
capacity 200-400 kgs/h. raw extrudates, depending of raw material
mixtures, used die equipment and TURBO Equipment
(9710 001b) Auslauf /Outlet (0244 010) order no. A13792/ plant extension
vorbereitet zum Anschluss des pneum. Transports/ Einlaufinjektor
prepared for connection of pneum. transport / inlet injector
2 GLEICHSTROM-MOTOR, BÜRSTENLOS/ B3 BL-N-160A 64kW 649550070624538 IP23 (Welle ι60x140mm) TAE
Keilriemen-Antrieb:
HAUPTANTRIEB IP23 (Keilscheibe 1 D W 500/ S PB/8- Antriebstechnik
Ausgangssp rillig(K12356+K12357)
DC MOTOR / BRUSHLESS 87103-OCDAF01 annung (Schaaf
(MAIN DRIVE) 400V Keilscheibe 2 DW 170/SPB Technologie
BUSS- /8-rillig (K 12358+K12359) GmbH)
54000/ Spannung 138 2000 Keilriemen 8x SPB 2430mm
(M 13156) 64000 560VDC (430) 2400 Endlos (K 12198)
3 LÜFTER, EXTERN D 060 406/623534 (Mehrbereich) Elektror

Angebaut an hinterer
HAUPTANTRIEB Gestellverkleidung
EXTERNAL MOTOR COOLER (P 11121)
(P 11120) Filtereinheit zu D 060 EU4
208…/ 2,4-3,3/ (P 11122)
550 460 1,4-1,9 2840 Filtermatte Ersatz zu D060
12
EXTRUDER PLANT
4 ZAHNRAD-PUMPEN-AGGREGAT 0,5 MZ 0,2-08 EB 0,2 l/min 10bar Baier + Köppel

Druckschalter
GEAR WHEEL PUMP UNIT vert. AZ-1833 Nr. 0180458011004 –
Zentrale Öl-Schmieranlage
eingestellt auf1bar
Central oil circulation (bearing housing) Rückschlagventil
(Kom. 94867)
Nr. 3003.0020.4.21.71
(P 14777)
5 DREHSTROM-MOTOR B5 3 M 004-4 0207 IP55 / 50/60Hz Baier + Köppel
Antrieb zentrale Öl-
3-PHASE MOTOR Schmieranlage
230/ 0,6/
(B+K) 80 400 0,35 1350
6 WASSER-DURCHFLUSSMESSER 400l Wasserkühlsystem am GEMÜ
Extruder-Verfahrensteil
WATER FLOW CONTROLLER Water cooling system at
(D 10260) Extruder processing section
7 MAGNET-VENTIL G 1/2" 0280 2/2-Wege, in Ruhestellung Bürkert

geschlossen
MAGNETIC VALVE Druckbereich 0,2-6 bar
NW 8mm/ tandardkabelkopf
(P 13001) Dichtwerkstoff NBR
8 24 Water cooling system
8 DREHSTROM-MOTOR B3 DR90S/4T 7040252 Antrieb Schneidvorrichtung EMOD

Drive of cutting device (FU)
3-PHASE MOTOR KL Antriebselemente: (Stemin)
180° Keilscheibe am Antrieb/
SPZ 1-rillig TAPER ∅140
230/ 4,8/
1100 1390
(M 11903) 400 2,75 (K 12452+K 12454)
Keilriemen
XPZ 962 (K 12283)
9 TEMPERATURFÜHLER W16-K023 mit Bajonettverschluss KRITEC

Schutzrohr 6mm,
TEMPERATURE SENSOR Widerstands- Federlänge 195mm
thermometer (E 22100)+ EL= 20...180mm
PT100 (E 22101) (3 Temperaturzonen, Zone
3 = Co-Extrusion)
(3 Stück)
10 DUNSTABZUGSHAUBE Schaaf
VAPOUR EXHAUST HOOD Technologie
(096 002c+9710 005) GmbH
11 MESSERSCHUTZHAUBE With two adjustable cover Schaaf
sheets
CUTTER PROTECTION HOOD Technologie
(094 031c) GmbH
13
EXTRUDER PLANT
12 EINLAUFTRICHTER Schaaf
INLET HOPPER Technologie
(0096 034b) GmbH
13 AUSLAUFTRICHTER Schaaf
OUTLET HOPPER Technologie
(0244 027c) GmbH
Schaltschrank / Switch board STAINLESS STEEL CABINET (FLI Special) [Bedientableau separat / Operating panel separately] № 90447-02, state 0004 (14777-1)
Fix connection from customer’s power supply/ fuse protection proposed 200A - 3~/PEN – 460V - 60Hz [109,0kVA/ 158,0A]
Wiring between switch board and Extruder/control panel to be done from customer’s side - pay attention to the maximum cable length of 25 meters!
At base frame: screwed bolt M8 for fixing grounding strand by customer (potential compensation)  to be desperate to connect
Bearing housing of Extruder head is filled with:

LUBRIPLATE SFGO 220 [LUBRIPLATE SFGO lubricants are approved NSF USDA -H1.]
14
Schaaf Technologie GmbH OPERATING INSTRUCTION
EXTRUDER PLANT
2.5 EXTRUDER & PERIPHERY EQUIPMENT
Extruder front views

Type 035 (0035 027)
Pivotable frame
Fixing point
Additional dosing unit ..KT20, vertical

outlet/ with hopper, protection grate
and cover/level sensor is installed
Type and fitting refer to technical
specifications
3-phase motor
dosing drives
(M 11921)
Operator’s flap
Bellows for dust free transfer

Art.-No. F 10056
Inlet hopper (0096 034b)
Connection piece NW100 for customer’s

vapour exhaust connection
Condensate drain 1/2” connection for
flex. tube
Vapour exhaust hood

(0096 002c+9710 005)
Cutter protection hood with cover

sheets for covering the hole for the
cutting device (0094 031c)
Oil sight
glass
Outlet chute (special)

(0244 027c) outlet opening=
330x200mm, hopper is fitted with flap
for discharge of waste product
inlet injector (0244 002)
Main switch board and operator’s panel № 90447-02, s tate 000 4 (14777-1), r efer t o EL -
documentation
15
9250A 14777 FLI Venezuela 12.2007-tke .doc} ©2007 Schaaf Technologie GmbH
EXTRUDER PLANT
Special design of hopper for discharging of waste products (no standard fitting)
cover sheet /additional fitting:

to be push across the upper hopper frame when
producing with shorter processing parts e.g.single
TURBO & forming plate (Spritzschutz/splash guard)
Outlet hopper (0244 027c)
Position for feeding Position for discharging
16
EXTRUDER PLANT
Outlet c hute is d esigned

for c onnection t he Schaaf standard i njector (included i n d elivery) of pne umatic
transport) in straight feeding direction, opening 200x300mm, flange frame 246x376mm.
17
EXTRUDER PLANT
Cutter protection & vapour exhaust hoods Cooling water return
2 pcs. cover sheets at cutter

protection hood - turnable,
adjusting is depending on
position of cutting device, one Flap for operating during
or the other will be turn away. assembling and disassembling
works with safety switch
Thermo elements + holders

Art.-No. E 22100 + E 22101
(3 Zones)
Clamping holders (D 11088)

for vapour exhaust and cutter
protection hoods
Oil sight glass
For checking the oil level
18
EXTRUDER PLANT
Detail of vapour exhaust hood:

(0096 02c + 9710 005)
NW100, connection
for customer’s vapour
front exhaust
Condensate drain 1/2” for

customer’s connection
Opening for cutting

device
Upper sliding sheet/

covering of cutting
device
Knurled screws
(4 pcs.) for fixing
of sliding sheets
(secured with chain
2x borehole, for fixing a

product guiding device (no
standard fitting)
Lower sliding sheet/

covering of cutting
device
Covering and fixing

flange
Clamping holders (D 11088)

for fixing the vapour exhaust
hood and cutter protection
hood at base frame
Please c onsider: d epending o n f ixing p osition o f c utting

device at die plate it is necessary to exchange both of the sliding sheets against each other.
19
EXTRUDER PLANT
Additional fitting for vapour exhaust hood / guiding device
When pr oducing p roducts li ke “ Flakes”-species (one h ole) mount t he g uiding d evice,

optional / no standard fitting, please refer to the die assembling instructions.
Vapour Exhaust hood with guiding device for „Flakes“- products, mount as shown:
back views
Depending on die
configuration the
lengths of the
distance/fixing bolts
are different either 89
or 44 mm
Leitbogen mit
Halterung /Guiding
device with holder
Art.-№ D 11059
2 screws M6x20 (V 29608)

with large diameter washers
(inner fixing)
2 screws M6x20 (V 29608)

with large diameter washers
(outer fixing)
front view
20
EXTRUDER PLANT
Safety Switches:
Extruder top frame: operating flap
to open for operating works
before and after production
Safety switch at operating flap (open)
Art.-No. E 23203 + E 23202
(Schmersal)
Cutter protection hood

Cutter protection hood (0094 031c)
Safety switch at cutter protection hood
(shown in closed mode)
Art.-No. E 23203 + E 23202
(Schmersal)
3-phase motor/cutter drive

Art.-No. M 11903
V-belt pulley ∅140mm (Taper)
K 12452 + K 12454
V-belt XPZ 962,
Art.-No. K 12283
21
EXTRUDER PLANT
DANGER If the operator flap is opened by mistake during production, the safety switch
switches off the plant.
You absolutely have to pay attention to: the main drive and the V-belt may follow up/lag.
Never touch into the motor space or put on tools as long as the driving elements are
moving.
Very bad injuries are possible !
All operators must be informed about this danger.

Furthermore you have to note that after a production stop over the safety switch extensive
and time consuming cleaning work is necessary as the extruder can no longer be correctly
stopped with the "stop-mix".
Additional EL-fitting / front base frame:
Plug socket for heating

Ring of co-Extrusion die
Plug socket for sleeve/colour

injection pump
22
EXTRUDER PLANT
Additional fitting / Connection block for high pressure hoses from sleeve injection pump unit
Anschluss-Schlauch 3 (0,6m) (R 28377)

Connection hose 3, supply into processing part
Connection pieces for supply hoses from injection

pumps / connecting of two hoses is possible, when
connecting one hose the other connecting piece must
be closed
Anschlussblock
Connection block / fixed at Extruder
base frame
Extruder base
frame/ mounting
plate
23
EXTRUDER PLANT
Water cooling system of processing part:
The cooling water system at the extruder processing part is never

allowed to be operated at a closed water circuit!
Water connection and drain at backside of Extruder base frame
Extruder top frame
Cooling water return line 1/2-hose clip connection

for connecting a hose, water flows into drain
Must ever been open!
Cooling water supply line 1/2”-hose clip connection

for connecting of customer’s supply line
(with stop valve R 21021)
Inlet line into

processing section
Flow control
Art.-No. D 10260
Cooling water
Emptying valve
24
EXTRUDER PLANT
Magnetic valve
Art.-№o. P 13001
pressure reducer
with Manometer
Art.-No. R 02083 + R 02087
Water supply
line
Water return
line
Water supply
line
Central oil circulation/Pump sub-distribution for Blower of Pneumatic

aggregate Thermo elements transport
Art.-No. P 14777 (No Standard, Option)
Cooling water inlet and return at processing section
Cooling water return

(R 16065 =complete
with air escape valve
(R 16064)
(After venting don’t
forget to close)
Cooling water
Inlet/flow line
25
EXTRUDER PLANT
fittings of cooling water line (0096 037a)
back view,
customer’s connection
26
EXTRUDER PLANT
Main drive
V-belt Pulley TAPER 500 SPB 8/4040-80

Art.-No. K 12356
Bushing: T- 4040-80, Art.-No. K 12357
V-belts SPB 2430 endless 8x

Art.-No. K 12198
Greasing nipple
greasing with “KLÜBER ISOFLEX® NCA
15”, pay attention to TAE description in
enclosure
Pulley TAPER 170 SPB 8/3030

Art № K 12358
Bushing T-3030-60, Art. № K 12359
Terminal box of
main drive
Art.-No. M 13156
DC-Motor brushless, main drive
BL-N 160A
Tensioning of V-belts please refer to separate description (tension tester).
Motor rocker
to tense the V-belts
(0096a 004c)
27
EXTRUDER PLANT
For tightening the V-belts, please move the pivoting motor base to the below or above on
the th readed r ods, l oosen th e c ounternuts M30 a nd tur n b oth l ower n uts M30 i nto the
direction requested (spanner wrench SW46).
Please note:
Too strongly tightened V-belts might have so big forces that the shaft may bend, due
to t hat t he e xtruder s crew i s n ot co rrectly t aken i n an ymore, t he r adial di stances t o t he
sleeves are not correct any longer and as a consequence all process parts wear out within a
very short time.
In cas e t he V -belts a re n ot t ightened en ough, h ave a s lippage l arger t han 5 %, t he m otor
capacity is not optimally conveyed and the V-belts wear out unreasonably quickly and have
to be replaced.
The t ightening o f t he V -belts ( bowing f orce), p lease r efer t o t he s eparate d escription

(TenTester).
Daily and/or before every production start you have to check the correct tightening of the
V-belts.
A thorough work when checking and tightening the V-belts makes you safe time and costs
on the long run.
28
EXTRUDER PLANT
Main drive / External Cooler:
Main drive / External Cooler:
Blower and filter unit

Art.-No- P 11120 + P 11121
Spare part /filter pad Art.-No. P 11122
Adapter device (096b 007a)

for cooling line
Art.-No. P 00182
Schlauch PU/KM
Selectively it is possible to connect a fresh air supply line NW150 from customer’s side in
place of the filter box.
29
EXTRUDER PLANT
Extruder flange
6 pcs. Theaded bolts M30

M30 / 305mm lg. Art.-no. Extruder flange Art.-No.
D 11259 D 11830
with nuts and washers
After turning the flange

push it over this treaded
bolt
2 pcs. Guiding bolts

430mm lg Art.-no.
D 11258.
During disassembling and/or cleaning works turn the Extruder flange as shown.
Extruder flange
D 11830
Guiding bolts
D 11258-430mm lg.
screw-in the safety screw
in the face side
release handles/fixing of
guiding bolts
Art.-No. V 13500
Push the both guiding bolts forwards as far as possible - the right one (front view) is longer
for safe work – screw-in the safety screw in front of this bolt.
30
EXTRUDER PLANT
Take c are o f t he h eavy f ittings – Please f ollow ev er t he s afety in structions –

never work without protection clothes, shoes and heat resistance gloves!
Temperature sensors:
Temperature sensor /
zone 2
Plug for closing the inlet hole

W 84965
Temperature sensor / zone 1

(at inlet sleeve)
Cooling water controlling/
switches the magnetic valve
Temperature sensor / zone 3

(Alternative usage either
at Extruder flange or at
Co-extrusion die system,
(if available)
Temperature sensors PT100: Art.-No. E 22100

Holder for sensors: Art.-No. E 22101
(bayonet nut connector)
Inlet hopper: Vertical outlet of additional

Dosing unit T20
Bellows
F 10056
Inlet hopper
(0096 034b)
Fixing screw for

Inlet hopper
DIN933 M12x15
Plug for inlet hole

for closing during
start preparations
Art.-no. W 84965
31
EXTRUDER PLANT
Cutter drive / die face cutting:
Inlet hopper with fixing plate, Cooling water return Connection NW100 at vapour
Oil return
exhaust hood
Cutter Drive
Art.-№ M 11903
3-phase motor DR90S/4T
V-belt pulley (Taper) ∅140, Art.-№ K 12452 &
K 12454
V-belt SPZ/XPZ 962, Art.-№ K 12283
Cutter protection hood

(0094 031c)
Outlet hopper, design is

depending on order
Safety switch SCHMERSAL BNS 250-11ZG-5m

Art.-No. E 23201
The holding device for the cutter drive can be Magnet at hood SCHMERSAL BPS 250
adjusted in horizontal and/or radial direction. Art.-No E 23202
Cutting head
Art.-№ depending on
die system
Cutting device
Art.-№ C 16770
V-belt SPZ/XPZ 962,

Art.-№ K 12283
V-belt pulley (Taper) ∅140, Art.-

№ K 12452 & K 12454
Cutter Drive
Art.-№ M 11903
3-phase motor DR90S/4T
Cutter protection hood Cutter Drive

Turned ((0094 031c) Base plate & holding device
adjustable
(0096 003d)
32
EXTRUDER PLANT
Central Oil Circulation System

Filled with:
LUBRIPLATE® SFGO-220, from TOTAL, lubricating oil certified as per NSF H-1 und
USDA H-1. Application areas: Gears, Hydraulics etc. in the Food industry
Spare part:
Pressure switch Art.-№ P 14002 Oil return
Oil inlet into Refer to further operating
(Motor gear wheel pump, with motor,
bearing housing instruction
Pump, flange and suction pipe)
Art.-№ P 14010 (spare)
Gear wheel pump aggregate, complete with all Sight glass/oil control Oil level complete filled
fittings and pressure switch and tank= Indication during production about 16mm lower than the
Art.-№ P 14000 upper marking (corresponds to a filling volume of about
6,0 l.)
Screw-in type conical valve L8-G1/4 3bar

Art.-№ P 14011
33
EXTRUDER PLANT
Cover of oil aggregate:
refer also following picture.
Filling piece. Motor-Gear pump with drive

Screw cap with Art.-№ P 14002
coarse filter
Art.-№ P 14008 Pressure switch, set to 1 bar
Art.-№ P 14010
Connector, supply line threaded conical

valve L8-G1/4 3bar
Art.-№ P 14011
Connector fitting
Art.-№ P 14012
Suction pipe ∅ 8mm

with compartment filter Threaded connector, straight
Art.-№P 14007 Art.-№ P 14013
Cover sealing cord

Art.-№ P 14005
Generally it s hould b e n o p roblem t o l eave the c over assembled t ogether w ith t he g ear
pump, suction pipe, connectors, pressure switch etc.
34
EXTRUDER PLANT
Port for oil return and oil filling

Art.-№ P 14008
Tank cover with sealing, venting

piece integrated,
screwed on to the oil tank.
Oil tank (Design depends on extruder

model) with view glass
Pump unit with suction line

and filter
Art.-№ P 14002
4x Screw connectors for

fixing the oil tank (Holder
frame is different depending
on the extruder model)
Mounting plate / Lower frame

Bearing housing
Oil discharge
Mounting plate
Before letting out the oil from the bearing housing, first remove the protective cover on
the mounting plate of the extruder frame. Place a suitable container below. Remove the
stopper on the bearing house, allow the oil to run out and collect in the container.
35
EXTRUDER PLANT
Please observe the locally valid environmental regulations in

connection with the handling of „Used Oil“ and the oiled napkins!
Extruder outlet for face cut products /feeding via pneumatic transport:
Pipe line NW120 (incl.) from blower to the

injector with quick-acting ring (R 26389)
Special outlet hopper for connecting the

injector of pneumatic transport (0244 027c)
with turnable flap for discharging of waste
products
Sliding/clamping device for fixing the

injector at outlet hopper
Inlet injector
(0244 002)
Feeding pipe line NW150, to be provided

from customer’s side
Blower of pneumatic transport, mounted

into Extruder base frame, Type DG90/
Art.-No. P 11012a
with throttle valve (P 11027) at suction side
for adjusting the air capacity
Pressure side / air line

into injector NW120
Extruder base
frame
Protection
grate
throttle flap (P 11027) at suction side

for adjusting the air capacity turn the
rocker arm levers
Electrical supply from Extruder main switch board.
36
EXTRUDER PLANT
The device is switched-on at the switch board of Extruder at the correspondingly marked
switch "FAN"
Special outlet hopper

with safety outlet device
for waste products
Feeding line lengthwise
Fixing of injector:
Sliding/clamping device and
Inlet injector (0244 027c) locking pin
Air line NW120 (incl.) 
Feeding line NW 150 (not incl.)
Flap position for discharging of

waste products
Flap position for feeding
Feeding line NW150 to be

provided from customer
37
EXTRUDER PLANT
Never allow product to enter the inlet of the pneumatic transport,

when the blower is not switched on. This will invariably cause product
jamming in operation.
Schaaf parts of pneumatic transport are manufactured from materials and finished part
components, w hich c orrespond t o t oday's d emands i n t erms o f hyg iene f or t he p arts
coming i n contact w ith t he p roduct. Lo ng l ife o f t he u sed t ools as w ell as l ow r epair an d
maintenance requirements are achieved by optimisation of all production components.
The pneumatic transport has a very simple design and is virtually maintenance free. It is
made completely from stainless steel (apart from the filter sacks), thus needing very little
cleaning effort.
The a ir f low is p roduced t hrough a medium-pressure v entilator (fo r ty pe a nd c apacity
details please see the Technical Specification) which is mounted into the base frame of the
Extruder.
At t he s uction s ide o f t he f an a c onnection p iece w ith a t hrottle f lap t o b e o perated
manually is mounted to regulate the air capacity.
Feeding line NW150 is not included in Schaaf delivery– to be provided by customer.
The outlet of the transport system consists of one cyclone and hopper box (air separator),
these p arts are in cluded. T he o utlet o ut of the cyclone in to t he f ollowing p lant p art t akes
place through a pipe system NW200.
The cyclone and air separator are hold through fixings to be prepared from customer (see
follow sketch).
38
EXTRUDER PLANT
Outlet device of pneumatic transport (incl.):
Recommendation:
 ground the feeding pipe line against electrostatic charge.
39
EXTRUDER PLANT
Special design / main dosing unit with buffer silo

Transfer pipe transparent
(Ident. No. 0039 003c)
Level sensor KN5101 art.-no. E 16019 Continuous moisturiser
Switches off water dosing when shortage of type 035
material
Hopper of additional dosing unit

(Ident. No. 089 049a)
prepared for manual charging
Dosing unit T20/additional

dosing Art.-No. F 10286
outlet vertical Art.-No. F 10287
Screw pair VB, coarse profile
Art.-No. F 10288
Special clamping rings,

on safety reason the clamping rings
Drives dosing units / Dosing unit T35/Main dosing are screwed
3-phase motor Art.-No. F 10291
Art.-No. M 11921 outlet horizontal Art.-No. F 10285 Inlet /continuous moisturiser
frequency controlled Screw pair DK, fine profile
Art.-No. F 10289
Additional dosing unit T20:

Hopper of additional dosing unit
(Ident. No. 089 049a)
Level sensor KN5100 Art.-No. E 16023
with protection grate and cover
with inspection window r
prepared for manual charging
(charging height 2600mm)

outlet vertical Art.-No. F 10287
Screw pair VB, coarse profile
Art.-No. F 10288
40
EXTRUDER PLANT
Buffer silo with stirrer:

Continuous moisturiser
Buffer silo type 035
(ident-no. 0039 121a)

Special clamping rings,

on safety reason the
clamping rings are
Inspection cover screwed
screwed
Outlet
Buffer silo
Stirrer drive Transfer pipe transparent Dosing unit T35/

Worm gear-3-phase motor (Ident. No. 0039 003c) Main dosing
(hollow shaft) Level sensor KN5101 art.-no. Art.-No. F 10285
Art.-No. G 10065 (50/60Hz) E 16019
2 pcs.
hexagon cap nuts M6
wrench size SW10
Inspection-/cleaning cover / bird’s view.
Only open under power-off condition!
41
EXTRUDER PLANT
Cleaning/ emptying connection piece NW150 (bottom area)
Closed situation with cover and safety switch BNS 250-11ZG-10m, article no. E 23203/
counter piece BPS 250, article no. E 23202, fixed at cover.
For emptying the silo when cleaning or raw material

changing, disassemble t he c over a nd m ount the
elbow with c ounter p iece BPS 2 50 and th e transfer
pipe as shown
Hang the transfer pipe with the holders up to the top frame.
42
EXTRUDER PLANT
Detail of cover and elbow of inspection/cleaning piece NW150:
To avoid injuries through the rotating stirrer, the safety switch at

DANGER
cover switches-off the plant part.
Never set the safety fittings out of function!
43
EXTRUDER PLANT
Level monitoring “MIN” and “MAX” solely signal for customer’s controlling
Buffer Silo with stirrer

(0039 122)
Signal “MAX”
Level limit switch Soliswitch FTE30
(E+H), Art.-No. E 16107
Signal “MIN” adjustable

Level sensor KN5101 (IFM)
Art.-no. E 16019
Cleaning / inspection opening NW150

with cover (ident. No. 0039 114, …115)
(safety switch installed)
Mounting angles
For fixing at Extruder top frame
As the buffer silo is dismantled for transport the cable connection of the level limit switch
is fitted with plug and socket.
44
EXTRUDER PLANT
Level monitoring at bottom area “MIN” only signal for customer’s controlling
Inspection window
Level sensor KN5101, art.-no. E 16019

adjustable for height
4 pcs. Mounting angles for fixing of buffer

silo onto Extruder top frame
Slide holders for

level sensor
As t he b uffer s ilo is d ismantled for tr ansport th e cable c onnection o f the l evel sensor is
fitted with plug and socket.
45
EXTRUDER PLANT
Silo Cover:
Ventilation piece NW120

(0039 051)
With filter sack,
Art.-No. R 26970
Inlet piece NW150
For customer’s charging system
Opening NW350 for

Cleaning/inspection with
cover, fixed with screwed
clamping ring
2 mounting plates for fixing

the holder device for conveyor
screw
DANGER On safety r ules al l clamping r ings/covers e tc. are s ecured with s crewed
connections.
Never s tart the pl ant without pr oper mo unted h opper, c lamping r ings a nd o ther s afety
fittings.
Rotating tools can cause bad injuries!
46
EXTRUDER PLANT
Stirrer drive
The stirrer as well as the drive are mounted at the bottom area of the silo. The worm gear
3-phase motor with hollow shaft is attached at the stirrer shaft and flange-mounted at the
silo bottom flange with 4 screws M12x45 (wrench SW19). Additional fixing on the face of
the hollow shaft/stirrer shaft with flat washer (special) and screw M10x25 (wrench SW17).
The bearing flange is fitted with a shaft sealing ring and a grease nipple.
47
EXTRUDER PLANT
Silo bottom &

flange
4x screws M12x45
fixing of drive
Stirrer drive
Worm gear-3-phase motor
(hollow shaft)
Art.-No. G 10065 (50/60Hz
multi range design)
1 screw M10x25
with flat washer fixing of
stirrer shaft
Grease nipple
Some comments regarding the greasing:

The grease in the bearing unit is first of all not for the greasing of the bearing, but mainly
to avoid incoming dirt during production.
It i s a bsolutely n ecessary th at y ou c arefully p ut fo od-grade g rease over t he g rease n ipple
before each production start and after each cleaning with water about 5 cm3. Never press
in too much grease because then the sealing- and bearing elements could be destroyed. As
soon as grease comes out do not press in anymore grease.
Attention, fill only with lubricant for food processing industry (e.g.
Klübersynth UH1 64-62 or LUBCON Turmosynthgrease ALN 2502 or
equipollent).
48
EXTRUDER PLANT
Controlling of the level in the buffer silo through level sensors:
Above: Signal “ MAX” ( Level l imit s witch S oliswitch F TE30 ( E+H), A rt.-№ E 16 107)
Signal for customer’s controlling (or a conveyor screw is
included in scope of delivery)
Below: Level sensor “MIN” (KN5101, Art.-№ E 16019 adjustable for height)
Signal for customer’s controlling (or a conveyor screw is
included in scope of delivery)
The s ilo is constructed f or b uffering o f r aw m aterial m ixtures. T he charging o f t he s ilo i s
done t hrough c onveyor s crew f rom ba tch m ixer (if av ailable); a n i nlet p iece N W150 in cl.
screwed clamping ring at top cover is designed for this. Ventilation during charging occurs
through the ventilation piece with filter sack mounted at cover inspection piece NW350.
The s tirrer is switch-on at o perating p anel a t switch b oard o f E xtruder. T he l evel sensor,
which is i nstalled in t he u pper t hird o f t he silo w all, r equires t he raw m aterial m ixtures
from the batch mixer or the like (the latter is not included in delivery).
Please pay attention to the appropriate raw materials!
The level in the buffer silo, controlled through the level switch is held constantly. In the silo
a s tirrer is in stalled w hich r uns d uring t he whole o perating process, t o a erate and a void
arching o f t he r aw m aterial m ixing. F rom h ere t he t ransfer into t he d ouble-screw do sing
system i s do ne au tomatically. T he do sing de vice transports th e r aw m aterial i nto t he
continuous moisturiser through a complete closed system (partially transparent for visual
control).
In the transfer section to the dosing device a level sensor is in stalled with the function of
alarm at raw material deficiency and switch-off the water dosing pump. It has no bearing
on control of raw material preparation or feeding.
The v entilation o f t he s ilo is d one either t hrough a v entilation p iece w ith f ilter s ack o r
through the outlet devise of the conveyor screw (depending on order).
The drive of the stirrer take place through a 3-phase motor- gear unit, constant rpm. (type,
design and capacity see technical specifications)
On safety rules, never work without proper mounted safety devices.

All safety devices must be active before operation start!
49
EXTRUDER PLANT
Cleaning of the buffer silo
The complete buffer silo must be cleaned intensively after every interruption of production
or ev ery p roduction stop, o therwise t he f orming o f m ould is possible and t he n ext
production batch might be polluted.
Only open for cleaning and maintenance and under zero potential condition
Remove loose production residues with a vacuum cleaner through the inspection cover on
top cover; if necessary remove sticking and incrustations with water and detergent. If you
clean wet, all the parts must be dried thoroughly.
Dismount the filter sack at ventilation piece and shake out or wash, before re-mount.
The use of high-pressure cleaners is not allowed because sealing surfaces might be
damaged and remaining raw material might be pressed into the bearing elements. By this
the c omplete b earing- and s ealing e lements o f t he s tirrer s haft w ill b e dam aged an d w ill
have to be exchanged. A longer production breakdown would be the consequence!
50
EXTRUDER PLANT
DANGER The screw safety units at the moisturiser frame and at the
moisturiser itself, connection to the main dosing, are exclusively allowed to
be dismantled in a tension free condition – main switch OFF – and only to do
maintenance and cleaning work!
3-phase motor
Art.-No. M 11990
(50/60 Hz!)
Pivotable frame for supporting of

continuous moisturiser and additional
dosing unit T20
Flexible hose NW70

Art.-no. P 00173
to transfer moisturised mixtures through
vertical outlet of additional dosing into inlet
hopper
Horizontal outlet of main dosing unit

transfer into continuous moisturiser
Screw connection M8
Fixing of main dosing outlet at inlet
section of continuous moisturiser
Screw fixing M10

Fixing of pivotable frame
51
EXTRUDER PLANT
Water connection at moisturiser outer pipe

Supply line from water dosing pump / hose
Art.-No. R 28080
Check valve
IMain dosing Art.-No. P 13023
unit T35 (VA) beids.I 1/4", opening pressure 2bar
Special outlet pipe of

main dosing unit with flange fixing at
moisturiser (0035 010a)
Inlet piece of
Pipe mixer
Screw connections M8 (2pcs.)

Fixing of main dosing outlet at inlet
section of continuous moisturiser
Flange bearing of
Mixer tool
2 pcs. screw fixings DIN931 M10 (SW17) or

DIN912 (SW 8)
dosing unit at moisturiser
Outer pipe and

flange
Static bearing flange

Fixed at flange of outer pipe
dynamic bearing flange

(knurled)
Greasing nipples (2 pcs.)

Re-greasing before every production
start with the moisturiser running
about 5cm3 (each one) over a time of
at least 60 seconds
Some comments regarding the greasing:

The grease in the bearing unit is first of all not for the greasing of the bearing, but mainly
to avoid incoming dirt during production.
52
EXTRUDER PLANT
It i s a bsolutely n ecessary th at y ou c arefully p ut fo od-grade g rease over t he g rease n ipple

before each production start and after each cleaning with water about 5 cm3. Never press
in too much grease because then the sealing- and bearing elements could be destroyed. As
soon as grease comes out do not press in anymore grease.
Attention, fill only with lubricant for food processing industry (e.g.
Klübersynth UH1 64-62 or LUBCON Turmosynthgrease ALN 2502 or
equipollent).
The c ontinuous m oisturiser i s m ounted o nto a pi votable f rame i n c ommon w ith t he

additional do sing u nit, f ixed at the to p fr ame o f E xtruder. F or b etter h andling d uring
cleaning an d m aintenance you c an tur n th e fr ame a side, b ut o nly un der de-energized
condition, please absolutely consider the safety instructions !
Continuous
moisturiser
Additional
Dosing unit outlet of mainDosing unit &
Main Fixing points of moisturiser inlet
Dosing unit
Fixing point, screws M8x40

For fixing of dosing outlet and
moisturiser inlet
Fixing point, screw M10 of

Pivotable frame
frame turned (left hand

or right hand rotating direction depending on Extruder model)
53
EXTRUDER PLANT
Pivot side/
Joints of turnable frame fitted with
greasing nipples (grease with
lubricants for food industry)
Screw fixing of
turnable frame
M10
Lower bearing unit of mixing shaft / greasing point (grease before each production start)
54
EXTRUDER PLANT
Drinking water tank and pump / Liquid dosing system

Drinking water connection 3/8“, 4 bar (max. 50l/h), fitted with mechanical float valve.
Tank for drinking water or other low

viscous liquids (food stuff)
Supply line (Ident.-no. 0096c 027a)
into moisturiser/
hose art.-no. R 28080
Membrane dosing pump for liquids type

EH-E45VC/ Art.-No. P 14690 (50/60Hz)
connection 3/8”“ for customer’s

supply line
with mechanical flotation valve
Art.-No. R 02210 + R 02211
Emptying valve (stop cock)
55
EXTRUDER PLANT
3. OPERATING DESCRIPTION
3.1 CONTINUOUS MOISTURISER
It is absolutely forbidden to switch on the continuous moisturiser and the

main dosing, if the moisturiser frame is not correctly mounted at the
extruder base frame and if the moisturiser is not mounted at the main dosing
unit
The continuous moisturiser basically consists of 3 parts -

a. A vertical pipe mixer
b. One dosing unit
c. One or more fluid dosing unit(s)
Level Sensor
Art.-No. E 16019
Switches-off the water dosing
pump / shortage of raw Continuous Moisturiser
materials type 035
hose NW70/ transfer of

moisturized mixtures Art.-
№ P 00173
Vertical outlet
piece of additional
dosing unit T20/
transfer of mixtures
Horizontal outlet of main

dosing unit T35/ feeding of
main components into
moisturizer
The c ontinuous m oisturiser i s m ounted o nto th e to p fr ame o f E xtruder. F or b etter

handling during cleaning and maintenance the moisturiser is fixed at a pivotable frame.
56
EXTRUDER PLANT
Water dosing and reservoir:
Membrane dosing pump for liquids

Art.-No. P 14690 (50/60Hz)
(approx. 45 l/h max.)
Wasservorratstank / Buffer tank (0035

028) for drinking water or other low
viscous liquids (food stuff)
Flüssigkeitsleitung in Befeuchter/
Supply line into moisturiser
Never switch off the dosing pump at the individual operation unit.
The principle function of the continuous moisturiser is to moisturise the dry

extrusion mix to a preset level.
For a chieving t his o bjective, t he d ry extrusion m ix is d osed in to t he p ipe m ixer w ith t he

help of a double screw dosing unit with variable speed.
Simultaneously water is dosed into the pipe mixer with the help of an accurate membrane
dosing pump. Besides water other low-viscous fluids may also be dosed using this pumping
system. For dosing higher viscous masses, separate eccentric screw pumps and ports in the
pipe mixer may be used.
The continuous moisturiser can be operated automatically or manually:

Normally the moisturising and extrusion processes run automatically.
Here you absolutely have to consider:
57
EXTRUDER PLANT
Danger
It is absolutely forbidden to switch on the continuous moisturiser
and the main dosing, if the moisturiser frame is not correctly mounted at the
extruder base frame and if the moisturiser is not mounted at the dosing unit!

58
EXTRUDER PLANT
DANGER Never switch on the dosing unit in the manual way, if the
continuous moisturiser is not in operation.
If the dosing unit transports in a standing moisturiser there is the danger
that bearing- and sealing elements as well as processing parts may be
destroyed!
The screw safety units at the moisturiser frame and at the

If th e v alue fo r the conveyor capacity o f th e m ain dosing s hall b e fo und m anually b efore
production s tart, th an th is c an o nly b e d one o ver th e o utlet of th e m oisturiser. T he
transfer hose is led to a bowl/measuring cup prepared, the medium is being caught and the
dosing capacity is discovered according to the local circumstances !
Regarding th e automatic o peration (s tandard a djustment up on d eliver), th e c ontinuous

moisturiser is b eing put in permanent o peration. H ere t he d ifferent d evices o f t he
moisturiser switch on after having used the Push-button "moisturiser", depending on the
signal of the sensor mounted at the transfer pipe to the main dosing. This sensor is always
active.
All v alues can b e s witched o n individually in th e m anual s tatus w ithout h aving an y

influence on the other units of the extruder plant.
!!Never switch on the dosing unit before the continuous moisturise is running !!
ATTENTION The fluid pump must always be switch on, because no flow
measurement is done. Never switch off the pump at the individual operation
unit.
59
EXTRUDER PLANT
The raw materials are again well mixed in the tube mixer and are moistened corresponding
to the need fixed before the production start and depending on the ready product. These
processes run in a continuous method.
Because o f t he s pecial ex ecution o f t he m ixing t ools, the moistened r aw m aterial m ix is

transported to the outlet tube and is conveyed into the inlet hopper of the extruder process
part through a flexible tube connection.
If t here is a l ack o f r aw m aterial, i ndicated by t he s ensor at h opper of the m ain d osing

unit, the w ater d osing p ump i s s witched o ff to a void a sludging i n t he f ollowing process
parts. I f there i s ag ain e nough r aw m aterial, t he do sing p ump automatically s tarts up;
the alarm is still indicated and must be cancelled/set back.
The operation of the continuous moisturiser involves the setting of the dry dosing and the
water dosing rates, from available dosing rate data for the particular materials being dosed
for a p articular product. T he r ates can b e s et fr om th e a djustments fo r d ry-dosing an d
water-dosing respectively.
All three devices are switched on in the automatic operation when using the push-button
"moisturizer", the raw material and water dosings are connected and influence each other
in case of a change according to the adjustment.
Each i ndividual ag gregate must b e s witched o n s eparately a t t he c orresponding f eelers

concerning the manual operation.
ATTENTION
Please ensure that the pipe mixer is already on before the dry
material and water dosing units are switched on.
The co ntinuous m oisturiser ca n b e o perated m anually o r u nder automatic m ode. U nder

automatic m ode (standard a djustment up on d eliver), w hich c an b e sw itched o n b y t he
switch marked "Automatic" on the operating panel, the continuous moisturiser is set into a
periodic m ode. H ereby t he v arious u nits o f the m oisturiser s witch o n a nd o ff
simultaneously d epending o n t he s ignal r eceived b y t he s ensors mounted in t he cover of
the main dosing hopper. The sensor is always active.
When p ushing t he " Reset"-button, t he a coustic s ignal is s et b ack, t he r ed LED s hows

permanent light as long as there is a defect.
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EXTRUDER PLANT
If the sensor does not indicate "Full" after another 10 seconds (time can be adjusted), the
water dosing is switched off, and dosing and mixer go on running.
You s till h ave a s hort space o f t ime, d epending o n t he d osing c apacity, u ntil t here is n o
material and your extruder is not supplied with material anymore to re-fill the silo so much
that the sensor indicates "Full" again. Then the water dosing starts up again automatically.
The complete operation of the moisturiser is carried out with the help of a PLC built in the
switchboard. It allows the setting of various activity sequences, incl. any desirable time lags
between various steps of a sequence.
Once the various units of the continuous moisturiser have been set and have been operated
manually for obtaining one batch of moisturised material, the unit can be switched to the
automatic mode for further operation.
ATTENTION
Never run the water dosing pump alone without the dry material
dosing being on. Availability of excess water in the pipe mixer can cause the
formation of sticky and lumpy material in the pipe mixer which can cause
material jamming and other problems in the following units.
1. Only fill the tank with drinking water (or other food grade liquids [low viscous])
2. Never switch on the water dosing pump when the dry material dosing is not running.
3. Never switch off the pump at the individual operation unit.
4. The pipe moisturiser should be cleaned at regular intervals of a few days or during the
weekly maintenance. Cleaning is all the more important, when the moisturiser is not
planned to be used for some time, in which case bacteria and fungus can develop. For
cleaning, t he e xit en d flange o f t he m oisturiser can b e s imply u nscrewed an d p ulled
out a long with th e s tirrer. For t horoughly c leaning t he p ipe mixer m ust been
disassembled.
For s hort p roduction break f eeding d ry r aw m aterial t hrough t he m oisturiser a nd
catch this in a separate container, it should be properly emptied after a cleaning run.
Clean the water tank in regular intervals to avoid sediment.
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EXTRUDER PLANT
5. The d ry d osing u nit d oes n ot n eed as m uch cl eaning e ffort as i t contains o nly dry
material. H owever, it s hould b e p roperly e mptied a fter a production r un. Remove
remnants with vacuum cleaner.
6. Ensure th at th e w ater-tank an d t he dry do sing u nit ar e al ways f ed w ith s ufficient

material. The water tank can be connected to a co nstant water source and the water
level can be controlled with the help of a ball valve.
7. The dry dosing unit is generally constantly filled from the silo (if available). However
in case of extreme lack of material, there is a sensor in the dry dosing unit, which sets
of a light alarm, when the material in the dry dosing unit is at a low level.
Drinking water supply and discharge into and from water-tank are integrated at extruder
frame, prepared with 1/2" couplings.
A c omplete functioning c ontrol o f t he ex truder p lant w as done b efore d elivery. A ll

mechanical and electric functions were checked.
Types, d esign a nd p ower o f t he d rive u nits a nd o ther a ggregates p lease r efer t o t he

technical specifications.
The extruder plant is only allowed to be operated by specially trained

personnel and personnel instructed by company Schaaf !
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EXTRUDER PLANT
4. OPERATING INSTRUCTION - EXTRUDER
4.1.) DESCRIPTION OF THE MACHINE
4.1.A.) EXTRUDER DRIVE
The extruder drive consists of a Brushless motor, model BL-N-160A; a motor V-belt pulley
of d iameter 1 70 m m, w ith 8 g rooves S PB-profile ( 17 m m [Taper]), 8 hi gh p erformance
narrow V-belts in XPB profile and of constant set of length 2430 mm.; and motor rocker.
4.1.B.) V-BELT DRIVE
TIGHTENING THE BELTS

Refer to description “V-belt Tension Tester”
(Use delivered tool)
The a djustable m otor r ocker a llows th e s pacing b etween th e m ain s haft a nd th e m otor
shaft t o b e m odified vertically t o a l imited ex tent in o rder t o e nable t he b elts t o b e
tightened correctly.
The force should not be less than 4.5 kN. This value is approximately maintained if the belt
at a point midway between the two pulleys can be pressed down approx. 1 cm by using a
finger (please refer to separate description “Tension tester”.
 It should be noted that inadequate belt tensioning entails the risk of slippage of the
belt and its damage. If the belt tension is too high, serious damage can be caused to
the motor bearings.
Under a ll c ircumstances i t s hould b e e nsured th at th e tw o b elt p ulleys a re in t he s ame

vertical plane and that the motor and the extruder body are axially parallel to each other.
Under certain circumstances, forces in the region of 20 to 30 t can come into play also in
the r adial di rection. T hese f orces have t o b e s upported b y t he b all-bearing t o p revent a
metallic friction between screw and sleeve and hence a direct wear.
Since these forces come into play at very high rpms, it is necessary to use roller-bearings of
the best quality and precision, which only after a strict selection on the basis of the bearing
tolerance can contribute towards a long life of the bearing combination.
For this reason, it is self-explanatory, that in maintenance as well as in exchanging of the
bearings, it is necessary to work with utmost care and expertise, because in this area even
the smallest mistake can lead to disastrous and eventually costly consequences.
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EXTRUDER PLANT
(For d etails r egarding t he ex changing o f b earings p lease s ee p art CHANGING O F

BEARINGS.)
4.1.C.) EXTRUDER BODY
The extruder body consists primarily of three main components -

extruder head, bearing house and shaft. refer to illustrations : 0096.B.028
The extruder head is secured to the bearing house with 12 inner-hexagonal socket screws,
M 16. It has an aperture to allow entry of material and serves as an element for accepting
the in take r ing a nd t he s leeve, a nd f urther s erves f or s ecuring t he ex truder m ain f lange
with the pressure plates and dies.
Depending o n t he p articular c onstruction, t his c an b e air- or fl uid-cooled. Th e coolant
flows directly around the sleeve.
The sha ft i s i n t he f orm o f a ho llow r od. O n o ne si de it ha s a ho le f or l ocating t he sc rew
shaft and on the other it serves for mounting the large belt pulley. The shaft is mounted on
three generously dimensioned roller bearings {please refer to drawing No. 0096.B.028}.
Axial swivel-roller bearing No 29422

Cylinder roller-bearing No. N226
Grooved ball bearing No. 6228
During t he ex trusion process, t he s crew ex erts v ery h igh r adial and axial f orces o n t he
shaft. When starting up or after brief interruption in production, axial forces of the order of
100 tonnes are exerted on the bearings.
4.1.D.) LUBRICATING-OIL CIRCULATION SYSTEM
As a lready m entioned, t he r oller b earings a re s ubject t o c onsiderable s tress in o peration.

As a consequence, they are only able to function under these conditions for a satisfactory
period o f t ime if t hey a re a dequately a nd continuously l ubricated. A n o il t ank w ith a
capacity of 6 l ., w ith f langed ge ar-type o il p ump i s m ounted to th e fr ont s ection o f th e
extruder f rame. T his oil p ump f orces l ubricating o il in a c ontinuous c ircuit through th e
bearing h ouse. T he p ressure s ide o f t he o il p ump is f itted w ith a p ressure s witch w hich
allows the main motor to operate only if adequate oil pressure has been built up.
The oil tank is fitted with an inspection glass for checking the oil level. The oil return line is
mounted approximately in the centre of the bearing housing so that approx. 2.3 litres of oil
is always available as oil sump in the bearing house. This is to be taken into account while
changing oil and in particular when refilling.
The amount of oil in the system must not be allowed t o drop below 3 ,0 l an d n ot e xceed
6,5l, please avoid overfill.
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EXTRUDER PLANT
Because o f t he h igh o perational r equirements t o b e m et b y t he l ubricating o il, u nder n o

circumstances s hould o ne d eviate f rom t he g iven l ubricant s pecifications w ithout p rior
consultation with the manufacturer.
Wide experience in this field has shown that lubricants with supposedly
superior specifications can lead to significantly reduced durability of the
bearings. The specifications marked by a cross are those which have given the
best results in terms of bearing durability.
(See enclosed lubricating oil specifications 4.13…)
4.1.E.) COOLING
The Extruder, according technical specification is fitted with water cooling system.
When u sing w ater c ooling, o nly s leeves w hich a re f itted w ith s ealing r ings c an b e
employed. En sure t hat t he s ealing r ing m ounted in t he ex truder h ead is u ndamaged.
Ensure that the water connection exists and that the shut off valve is open
The fl ow c ontroller a llows th e q uantity o f f low o f w ater t o b e s et a nd r ead d uring th e
operation.
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EXTRUDER PLANT
4.2.F.) SETTING THE CUTTER

Standard cutting device (only for information)
First the cutting blades are properly cleaned and the cutting edge checked for perfect state
for a g ood cu tter adj ustment. T hen t he cy linder s tud b olts i n t he b lade ar e r eleased an d
pushed back.
(shown die system only for example, NOT included)
The b lade c arrier is s crewed in to t he t apped h ole p rovided a nd t ightened well u sing t he
twist handle.
After ti ghtening, th e c utter s haft m ust b e p ressed fl at o nto the n ozzle p late. T he s liding
bearing bushing must turn easily on the cutter shaft. Neutral adjustment is 3,0 mm. The
amount of clearance is adjusted by turning the adjustment nut provided for this purpose.
ith the cylinder stud bolts released, the cutting blade can be easily positioned as required
on the sliding bearing bushing.
With the cylinder studs loosened, first carry out a rough adjustment of the blade position.
Having sl ightly t ightened t he st uds, c arry o ut f ine a djustments a nd p osition t he b lades
precisely.
The tightening of the cylinder stud bolts leading to the fixation of the cutter head must be
done very carefully.
Extreme t ightening l eads t o a d eformation o f t he s liding b earing b ushing, w hich c an
further lead to the blocking of the cutter system.
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EXTRUDER PLANT
This positioning must be carried out extremely carefully and is all-

important for perfect cutting quality and operational safety of the cutter.
The blade is pushed forward so that it is in slight contact with the studs. At the same time,
the s tuds a re c arefully a nd p rogressively t ightened. A t t he s ame t ime c heck t o en sure a ll
the cutting surfaces are level and in slight contact with the nozzle surface. When tightening
the cylinder studs, pay careful attention to ensure that the sliding bearing bushing is not
deformed by the studs.
Depending on
the length of the die system, it may be necessary for the cutter drive to be
axially re-positioned on the adjustable mount, after loosening the fastening
screws, so that the motor belt pulley is located exactly on the same plane as
the cutter belt pulley.
With th e b elt i n position, th e te nsion s hould b e set s o th at th e centre o f th e s trand c an

easily be pressed down approx. 10 mm.
In so far as appropriate safety measures can be taken,

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EXTRUDER PLANT
it is p ossible b y switching o n t he cutter drive at t he s etting 0 and carefully r evving u p to

moderate s peeds to r echeck th e w orking o f th e c utter w hilst ta king i nto a ccount p ower
take-up by the drive motor.
After th ese a djustment p rocedures, g rease i f n ecessary th e c utter us ing a l ubricant,

approved for food machinery, applied to the nipple provided: switch off and after removal
for extruder operation set aside on a soft underlay.
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EXTRUDER PLANT
CUTTING UNIT ART.- NO. C 16770, ADJUSTABLE DURING OPERATION:
1. before ev ery u se o f t he c utter d evice it m ust b e en sured t hat t he brass b ushing D

13350 has a sufficient crack to the shaft collar of the shaft wave (neutral adjustment
= 3 mm, please refer to the draft) to surely prevent a bracing in the case of later axial
shiftings.
2. The c utter he ad w ith t he c utter b lades is pushed o n t he b rass bushing a nd i s

adjusted, as already known, relatively to the die surface und fixed with the screwed
pins.
Contrary to the above mentioned practise to let the blades get into contact with the
die surface already during the adjustment, it is recommended to put the blades to a
paper t hick d istance t o t he d ie surface r egarding t he a djustable d evice in o rder t o
achieve contact after the temperature compensation (thermal expansion of the brass
bushing) and to minimize the wear. The fixing bolts must be really pressed and you
must h owever t ake car e t hat t he b rass b ushing i s n ot b raced and leads t o a h ard
running of the cutter device.
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EXTRUDER PLANT
3. The product collecting-/vapour exhaust hood

is fixed at the holding frames.
Please ta ke care th at th e a djusting n uts S W
27 can b e easily r eached t o a djust t he cu tter
blades a t th e c utter d evice a fter h aving
mounted th e c utter protection h ood. Th e
lock n ut a s w ell a s the fl at w idth o f th e
bearing adjusting bushing must be in front of
the cutter protection hood.
Having adj usted the cu tter head ac cording

the a bove described p rocedure c heck t he
correct adjustment with a piece of paper by a complete rotation of the cutter head by
hand. T he p aper m ust n ot b e da maged. M ake s ure t hat b oth s crewed b olts ar e
secured to avoid a loosening during production.
Example: shown with spring blades cutter head, also valid for a standard cutter head with
fix cutter blades.
4. The e xtruder i s s tarted a nd th e c utter q uality i s o bserved. T he cutter d evice w ill

warm u p b ecause o f the o peration t he o peration a rea a nd w ill e xtend s lightly
regarding t he l ength w hich l eads t o a h orizontal d irection o f t he blades t o t he d ie
surface. After about 10-15 minutes of operation the final operation temperature will
have adjusted. Cut products that might occur during that time should be tolerated in
favour of the lower blade wear.
5. Because o f the in clined b all b earings

that a re p restressed t o ea ch o ther, t he
cutter d evice r otates a xially t olerance-
free o n th e c utter s haft. T his e nsures
that t he b lades do n ot h ave a n
unnecessary contact to the die surface.
Now t he fine a djustment o f the c utter
device is d one. F or t his t wo s mall
open-end s panners SW 27 a re
necessary. T he b earing a djusting
bushing is held with one of the open-end spanners SW27 at the key dog and with the
second o pen-end s panner t he l ock nu t i s l oosened sl ightly ju st so m uch t hat t he
bearing adjusting bushing can be turned for the adjustment. If the fixing by the lock
nut is opened to widely or the bearing adjusting bushing is not fixed correctly with
the help of the opened-end spanner, it can twist and this leads to an axial, undesired
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EXTRUDER PLANT
adjustment of the cutter blade immediately. N ow the blade distance relative to the
die is a djusted b y a f ine t wisting o f t he b earing a dapter b ushing ( RH-thread) w ith
the help of the open-end spanners SW27 as long as the cutting result corresponds to
the given data.
With this you must be very careful as a too strong horizontal direction
leads to a sudden braking and standstill of the cutter.
The pitch of thread of the bearing adjusting brushing is 1.5 mm. Therefore
an axial adjustment of 1.5 mm results from a rotation and this must be
absolutely considered as normally the horizontal direction is in the tenth
area of a millimetre.
If the optimal adjustment of the cutter blade to the die surface is reached, the axial
position of the bearing adjusting bushing and consequently the cutter head is fixed
by the lock nut with the help of the open-end spanner SW27.
6. Because of the possibility to adjust during operation, the wear of t he cutter blades
resulting fr om th e p roduct d uring a l onger o peration c an b e compensated b y pr e-
adjusting a nd t his l engthens t he o peration t ime o f t he b lades c onsiderably. I f t he
cutting q uality decreases during o peration, r e-adjust the cutter as described under
point
Please also consider here that a t oo strong horizontal direction may lead to a b raking or
even standstill of the cutter device. As the most positive consequence this can release the
automatic stop routine, if all conditions are fulfilled for that. If, however, the stop routine
is not prepared, the extrudate strands can block the product collecting-/vapour exhaust
hood in a v ery short time. Or a machine safety stop is activated. Large-scale dismantling
and cleaning work will be necessary at the process part an d the protecting hoods, if the
extruder is not stopped with a stop mixture according to the instructions.
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EXTRUDER PLANT
C 16770 Cutting device, adjustable
In case of a wrong handling of the cutting unit, for example if:
the cutter bushing has not been put in a neutral position before production start and the
brass bushing has touched at the cutter shaft during the re-adjusting -
or
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EXTRUDER PLANT
the k nife h ead has b een a djusted t oo t ightly t o t he d ie s urface – and d ue to th e th ermal
expansion during production -
it is very probable that the tightening ring for ball bearing on the bearing adjusting bushing
has been shifted and because of that the inclined ball bearings are not correctly tightened
anymore.
In order to put the bearing play to „0“ again, loosen the two threaded pins M6 (SW 3) at
the tightening ring for ball bearing -
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EXTRUDER PLANT
Art.№ D 13367
Position the special ring D 13367 (included in delivery) on the cutter shaft as shown. Turn
the t wo a djusting sc rews e qually w ith o pen-end s panners S W8 in t he d irection o f t he
tightening ring for ball bearing to the stop.
Now f ix again t he t ightening r ing f or b all b earing w ith t he t wo t hreaded p ins M 6 ( SW3).
Release t he t ension o f t he a djusting sc rews a t t he sp ecial r ing D 1 3367, d raw o ff t he
auxiliary tool from the cutter shaft and put it aside until you need it again.
4.1.G.) BLADE SHARPENING

(refer to illustration no. 13000.B.001)
Schaaf blades, if treated properly,

are r emarkable f or t heir
dependability and, p rovided t hey
are co rrectly s et, o ffer a c onstant
cutting q uality o ver a l ong p eriod.
The b lades must b e sha rpened
extremely carefully. Ensure that all
the cu tting s urfaces a re ab solutely
level, on a plane and at right angles
to the center axis.
We r ecommend s harpening t he
blades o n a s urface g rinding
machine b y m ounting the b lade o n
to a perfectly matching arbour, 35 mm in diameter, and grinding the cutting surfaces until
they are absolutely even. Following this, use a fine grain for obtaining the necessary angle
of clearance on each cutting surface, in accordance with illustration no. 13000.B.001. After
removing any burr, carry out a check for proper functioning by mounting the blade on to a
cutter and screwing into a nozzle plate.
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EXTRUDER PLANT
The blade is pushed forward so that it is in slight contact with the studs. At the same time,
the s tuds a re c arefully a nd p rogressively t ightened. A t t he s ame t ime c heck t o e nsure a ll
the cutting surfaces are level and in slight contact with the nozzle surface. When tightening
the cylinder studs, pay careful attention to ensure that the sliding bearing bushing is not
deformed by the studs.
Depending o n t he l ength o f the d ie s ystem, it m ay b e n ecessary f or t he b lade d rive t o b e

axially re-positioned on the adjustable mount, after loosening the fastening screws, so that
the motor belt pulley is located exactly on the same plane as the cutter belt pulley.
4.2.) PREPARATIONS FOR PRODUCTION

(refer also to “short operating Manual Turbo-Extruder 925(0)” & “start-up instruction of a
Turbo Extruder during cold start”)
 Before s tarting to us e th e Extruder, i t i s e ssential th at th e fo llowing r outine

maintenance checks are carried out with the main switch off:
a. After o pening o ne o f the s ide t op do or p anels, car ry o ut a v isual ch eck an d ap ply

thumb pressure to the centre of the strand to ensure correct belt-tension ( also refer
to "Tensioning of the V-belts")
b. The oil level can be checked at the inspection glass, it must be half filled
(at least). Use t he m aintenance c heck l ist t o en sure t hat t he p rescribed o il c hange
intervals are not exceeded - if necessary advise maintenance personnel.
c. Use the maintenance check list to ensure that the prescribed inspection intervals for
the c arbon b rushes o f a ll t he D .C. drive u nits (if ex isting/no s tandard) are n ot
exceeded - if necessary advise the electrician responsible.
d. Check to ensure that the dosing units are clean and that no material residues or other
foreign bodies adhere and prevent their proper functioning.
e. Take ex treme c are t o en sure t hat a ll the in ternal p arts o f t he e xtruder h ead are
perfectly clean. These include the intake ring, the intake orifice, the intake funnel, the
air p assages, t he sleeve seat, t he screw l ocation hole, t he k ey g roove, t he k ey groove
undercut.
f. Ensure t hat t he o rifice ( pos. 5 5) in the ex truder h ead b ehind t he i ntake r ing is
completely free of dirt and foreign bodies.
This o rifice h as t he i mportant t ask o f p reventing in gress o f l ubricating o il in to t he
product in the event of a failure of the sealing rings. It must be free at all times.
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EXTRUDER PLANT
g. Before assembly ensure once again that all the extruder tools are absolutely clean.
Check t he sealing r ings o n t he extruder s leeve f or p roper f unctioning a nd r enew if

necessary. When doing so, fill the groove with lubricating grease for food processing
industry before fitting the new sealing ring.
Having a pplied a mple l ubricating g rease f or f ood p rocessing in dustry t o t he s eats in t he

extruder h ead an d t he j acket s urface o f t he s leeve, p lace t he s leeve at an an gle at t he
extruder h ead l ocation h ole a nd i nsert up to th e fi nal p osition without tilting i t a nd
without applying any force.
Check the screw to ensure perfect fit, mounting and proper working of the key. Generously
grease t he s crew s haft in cluding t he k ey with l ubricating g rease f or f ood p rocessing
industry a nd insert c arefully in to the s leeve s o t hat t he s crew k ey aligned w ith t he s crew
nut is inserted into the location hole.
Any damage to the counter support as a result of incorrectly moun-

ting the screw without ensuring that the key and the key groove are aligned
leads to major malfunctioning including even a totally defect counter
support.
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EXTRUDER PLANT
With t he a id o f t he d rawing-in d evice (C 5 1004) supplied, t he s crew is t hen p ulled i n

through th e c ounter s upport a perture a s f ar a s th e e nd p oint o f th e l ocation h ole.
fastening torque 320 Nm (use a suitable tool e.g. torque spanner).
!! It is of essential importance that the screw is firmly clamped in the shaft

during production! Only then you may avoid damage through extremely
oscillating loads during operation !
In case you operate the extruder without using the pull-

in/clamping spindle, the shaft/the screw will be destroyed within the
shortest period of time !!
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EXTRUDER PLANT
Properly a ssembled, t he f ront ed ge o f t he s leeve m ust p roject 0 .5 - 1.0 mm b eyond t he

front surface of the screw.
(shown assembly configuration with injection sleeve)
Check with a suitable gauging tool!
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EXTRUDER PLANT
screw front
surface
sleeve front
surface
0,5-1,0mm
 Refer also to the following Short Operating Instructions "TURBO-EXTRUDER".
The n ozzle s ystem p rovided f or p roduction is , after a mple g reasing w ith ed ible f at a nd
taking i nto acco unt t he o perating i nstructions r egarding t he di e, attached at r ight an gles
without tilting a nd w ith th e a id o f th e tool s upporting f lange. T he f astening b olts a re
tightened to uniformly and progressively in diagonal sequence to approximately 350-400
Nm. A lso r efer to figs. D ie A ssembling in structions a nd/or specified Customer's d ie
systems.
h.) mount the temperature sensors at the processing part
Hold the start mixture in readiness

2,7 kg fine corn grits (< 0,7mm)
+ 0,3 kg Dimodan HP (Emulsifier made of Mono- & Di Glycerides)
+ 800 ml Water, properly mixed together without lumps
(Quantity is depending on used die system)
 It is important that the starting mixture is produced fresh and immediately

before the machine starts up.
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EXTRUDER PLANT
Unless o therwise st ated i n t he o perating i nstructions f or t he d ie syst em, t he st arting

mixture consists of 1.5 kg corn grits, a grain size not exceeding 1 mm, which is thoroughly
mixed w ith 1 50 m l o f w ater. T he m ixture is f ed in to t he m ain d osing u nit ( I) a nd t he
agitator I is switched on. In the setting "manual operation", the dosing unit is switched
on an d s et in s uch a manner t hat t he m aterial f lows u niformly from the dosing tube at a
rate of 70-90 kg/h.
The mixture is collected, without being allowed to enter the intake opening. Following this
setting, the dosing unit is once again switched off and the mixture is returned to the dosing
unit.
Turn the pulley to ensure that the cutter is properly mounted and functioning.
i.) After p lacing t he V -belt and closing the protective hood make sure that the complete
cutting de vice is p roperly s ecured an d t hat an y r otating p arts d o n ot co ntact t he
protective hood or the vapour escape.
Turn the pulley to ensure that the cutter is properly mounted and functioning.
After p lacing t he V -belt an d

closing the protective hood make
sure th at th e c omplete c utting
device is p roperly secured an d
that an y r otating p arts do n ot
contact t he p rotective h ood o r
the vapour escape.
turned cutter
protection hood,
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EXTRUDER PLANT
j) The RPM setting of the main motor is set to 0. After switching on, it is briskly set to a
screw speed of 400 to 450 RPM. The dosing unit is immediately switched on. When
the main switch is switched on the Oil pump starts operating automatically
After switching on and revving up the screw speed, the dosing unit must be
switched on immediately and without delay.
Reduce any idling speed of the machine to a minimum in order to prevent

damage to the axial bearing.
k) Immediately a fter s witching o n t he m aterial f eed, ensure b y c orrespondingly

adjusting t he s peed setting of the d osing un it th at th at th ere i s un iform p ressure
build-up in the extruder with current flow in the main motor approximately 60-80 A.
When about half of the start mixture has been used up, fill the main mixture into the
feeding h opper o f t he dosing u nit in o rder t o en sure s mooth m aterial f low in to t he
extruder.
l) As so on a s t he e xtruder ha s p rocessed t he p roduction m ixture, t he d osing unit, in

other words, the input quantity has to be adjusted in order to regulate the amount of
energy fed into the product and thus the degree of expansion and texture as desired.
Generally s peaking, a n in crease in t he in put q uantity r esults in in creased current

take-up (A) of the main drive unit and thus an increase in the screw torque.
At th e s ame ti me th e e nergy i nput i nto the p roduct i s r educed a nd th us th e
temperature, the consequence being that the texture becomes more compact, crisper.
At a given screw speed, the maximum input quantity is limited by the maximum conveying
capacity of the screw. This capacity is exceeded as soon as the hopper input runs full.
The cutter speed determines the cut-off length of the product.

After approximately 1 0-15 mi nutes p roduction t ime during w hich it is p ossible t o correct
the d egree t o w hich t he h opper f ills, t he t orque o f t he s crew is r ead and t he r eading is
transferred to th e a djusting p otentiometer maintained for a utomatic o peration. A fter
switching to a utomatic operation t he s crew t orque is a t a c onstant l evel. T his t orque
governs primarily the temperature of the material and thus the texture of what is extruded.
 By raising the speed of the screw, the input quantity is automatically in-
creased and thereby also the output of the unit.
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EXTRUDER PLANT
As the extruded material leaving the extruder during the first five
ATTENTION
minutes might possibly contain impurities and traces of lubricant, it must be
separately collected and not be allowed to enter the subsequent production
process.
Ensure at regular intervals during production that the cutter is adequately lubricated with
a lubricant p ermitted f or use in f ood p rocessing (e.g. K lübersynth® U H1 64-62 or
LUBCON A LN2502). Th e l ubricant s hould b e a pplied t o t he n ipple p rovided f or t his
purpose.
m) If your extruder is fitted with a second dosing unit, you have the possibility of adding
such things as spices, sugar etc. directly to the input hopper.
It is to be observed that such additives are compensated through the torque automatic
mechanism by lowering the input quantity of dosing unit 1 with reference to the screw
torque.
The second dosing unit is also very successfully used with several extruders provided with
a r aw material m ixing f acility. D iffering d egrees o f t ool w ear a re c ompensated by a dding
differing amounts of heavily moistened materials.
Every break in the flow of material during the operation of the

extruder leads to an immediate overheating in the processing section.
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EXTRUDER PLANT
The consequent caking of the material, can no more be removed, which then
naturally leads to a situation, where the machine must be shut-off, cleaned
and started anew.
(Removal of “Blockage of the Extruder processing section” due to caking  Please see separate description in
enclosure !)
Your machine is equipped with many safety devices, which prevent, to a

great extent, especially damages caused by overloading of the drive motors, as long
as they are not rendered ineffective by unqualified setting changes or operation.
In o rder t o o vercome load p eaks, l ike t hose caused b y s udden in flow o f m aterial d ue t o
breakage o f m aterial b ridges in t he e xtruder h opper, a nd e nsure a r eliable p roduction
process, additionally, the DC converter unit is set at a current level, which is approx. 30%
higher, i.e. at about , than the nominal current of the motor:
Adjust to 190A
nominal current = 145A
corresponds to a torque at Extruder screw of 750Nm
During production at normal operating temperatures, the motor is effectively protected by

built-in temperature sensors, which switch off the drive in case of overheating.
If the motor is blocked or if it has not reached its normal operating temperature, there is a
risk, th at th e te mperature s ensors a re un able to s witch-off th e motor in t ime so t hat
damages to the Collector and the Armature coil are caused.
Therefore : Never switch-on a motor, in a blocked condition, for more than

max. 5 seconds !
Operate the extruder within its working range
If the motor reaches this limit due to improper or unqualified operation, the speed of the
screw will fall to zero and the extruder drive is switched-off.
ATTENTION
Cleaning and a new start become necessary.
Under no circumstance is it permitted to change the set current limit values.
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EXTRUDER PLANT
n) After a pprox. 1 0-35 m inutes p roduction t ime, t he m achine w ill h ave f inally r eached
its o perating te mperature. T he te mperature r elevant to th e p roduct c an b e us ed fo r
controlling the liquid or air cooling by setting the actual temperature reading as target
value on the control thermostat.
After s witching o n t he cooling system, t he m agnetic v alve in t he c ase o f l iquid cooling o r

the ventilator in the case of air cooling is switched on by the thermostat when this target
value i s r eached. T he co oling u nit s imply s erves t o c ompensate f or, o r a bsorb s mall
temperature variations.
The p rocessing t emperature is p rimarily i nfluenced b y t he v iscosity o f t he m aterial

(moisture content) and the energy dissipation, in turn affected by the input quantity and
thus by the screw torque.
4.3.) END OF PRODUCTION
Once the production mixture has been used up, a phase out mixture of approximately 2 kg
is fed into the extruder. This phase-out mixture should if possible consist of monoglyceride
bound by starch. The manufacturer will state corresponding alternatives for those cases in
which such material is not available. At the latest 10 seconds after the phase-out mixture is
used up, switch off:
the dosing unit
the continuous moisturiser
the main drive
the cutter
in the order stated
When carrying out the following disassembly steps, heat-protection

gloves should be used to protect against burns.
The belt protective hood is raised and the vapour escape removed.
The b elt is r emoved and t he cutter screwed o ut of t he n ozzle. A fter l oosening t he s crews,
the m ain f lange i s carefully s lid f orward al ong t he s ide g uide b olts an d p laced o n a s oft
surface after r emoval of t he n ozzle system. With t he aid o f t he r emoval devices supplied,
screw and sleeve are pressed out of the extruder head.
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EXTRUDER PLANT
Extruder, s crew, s leeve, n ozzle s ystem a nd c utter a re d esigned t o r esist m aximum st ress
during t he ex trusion p rocess f or h igh d urability. T hey a re nevertheless e xtremely
vulnerable to improper use, in particular, when installing and removing, and cleaning.
Any knocks or impacts to which these parts are exposed, in particular on the seat or sealing
surfaces results in immediate malfunctioning.
When installing or removing and especially when cleaning, handle the tools with extreme
care. P lace t hese p arts o n s oft s urfaces an d avoid abrasive t ools. Grinding m edia o f a ny
kind and impact tools must not be used under any circumstances.
Cleaning s hould b e c arried ou t t horoughly a nd ge ntly, u sing f or e xample a n aluminium
spattle, s oft b rushes o n a n a nti-slip u nderlay c onsisting p referably o f p lastic m oulded t o
the shape of the part to be cleaned.
The in terior o f t he extruder head i ncluding t he in let r ing, in let o rifice and screw l ocation
hole s hould b e cleaned w ith care, p referably b y v acuum removal o f a ny r emaining
materials. Following this, the area should be wiped clean with a soft cloth and allowed to
dry.
Do not use compressed air on the interior of the extruder head as this
causes residual material to reach the lips of the shaft sealing ring and destroy them.
Do n ot u se w ater a nd s olvents f or c leaning t he in terior o f the ex truder h ead. W ater m ay

only be used for cleaning the screw, sleeve and parts of the nozzles if the water is precisely
of the same temperature as the parts to be cleaned and provided that these are then wiped
dry by a fuzz-free cloth.
Leaving extruder tools in water for lengthy periods of time is not only
unhygienic but also damaging to these parts. Any remaining raw materials adhering
to the dosing units must be removed under all circumstances. Do not use water for
cleaning the dosing units.
Having t horoughly c leaned t he in terior o f t he ex truder, in p articular t he s crew l ocation

hole and the key undercut, apply ample Lubricating grease for food processing industry to
the s crew l ocation h ole, t he k ey g roove in cluding t he u ndercut. M eticulously c arried o ut
cleaning is e ssential t o t rouble-free o peration, d urability a nd in t he l ong r un s aves t ime
and money.
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EXTRUDER PLANT
4.4.) ASSEMBLY INSTRUCTIONS FOR DIE SYSTEMS
DRAWINGS:
DISASSEMBLING AND CLEANING INSTRUCTION FOR DIE SYSTEMS
Specificated CUSTOMER´S DIE SYSTEMS & DIE PARTS/Assembling instruction:
Bezeichnung/name Article- № Drawing- №
Die forming plate “GPS Curls” D 04886 (d) 04886.B.001

products 3,2mm/8-fold individual parts
(when using standard sleeve)
Cutting device C 16770

Cutter head 1-blade, 108mm D 13016
Die assembling instruction -- (d) 04886.B.002
die parts & TURBO tools assembly example with
“FLIPS/CURLS” (Standard sleeve) TURBO 2-stage/ standard
sleeve
Die forming plate “GPS Curls” D 04886 (d) 04886.B.003
products 3,2mm/8-fold individual parts
(when using injection sleeve)
Die assembling instruction -- (d) 04886.B.004

die parts & TURBO tools assembly example with
“FLIPS/CURLS” (Injection sleeve) TURBO 2-stage/ injection
sleeve
Please consider:
all TURBO parts be in no accordance with standard GPS-Curls
The following assembly instructions of the die systems and their respective TURBO
equipment are examples. The final choice of the process parts depends on the ingredients
of the raw materials and the desired shape of the extruded product. To keep the setting-up
time as low as possible, would you please make out your own protocols for each product in
which the tools used as well as the raw material recipes are fixed.
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EXTRUDER PLANT
General a ssembling i nstructions f or d ifferent k inds o f d ie systems a t E xtruder

processing part – various assembling facilities, only for information (not in scope of
suppy)
Bezeichnung/Name Drawing no.
Assembling instruction for “Head Die Systems” 0096.B.031
processing section 9250 with standard sleeve (C15006) and pgs. 1+2
TURBO 1- and 2-stage
Assembling instruction for “Head Die Systems” (with 0096.B.038
intermediate pressure plate) 0096.B.039
processing section 9250 with standard sleeve (C15006) and
Assembling instruction for “Forming plate Systems” e.g. 0096.B.030
“Flips, Balls”, etc. pgs. 1+2
processing section 9250 with standard sleeve (C15006) and
Assembling instruction / Die system with colour injection 0096.B.043
TURBO / for example “Head die system”, die face cutting
TURBO/ for example “Forming plate system”, die face cutting
TURBO / for example “Forming plate” cut through cutting
machine, e.g. “Bread-Chips”
Assembling instruction / “Head Die Systems” 0096.B.055
processing section 9250 with injection sleeve (C 15072) and
TURBO 1-stage
Assembling instruction / “Head Die Systems” 0096.B.056
TURBO 2-stage
Assembling instruction / “Forming plate die Systems” e.g. 0096.B.057
“Flips”, etc.
TURBO 1-stage
Assembling instruction / “Forming plate die Systems” e.g. 0096.B.058
“Flips”, etc.
TURBO 2-stage
Assembling instruction / “Multiple die systems” e.g.
BiCHEETOS, individual parts 06598.B.001
Assembly with TURBO 1-stage 06598.B.002
Assembly with TURBO 2-stage 06598.B.003
(with standard sleeve)
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EXTRUDER PLANT
4.5.) CHANGING OF BEARINGS
ATTENTION Proper k nowledge a nd c leanliness are t he p rimary p reconditions f or m oun-

ting/dismounting of the bearings so that the bearings function without problem and do not
fail prematurely.
The w ork m ust b e u ndertaken, a s f ar a s p ossible, in a d ry, d ust f ree r oom. T he w orking
place m ust n ot b e in the v icinity o f a cutting o r m achining m achine o r a machine t hat
generates dust.
Lagergehäuse / Verfahrenseinheit /
Bearing housing Processing section
Öl-Rücklauf / Oil return
Befestigung/Extruderkopf
Fixings of Extruder head
Montageplatte/Grundgestell
Mounting plate/base frame
Proper k nowledge a nd c leanliness a re t he pr imary pr econditions f or mo un-

ting/dismantling of the bearings so that the bearings function without problem and do not
fail prematurely.
The work must be undertaken, as far as possible, in a dry, dust free

room. The working place must not be in the vicinity of a cutting or machining
machine or a machine that generates dust.
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EXTRUDER PLANT
Refer to drawing no.: 0096.B.028, pgs. 1+2
A. DISMANTLING OF THE WHOLE EXTRUDER HEAD
You have to follow the below mentioned sequence for this:
- release the V-belt of the main drive by lifting the motor,
- remove the V-belt from the V-pulley
- loosen the screws of the TAPER bushing of V-pulley (50) and pull the V-pulley from
the shaft with an appropriate pulling device,
- dismantle the fitting key ,
- pull the thermocouple[s] (60) out of the process unit,
- loosen the oil supply line (57) from the bearing housing 2 (3),
- discharge the oil out of the bearing housing and for this remove the cover plate (61) at
the m ounting p late o f th e e xtruder fr ame. Have an a ppropriate bucket a vailable.
Remove the plug (59+60) and let the oil come out and collect it.
Consider the locally valid regulations on the care of the

environment when handling “waste oil”
- water connection, dismantle the forward and back run

(66 + 67 at the process part 1),
- loosen the fixing bolts (70) of the bearing housing device,
- lift o ff th e w hole E xtruder h ead fr om th e fr ame w ith an a ppropriate l ifting tr ackle

(about 500 kg) and put it on the mounting table.
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EXTRUDER PLANT
B. DISMANTLING THE WHOLE SHAFT
- When s crew a nd s leeve a re still i nstalled, lo osen t he cylinder h ead b olts M 16 ( 4),
connection of the bearing housing (2) and the process part (1) carefully,
- lift the process part with an appropriate lifting chain hoist carefully
(caution: just relieve the weight until the screw and the sleeve do not
have any contact anymore),
- pull the process part (1) carefully out of the centering in the bearing housing (2) and
put it aside,
- push out the screw (11) out of the shaft (7),
- pull the sealing ring (24) to take in the O-rings (26) and the air seal rings (27+28) at
the output side of the shaft witch an appropriate pulling device from the shaft or out
of the boring of the bearing housing (2).
ATTENTION
Doing this you absolutely have to avoid a damage of the sealing area
for the air seal rings (27 + 28) on the shaft.
- Loosen the bearing/sealing cover (30) at the output side and remove it carefully,
- loosen the cylinder head bolts M 16 (5) and pull the bearing housing (3) carefully to
the back. The outer ring of the swivel roller bearing (38) is also pulled from.
ATTENTION
Doing this you have to act with the utmost care to avoid any damage
at the sealing area for the air seal ring (32).
Also take care that a cocking and therefore a damage of the boring area will be avoided.
- Push o ut th e s haft (7 ) to th e b ack w ith a n a ppropriate to ol. T he inner r ings o f th e

bearing (35, 36, 37) as well as the distance washer (29) remain of the shaft and are
therefore also pulled from.
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EXTRUDER PLANT
- lift the circlip (37) for the cylinder roller bearing ( 36/output side) out of the notch in
the bearing housing (2) with appropriate pincers,
- pull the o uter r ing o f the cylinder r oller b earing o ut o f t he b earing housing ( 2) w ith
appropriate tools,
- pull the o uter r ing o f th e b all b earing (3 5) o ut o f the b earing housing (2 ) w ith
appropriate tools,
- pull out th e b earing units o n th e s haft w ith appropriate t ools af ter a w arming u p at
about 80°C,
- pull the axial bearing disc (24) out of the bearing housing (2).
ATTENTION
When dismantling the bearing housing part (3), you have to take care
that the spring bolts (39) and the attached cup springs are not exchanged or
are not mixed up in their order.
You have to check whether the contact surface of the casing ring is not
damaged.
Clean al l p rocess and bearing p arts p roperly an d ch eck w hether t here i s any d amage, i f
necessary, replace the parts. Check all bearing and sealing areas.
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EXTRUDER PLANT
C. MOUNTING OF THE NEW BEARINGS
Generally the following is valid:
ATTENTION
Direct strokes on bearing rings, cages or roller bodies are to be
absolutely avoided.
- cylinder roller bearing (36)

take the bearing out of the package. Remove the anti corrosion agent from the boring
and f rom t he o uter r ing. W arm u p the t he in ner r ing o f t he b earing at 8 0°C in a o il
bath and shift it on the bearing seat of the shaft (7) in a axle parallel manner (without
cocking),
- shift the distance washer (29) on the shaft,
- axial swivel roller bearing (38, cage unit)

mounting refer to description “cylinder roller bearing”,
- warm up the bearing housing (2) at the front on the bearing seat for the ball bearing
housing (35) at about 100°C.
After unpacking and removing the anti corrosion agent, insert the ball bearing in an
axle parallel manner in the bearing housing,
- warm up the bearing housing (2) at the back at the bearing seat of the cylinder roller
bearing (36) at about 100°C.
Insert t he o uter r ing of t he c ylinder r oller bearing in a a xle p arallel m anner in t he
bearing housing (2),
- insert the circlip (37) in the notch with appropriate pincers,
- with mounted bearing units pull in the shaft (7) from the back in the bearing housing
with appropriate devices.
Concerning this it is better to slightly prewarm (80°C) the casing with an appropriate
device t o m ake t he in serting o n t he o uter r ing o f t he c ylinder r oller b earing ( 36)
easier,
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EXTRUDER PLANT
grease t he b earing b olts a nd c up s prings ( 39) a nd i nsert t hem i n t he c orresponding

borings in the bearing housing (3). Please make sure that the cup springs are installed
correctly (refer to drawing no. 0096.B.028),
- put the casing ring of the axial swivel roller bearing (38) in the bearing housing (3),
- carefully shift the bearing housing (3) over t he shaft on the centering of the bearing
housing (2) up to the stop.
ATTENTION
Doing this you absolutely have to take care that any damage at the
sealing area for the shaft sealing ring (32) is avoided.
- tighten the bolts (5) evenly and in a crosswise manner,
- push t he se aling d isc ( 24) w ith m ounted sha ft se aling r ings ( 27+28) a nd O -rings
(26) over the shaft into the bearing housing (2) with appropriate auxiliary means.
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EXTRUDER PLANT
Please m ake su re t hat t he sha ft

sealings are installed correctly (refer to drawing no. 0096.B.028, pg. 1 detail B),
This work has to be done with the utmost care to avoid any damage of the
sealing area,
- carefully shift th e b earing c over (3 0) w ith m ounted s haft s ealing r ing (3 2) o ver th e
shaft.
This work has to be done with the utmost care to avoid any damage of the
sealing area,
- mount the bolts (31) and tighten them in a crosswise manner.
ATTENTION
Even if the shaft sealing rings seem to be obviously intact, it is
recommended to replace the shaft sealing rings as well as the O-rings when
doing a bearing change.
Before p utting in t he n ew O -rings, t he corresponding n otches h ave t o b e cl eaned an d

greased.
The notches in the shaft sealing rings have also to be filled with grease.
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EXTRUDER PLANT
D. MOUNTING OF THE PROCESS PART
- insert t he s crew in t he f itting b oring a nd c ramp it w ith t he h elp o f t he p ulling-in

device delivered,
- carefully l ead t he p rocess p art ( 1) over t he screw and m ove it in the direction o f t he
bearing housing ( 2). W hen a pplying t he centering f rom t he pr ocess pa rt t o t he
bearing housing, y ou have t o w ork w ith t he u tmost c are t o a void a ny damage a nd
misalignments resulting from that. Furthermore take care of the right position of the
inlet hole.
- the bolts M16 (4) are slightly tightened and the perfect rotation symmetric position of
the s crew t o t he s leeve is c hecked b y a distance s heet/gauge. ( The g ap b etween t he
screw and the sleeve must be constant on the whole circumference).
If the position is perfect, the bolts M16 (4) are tightened diagonally shifted,
- the oil outlet bolt (59+60) is screwed in.
MOUNTING OF THE EXTRUDER HEAD
Carefully p ut the c omplete e xtruder h ead o n th e m ounting p late o f th e e xtruder

underframe so that the mounting borings are one on the top of the other, slightly tighten
the bolts (70).
Insert the fitting key in the shaft (7).

The p ulley (5 0) i s s hifted o n th e s haft p in a nd fi xed w ith T APER b ushing a fter h aving
greased th e fi tting a reas a bundantly (r efer to s eparate i nstructions “ Mounting o f T APER
bushing”).
Adjust the whole extruder head and firmly tighten the bolts (70). Both pulleys, the one at
the s haft a nd th e o ther a t th e m otor, m ust b e arranged i n a n a xle p arallel a nd p lane
manner to each other.
Put on the V-belt and tense (refer to the description “Tension of the V-belt”),
finally the connection of the oil central greasing (57+58) and of the water cooling tubes is
done (66+67).
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EXTRUDER PLANT
Fill in the oil according to the specification below after the gear wheel pump aggregate has
been checked for proper functioning. (Please refer to chapter “disturbances in the central
oil supply”).
Put in the temperature sensor(s).
OIL SPECIFICATION
The screw bearing unit of the Schaaf extruder system consists of bearings rotating at high
speed and subjected to extreme loads, which as a result sets high demands in terms of the
quality o f t he used l ubricants a nd t he r egular m onitoring o f the o il-exchange in terval, in
order t o en sure in terruption f ree p roduction a nd a chieve a l onger w orking l ife o f t he
bearings and the sealing elements.
We would like to ask you to always use the recommended oil :

type LUBRIPLATE SFGO-220 from TOTAL “ food grade
when making an oil change in the lubrication-oil circulation system.
Never mix food grade lubricant with other kind of Oil!

Due t o t he f act t hat w e h ave h ad b ad e xperience in t he p ast w ith other b rands o f o il, w e
would like you to stock the recommended oil.
Oil changing Interval: after 4000 working hours
Discharge the used oil through the lower oil outlet bore, after disassembling the screw and
sealing (59+60). For better handling remove the cover device (61) under this screw at the
mounting plate of the base frame. Consider the locally valid regulations on the care of the
environment when handling “waste oil”
New filling according to the following steps:

Fill the tank with 5 litres and start the main switch, the oil pump starts automatically-
After 30 minutes run the bearing housing is filled until return-
Repeated filling approx. 1,5 litres-
During rest the sight glass is filled up to ¾ indication-
During production the sight glass is filled up to ½ indication.
 Please avoid overfilling!
The o il l evel s hould b e h old c onstantly. W hen it b ecomes l ower, r efill t he r ecommended
oil-
or the maintenance interval is reached and an oil change is necessary.
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EXTRUDER PLANT
4.6.) JAMMING OF THE EXTRUDER PROCESSING SECTION
Situation :
The screw is blocked and jammed in the sleeve. The drive is not in a position to rotate and
free the screw.
Possible causes :
• The dosing rate has been set too high

• A r aw-material b ridge f ormed u nintentionally in t he ex truder in let
hopper has broken leading to a sudden increase in the material input into
the extruder
• Erroneous extruder starting operation, incorrect start-mix
DANGER
High temperatures prevailing in the extruder processing section can
cause burns during the following activities. Never work without suitable protection,
heat insulating gloves, protective clothing etc.
Falling tools or machine parts during the assembly or disassembly work can cause
bruises, fractures etc. During the following activities never work without suitable
safety measures and safety clothing.
What is to be done ?
A. ATTEMPT TO FREELY ROTATE THE SCREW WITH THE HELP OF THE DRIVE.
ATTENTION The Main drive and the corresponding electronic controls have been
set in such a manner so as to allow a maximum current which is higher than
the rated current of the motor.
Hence for peak loads lasting only for a short time during the production, a higher torque is
available.
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EXTRUDER PLANT
The m otor c an b e s eriously d amaged if it is operated w ith t his h igher c urrent f or l onger
time p eriods, a s t he t hermal p rotection d evices cannot o perate ef fectively d uring t hese
peak load conditions.
Working sequence :
• Disassemble t he e xtruder o uter f lange, r emove t he d ie-system a nd if r equired t he

pressure plates and the turbo tools,
• Place the spacing ring provided on the inside of the outer flange and tighten the same
again.
ATTENTION If t he s crew is b locked, it i s e xtremely i mportant t o f ix t he s leeve r eliably, t o

ensure, that this does not rotate along with the screw in the following steps.
The sleeve can be properly fixed in its position by seating the spacing ring correctly and
proper tightening of the flange.
• Set th e R PM p otentiometer o f th e m ain d rive a t a bout 2 0% a nd switch-on t he

motor for max. 5 seconds.
• Observe t he sc rew a nd c heck i f t he sa me sho ws a ny movement. I n c ase no

movement is o bserved, immediately stop a ll e fforts to o vercome th e j am w ith
the h elp o f t he m ain drive ! I n s uch a c ase it is n ecessary t o d isassemble t he
complete processing section , See disassembly.
• In case a slow movement of the screw is observed, there is a good chance to get it
freely r otating in in tervals w ith t he h elp o f t he m ain d rive. P lease however t ake
care to ensure strictly that the drive is operated under max. load for max only 5
seconds to b e followed b y a p ause o f minimum 10 seconds in o rder t o avoid
an overheating and consequent damage to the motor commutator.
• If t he j ammed parts a re n ot f reed ev en a fter max. 10 attempts and t he s crew

does n ot r otate, d iscontinue t he attempts and d isassemble t he p rocess se ction a s
described in the following section.
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EXTRUDER PLANT
B. DISASSEMBLY
In case the attempts to free the jammed screw with the help of the main drive fail, proceed
further as follows :
• Release t he o uter f lange, r emove t he s pacing r ing, c lose t he m ain v alve f or t he

cooling water and empty the water from the cooling system.
• Using t he screw push-out device p rovided, slowly an d car efully s tart p ushing o ut
the screw and the sleeve together out of the extruder housing. Take care to ensure,
that the process parts do not fall down.
remove the sealing ring from the sleeve carefully!
Attempts to separate the parts from one another by softening the mass between
them by use of water is useless. It would take many weeks to remarkably soften the dough
mass between the screw and the sleeve!
The attempts to separate the parts from one another by the use of mechanic or hydraulic
presses are full of risk. The danger of destruction of the parts themselves is very high!
• Put the parts in a thermostat regulated hot-air oven or conventional baking oven
and set the temperature between 140 and 160 deg C. Over a period of 8 to 16 hours
the dough mass between the screw and the sleeve dries up, loses its elasticity and
becomes brittle.
• Avoid use of any type of force after removing the parts from the oven.
In case the parts do not separate on their own when the screw shaft is gently hit
against a wooden base, let the parts cool down. Clean carefully the surface of
the screw shaft as well as the outer surface of the sleeve.
Grease the processing parts as usual and place them back carefully in the cleaned
and greased extruder housing.
Please follow strictly the usual rules for assembly of these parts.
• Place the spacing r ing on the inner side of the outer flange, mount it and tighten
the flange.
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EXTRUDER PLANT
• Now you should be able to push out the screw from the sleeve with the help of the
push out device provided. Clean the screw and prepare it for further use.
• Now disassemble the sleeve again, clean it carefully and put the sealing rings back.
Grease as instructed and reassemble the sleeve.
Now y ou can p repare t he e xtruder ac cording t o t he u sual s teps f or n ormal
production.
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EXTRUDER PLANT
4.7.) TURBO EXTRUDER / SHORT OPERATING MANUAL
Short-operating Manual Turbo-extruder 925(0)
Action Background/Observations/Tips Faults: Background/Consequence
Checks / Pre-conditions / Preparations
The occurrence of avoidable faults during

Condition and tension of the V-belts, oil the start-up phase or the operation phase of
Check the extruder for operational
1 readiness
level, condition of the carbon brushes, the the machine requires significantly more time
air filter of the motor and switching panel than a regular control on the basis of a
maintenance check-list
Uncleaned or not properly cleaned parts lead
Check for cleanliness: dosing-units, Careful cleaning and cleanliness of
to operation faults or to burn-ons and
extruder shaft, entry ring, screw, especially the parts used for extrusion is
2 sleeve, die-elements, hood and the most time saving method for a
incrustings on the parts, which can be
removed only with significant investment of
cutter productive and fault-free operation
time
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EXTRUDER PLANT
Prepare the Die-parts and TURBO elements pre-selected for use in production as per the assembly instructions and keep ready for
installation on machine. Take care to adjust fixing and guiding bolts correctly !
Take care to properly select the die-adaptor. When producing FLAKES please mount the additional guiding device into the vapour
exhaust hood.
Important !
The guide rails have to be adjusted in accordance with the TRUBO and die-system selected for production. If these protrude too
much in front of the extruder flange, they do not allow the proper installation of the steam and cutter protection hood, or prevent
the proper discharge of the cut product. After assembling the bolts should protruded approximate 10-20mm in front of the flange.
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EXTRUDER PLANT
Assembly
If not regularly and properly greased, it leads

to corrosion and wear of the extruder shaft.
Carefully smear the screw shaft Higher force and more time is required
with a heat-resistant, food-grade during assembly and disassembly of the
greasing fat– Do not apply grease to screw.
Preconditions for a violence free insertion
the head surface of the shaft, shaft hole In case that no or not enough
1 and screw profile. On the head end of the
and removal from the shaft. Protection
prescribed greases have been used,
from corrosion and incrusting
screw is the TURBO Adaptor, which is tribological corrosion (fretting)
fixed as per the TURBO system required might happen that will irreversibly
for the particular production session. damage the material structure of the
screw and shaft and may lead to
breakage and therefore breakdown.
Check the position of the guide rails. These should not protrude sufficiently in front of the processing section, so that the flange,
the TURBO and the die-parts can be installed properly.
Please take care when the guide rails are shifted. The clamping lever on the side of the processing section for the fixation of the
guide rails must be positioned and tightened again !
Fix the securing screws in one of the guide rails.
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EXTRUDER PLANT

Carefully insert the screw inside the When the screw and the shaft have the The reason for higher force requirement
sleeve in such a manner, that the same temperature, it is possible to draw during pulling-in can be caused only due to
2 key and the key groove are aligned in the screw into the shaft with minimal incrusting, dirt or mechanical damage due to
properly effort. the insufficient greasing of the shaft
If the spindle is not screwed in sufficiently
deep into the screw (min. 20mm), it can lead
It is important to check that the screw
to the damage of the spindle.
pull-in device is in perfect condition in
order to ensure that the necessary pulling
torque can be applied with the help of the
In case you operate the extruder
spindle M20 and the that screw can be
without using the pull-in/clamping
Pull in the new screw with the help pressed with the corresponding force
spindle, the shaft/the screw will be
of the „Pull-in/clamping“ device – axially into the front end of the shaft.
destroyed within the shortest period
Article No. C 51004 (C 51000) into !! It is of essential importance that
3 the extruder head / shaft and with a the screw is firmly clamped in the
of time !
In case that the screw is not
tightening torque of 320 Nm pull shaft during production! Only then
sufficiently fixed in the shaft boring
and fix the screw into the shaft. you may avoid damage through
and in case that no or not enough
extremely oscillating loads during
prescribed greases have been used,
operation !
tribological corrosion (fretting)
If necessary, exchange the defective parts!
might happen that will irreversibly
Also the pulling spindle works best when
damage the material structure of the
its threads have been slightly greased
screw and shaft and may lead to
breakage and therefore breakdown.
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EXTRUDER PLANT

Only dirt or foreign particles behind the
The front surface of the screw must The screw and TURBO can be
screw or between the sleeve and the entry
4 lie min. 0.5 mm and max. 1 mm
ring can be the cause for an incorrect gap.
significantly damaged by a screw
behind the sleeve front surface installed either too inside or outside
Remove positively !
Material which has unintentionally
Hereby it will be avoided, that entered the extrusion chamber before
5 Cover the extruder entry port undesirable materials or foreign particles the start can lead to material blockage
fall into the extrusion chamber or die blockage and hence to a false
start
Prepare and keep ready the Die-parts and the TURBO as the desired production session.
grease the TURBO parts and the die A regular and careful cleaning as well as
Insufficiently or non-uniformly greased
elements with vegetable greasing of the parts prevents long-term
6 fat/bees-wax (e,g, Boeson burning-on and is thus the most time
parts can lead to false start or remaining
flow disruptions during the operation
Trennwax, solid) saving method
For greasing the winding of the TURBO-rotors and the adapter we would like to recommend to use the mounting paste: type HT 1200
from “Interflon”.
This is suitable for using in the field of high temperatures and is also allowed to be used regarding an occasional contact in the product
touching area of food supply machines, approved by the FDA. The dismantling of the TURBO-parts will be made much more easier after
production end due to the use of this mounting paste.
Please find the specification and the data sheet in the chapter "oil-specification" of the extruder operation instruction.
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EXTRUDER PLANT

Set the first (thicker) TURBO plate Check the proper and plane seating of the In case of an ungreased or
with the conical openings of the plate. Grease the rotor thread and tighten insufficiently greased or insufficiently
7 holes towards the screw and screw with the special key using one jerk. tightened rotor, dough can enter into
in the rotor with left-hand Recheck the gap between the rotor and the threading and harden itself
threading the plate. irreversably
This safety screw is an important unit In case of non-usage of the safety

Fix the safety screw on the flange
8 guide-rails
without which a tool flange must never be screw, the flange can slip out of the
handled. Wear safety boots. hands and cause major injury to the
feet!
Angled installation of parts leads to
Carefully guide-in the second
Watch out for the correct direction of the damages during tightening of tool flange &
(thinner) TURBO plate, with the
pressure plates, correct position of the dough leakage leading to a false start.
conical openings towards the screw,
9 together with the die-system into
die-system (position of the cutting unit), Wrong position of the die pin causes
correct and symmetrical position of the damaged product. Incorrect positioning of
the flange, oriented centrally and
die-pin, plane seating of all plates. the cutter unit threading - the hood does not
push in without angling.
close !
2-stage Turbo-equipment
After mounting of screw with correct TURBO adaptor (C 14062), the pressure plate 1 and TURBO rotor (C 14072) place the
9.1 medium TURBO plate with the larger end of the conical openings towards the screw and affix the 2nd rotor (counter threaded).
Then place the TURBO plate 2 and die system as described under 9.
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EXTRUDER PLANT

When during the alternative diagonal
Tighten the fixing bolts of the tool
tightening of the bolts, a bolt, which Angled tightening of the tool flange leads to
flange uniformly first with the hand
10 and then uniformly & diagonally
earlier was only slightly tightened, but is damage of the die-tools, leakage of dough
extremely tight during the next round, and false start
with 350 - 400 Nm force.
something is surely not OK !
Incorrect position of the die-pin leads to
This is the last chance to correct any
Check the proper and symmetrical damaged product. If the cutter threading is
11 seating of the die-system.
mistakes which may have occurred during
incorrectly positioned the hood does not
the assembly
close !
Hammer the guide rails with the help of the hammering weights. The protrusion of the guide rails in front of the extruder flange
depends on the die-system built in as well as the hood, which can be referred to in the assembly instructions. Retighten the
12 clamping lever for fixation of the guide rails !
Check the cutting unit, v-belt drive system and the hood for correct position and operation. If required, adjust.
Production start
Switch on the mixing-/ moisturising For the start of the extruder, preferably select a higher moisture and then reduce after
1 units (no standard equipment) the start
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EXTRUDER PLANT

Till the moisturising unit is properly
Remove the material existing at the Too dry or incrusted raw-material can
2 beginning of operation.
filled, the mix does not have the right
lead to start problems
moisture level
Fill in the main dosing unit with Specially for the start it is important, that
3 sufficient quantity of the fresh the raw-material is not too dry, in order Dried raw-material remnants can lead
moisturised raw-material mix to ensure a homogenous flow to false start or to die-blockages
Prepare the start-mix and put into + 0,3 kg Dimodan HP (Emulsifier
the additional dosing unit (no made of Mono- & Di Glycerides) The recipe of the start mix is the result of
4 standard equipment) + 800 ml Water, properly mixed extensive tests. Deviations can lead to false
or put manually into the inlet together without lumps starts.
hopper (Quantity is depending on used die
system)
+ 0,3 kg Dimodan HP (Emulsifier
An unforeseeable stoppage of the extruder
made of Mono- & Di Glycerides)
Prepare the stop mix and keep without the pushing out of the raw-material
5 ready + 800 ml Water, properly mixed by a smearing, fat like substance (eg. )
together without lumps causes difficulty in cleaning
(Quantity is depending on used die
system)
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EXTRUDER PLANT

It is important, that the cover is removed
only at this stage to prevent, that Material entering the extruder
Remove the cover from the inlet
6 port and set the hopper
undesirable materials go into the unintentionally before the start can
extruder. Check the free signal from the cause material and die blockage and
safety switches. thus cause false starts
If the oil pressure sensor switch does not
When all safety switches give „Ready“
When the main switch is switched give the OK signal, the main drive cannot be
signal and the pressure sensor senses the
7 ON the oil pump starts operating
oil pressure, the main drive is ready for
started. Specially at higher temperatures, it
automatically. can take a little while for the switch to react
operation.
to the oil pressure.
This corresponds to about 400 rpm for Lower screw speeds can cause false starts.
Main drive adjustment to
8 60% Do not switch on yet !
the extruder screw, hence optimum start Higher speeds naturally cause higher wear of
condition the axial bearing during the start phase
After switching on the dosing unit, the
A very high material flow rate
Main dosing setting to 0. Do not dosing rate should be carefully increased
9 switch on yet ! from 0 under observation of the
immediately on switching-on the main
dosing unit can lead to false start
Ampere-meter.
Additive dosing (no standard
This corresponds to an optimum start A lower or higher dosing of the start mix can
10 equipment) adjusting to 100 %. Do
dosing rate of approx. 70 kg/hr lead to a false start
not switch on yet !
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EXTRUDER PLANT

Under too high speed of the cutter, the
The cutter must rotate fairly fast at the initially emerging material is smeared on the
11 Cutter drive adjusting to 20 - 30 %.
start to prevent product congestion die-face and the hood is dirtied by the cut
particles
Cutter drive does not run if the safety
switches and the oil pressure sensor switch
12 Switch on the cutter drive
do not close. Check and if required, push the
reset button
Main drive does not run if the safety
The main drive has a soft start, ie. it
switches and the oil pressure sensor switch
13 Switch on the main drive needs approx. 3 secs. to reach the set
do not close. Check and if required, push the
speed
reset button
Dosing of the start mix before the set
Continuously observe the torque
Switch on the additive dosing (no screw speed is reached leads to false
indicator. The torque of the main drive
14 standard equipment) as soon as the
goes up during the start-mix use to 140-
start. Operation of the screw without
screw rpm reaches 200 rpm. material/load leads to high wear of the
210 Nm, depending on the die-system.
axial bearing
In case of cold-start, the start mix
Switch on the main dosing as soon
assumes major importance. Only after Too early dosing of the main mix can lead to
15 as some material starts emerging
this has passed the die, start adding the die blockage and a false start
from the die opening.
main-mix slowly
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EXTRUDER PLANT

Increase the adjusting of the main
Watch the torque-indicator of the main Do not increase the dosing of the main-mix
16 dosing from 0 to 10 % in approx. 4
drive. Rises to about 280 Nm. rapidly
secs.
Watch the torque-indicator of the main
drive. Do not go over 280 Nm. With
Increase setting of main dosing increasing temperature of the material, Abrupt changes in the mass-flow can lead to
17 slowly and steadily. the pressure at the die gradually reduces, die-stoppages and false start
thus allowing an increase in the main
dosing rate.
At the same time reduce the dosing 1% at main dosing unit does not correspond
Watch the torque indicator for the main
of the start-up mix drive with 1% at the additional dosing unit
During the use of the start-mix, try
to keep the torque of the main drive A steady and constant torque during the start procedure prevents die stoppages and
18 as far as possible constant by leads to the desired product in the shortest time.
adjusting the main dosing
Too sudden an increase in the screw speed
After the use of the start mix set the Do not change the screw speed in large without taking care of the dosing leads to
19 screw speed, dosing rate and the jumps. Always watch the RPM-meter and product overheating. Sudden reduction in
cutter speed adjust the main dosing gradually the screw speed without reducing the dosing
leads to overload of the drive/stoppage.
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EXTRUDER PLANT
Dispose of the product obtained Greasing materials in the

The product at the start can contain dirt
20 during the start phase and greasing material product, if consumed, can lead to
poisoning!
The special discharge chute is fitted with a cover. By closing the cover the products in the start phase, which
should not go to further processing stages can be easily directed away. (No standard equipment)
Higher screw speed at constant Higher screw speeds bring in more energy into the product. The temperature and
21 dosing = higher temperature, expansion increase. The expansion in the longitudinal direction is more than in the
stronger expansion and vice-versa cross section.
Higher screw speed at higher
At higher die-pressures, the expansion increases in the cross-section, the product
22 dosing = higher capacity, higher
becomes larger. The temperature also rises.
pressure and vice-versa
In case of any defects / interruptions do not switch off the Extruder and absolutely try to add stop mix!
Although tools with burnt or charred dough are more difficult to clean this is however much more advantageous
than to risk any damage when removing tools with force. {index A/26.04.03}
It does not harm the Extruder to go on running at a low r.p.m.
Please consider that the torque threshold of 500 Nm given (or 40% of the indication) depends on the recipe and
is just estimated by us.
The lower this value, the better it is. Your operators should get some experience and should write down at which
values the screw can still be normally pushed out. {index A/26.04.03}
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EXTRUDER PLANT
A quick work is important to avoid a cooling down and a hardening of the dough.
This makes the disassembly of the Extruder process parts (dies, pressure elements, TURBO-tools, screw, a.s.o.)
easier.
It is better to keep the machine turning slowly and to do all necessary preparations for the stop than to switch off
the machine in case of any defects and to let a long time pass until the disassembly of the Extruder-tools. {index
A/26.04.03}
End of Production
A higher screw speed is favourable for a At too low screw speeds, the stop-mix may
Set screw speed between 400 and
1 600 rpm
better stopping of production but can also be sometimes not properly drawn-in. Also
lead to higher wear. the motor may be overloaded.
+ 0,3 kg Dimodan HP (Emulsifier
made of Mono- & Di Glycerides) If the quantity of the stop mix is too low, the
2 Keep the stop mix ready + 800 ml Water, properly mixed dough is not completely pushed out of the
together without lumps die-system.
(Quantity is depending on used die
system)
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EXTRUDER PLANT

The monoglyceride or other similar
fat-like substances disrupt the dough
If the stop-mix is lumpy or moist, ie. not free
Switch off the main dosing and put formation/fluidisation process in the
flowing and is put into the hopper in one
3 in the stop-mix immediately into extruder. The material passes through the
shot, it can cause blockage and block the
the hopper extruder in a powder form and is hence
passage to the screw
easier to remove from the different
extrusion elements.
It may be eventually necessary to assist
Never use metal items to push in ! Danger of
Ensure, that the stop mix is the drawing-in of the mix with the help of
4 completely drawn in and extruded a round wooden (plastic) stick of min. 30
high force injuries, damage to/destruction of
screw, sleeve and die-elements.
mm diameter.
After the stop-mix has been used If the main drive is not switched OFF after
the stop-mix has been used up, the
5 up, switch off the main drive and all The extrudate during the stop
other units of the extruder procedure must be disposed off and must temperature of the process section rises
not be available for consumption. rapidly : Material burning, baking and wear !
Remove the cutter unit protection
It is of advantage to clean these parts now with a brush as the monoglyceride powder is
6 hood, cutter unit and the steam
much easier to remove in a warm condition.
hood
7 Remove the coarse dirt on the process parts with a brush or a broom
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EXTRUDER PLANT

Slide the guide rails so far to the A hammering weight is delivered for
front that it is possible to carry out shifting the guide rails. This has to be
a safe disassembly. The right guide screwed on to the head end of the guide
rail, when looking at the processing rail. The protruding right guide rails
section, should protrude forward proves to be extremely helpful later when In case of non-usage of the safety
8 about 2 flange widths further when the extruder flange has to be turned to the screw, the flange can slip out of the
compared to the other. Tighten the right, while hinged to it. hands and cause major injury to the
claming lever for fixing the guide feet!
rails. This safety screw is a very important unit
Secure the safety screw on the without which the tool flange must never
flange guide rails be handled. Wear safety boots !
The fixing bolts must be loosened Too quickly loosened flange

carefully to allow any residual pressure to holding bolts can lead to sudden and
9 Crosswise loosen the 6 flange fixing
be released. During this, wear the intensive release of steam.
screws carefully
prescribed safety gloves.
Danger of injury due to hot
steam.
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EXTRUDER PLANT

Wear heat
protective gloves !
Separate the die-tools from the During pulling out
10 TURBO with the help of special of the tool flange,
tools provided hold the die
elements in place.
Wear heat Falling die- and TURBO-elements

protective gloves ! can cause injuries on legs and feet!
Hold the
Push and remove the front TURBO
11 plate with the special tool provided
TURBO-elements
properly while
pushing out.
12 Remove the balance material from the TURBO as far as possible
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EXTRUDER PLANT

Loosen the rotor with a jerk, in order to
prevent, that the screw rotates along and
that eventually the sleeve also shifts ! The
marking on the sleeve must always be at
If the extruder sleeve shifts horizontally or
12 o'clock position.
Loosen and remove the TURBO rotates during the mounting/dismounting
13 rotor (left-hand thread) with the
Please consider:
procedures, it must be dismounted, cleaned
Once per week please turn around the
special key and mounted again afresh.
sleeve.
One week one mark is visible -
Next week two marks are visible –
(that means a longer edge life of sleeve)
If the extruder sleeve dislodges itself from its
Push alternatively and uniformly from
Push and remove the back TURBO seat, dirt can get lodged on the sealing
14 plate with the special tool provided
both sides to prevent angling and edge
surfaces. Danger of a false start next time
damage.
and higher wear due to non-centred seating
The entry ring positioned behind the sleeve is fixed to the process section with a threaded plug. If the entry ring has to be
readjusted or exchanged, the plug must be loosened and removed first. If the securing plug is not removed, the inner sealing
surfaces on the process parts can be damaged and in the worst case completely destroyed !
A rotation of the screw without a sufficiently
The sleeve is fixed with the help of the
Place the Adaptor ring and tighten fixed sleeve leads to destruction of the sleeve
15 the tool flange again
adaptor ring and prevented from rotating
and to significant damage of the extruder
along or shifting
head !!!
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EXTRUDER PLANT
Set the adjusting of the main dosing

Watch out for the free signal from the
16 to a low screw speed (approx. 70
safety switches
Never switch on the main drive till the
Nm) sleeve is fixed with the help of the tool
flange!
If the lubricating oil pressure sensor switch
Only when all safety switches give the free
Oil pump switches ON does not close, the main drive cannot be
signal and the oil pressure sensor
17 automatically when the main switch
registers lubricating oil pressure, the
switched on. Specially at higher
is switched ON temperatures, it can take some time till the
main drive is ready for operation
sensor reacts to the oil pressure.
Switch on the main drive shortly Some balance material is pushed put. Extended rotation of the extruder screw
18 and switch off again as soon as the Precondition for a problem-free removal without axial load causes significantly higher
screw rotates freely of the screw wear of the bearing
Remove the cover at the main drive
to push out the screw from the back Push out the screw only when the sleeve Impact of the screw shaft on the inner parts
19 using the special spindle and is fixed with the help of the tool flange of the sleeve can lead to damages
remove from the front
Loosen the screw connections on the extruder flange, remove the adaptor ring and place on the side.
Pull the flange so far forward that it is resting only on the right guide rail. The rotate the flange to the right by 180
° and slide it over the flange hanging rail after aligning the corresponding screw hole with it.
Hereby support the flange against falling to avoid serious injuries !
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EXTRUDER PLANT
The use of high pressure cleaners as

well as compressed air is prohibited.
Carefully dry clean the extruder Utilise special tools provided for this
20 internal parts purpose and a vacuum cleaner.
The use of high pressure cleaning
implements and/or compressed air causes
the dirt to enter the sealing system and
damage it. Oil leakage.
21 Clean the screw and the die-elements by using the accessories and tools specially provided for this
purpose Please use lint-free clothes.
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EXTRUDER PLANT
4.8.) WHITE PAPER ON RESTART OF A SCHAAF TURBO EXTRUDER
OPERATING WITH DOUBLE TURBO AFTER AN UNSCHEDULED SHUTDOWN
In v iew o f t he in convenience b eing f aced b y v arious c ustomers o perating S CHAAF

extruders w ith double T URBO, in t erms o f t he p rohibition o f a restart e ffort, a fter a n
unscheduled shutdown, SCHAAF has intensively discussed this issue internally and would
like to now state as follows –
1. While SCHAAF has always recommended that the operator is allowed to make a restart
effort in a s ingle T URBO o perating e xtruder, a fter a n un scheduled s hut-down, u sing
proper recommended procedure, the same was explicitly prohibited in double TURBO
machines due to risk of breakage of the TURBO adaptor.
2. Calculations and detailed review of design considerations show clearly that the TURBO
adaptor c an e asily w ithstand t he m ax. t orque w hich c an b e exerted b y t he m ain
motor/drive ( e.g. 1 400 N m i n a 1 200 s eries e xtruder) an d t o w hich i t h ence can b e
theoretically subjected, during a restart procedure.
3. Practically however, there have been a few instances, where the TURBO adaptors have
broken.
4. SCHAAF believes, that the breakage of the TURBO adaptors has occurred in a few cases
not p rimarily d ue t o t he ex cessive t orque t o w hich t he p art w as s ubjected d uring t he
restart procedure but significantly due to certain other preconditions which would have
led t o t he w eakening o f t he T URBO adaptor, t hus r endering it in capable o f
withstanding th e e xtraordinary h igh to rque d uring th e s tart-up. I n fa ct, m uch l ower
torque conditions may also cause such a breakage, if the adaptor is already weakened.
5. One o f t he m ajor p robable c auses f or t he w eakening o f t he a daptor is a pplication o f

excessive force during the disassembly of the TURBO rotors. As is known, the threading
of the TURBO rotors is left-handed. Further a certain amount of impact force has to be
applied o n t he r otor ( using t he s pecial h ook k ey a nd s pecial s panner p rovided) t o
loosen it in itially d uring t he d isassembly. Numerous in stances have b een o bserved
where operating personnel have forgotten about the left-hand threading of the adaptor
and have applied excessive impact force in the wrong direction in an effort to loosen the
TURBO r otors! S uch a pplication o f f orce ca n cau se s ignificant damage t o t he T URBO
adaptor (e.g. through thread lengthening) and lead to its premature failure.
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EXTRUDER PLANT
6. If the threading between the rotors and the adaptor is not properly greased, using the
recommended high temperature grease, it may require a significant amount of, usually
avoidable, force to loosen the rotors. The most common reason for the damage to the
TURBO adaptor is the dough which manages to squeeze into the threading between the
adaptor and t he T URBO r otor. T his do ugh hardens o ver m any p roduction h ours an d
can b ecome as h ard a s ce ment. P roper g reasing o nly i s no t e nough t o pr event t his
situation. I t i s i mportant to e nsure th at th e s ealing s urfaces o f th e T URBO r otors
against the screw or another rotor must be smooth and free of any markings or damage.
Also t he t hreading m ust b e c ompletely f illed w ith grease. O nly t hen it is p ossible t o
ensure t hat n o d ough c an m anage t o en ter t he t hreading. S ince g rease is n ot
compressible, any space already occupied by grease cannot be occupied by the dough.
7. Extensive t ests n eed t o b e c arried o ut t o d etermine t he p ractical limit to rque o f the

adaptor and also the weakening effect caused on it due to various erroneous procedures
and t heir c onsequent ef fect o n t he l imit t orque. T he p lanning a nd e xecution o f t hese
tests will need a significant amount of time and effort.
8. For the moment, SCHAAF would like to make the following recommendations for users
of double TURBO systems on the SCHAAF extruders –
a. Ensure that the operators do not use excessive/incorrect force on the TURBO rotors
during a ssembly/disassembly. D uring a ssembly, i mpact f orce o n t he s pecial
spanner must be applied by hand and not by hammer.
b. Check the adaptor regularly for any visible damage/deformation. In case of any such
observation immediately prohibit restart effort with the same and consult SCHAAF
with details.
c. In case of an unscheduled stoppage of an extruder, operating with double TURBO, a
restart may be attempted within max. 5 minutes from the time of stoppage. This is
a principle recommendation and users should reconfirm the same with SCHAAF for
each specific p roduct, a fter p roviding t he d etails o f t he ex trusion m ix, e xtrusion
moisture l evel, d ie d etails a nd o perating p arameter d etails. A r estart m ay n ot b e
recommended in specific cases where the restart effort is expected to exert extreme
torque on the TURBO adaptors.
d. Restart must be attempted STRICTLY IN ACCORDANCE WITH THE PROCEDURE
RECOMMENDED BY SCHAAF.
e. Since t he r isk o f adap tor b reakage can not b e r uled o ut co mpletely, cu stomers ar e
advised to have necessary alternative parts in stock, which will allow continuation of
production even if the adaptor in the stuck screw is broken rendering the particular
screw unusable.
121
EXTRUDER PLANT
f. In case an y of the conditions necessary for a r estart are not fulfilled, the operators
must r emove t he d ie syst em, t he T URBO p ressure p lates an d t he T URBO r otors
immediately and A FTER P ROPERLY F IXING T HE S LEEVE W ITH T HE S PECIAL
RING P ROVIDED, a ttempt to r otate th e s crew a t a s low s peed us ing th e m ain
motor, in order to free the same for easy removal from the sleeve.
9. The a bove r ecommendations have b een m ade b y S CHAAF b ased o n t he f acts and
figures available with it. However, since SCHAAF has no means to check the condition
of e ach i ndividual a daptor o r e valuate t he ch ances o f i ts b reakage an d also h as n o
means t o v erify if t he r ecommendations f or r estart h ave b een p roperly a dhered t o b y
the operators, it accepts no responsibility for any breakage of the adaptor caused during
a restart attempt or for any consequences as a result of such breakage.
10. Users a re st rongly a dvised t o u se t heir own d iscretion w hile s etting d own a r estart
policy after t aking in to consideration t he above r ecommendations as w ell as w eighing
the p ros a nd c ons o f a r estart a ttempt, in v iew o f t heir s pecific in dividual p roduction
requirements and conditions.
122
EXTRUDER PLANT
4.9.) EXCHANGE OF A DEFECTIVE TURBO-ADAPTOR
Safety Indications
We would like to ask you to absolutely follow the danger indications when doing the work
described below to avoid an injury of persons and economical loss.
Hot surfaces and falling heavy processing parts, (please note the
DANGER
indications of weight in the table).
Very heavy burnings and injuries because of a screw falling down are
possible!
The screw might be completely damaged due to the fall!
Always wear appropriate protection clothes when doing the work described
below - heat protective gloves & safety gloves, a.s.o.
Always secure the screw from a falling down!
Disassembling of the TURBO-Adaptor:
TURBO ADAPTOR
1. Drill a through hole (diam. 12mm) in the centre of the TURBO adaptor proposed to
be exchanged.
123
EXTRUDER PLANT
IMPORTANT Background: The adaptor and the screw can expand differentially
during warming up in an oven. Without a hole drilled in the adaptor, the adaptor
can expand only outwards radially. In some cases this can lead to a cracking or
splitting of the front end of the screw. The hole allows the metal of the adaptor to
expand towards the centre during the warming up process in the oven.
2. Warm up the complete screw uniformly (we recommend use of a suitable oven) for
about 3 hours at 250°C, to dissolve the thermally soluble thread fixing fluid used.
3. Fix t he s crew w hile it is s till hot in a s uitable d evice ( Lathe machine o r a B ench
vice).
Please use Aluminium jaw covers to protect the screw from

any damage!
4. Screw on 2 nuts on the defective adaptor so that they lock each other (refer to table)
Extruder MODEL Nuts to be used Weight/

screw approx.
Extruder 640 M20 Left-hand threaded 6,0 kg
Extruder 760/9250 M24 Left-hand threaded 16,5 kg (max.)
Extruder 1200 M30 Left-hand threaded 33,0 kg
124
EXTRUDER PLANT
5. Turn the Adaptor C L O C K W I S E ! to take it out of the screw.
6. Repeat t he p rocess o f heating t he s crew in t he o ven if t he a daptor d oes n ot a llow

itself to be turned and taken out of the screw.
125
EXTRUDER PLANT
Disassembly of a broken off TURBO Adaptor
1. Machine the broken adaptor to get a plain surface.
2. Drill a hole (as per the table below) in the TURBO-Adaptor and tap threads in the
hole.
Extruder Model Hole Threading Weight/

screw approx.
Extruder 640 Diameter: 14,0 M 16 6,0 kg
Extruder 760/9250 Diameter: 17,5 M 20 16,5 kg (max.)
Extruder 1200 Diameter: 21 M 24 33,0 kg
3. Heat up the complete screw uniformly (we recommend use of an oven) for 3 hours
at 200°C to dissolve the thermally soluble thread fixing fluid used.
126
EXTRUDER PLANT
4. Fix t he s crew w hile it is s till h ot in a s uitable d evice ( Lathe machine o r a B ench

vice).
Please use Aluminium jaw covers to protect the screw from

any damage !
5. Tighten a bolt into the adaptor of the screw while it s still in a hot state (refer to the
table below)
Extruder Model Bolt to be used Weight/

screw approx.
Extruder 640 M 16 x 30 DIN 933 8.8 6,0 kg
Extruder 760/9250 M 20 x 40 DIN 933 8.8 16,5 kg (max.)
Extruder 1200 M 24 x 50 DIN 933 8.8 33,0 kg
6. Turn the Adaptor C L O C K W I S E , using a spanner on the affixed bolt, to take

it out of the screw.
7. Repeat t he p rocess o f heating t he s crew in t he o ven if t he a daptor d oes n ot a llow

itself to be turned and taken out of the screw.
127
EXTRUDER PLANT
Installation of the new TURBO-Adaptors
We would like to ask you to absolutely follow the danger indications at the beginning.
1. Fix the screw on a suitable device (Bench vice). Please use Aluminium jaw covers to
protect the screw from any damage.
Always secure the screw from a falling down!
Very heavy injuries because of a screw falling down are possible!

DANGER
The screw might be completely damaged due to the fall!
2. Remove thoroughly any remains of the old adhesive fluid out of the threading in the
hole in the screw with the help of a suitable wire brush.
3. The n ew a daptor a nd t he t hreading in t he s crew m ust b e cl eaned w ith a b rake

cleaning fluid or other similar suitable fluid to make them completely oil and grease
free.
128
EXTRUDER PLANT
4. Affix a nut (refer to the table below), which would be used later for gripping the
adaptor, on the coarse threading of the TURBO adaptor.
Extruder MODEL Nuts to be used

Extruder 640 M20 Left-hand threaded
Extruder 760/9250 M24 Left-hand threaded
Extruder 1200 M30 Left-hand threaded
Nut for gripping the

adaptor
129
EXTRUDER PLANT
5. Screw in the new TURBO-Adaptor without using any adhesive into the screw
C O U N T E R C L O C K W I S E as a pre-installation check.
6. Check the measure according to the drawing and table below:

Face side screw up to face side TURBO-Quirl.
Extruder TYPE Control measure X

Extruder 640 218 mm
Extruder 925 256 mm
Extruder 9250 296 mm
Extruder 1200 355,5 mm
Should t he m easure n ot correspond w ith t he v alue v alid f or your extruder t ype, it can b e
adjusted with distance discs behind the TURBO-adapter.
130
EXTRUDER PLANT
7. Apply s ome o f t he s pecial a dhesive f luid ( e.g. L octite 6 38) o n the t hreading in t he
hole in t he s crew a nd a lso o n t he c orresponding t hreading o n t he n ew T URBO-
Adaptor.
8. Screw in t he a daptor immediately C O U N T E R C L O C K W I S E into

the s crew t ill the en d. T ake c are t o en sure, that n o d irt p articles come in c ontact
with the adhesive fluid.
9. Tighten the adaptor, with the help of a spanner at the nut affixed earlier on the
adaptor. The following tightening torques should be used.
131
EXTRUDER PLANT
Extruder Model Tightening Torque
Extruder 640 130 Nm
Extruder 760/9250 180 Nm
Extruder 1200 350 Nm
The final strength of the adhesive is achieved after 24 hours!
132
EXTRUDER PLANT
4.10.) ILLUSTRATIONS
ILLUSTRATION № DESCRIPTION
PFI 9250A.B.003 EXTRUDER DIMENSIONS & EQUIPMENT
0096.B.028 EXTRUDER PROCESSING DEVICE
(page 1+2) (spare parts listing)
Extruder 9250 Pictures with art.-nos.
Standard TURBO- Sets 2-fold, 1-fold
0096.B.005 SLEEVE – SCREW
Assembling instruction
0096.B.041 PROCESSING PART, PREPARED FOR LIQUID
INJECTION SYSTEM
With injection sleeve C 15072/ additional fitting
no standard
(c) 14560.B.003 TURBO EQUIPMENT / COLOUR INJECTION
Individual parts - additional fitting NO standard
0096.B.052 TURBO EQUIPMENT / COLOUR INJECTION
Assembly example with Bread-Chips die –
TURBO equipment and die additional fitting NO
standard
0096.B.014 DEMONTAGE/DISASSEMBLING
Disassembling of screw, sleeve fixing ring
Standard sleeve
0096.B.015 DEMONTAGE/DISASSEMBLING
Disassembling of screw, sleeve fixing ring
Sleeve for liquid injection (no standard fitting)
C 16770 01 CUTTER
13000.B.001 SHARPENING OF THE
CUTTER BLADES
13000.B.002 CUTTER HEAD, STANDARD
Cutter blades fix for resharpening
13700.B.001 CUTTER HEAD WITH SPRING BLADES, blades
are changeable, not resharpening necessary
0035.B.012 CONTINUOUS MOISTURISER
Spare parts and assembly
0039.B.102 BUFFER SILO WITH STIRRER
Assembling / spare parts
133
Power
Position- und Ersatzteilliste

Index and Spare Parts - List
Liste des positions et des pièces de rechange
Zeichnungs-Nr./drawing No./No. de dessin: 0096.B.028
(Status Mai. 2003, Schnecke neue Generation & modifizierte Dichtelemente)
EXTRUDER-VERFAHRENSTEIL
EXTRUDER PROCESSING SECTION
SECTION DE PROCEDE DE L´EXTRUDEUSE
TYPE 9250
Stck. Artikel-Nr.
Pos. Bezeichnung/name/nom
pcs. Article-No.
№
pièces No. d'article
Verfahrens-Teil
1 1 Processing section C 12160
Section de procédé
Lager-Gehäuse 1
2 1 Bearing housing 1 C 12152
Logement du palier 1
Lager-Gehäuse 2
3 1 Bearing housing 2 C 12155
Logement du palier 2
Schraube, DIN 6912, M16 x 75 & Federring DIN 127 (8.8)
V 51209 &
4 16 Screw, DIN DIN 6912, M16 x 75 & Spring washer DIN 127
V 65860
Vis, DIN 6912, M16 x 75 & rondelle élastique DIN 127
Schraube DIN 912, M 16 x 200 & Federring DIN 127 (8.8)
V 50277 &
5 16 Screw, DIN 912, M 16 x 200 & Spring washer DIN 127
V 65860
Vis, DIN 912, M 16 x 200 & rondelle élastique DIN 127
6
Pinole / shaft / Douille de la contre-poupée
7 1 C 12163
(mit Stirnbuchse 1.4122)
Gewindehülse/Vorrichtung für Schnecken-Ausdrückvorrichtung
8 1 Tapped bushing/device for screw puller D 11502
Douille fileté/dispositif pour éjecteur de vis
Zentrierbuchse
9 1 Centering ring D 11509
Bague de centrage
Schnecken-Einziehvorrichtung
10 1 C 51004
Screw drawing in device
siehe Turbo-
Ausrüstung/
Schnecke, gehört zur Turbo-Ausrüstung (Art ist abhängig vom Auftrag)
11 1 according to
Screw , part of TURBO-Equipment ( kind is depending on order)
TURBO-
equipment
Gewinde-Bohrung M20/ Schneckeneinzieher ohne/without
12 1
Taphole M20/ Screw push-in special tool Article-No.
Abhängig von
TURBO-Adapter, geklebt in Schnecke, Auswahl nach TURBO-Ausrüstung, Gewindebohrung
der TURBO-
M30x1,5/ ACHTUNG! Linksgewinde/ zur Montage des Turbo-Adapters
13 1 Ausrüstung/
TURBO-Adaptor, glued into screw, selection depending on kind of TURBO, taphole M30x1,5 /
depending on
ATTENTION! Left-Hand Thread / for mounting of TURBO-Adapter
TURBO fitting
Paßfeder DIN 6885 20x12x140lg
fit-in key DIN 6885 20x12x140lg
14 1 V 17222
clavette parallèle fixée par vis DIN 6885, 20x12, longueur 140mm
(Schraubbefestigung M6 DIN912, 2x Gewinde M6 zur Demomtage der Paßfeder)
15
Einlaufring Spezial
16 1 Inlet ring special C 15530
Bague d'entrée
Stator/ für Wasserkühlung - Standard
17 1 C 15006
Sleeve/ prepared for water cooling: - standard
O-Ringe 122,0 x 3,0mm
18 2 O-Rings 122,0 x 3,0mm K 40000
O-bagues 122,0 x 3,0 mm
19
Zentrier-Ring
C 15008
20 1 Sleeve center ring
Bague de centrage
1
[{Index{} April t, jjjj} C:\DOKUMENTE UND EINSTELLUNGEN\TT\EIGENE DATEIEN\STUECKLISTE.DOC\0096-28.DOC] Mai 2003 © Schaaf Technologie GmbH

TYPE 9250
Stck. Artikel-Nr.
pcs. Article-No.
№
Schraube DIN 6912, M 8 x 12 (8.8) / Zentrierring-Fixierung
21 2 Screw, DIN 6912, M 8 x 12 / fixing of sleeve center ring V 51199
Vis, DIN 6912, M 8 x 12
O-Ringe 157,0x 3,0mm
22 1 O-Rings 157,0 x 3,0mm K 40060
O-bagues 157,0 x 3,0 mm
23
Dichtring
24 1 sealing element/take-up-ring C 12151
Bague d'étanchéité
Gewindebohrungen M6 / Demontagehilfe ohne/without
25 2
Taphole M6 / help for disassembling Article №
O-Ringe 239,3 x 5,7mm
26 2 O-Rings 239,3 x 5,7mm K 40110
O-bagues 239,3 x 5,7mm
Wellen- Dichtring 140 x 170 x 15
27 1 K 22230
Sealing ring 140 x 170 x 15
Wellendichtring 140x170x15 PTFE/Niro
28 1 K 22239
Shaft sealing ring PTFE/Niro
Axial-Distanzscheibe
29 1 Axial Distance plate C 12154
Douille d écartement axial
Lager-/Dichtdeckel
30 1 Bearing/seal cover C 12156
Chapeau de palier/capot étanche
Schraube DIN912 M8x25
31 4 V 50058
screws DIN912 M8x25
Wellen- Dichtring 100 x 125 x 12mm
32 1 Sealing ring 100 x 125 x 12mm K 22150
Bagues d'étanchéité à lèvres 100 x 125 x 12mm
33 1 O-Ring Dm 250,0x3,0 mm, Werkstoff: NBR 70 Shore A K 40069
34 1 O-Ring Dm 135,0x2,5 mm, Werkstoff: NBR 70 Shore A K 40005
Rillen-Kugellager Typ-Nr. 6228
35 1 Ball-bearing No. 6228 K 62450
Roulement rainuré à billes Type No. 6228
Zylinder-Rollenlager Nr. N 226
36 1 Cylinder Roller-bearing No. N 226 K 63135
Roulement árouleaux cylindriques No. N 226
Sicherungsring 230,0x5,0 DIN 472
37 1 Tab washer 230,0x5,0 DIN 472 V 61184
Circlip 230,0x5,0 DIN 472
Axial-Pendel-Rollenlager Typ-Nr.29422
38 1 Axial-swivel-roller-bearing No. 29422 K 60240
Butée à roulement à rotule type No. 29422
Satz Vorspannbolzen mit je 4 Tellerfedern, komplett
39 4 sets tension bolts with spring caps, complete C 12158
Ensemble de boulon de précontrainte avec chaque fois 4 ressorts à disques, complet
40
Extruder-Flansch
41 1 Extruder flange D 11830
Bride d'extrudeuse
Gewindebolzen M30, 305mm lg., einstellbar
42 6 (threaded bolts M30, length 305mm, adjustable D 11259
Boulon fileté M30
2

TYPE 9250
Stck. Artikel-Nr.
pcs. Article-No.
№
Optional/kein Standard/No standard
43 6 Schraube mit kugeliger Spitze/DIN 933 M 8x 18 V 26360
Special screw DIN 933 M 8x 18
U-Scheiben DIN 125 M30
44 6 Washers DIN 125 M30 V 66380
Rondelle chamfreinée DIN 125 M30
Mutter DIN 934 M30
45 6 Nuts DIN 934 M30 V 40495
Écrou DIN 934 M30
Führungsbolzen Durchm. 30mm, 430mm lg., einstellbar
46 2 Guide bold diameter 30mm length 430mm, adjustable D 11258
diamètre 30mm
Klemmhebel / Fixierung der Führungsbolzen
47 2 Clamping lever / fixing of guide bolt V 13504
Vis à poignée-étoile / fixation de Broche-guide
Flansch-Düsenadapter, Einsatz bei “Kopf”-Düsensystem
48 1 D 11833
Flange die adaptor, necessary when producing with „Head“ die systems
49
Keilriemenscheibe SPB /8-rillig DW 500 und Taperbuchse 4040-80/Passfeder A22x14x110
K 12356+
1 V-belt pulley SPB /8-grooves diameter 500mm and Taper bushing 4040-80
K 12357
Poulie à courroie trapézoïdale
50
Keilriemen SPB 17, 2430mm lang endlos
8 V-belt SPB 17, length 2430mm endless
K 12198
Courroie trapézoïdale SPB 17, longueur 2430mm, sans fin
51
52
53
54
Öl-Rücklaufbohrung
WICHTIG: "DIESES MUSS IMMER SAUBER SEIN"
Oil outlet ohne/without
55
IMPORTANT! "MUST EVER BE CLEAN" Article-No.
Tuyau de retour pour huile
IMPORTANT! "DOIT TOUJOURS ETRE PROPRE"
56
Anschluß-Versorgungsleitung für Öl
ohne Artikel-Nr.
(Zentrale Ölschmierung)
57 1 sans No.
Oil supply connection (central oil-circulation)
d'article
Connexion pour alimentation d'huile (graissage central)
Öl-Rücklauf ohne Artikel-Nr.
58 1 Oil Return sans No.
Tuyau de retour pour huile d'article
Schraube DIN 912, M16 x 30 /Öl-Ablaß bei Ölwechsel
59 1 Screw DIN 912, M16 x 30 / Oil outflow V 50247
Vis DIN 912, M16 x 30
U-Scheiben Cu / D 26/d17/S3
60 1 Washers Cu / D 26/d17/S3 V 66371
Rondelle chamfreinée Cu / D 26/d17/S3
ohne Artikel-Nr.
Abdeckvorichtung am Gestell/ muss bei Öl-Wechsel demontiert werden
61 1 sans No.
Cover device at base frame / must be disassembled during oil changing
d'article
62
63
64
3

TYPE 9250
Stck. Artikel-Nr.
pcs. Article-No.
№
Anschlußbohrungen für Temperaturfühler
ohne Artikel-Nr.
(1x im Flansch, 2x im Verfahrensteil)
65 2 (3) sans No.
Connections for Temperature sensors
d'article
(1 pc. at flange, 2 pcs. at processing section
Kühlwasser-Rücklauf ohne/without
66 1
Colling water return pass Article-No.
Kühlwasser- Zulauf ohne/without
67 1
Cooling water supply Article-No.
Haltevorrichtung für Verfahrenseinheit, befestigt auf Montageplatte am Extrudergestell
68 2 C 12157
holding device of processing section, fastening to mounting pate at Extruder base frame
Gewindestift DIN915 M12x20
69 6 V 12197
headless screw DIN915 M12x20
Schraube DIN 912 M20x40 / mit je einer U- Scheibe DIN 125
70 4 V 50284
Screw DIN 912 M20x40 / with washer DIN 125
Auftrags-
Spezial-Einlauftrichter abhängig/
71 1
Special inlet hopper depending on
order
Schraube DIN 933 M12 x 15 / Fixierung des Einlauftrichters

73 1 Screw DIN 933 M12 x 15 / Fixing of inlet hopper V 50790
Vis DIN 933 M 12 x 15
Temperaturfühler PT100, mit Gegenstück] M12x1 Typ GSL E 22100 +
74 3
Temperature sensors, PT100 wtih holders M12x1 E 22101
Änderung:
Sehr geehrter Kunde!

Bei Ersatzteilbestellungen bitte die Artikel-Nr. angeben. Bei Neubestellung der Schnecke oder des Stators bitte die Nummer angeben,
die auf dem zu ersetzenden Teil eingraviert ist.
Dear Customer !
At time of order please give details concerning the article-No. or the item-No. especially when ordering screw or sleeve please give us
the engraved number.
Messieurs,
nous vous prions d'indiquer le no. d'article en cas de commande de pièces de rechange. Quand vous commandez la vis ou le stator,
nous vous prions de nous communiquer le numéro gravé sur les pièces à remplacer.
4
Extruder 9250
TURBO- Set 2-fold
pressure plate 2 pressure plate M pressure plate 1

3mm : D 00995 3mm : D 00984 3mm : D 00982
4mm : D 00986 4mm : D 01205 3,5mm : D 01200
5mm : D 00999 5mm : D 01206 4mm : D 00996 TURBO screw conical two outlet
5mm : D 00998
( C 14725 )
( C 17051 )
Turbo A Turbo Z Turbo drive

( C 14071 ) ( C 14072 )
adapter ( C 14062 )
Copyright 2003 by
D-65520 Bad Camberg Germany /Vorbereitet und geschrieben von Technical Documentation -Schaaf Technologie GmbH- Technische Modifikationen und Druckfehler sind möglich!
Extruder 9250
TURBO- Set 2-fold
pressure plate 2 pressure plate M pressure plate 1

3mm : D 00995 3mm : D 00984 3mm : D 00982
4mm : D 00986 4mm : D 01205 3,5mm : D 01200
5mm : D 00999 5mm : D 01206 4mm : D 00996
5mm : D 00998
TURBO screw four outlet
( C 14801 )
( C 17071 )
Turbo A Turbo Z Turbo drive

( C 14071 ) ( C 14072 )
adapter ( C 14062 )
Copyright 2003 by
Extruder 9250
TURBO- Set 1-fold
pressure plate 2 pressure plate 1

3mm : D 00995 3mm : D 00982
4mm : D 00986 3,5mm : D 01200
5mm : D 00999 4mm : D 00996 TURBO screw four outlet
5mm : D 00998 ( C 14801 )
( C 17071 )
Turbo A Turbo drive

( C 14071 ) adapter ( C 14060 )
Copyright 2003 by
Schaaf
EXTRUDER PLANT
4.11.) GENERAL INSTRUCTIONS FOR MAINTENANCE AND CLEANING
Please ensure t hat t he p ower connection t o t he p lant i s disconnected b efore

cleaning and maintenance
The f ollowing m aintenance in structions are f or o peration u nder r elatively n ormal

conditions.
 In c ase extreme o perational c onditions e xist, e.g. high r elative h umidity, ag gressive
environment, higher d ust levels and strong temperature v ariations, t he m aintenance
intervals are to be correspondingly shortened.
In c ase o f h igh d ust levels t ogether w ith h igh r elative h umidity, the c leaning a ctivities,
especially f or t he d rive el ements, b lowers a nd c ooling fans must b e c arried o ut i n
correspondingly s horter in tervals. D ust s ettlement, especially on the dr ives, c an l ead t o
negative influence on their performance and even permanent damage, due to overheating.
Changes r elative t o t he n ormal o peration, e.g. higher l oad u ptake an d t emperatures,

unusual v ibrations an d n oise e tc. as w ell as i ndicators f rom c orresponding s afety d evices
are signs of improper operation.
Changes r elative t o t he n ormal o peration, e.g. higher l oad u ptake an d

temperatures, un usual v ibrations a nd n oise e tc. as w ell a s i ndicators fr om
corresponding safety devices are signs of improper operation.
DANGER
Danger of extreme personal damage.
Material damage is possible.
SWITCH OFF THE ELECTRICAL POWER TO THE UNIT IMMEDIATELY AND
INFORM THE CORRESPONDING MAINTENANCE PERSONNEL.
4.11.1) BASICS FOR CHANGE OF LUBRICATION
The l ubricant s pecifications, t ogether w ith o ptions, h ave b een indicated a gainst e ach
maintenance instruction.
134
EXTRUDER PLANT
Generally valid:
In case of use of synthetic lubricants, the maintenance deadlines are doubled.
Synthetic l ubricants must n ever b e m ixed t ogether w ith mineral

IMPORTANT!
lubricants.
The l ubricant ch anges s hould al ways b e p receded b y a p roper cl eaning o f t he co mplete

drive (motor and gear box).
The grease filled roller bearings of the DC motors should be cleaned in a cycle of one year
and refilled w ith f resh r oller b earing g rease. T hereby, it is n ecessary t o en sure, t hat o nly
1/3rd of the bearing space is filled with grease.
4.11.2) GENERAL INSTRUCTIONS FOR CLEANING
 During cleaning, blows and impacts, especially on bearings and sealing surfaces are to
be avoided.
 The c leaning o f en crusted m aterials s hould b e t horough b ut g entle, e.g. with a n

aluminium spatula and/or with a soft brush.
 IMPORTANT
The filters in the switchboard ventilators and in the cooling ventilator of main drive
must be checked regarding dirt daily. If necessary, clean and/or replace them.
Dirty f ilters d o n ot gu arantee a correct cooling of t he s witchboard a nymore. A s a
consequence c ontrol u nits m ight b reak d own t here d ue t o o verheating a nd in t he
worst case they might be disturbed.
 The use of compressed air as well as pressure cleaner for cleaning is prohibited.
In general water, without any additives, should suffice for cleaning.
 If cleaned with water, the cleaned part must be immediately wiped dry with the use of
a lint-free cloth.
 Long pe riods o f i mmersion o f pa rts a nd t ools i n w ater a re not pe rmitted. T his no t

only causes damage but is also unhygienic.
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EXTRUDER PLANT
Careful executions of numerous cleaning and maintenance

activities are the pre-conditions for problem-free operation and
long-life of the machines
4.10.3.) SPECIFIC DISASSEMBLING AND CLEANING/MAINTENANCE INSTRUCTIONS FOR

EXTRUDER-PROCESSING SECTION AND CONTINUOUS MOISTURISER
DANGER
The screw safety units at the moisturiser frame and at the
At disassembly and cleaning please pay attention to the safety instructions !
At the end of production it has to be ensured that no moisturised raw material

mixing stays still in the process parts, continuous moisturiser and extruder.
a) Cleaning instructions a nd activities t o b e d one at t he en d o f production a t t he

extruder processing section could be gathered from part 3.4 of the previous extruder
operating instructions.
b) The c ontinuous m oisturiser is t o b e cleaned a s f ollows, if t he in terruption o f

production is not longer than 8 hours:
The transfer pipe, fixed at the discharge tube of the continuous moisturiser, is pulled out of
the intake hopper and lead into a prepared storage tank,
The water supply is interrupted through disconnecting (3/8" screwing) of the supply pipe
at the vertical mixer outer pipe,
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EXTRUDER PLANT
Through t he m ain d osing d evice t he m ixer is f eeding w ith dry r aw m aterial ( quantity
according t o t he c apacity of the h opper). Th rough t he c ontinuous passage o f t he d ry r aw
materials t he p rocess parts in t he m ixer w ere cleaned and m oisturized r est m ixings w ere
lead outside. Your moisturiser/mixer is usable for the next start of production.
c) Once per week and if an interruption of production is planed for more than 12 hours
the c ontinuous m oisturiser m ust b e c leaned c arefully t o a void d evelopment o f
harmful substances:
1.) the water s upply connec-

tion(s) at the outer pipe of the G e el n ke
moisturiser is removed,
2.) the t ransfer t ube is p ulled o ut 1

of the intake hopper,
3.) the t wo sc rews ( 1) - con-

nection b etween m ain d osing
device and intake o f t he
continuous mo isturiser - are 3
loosen w ith a s ocket w rench

S6,
4.) The s crew ( 2) f ixing o f

swingable frame, is loosen with wrench S19,
the f rame, s upported at t wo j oints is t urned t o t he r ight s ide, n ow t he m ixing t ools a re

accessible in a free way,
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EXTRUDER PLANT
5.) the four screws (3) M8 are loosen with a fork wrench S13 and removed carefully,
ATTENTION
Please Consider:
after l oosening o f t he s crew c onnections the m ixer c an f all d ownwards w ithout th e
necessary preparation.
Keep hold the mixer to avoid fall !
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EXTRUDER PLANT
Now the mixer first can completely pulled away vertically downwards until the mixer shaft
is loosen itself out of the coupling. Then the complete mixer unit can removed - diagonal
by the extruder process part - to the side. The upper coupling is saved with a threaded pin
at the motor shaft and therefore will stay in its position.
For t he complete cleaning o f t he p ipe, t he outlet a nd t he m ixer shaft it is advisable t o

demount t he l ower b earing f lange. F or t his t he f our s crews are l oosen w ith a f ork
wrench S13. Now the mixer shaft can completely pulled out together with the static bearing
flange.
 Please consider that the bearing and sealing surfaces are not damaged.
Now the mixer shaft and the pipe can be cleaned thoroughly (acc. to the general cleaning
instructions !).
d) The mounting is done in reverse order,
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EXTRUDER PLANT
140
EXTRUDER PLANT
141
EXTRUDER PLANT
142
EXTRUDER PLANT
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PLEASE CONSIDER:
1.) with th e fo ur s crews m ount

the c omplete l ower bearing
G e le n ke
onto t he m ounting f lange of
the m ixer p ipe. T he s crews
were t ightened c arefully
crosswise w ith a f ork w rench 1
S13.
Please ch eck t he co rrect
position o f th e m ixer s haft.
Turn c arefully a t the k nurled-
head sc rew ( 4). I f t he sha ft i s 3
co-rotating, t he p osition i s
correct,
if not,
4
please turn the shaft by hand until the carrier device is locked audible.
2.) Please c heck t he s crew, m ounted at the m otor c oupling, if it is d amaged. N ow t he

mixer unit can be mounted carefully from the bottom. Please ensure the congruence
of t he a djusting s pring a nd gr oove i n t he c oupling. A lso, t hrough t urning of t he
knurled-head screw (4) the correct position can be reached. Now the four screws (3)
are tightened crosswise with a fork wrench S13.
3.) Turn the pivotable base frame to the side in its position and fix it with screws pos. 1
and 2.
4.) Couple the w ater s upply a nd y our m oisturiser/mixer i s us able fo r t he n ext s tart o f
production.
Half-yearly t he s haft s ealing r ings s hould b e ch ecked o n co rrect f unction an d e ventually

cleaned. For this maintenance please remove carefully the dynamic bearing bolt (please see
spare part drawing 0035.B.012).
After cleaning and checking works, please fill the interspace of the sealing ring with grease,
licensed for foodstuffs. Check the function of the grooved ball bearing. If defective please
exchange it.
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EXTRUDER PLANT
The bearing unit of the moisturiser is fitted with grease nipples for re-greasing.
Before re-greasing:
Clean t he g rease n ipple w ell ( each o ne, d epending o n d esign 1 o r 2 n ipples), p ush in t he
grease s lowly, w hile t he b earing is r unning as l ong a s f resh grease c omes ou t ( approx. 5
cm3 / daily and each o ne). Avoid too much pressure in order not to damage the sealings.
The g reasing in tervals a re d ependent o n t he o peration r elations a nd t herefore it is q uite
difficult to fix general rules. If you plan a temporary shutdown of the plant, we would like
to recommend re-greasing the bearings at the end of the operation period.
Attention, fill only with lubricant for food processing industry (e.g. Klübersynth UH1 64-62
FDA or LUBCON Turmosynthgrease ALN 2502 or equipollent).
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EXTRUDER PLANT
4.12.) MAINTENACE & CLEANING
IMPORTANT The f ilters in t he s witchboard v entilators a nd in t he c ooling v entilator o f

main d rive m ust b e c hecked r egarding dirt dai ly. I f n ecessary, c lean an d/or
replace them.
Dirty filters do not guarantee a correct cooling of the switchboard anymore. As a
consequence control units might break down there due to overheating and in the
worst case they might be disturbed.
This must absolutely be paid attention to!
Wartung / maintenance Reinigung / cleaning

Gegenstand / Typ / Spezifikation Schmiermittelbe
täglich ¼- ½- jährlich täglich wöchentl. ¼ -jährlich darf Öl-Spezifikation
object / type / specification jährlich jährlich
necessary grease oil specification
(Art.-No.) daily quarterl ½- yearly daily weekly quarterly
y yearly cm3
Frame parts, surfaces, hoppers etc. Check safety fittings X1 X4
inspection of bearing unit and and and
sealing elements wheneve whenever
r required
X required
Filters at switch board and main Check the filters, cleaning X1

drive blower and/or exchange and
wheneve
r
required
Processing section & Extrusion inspection of bearing unit and X1 X4 as per lubricant for food
tools sealing elements/ and and requirement industry
when mounting the wheneve whenever refer to following
extrusion-tools r required list
required
X2
Stator / sleeve Disassembling, cleaning & as per Molykote P40 or
greasing. Each production requirement Interflon HT1200
start and stop
Standard sleeve (C 15006) X2

Turn around:
One week one mark visible
Next week two marks visible
Schnecke / Screw Screw shaft X2 as per ALN2502 or
(do not apply grease to the and requirement Molykote P40
head surface of shaft wheneve and
Threaded hole for TURBO- r Interflon HT1200
required
Adaptor. Each production
start and stop
Grease all processing parts: pressure plates, die-tools etc. as per e.g.
requirement Boeson Trennwax,
solid
Windings of TURBO rotors as per Interflon HT1200
requirement
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EXTRUDER PLANT

y yearly cm3
For greasing the winding of the TURBO-rotors and the adapter we would like to recommend to use the mounting paste: type HT 1200 from
Interflon. This is suitable for using in the field of high temperatures and is also allowed to be used
regarding an occasional contact in the product touching area of food supply machines, approved by the FDA. The dismantling of the
TURBO-parts will be made much easier after production end due to the use of this mounting paste.
Please find the specification and the data sheet in the chapter "oil-specification" of the extruder operation instruction.
grease the cutting device after 12 working hours and if necessary during production through as per lubricant for food
grease nipple requirement industry, e.g.
"UH1 64-62"
Cleaning instructions and activities to be done at the end of production at the extruder process part could be gathered from the previous
extruder operating instructions.
Main drive, brushless
X2* X4
and
as
requirement
per Roller bearing
grease
Regrease through grease whenever approx. 23gr “ISOFLEX NCA 15”
required
nipples, interval please refer
to maintenance instruction
„TAE“
V-belts carry out a visual check and
apply thumb pressure to the X6
And/ or
centre of the strand to ensure before
correct belt-tension each
the belt at a point midway start
between the two pulleys can
be pressed down approx. 1
cm by using a finger,
or use the tension tester
External Blower/Main drive X3

if
X1 X4
and whenever
as per
requirement
Roller bearing
grease
and
3-phase motor necessa when required
ry ever
required
The bearings in the fan are Cleaning Filter unit and/or

lubricated for life-long exchanging filter clothes
operation. Exchange if
defective
Gear Wheel Aggregate All parts of the gear wheel X4 During production
3-phase-Motor unit are maintenance free/ and the oil level in the
Exchange if defective whenever sight glass must
required half filled
X5
ca. 6500 Lubriplate SFGO
X3 OIL CHANING 220
(food grade)
AFTER 4000 WORKING
HOURS
3-phase Motor X3 X4 as per Roller bearing
cutter drive if and whenever requirement grease
necessa required
ry
Double Screw Dosing unit All parts are maintenance X1 lubricant for food
K2 MV KT35 free, exchange if defective and industry, e.g.
wheneve "UH1 64-62"
r
Before assembling the required
screws, grease the shaft
slightly
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EXTRUDER PLANT

y yearly cm3
Gear box type A Check Oil level, yearly or X4 as per lubricant for food
latest after 2000 working and requirement industry,
hours change the oil, please wheneve e.g. Cassida
refer to K-Tron description r (food grade/Shell)
required
X5 X
3-phase motor 80 L/4 T X3 X4 as per Roller bearing
drive of dosing unit if and whenever requirement grease
necessa required
ry
Double Screw dosing unit All parts are maintenance X1 lubricant for food
K2 MV KT20 free, exchange if defective and industry, e.g.
wheneve "UH1 64-62 or
r similar
Before assembling the required
screws, grease the shaft
slightly
Gear box type A Check Oil level, yearly or X1+4 as per lubricant for food
latest after 2000 working and requirement industry,
hours change the oil, please wheneve e.g. Cassida
refer to K-Tron description r (food grade/Shell)
required
X5 X3
X if
necessa
ry
3-phase motor 80 L/4 T X3 X4 as per Roller bearing

drive of dosing unit if and whenever requirement grease
necessa required
ry
Continuous moisturiser The bearings are X4 aprrox. 5 lubricant for food

Bearing and sealing elements maintenance free, exchange if and as per industry
defective whenever requirement
Checking and greasing sealing required
(avoid to much
ring through greasing nipple pressure)
X2*
3-phase motor X3 as per Roller bearing
100 L/4 if requirement grease
necessa
ry
X4
and whenever
Checking of ball bearings. required
Exchange if defective.
Please refer to description of
“EMOD” in enclosures
Membrane dosing pump
(Water dosing pump) X2 X4
and
Checking and exchange whenever
defective parts required
please refer to description
„IWAKI“
Water tank, connection lines and
hose connections X4
and
whenever
required
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EXTRUDER PLANT

y yearly cm3
Buffer silo & Stirrer The bearings are maintenance X1
free, exchange if defective and
Checking and greasing sealing wheneve aprrox. 5 lubricant for food
ring through greasing nipple r
as per industry, e.g.
required
daily requirement Kübersynth
(avoid to much " ALN2502"
X2* pressure)
X 3 if Mineral Oil
Worm gear box X4
SK12080AF- X5 necessa
ry
and whenever
2.200 for normal
temperature
ambient
design H5 required -5.. 40°C

(stirrer drive)
3-phase Motor X3 if
necessa
X4 100
Roller bearing
80L/4 ry
and whenever grease
required
Injector, pipe system, air separator X1

and filter and
wheneve
r
required
Medium pressure fan The bearings in the fan are X4

DG 90 lubricated for life-long and as per Roller bearing
3-phase motor operation. Exchange if whenever
requirement grease
defective required
4.12.1) CLEANING AND MAINTENANCE INSTRUCTIONS / LEGEND
X1 Clean after each end of production

X 2 Clean, oil or grease
X 2 * The bearing unit is equipped with a greasing nipple for re-greasing. Please use high-grade roller bearing grease (food grade) for
re-greasing: C lean t he g rease nipple we ll b efore r e-greasing, push in t he g rease s lowly while th e b earing is running as l ong as
fresh grease comes out of the bearing. Avoid too m uch pressure in order not to damage the sealings. The greasing intervals are
dependent on the operation relations and therefore it is quite difficult to f ix general rules. At operation temperatures of about
+100°C, high r.p.m.s and/or strong moisture and polluted room air we would like to recommend to re-grease every second week.
If you plan a temporary shutdown of the plant, we would like to recommend re-greasing the bearings at the end of the operation
period.
X3 Clean and fill fresh
X4 Clean as per dust settlement, above all for proper cooling of the drive elements
X5 check the oil level
X6 check the proper function of each part daily
The indicated maintenance und cleaning intervals are based on the one-shift
operation of the machines.
At multi-shift or continuous operation these are reduced accordingly.
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EXTRUDER PLANT
4.13. OIL SPECIFICATION
4.13.1 OIL SPECIFICATION OF CENTRAL LUBRICATION & JAMMING OIL PRESSURE
DEAR CUSTOMER !
We would like to ask you to always use the recommended oil (filled when delivered)
Lubriplate “SFGO 220” (food grade)

(Specifications please according following pages)
when making an oil change in the lubrication-oil circulation system. Due to the fact that we
have had bad experience in the past with other brands of oil, we would like you to stock the
recommended oil.
When Oil refilling as following steps:

At first fill approx. 5,5 litres into tank,
Switch on the main switch,
the oil pump starts automatically,
after 30 minutes the bearing housing is filled until return,
refilling still approx. 0,5-1,0 l.
At standstill of the machine, the filling position at sight glass is complete filled.
During running time of production the level in the sight glass is approx. 9mm under upper
marking.
If the indication is half-empty, you must refill,
 Please avoid overfilling – in either case!
The oil level should be hold constantly. When it becomes lower, refill the recommended oil
- or the maintenance interval is reached and an oil change is necessary.
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EXTRUDER PLANT
FAULT OF THE EXTRUDER OIL CIRCULATION SYSTEM
D reh s trom M
- o to r
3 -pha seM o to r
2 rn
o il re tu
3 al u f /
- ü ck
Ö lR
1 1= sc rew ni g /V e rsch raubung

2= S c rew ni g /V e rsch raubung
3= p re ssu re sw itch /D ru ckscha lte r
w ith p al s tci co ve rm
/ itK un s ts to ffkappe
4= p re ssu re regu al toi n va vl e /F e s td ro sse l
Z ahn radpum penagg rega t

gea rw hee lpum p agg rega te
F ilet r
Ö l-F ü lsl tand skon tro lel
o il el ve lcon tro l
S ch aa f
Ü be rp rü fung be iS tö rung Ö " dl ru ck "
D si tu rb ni g sc reen ni g / O
" ilp re ssu re " d :\ ...\b ta \0 0 7 3 \0 0 7 3 -2 .s k d
Situation :
No Oil Pressure when beginning the Production:

You can’t start the Extruder!
Please check in following steps:
(see enclosed sketch)
1 Dismantle screwing (1)

Switch on the oil pump
Oil is running = OK
Oil is not running: Switch off oil pump
Dismantle cover and clean filter
Close again screwing
2 Dismantle screwing (2)

Oil is running = OK
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EXTRUDER PLANT
Oil is not running: Switch off oil pump

Dismantle pressure control (3)
Clean pressure control valve with air pressure
Assemble again pressure control (3) and close screwing (2)
3 If no oil is running at screwing 1+2:

Take off plastic cap of the pressure control (3) thus the adjusting screw is visible

Adjust t he p ressure a t t he a djusting sc rew o f t he p ressure c ontrol thus t he „ READY”
lamp a t t he o perating p anel is o n ( depending o n t he v iscosity o f the o il t he p ressure
control must be adjusted again).
However, if in spite of this adjustment no pressure is indicated, the pressure switch can
be defect and must be exchanged.
The pump can be defect too. If defective please exchange.
If a larm “Ö ldruck/Oil p ressure” d uring p roduction (i ndication th rough a n a coustic o r

optical alarm):
 Loosen the screwing at the supply of the bearing unit and check whether oil is
running
1. If oil is running: 180 – 200 ml/min. (depending on the viscosity)

 Fasten the screwing and press “RESET” button without interruption of production
 In any case, please check the oil pressure button and oil pipelines after finishing of
production according to above described steps.
 If necessary, please adjust the oil pressure button or exchange it if defect.
2. If no oil is running or not enough:

 Immediately, but latest within the next 5 minutes, start the extending process
to finish the production. Otherwise there is the risk of total damage of the roller-
bearing.
 Afterwards, please check the oil rotary system according to above described steps.
 While refilling, please consider the oil specification and check the oil quantity.
152
EXTRUDER PLANT
Pressure switch view without cover

Adjusting screw appears
Left turn: the switching pressure becomes lower
Right turn: the switching pressure becomes higher
Adjustment is depending on oil viscosity
basic setting 1 bar
For remove contamination

disassembling the pressure regulation
valve and Pressure switch
Clean the device with help of pressure

air
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EXTRUDER PLANT
4. 13.2 OIL-SPECIFICATION MINERAL OIL & ROLLER BEARING GREASE (GENERAL)
For all roller bearings of motors, except for main drive:
for main drive use:

Roller b earing g rease “ISOFLEX N CA 1 5”, s pecification p lease r efer t o f ollowing p ages /
Application areas:
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EXTRUDER PLANT
4.13.3 APPLICATION AREAS - OIL SPECIFICATIONS
Our lubricant recommendations are results of partly extensive tests under consideration of
lubrication characteristics, corrosion protection a.s.o. Of course we are not able to check all
alternative q ualities o f o ther m anufacturers a nd th erefore w e h ave to r efer to the
experience, recommendation and guarantee of the respective seller
Screw shaft, sleeve, intake sleeve, intake ring, inner processing part, cutting device grease
with:
TURMOSYNTHGREASE A LN 25 02 / L UBCON ( food gr ade) –(also f or re -greasing

the cutting device)-
or
Klübersysth U H1 64-62 (food g rade) alternative t o A LN 2 502–(also f or re -greasing
cutting device)-
or
MOLYKOTE P40 (not food grade)
…or equipollent
Widings of TURBOS grease with:
Interflon HT1200 (food grade)
Die parts and pressure plates grease with:
Beoson Trenwax, solid, or similar (food grade)

…or equipollent
Bolted connections
MOLYKOTE D (not food grade)

or
MOLYKOTE P40 (not food grade)
or
TURMOSYNTHGREASE ALN 2502 / LUBCON (food grade)
…or equipollent
Gears / Dosing units (..Kt35 & ..KT20)
Cassida Fluid GL (food grade)

…or equipollent
155
EXTRUDER PLANT
Main drive
Klüber ISOFLEX NCA 15 (also refer to TAE description)
Extruder Bearing Section – Central oil circulation system
Lubriplate SFGO 220 (food grade)
Screw connection generally
OKS 260, mounting paste white
Data sheets please according following pages:
156
TURMOSYNTHGREASE ALN 2502 Issued: 06.05.2004
K HC P 2 P -40
LUBCON Special Grease
TURMOSYNTHGREASE ALN 2502 is a synthetic special grease for high temperatures based on
synthetic hydrocarbons with a partial special thickener of high metal affinity.
TURMOSYNTHGREASE ALN 2502 posseses the NSF/H1-registration, the continuation of the former
USDA/H1-approval of lubricants which are allowed for food contact.
NSF/H1-registration No. 126460
Quality Features
- fulfils the USDA-H1 regulations (approval)

- high thermal and oxidation stability
- high load factor
- very good wear protection
- high service life and wide temperature range
- optimum lubricating effect at low friction values
Technical Data TURMOSYNTHGREASE ALN 2502
Colour/appearance beige
Temperature range -40°C to + 160°C
Thickener Aluminium special soap
Base oil PAO
Base oil viscosity DIN 51562
at 40°C 250 mm²/s
at 100°C 30,1 mm²/s
Dropping point DIN ISO 2176 > 220°C
Working penetration DIN 2137 265 – 295
Consistency class DIN 51818 2
Speed factor ( n x dm ) 650 000
Dynamic viscosity DIN 51398 8000 mPa s
Applications
Roller and sliding bearings in humid working process areas at low speed.
Original Packing
6 x 1 kg cans, 25 kg hobbocks, 180 kg drums
Safety data sheet according to directive 2001/58 EEC
Date: 04/2002 Name: Turmosynthgrease ALN 2502 Page 1 of 4
Updating: 30/05/03 Printed: 27.08.04 14:41
1. Commercial product name and company identification:
Trade name: Turmosynthgrease ALN 2502

Company: LUBRICANT CONSULT GMBH
Gutenbergstraße 13
D-63477 Maintal 2 (Germany) Tel.: +49 6109/7650-0 FAX: +49 6109/7650-51
2. Composition / Information on ingredients:

Combination of synthetic hydrocarbons, aluminia soap, polyurea and additives.
3. Hazards identification:
The product when properly handled is not dangerous for the human health.
Harmful effects are expected only in case of misuse especially in case of thermal decomposition.
4. First aid measures:

Skin contact: Wash with water and soap. Remove contaminated clothing.
If grease has penetrated skin by force (in case of misuse of a grease press): See a
physician* immediately.
Eye contact: Flush with plenty of water for at least 15 minutes. See a physician* if the eye
irritation remains.
Ingestion: See a physician* if necessary. Do not induce vomiting.
Inhalation: Remove the patient to fresh air.
*Show the physician this safety data sheet.
5. Fire fighting measures:

Suitable extinguishing media: dry chemicals, powder, foams, carbon dioxide
Do not use water.
In the case of fire, the vapour can involve toxic compounds (carbon monoxide).
Use a respirator to protect from vapours.
6. Accidental release measures:

Absorb small amounts on inert material. Collect the released product and the used absorbent mate-
rials in suitable containers for disposal (see sect. 13). Avoid the uncontrolled discharge in sewage
systems, in surface and underground waters.
Do not smoke while handling with the released grease. Avoid contact with fire and sparks.
7. Handling and store measures:
Store in cool and dry areas.
Keeping quality in original drums for the storage conditions mentioned above: minimum 5 years.
If the grease is exposed to high temperatures, good ventilation in the working areas is commend-
able.
In case of misuse of a grease press highly pressed lubricants can penetrate the skin and may be
dangerous for the human health.
8. Exposure control / Personal protection:

Hand protection: Not necessary in normal use. When often handling the product wear rub-
ber gloves
Respiratory protection: Not necessary in normal use. Avoid breathing the vapours above the de-
composition temperature.
Eye protection: Not necessary in normal use.
9. Physical and chemical properties:

Physical state: pasty
Colour: light beige
Odour: none
Dropping point: > 220°C (> 248°F) DIN ISO 2176
Boiling point: >300°C (>570°F)
Density: 0,89 g/cm3 at 20°C (68°F) DIN 51 757
Vapour pressure: < 0,1 mbar at 20°C (68°F)
Viscosity (basic oil): 250 mm2/s at 40°C (100°F) DIN EN ISO 3104
Solubility in water: insoluble
pH-value: not determined
Flash point: >200°C (>390°F) DIN EN ISO 2592
Ignition temperature: > 250°C (>480°F)
Explosion limits: lower: 2,8 Vol-% upper: 11,5 Vol-% (for oil mist)
10. Stability and reactivity:

Thermal decomposition: > 200°C (>390°F)
Hazardous decomposition products: No decomposition under normal storage and handling con-
ditions.
In the case of misuse at temperatures above the decomposition temperature harmful
vapours may arise from the product.
Materials to avoid contact: strong oxidising agents (compressed or liquid oxygen), very strong
acids, very strong alkalics.
11. Toxicological information:
Experimental toxicological data.
oral*: LD50 > 5000 mg/kg (rat)
Turmosynthgrease ALN 2502 when properly handled is not dangerous for human health.
Turmosynthgrease ALN 2502 has no known effects of irritation, sensitisation, chronic toxicity or
carcino-genesis (Based on data from components).
*in analogy to comparable products
12. Ecotoxicological information:

Use the product according to the good working practices avoiding polluting the environment.
Water Pollution Class WGK 1: Slightly water endangering (Classification according to German
VwVwS from May, 1999): Avoid the contamination of soil and water.
13. Disposal considerations:

Destroy the waste product by incineration according to local laws and regulations.
Turmosynthgrease ALN 2502 contains no halogens and no toxic metals.
LAGA- Waste code number (Germany):
542 02 for waste lubricants.
542 09 for solid materials contaminated with grease or oil.
EWC- Waste code number (European Community):
12 01 12 for used waxes and greases
15 02 99 D1 for used absorbent and filter materials, cleaning rags and protection
clothes contaminated with grease or oil.
17 02 99 D1 for wood, glass and plastics containing grease or oil (for example: residu-
als of grease in plastic tubes).
14. Transport information:

The product is not dangerous for transportation
Road transportation: (ADR) not classified
Rail transportation: (RID) not classified
Sea transportation: IMDG / IMO not classified
Air transportation: ICAO / IATA not classified
U.N.-number: not assigned
Packaging group: not assigned
15. Regulatory information:
No regulation and classification according to EEC directives necessary.
No labelling with hazard symbols.
Aquatic toxicity: 1 (=German water hazard classification)
16. Further Information:

The information given in this safety data sheet is for safety purpose only. It is given in good faith
and based on the best knowledge and experience of the company at the date of issuing. The com-
pany is not responsible for damages caused by the use of the product in applications for which it
was not intended or for conditions of use outside its control.
Former versions of this safety data sheet are no longer valid.
.
Klübersynth UH1 64-62
Food Grade Lubricant
@@1001= Klübersynth UH1 64-62@1002= 5.203@1003= 12.1995@1004= product information@
1005= e@1006= CD "PI A-Z"@@
Description cartridge or centralized lubrication
system. Klübersynth UH1 64-62
Klübersynth UH1 64-62 is a paraffin- Before using Klübersynth UH1 64-62
free grease for the food processing to replace other greases it is in- ● Good wear protection
and pharmaceutical industries. dispensable to clean the bearings
● Wide service temperature
It has a wide service temperature thoroughly. Grease exchange by
range and is suitable for universal relubrication is sufficient if the range
application of different friction and greases are miscible. ● Free from paraffin
lubrication points.
This highly efficient special lubricant ● Good water resistance
shows a good low and high tempera- Storage
● Good resistance to oxidation
ture behaviour, and good resistance
The storage period is 2 years if the and ageing
to water, corrosion, ageing and
oxidation. It is also very resistant to product is stored in the closed
● Efficient corrosion protection
cleaning agents. original container in a dry place.
Klübersynth UH1 64-62 meets the ● Good resistance to aggressive
Pack sizes media
requirement of the pertinent German
food regulations and complies with
1 kg can ● USDA-H1 authorization
the "guidelines of sec. 21 CFR
25 kg bucket
178.3570 of FDA regulations".
It has been authorized by the USDA
for use in federally inspected meat
and poultry plants (USDA-H1).
Application
Klübersynth UH1 64-62 is suitable

for lubrication points in machines Product data
and installations used in the food
Colour beige
processing and pharmaceutical
industries, particularly for all points
Texture homogeneous
where contact between the lubricant
and the food product cannot be
Density, DIN 51 757 at 20 °C, g/cm 3 approx. 0.92
excluded. We recommend lubri-
cating all friction points with
Drop point, DIN ISO 2176, °C none
Klübersynth UH1 64-62 in order to
avoid negative effects caused by
Worked penetration at 25 °C, DIN ISO 2137;
lubricant spreading.
0.1 mm 265 to 295
This special grease is suitable for
the lubrication of rolling bearings, Speed factor (n x dm), approx. 500,000
lifting cylinder, joints, guide rods,
cam disks, etc. Consistency, NLGI grade, DIN 51 818 2
Application notes Service temperature range, °C -40 to 150
Klübersynth UH1 64-62 is applied by Flow pressure, DIN 51 805, at 40 °C, mbar < 1400
brush, spatula, grease gun, grease
Product Information 5.203 e Edition 12.95

788.IV.95
Klübersynth UH1 64-62
Material Safety Data Sheet
Section I Section V – Health Hazard Data

Manufacturer's name: Klüber Lubrication München KG Threshold limit value: n/a
Chemical name and synonyms: Lubricating grease Effects of overexposure:
Trade name and synonyms: Klübersynth UH1 64-62 Eyes: mild irritation
Skin / Inhalation: n/a
Chemical family: Synthetic hydrocarbon oil, ester oil, clay
Ingestion: No more than slightly toxic if swallowed.
Formula: Proprietary
Emergency and first aid procedures:
Eyes: Flush with large amount of water.
Section II – Hazardous Ingredients
Ingestion: Do not induce vomiting.
Paints, preservatives, solvents Contact doctor for directions.
% TLV (units)
Pigments Section VI – Reactivity Data
Catalyst
Vehicle Stability: stable
Solvents Incompatibility (materials to avoid): Strong oxidizing
Additives materials, such as pure oxygen.
Others Hazardous decomposition products: n/a
Hazardous polymerization: will not occur
Alloys and metallic coatings
% TLV (units) Section VII – Spill or Leak Procedures
Base metal
Alloys Steps to be taken in case material is released or spilled:
Metallic coatings Eliminate all sources of ignition. Recover free liquid. Add
Filler metal plus coating or core flux absorbent to spill area. Collect absorbent. Keep product
Others out of waterways.
Hazardous mixtures of other liquids, solids, or gases Waste disposal method: Incinerate absorbed material or
dispose of it in accordance with your local, state and
USDA H1 registration
federal regulations.
Section III – Physical Data
Section VIII – Special Protection Information
Boiling point (°F): n/a
Respiratory protection (specify type): n/a
Vapor pressure (mm Hg): n/a Ventilation: n/a
Vapor density (air=1): n/a Local exhaust: recommended
Solubility in water: not soluble Mechanical (general):
Specific gravity (H 2O=1): approx. 0.92 Protective gloves: n/a
Percent, volatile by volume (%): 0 Eye protection: n/a
Evaporation rate (____=1): n/a Other protective equipment: no
Appearance and odor: beige, neutral
Section IX – Special Precautions
Section IV – Fire and Explosion Hazard Data Precautions to be taken in handling and storing:
Flash point (method used): (base oil) > 200 °C ASTM D-92 Minimize skin contact with all lubricants. Wash with soap
and water prior to eating, drinking, smoking or using
Flammable limits: – – Lel: Uel:
sanitary facilities.
Extinguishing media: Water fog, foam, dry chemical, CO 2
Other precautions:
Special fire fighting procedures: Use self-contained breath-
All chemical products should be handled as to prevent
ing apparatus, cool fire exposed areas and equipment.
constant or repeated contact.
Unusual fire and explosion hazards: Do not use direct
stream of water, material may float and reignite. n/a = not applicable
The data in this brochure is based on our general experience and knowledge at the time of printing and is intended to give information of possible applications to a
reader with technical experience without, however, constituting an assurance of properties for specific cases. We recommend contacting our Technical Consulting
Staff for information regarding specific applications. If required and possible we will be pleased to provide a sample for testing.
Klüber Lubrication, a member of the Freudenberg Group
Publisher and Copyright: Reprints, total or in parts, are permitted if source Klüber Lubrication München KG
Klüber Lubrication München KG is indicated and voucher copy is forwarded. Postfach 701047, D-81310 München
Tel. (089) 7876-0, Telex 5 23 131, Telefax (089) 7876333
c
d
Product Information
Specialty
Lubricants MOLYKOTE® P-40
Metal-free adhesive lubricating paste
Metal-free adhesive lubrication paste which can be used for all
FEATURES assembly and continuous lubricating jobs, particularly those
" Excellent adhesion exposed to corrosive environments such as splash water or
" Good corrosion protection humidity
" Good water resistance
" Good antifretting
" Assembly and continuous lubrication
APPLICATIONS
" Metal-free
" Assembly and threaded connections, spline shafts, mounting of bearings.
" Low water pollution class " Continuous lubrication: for various parts in brake systems, in brake rods, guide
bolts. Axles of commercial vehicles, cams and plain bearings.
Open Gears.
Marine applications.
TYPICAL PROPERTIES
Specification writers: These values are not intended for use in preparing specifications.
Please contact your local Dow Corning sales representative prior to writing specifications on
this product.
Test Method* Parameter Unit Value

Color Yellowish Brown
Consistency, viscosity
ISO 2137 Unworked penetration mm/10 310-350
DIN 51 562 Base oil viscosity at 40ºC (104ºF) mm /s2
360
Temperature
Service temperature
- as paste: ºC -40 to +230
ºF -40 to +446
- solid lubricants: ºC -40 to +1200
ºF -40 to +2192
Deutsche Bahn AG test
- stirrability at -35ºC (-31ºF) 4
DIN 51 805 Kesternich method - flow pressure at -30ºC mbar 960
(-22ºF)
DIN 2176 Drop point ºC None
ºF None
Load-carrying capacity, wear protection, service life
Four-ball tester (VKA)
DIN 51 350 pt.4 Weld load N 3000
DIN 51 350 pt.5 Wear scar under 800N load mm 0.94
Fretting corrosion - Deyber tester 25x106
Coefficient of friction
Press-Fit test, µ = 0.12
Screw test - µ thread1 0.16
Screw test - µ head 1
0.08
SRV Optimol Oscillating endurance test, µ=2 0.13
TYPICAL PROPERTIES (continued)
Test Method* Parameter Unit Value
Corrosion protection
DIN 51 802 SKF-Emcor method - degree of corrosion 0
Salt spray test h 500
1. Coefficient of friction in bolted connection, M12 x 1.75, material 8.8, blackened.
2. Load: 300N, frequency: 50Hz, amplitude: 0.5mm, 2h
* ISO: International Standardisation Organisation.
DIN: Deutsche Industrie Norm.
HOW TO USE HEALTH AND DOW CORNING SPECIFICALLY

How to apply ENVIRONMENTAL DISCLAIMS ANY OTHER
The sliding surfaces should be cleaned. INFORMATION EXPRESS OR IMPLIED
The paste should then be applied with a To support Customers in their product WARRANTY OF FITNESS FOR A
suitable brush, rag or grease gun. It safety needs, Dow Corning has an PARTICULAR PURPOSE OR
should not be mixed with greases or extensive Product Stewardship MERCHANTABILITY.
oils. organization and a team of Product
Safety and Regulatory Compliance DOW CORNING DISCLAIMS
HANDLING PRECAUTIONS (PS&RC) specialists available in each LIABILITY FOR ANY
Product safety information required for area. INCIDENTAL OR
safe use is not included. Before CONSEQUENTIAL DAMAGES.
handling, read product and safety data For further information, please see our
sheets and container labels for safe use, website, www.dowcorning.com or WE HELP YOU INVENT THE
physical and health hazard information. consult your local Dow Corning FUTURE."
The material safety data sheet is representative.
available on the Dow Corning website
www.dowcorning.com
at www.dowcorning.com. You can also LIMITED WARRANTY
obtain a copy from your local INFORMATION - PLEASE
Dow Corning sales representative or READ CAREFULLY
Distributor or by calling your local The information contained herein is
Dow Corning Global Connection. offered in good faith and is believed to
be accurate. However, because
USABLE LIFE AND conditions and methods of use of our
STORAGE products are beyond our control, this
When stored at or below 20ºC (68ºF) in information should not be used in
the original unopened containers, this substitution for customer's tests to
product has a usable life of 60 months ensure that Dow Corning's products are
from the date of production. safe, effective, and fully satisfactory
for the intended end use. Suggestions
PACKAGING of use shall not be taken as
This product is available in different inducements to infringe any patent.
standard container sizes. Detailed
container size information should be Dow Corning's sole warranty is that the
obtained from your nearest product will meet the Dow Corning
Dow Corning sales office or sales specifications in effect at the time
Dow Corning distributor. of shipment.
LIMITATIONS Your exclusive remedy for breach of

This product is neither tested nor such warranty is limited to refund of
represented as suitable for medical or purchase price or replacement of any
pharmaceutical uses. product shown to be other than as
warranted.
MOLYKOTE P 40 Metal-free adhesive lubricating paste WE HELP YOU INVENT THE FUTURE. is a trademark of Dow Corning Corporation.
2 20/02/2002 MOLYKOTE is a registered trademark of Dow Corning Corporation.
Ref. no. 71-0246C-01 DC 3829 ©1998-2002 Dow Corning Corporation. All rights reserved.
DOW CORNING CORPORATION
Page: 1 of 8
Version: 1.5
Revision Date: 2006/03/10
MOLYKOTE(R) P-40 PASTE
1. IDENTIFICATION OF THE SUBSTANCE AND OF THE COMPANY
Dow Corning Corporation 24 Hour Emergency Telephone: (989) 496-5900

South Saginaw Road Customer Service: (989) 496-6000
Midland, Michigan 48686 Product Disposal Information: (989) 496-6315
CHEMTREC: (800) 424-9300
MSDS No.: 02333562 Revision Date: 2006/03/10
Generic Description: Inorganic and organic compounds in mineral oil

Physical Form: Paste
Color: Light brown.
Odor: Slight odor
NFPA Profile: Health 1 Flammability 1 Instability/Reactivity 0
Note: NFPA = National Fire Protection Association
2. OSHA HAZARDOUS COMPONENTS
None present. This is not a hazardous material as defined in the OSHA Hazard Communication Standard.
3. HAZARDS IDENTIFICATION
POTENTIAL HEALTH EFFECTS
Acute Effects
Eye: Direct contact may cause mild irritation.
Skin: No significant irritation expected from a single short-term exposure.
Inhalation: No significant effects expected from a single short-term exposure.
Oral: Low ingestion hazard in normal use.
Prolonged/Repeated Exposure Effects
Skin: Repeated or prolonged contact may cause defatting and drying of skin which may result in
skin irritation and dermatitis.
Inhalation: No known applicable information.
Oral: No known applicable information.
Signs and Symptoms of Overexposure
No known applicable information.
Medical Conditions Aggravated by Exposure

Page: 2 of 8
Version: 1.5
The above listed potential effects of overexposure are based on actual data, results of studies performed upon similar compositions,
component data and/or expert review of the product. Please refer to Section 11 for the detailed toxicology information.
4. FIRST AID MEASURES
Eye: Immediately flush with water for 15 minutes.
Skin: Remove from skin and wash thoroughly with soap and water or waterless cleanser. Get
medical attention if irritation or other ill effects develop or persist.
Inhalation: No first aid should be needed.
Oral: No first aid should be needed.
Comments: Treat according to person's condition and specifics of exposure.
5. FIRE FIGHTING MEASURES
Flash Point: Not applicable.
Autoignition Temperature: Not determined.
Flammability Limits in Air: Not determined.
Extinguishing Media: On large fires use dry chemical, foam or water spray. On small fires use carbon dioxide
(CO2), dry chemical or water spray. Water can be used to cool fire exposed containers.
Fire Fighting Measures: Self-contained breathing apparatus and protective clothing should be worn in fighting large
fires involving chemicals. Determine the need to evacuate or isolate the area according to
your local emergency plan. Use water spray to keep fire exposed containers cool.
Unusual Fire Hazards: None.
Hazardous Decomposition Products
Thermal breakdown of this product during fire or very high heat conditions may evolve the following hazardous
decomposition products: Carbon oxides and traces of incompletely burned carbon compounds. Silicon dioxide. Nitrogen
oxides. Metal oxides. Fluorine compounds. Formaldehyde. Phosphorous oxides.
6. ACCIDENTAL RELEASE MEASURES

Page: 3 of 8
Version: 1.5
Containment/Clean up: Observe all personal protection equipment recommendations described in Sections 5 and 8.
Wipe up or scrape up and contain for salvage or disposal. Clean area as appropriate since
spilled materials, even in small quantities, may present a slip hazard. Final cleaning may
require use of steam, solvents or detergents. Dispose of saturated absorbant or cleaning
materials appropriately, since spontaneous heating may occur. Local, state and federal laws
and regulations may apply to releases and disposal of this material, as well as those materials
and items employed in the cleanup of releases. You will need to determine which federal,
state and local laws and regulations are applicable. Sections 13 and 15 of this MSDS provide
information regarding certain federal and state requirements.
Note: See section 8 for Personal Protective Equipment for Spills. Call (989) 496-5900, if additional information is
required.
7. HANDLING AND STORAGE
Use with adequate ventilation. At temperatures above 482F/250C this material may produce highly toxic gaseous
compounds such as hydrogen fluoride and perfluorohydrocarbons. Provide adequate ventilation or use the appropriate
respiratory protection if the possibility of exceeding 482F/250C exists. Avoid contamination of tobacco products.
Fluoropolymers on tobacco goods may cause adverse health effects by inhalation of the decomposition products.
Employees should wash their hands and face before eating, drinking or using tobacco products. Avoid eye contact.
Avoid skin contact.
Use reasonable care and store away from oxidizing materials.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Component Exposure Limits
There are no components with workplace exposure limits.
Engineering Controls
Local Ventilation: None should be needed.

General Ventilation: Recommended.
Personal Protective Equipment for Routine Handling
Eyes: Use proper protection - safety glasses as a minimum.
Skin: Wash at mealtime and end of shift. Contaminated clothing and shoes should be removed as
soon as practical and thoroughly cleaned before reuse. Chemical protective gloves are
recommended.
Suitable Gloves: Nitrile Rubber. Butyl Rubber. Neoprene Rubber(R). Polyvinylchloride.
Inhalation: No respiratory protection should be needed.

Page: 4 of 8
Version: 1.5
Suitable Respirator: None should be needed.
Personal Protective Equipment for Spills
Skin: Wash at mealtime and end of shift. Contaminated clothing and shoes should be removed as
soon as practical and thoroughly cleaned before reuse. Chemical protective gloves are
recommended.
Inhalation/Suitable No respiratory protection should be needed.

Respirator:
Precautionary Measures: Avoid eye contact. Avoid skin contact. Use reasonable care.
Comments: At temperatures above 482F/250C this material may produce highly toxic gaseous
compounds such as hydrogen fluoride and perfluorohydrocarbons. Provide adequate
ventilation or use the appropriate respiratory protection if the possibility of exceeding
482F/250C exists. Avoid contamination of tobacco products. Fluoropolymers on tobacco
goods may cause adverse health effects by inhalation of the decomposition products.
Employees should wash their hands and face before eating, drinking or using tobacco
products.
When heated to temperatures above 150 degrees C in the presence of air, product can form
formaldehyde vapors. Formaldehyde is a potential cancer hazard, a known skin and
respiratory sensitizer, and an irritant to the eyes, nose, throat, skin, and digestive system.
Safe handling conditions may be maintained by keeping vapor concentrations within the
OSHA Permissible Exposure Limit for formaldehyde.
Note: These precautions are for room temperature handling. Use at elevated temperature or aerosol/spray applications may require
added precautions.
9. PHYSICAL AND CHEMICAL PROPERTIES

Color: Light brown.
Odor: Slight odor
Specific Gravity @ 25°C: 1.0
Viscosity: Not determined.
Freezing/Melting Point: Not determined.
Boiling Point: Not determined.
Vapor Pressure @ 25°C: Not determined.
Vapor Density: Not determined.
Solubility in Water: 0 g/l
pH: Not determined.
Volatile Content: Not determined.
Note: The above information is not intended for use in preparing product specifications. Contact Dow Corning before writing
specifications.
Page: 5 of 8
Version: 1.5
10. STABILITY AND REACTIVITY
Chemical Stability: Stable.
Hazardous Hazardous polymerization will not occur.

Polymerization:
Conditions to Avoid: None.
Materials to Avoid: Oxidizing material can cause a reaction.
11. TOXICOLOGICAL INFORMATION
Component Toxicology Information
This material contains zinc oxide. Zinc oxide produced adverse developmental effects when fed to rats at 200 mg/kg/day
for 21 days prior to mating and throughout pregnancy. However, no adverse effects were observed at a dose of 100
mg/kg/day for the same duration.
Special Hazard Information on Components
12. ECOLOGICAL INFORMATION
Environmental Fate and Distribution
Complete information is not yet available.
Environmental Effects
Fate and Effects in Waste Water Treatment Plants
Ecotoxicity Classification Criteria

Hazard Parameters (LC50 or EC50) High Medium Low
Acute Aquatic Toxicity (mg/L) <=1 >1 and <=100 >100
Acute Terrestrial Toxicity <=100 >100 and <= 2000 >2000
This table is adapted from "Environmental Toxicology and Risk Assessment", ASTM STP 1179, p.34, 1993.
This table can be used to classify the ecotoxicity of this product when ecotoxicity data is listed above. Please read the other information presented in the
section concerning the overall ecological safety of this material.
13. DISPOSAL CONSIDERATIONS
RCRA Hazard Class (40 CFR 261)

Page: 6 of 8
Version: 1.5
When a decision is made to discard this material, as received, is it classified as a hazardous waste? No
State or local laws may impose additional regulatory requirements regarding disposal.
Call (989) 496-6315, if additional information is required.
14. TRANSPORT INFORMATION
DOT Road Shipment Information (49 CFR 172.101)
Not subject to DOT.
Ocean Shipment (IMDG)
Not subject to IMDG code.
Air Shipment (IATA)
Not subject to IATA regulations.
Call Dow Corning Transportation, (989) 496-8577, if additional information is required.
15. REGULATORY INFORMATION
Contents of this MSDS comply with the OSHA Hazard Communication Standard 29 CFR 1910.1200.
TSCA Status: All chemical substances in this material are included on or exempted from listing on the TSCA
Inventory of Chemical Substances.
EPA SARA Title III Chemical Listings
Section 302 Extremely Hazardous Substances (40 CFR 355):

None.
Section 304 CERCLA Hazardous Substances (40 CFR 302):

None.
Section 311/312 Hazard Class (40 CFR 370):

Acute: No
Chronic: No
Fire: No
Pressure: No
Reactive: No
Section 313 Toxic Chemicals (40 CFR 372):

CAS Number Wt % Component Name
Page: 7 of 8
Version: 1.5
1314-13-2 1.4 Zinc oxide
Supplemental State Compliance Information
California
Warning: This product contains the following chemical(s) listed by the State of California under the Safe Drinking Water
and Toxic Enforcement Act of 1986 (Proposition 65) as being known to cause cancer, birth defects or other
reproductive harm.
None known.
Massachusetts
1314-13-2 1.0 - 5.0 Zinc oxide
New Jersey
64742-62-7 40.0 - 70.0 Solvent-dewaxed petroleum residual oil
1306-06-5 15.0 - 40.0 Tricalcium phosphate, hydrated
68037-01-4 15.0 - 40.0 Hydrogenated decene homopolymer
94891-31-3 3.0 - 7.0 Quaternary ammonium compounds, Di-C16-18-alkyldimethyl, hectorite salts
9003-29-6 3.0 - 7.0 Polybutene
1314-13-2 1.0 - 5.0 Zinc oxide
Pennsylvania
64742-62-7 40.0 - 70.0 Solvent-dewaxed petroleum residual oil
68037-01-4 15.0 - 40.0 Hydrogenated decene homopolymer
94891-31-3 3.0 - 7.0 Quaternary ammonium compounds, Di-C16-18-alkyldimethyl, hectorite salts

Page: 8 of 8
Version: 1.5
9003-29-6 3.0 - 7.0 Polybutene
9002-84-0 1.0 - 5.0 Polytetrafluoroethylene
1314-13-2 1.0 - 5.0 Zinc oxide
16. OTHER INFORMATION
Prepared by: Dow Corning Corporation
These data are offered in good faith as typical values and not as product specifications. No warranty, either expressed or
implied, is hereby made. The recommended industrial hygiene and safe handling procedures are believed to be generally
applicable. However, each user should review these recommendations in the specific context of the intended use and
determine whether they are appropriate.
(R) indicates Registered Trademark

directive 91/155/EC
Int. Paste HT 1200
1. Identification of the substance/preparation and of the

company/undertaking
- Product details:
- Application of the substance / the preparation: Assembling and anti-
seize paste.
- Further information obtainable from: Product safety department.
MANUFACTURER/SUPPLIER:
Interflon b.v.
P.O. Box 1070
NL-4700 BB Roosendaal
The Netherlands
Tel: (31) 165 553911
Fax: (31) 165 538082
www.interflon.com
EMERGENCY CONTACT:
Tel: (31) 165 553911
2. COMPOSITION/INFORMATION ON INGREDIENTS
- Chemical characterization:
- Description:
Mixture of medicinal white oil, polybutenes and ceramic connections.
All components used in this product meet the requirements of the FDA for
"incidental food contact".
Interflon Paste HT 1200 is approved by the NSF in accordance with DIN V
10517 for the use in applications with incidental food contact (NSF-H1) with
registration number 122320.
The end product is approved by NFA (Swedish National Food
Administration) for use with incidental food contact.
Dangerous components:
Void
- Additional information: For the wording of the listed risk phrases refer to
section 16.
3. HAZARDS IDENTIFICATION
- Hazard description:
Not applicable.
- Information concerning particular hazards for human and
environment: The product does not have to be labelled due to the
calculation procedure of the "General Classification guideline for
preparations of the EU" in the latest valid version.
- Classification system: The classification is according to the latest editions
of the EU-lists, and extended by company and literature data.
4. FIRST-AID MEASURES
- General information: No special measures required.

- After inhalation: No special measures required.
- After skin contact: Generally the product does not irritate the skin.
- After eye contact: Rinse opened eye for several minutes under running
water.
- After swallowing: Do not induce vomiting; call for medical help
immediately.
5. FIRE-FIGHTING MEASURES
- Suitable extinguishing agents: Use fire extinguishing methods suitable to

surrounding conditions.
- For safety reasons unsuitable extinguishing agents: Water with full jet
- Protective equipment: No special measures required.
- Person-related safety precautions: Not required.

- Measures for environmental protection: Do not allow to enter sewers/
surface or ground water.
- Measures for cleaning/collecting: Pick up mechanically.
- Additional information: No dangerous substances are released.
- Handling:
- Information for safe handling: No special measures required.
- Information about fire - and explosion protection: No special measures
required.
- Storage:
- Requirements to be met by storerooms and receptacles: No special
requirements.
- Information about storage in one common storage facility: Not
required.
- Further information about storage conditions:
Store in cool, dry conditions in well sealed receptacles.
Ingredients with limit values that require monitoring at the workplace:
- Additional information: The lists valid during the making were used as
basis.
- Personal protective equipment:
- General protective and hygienic measures: The usual precautionary
measures are to be adhered to when handling chemicals.
- Respiratory protection: Not required.
- Protection of hands:
Protective gloves
- Material of gloves:
Nitrile rubber, NBR
The selection of the suitable gloves does not only depend on the material,
but also on further marks of quality and varies from manufacturer to
manufacturer. As the product is a preparation of several substances, the
resistance of the glove material can not be calculated in advance and has
therefore to be checked prior to the application.
- Penetration time of glove material: The exact break trough time has to
be found out by the manufacturer of the protective gloves and has to be
observed.
- Eye protection:
Goggles recommended during refilling

General Information
Form: White paste.
Colour: Whitish
Odour: Odourless
Change in condition
Melting point/Melting -10°C
range:
Boiling point/Boiling range: > 200°C
Flash point: 220°C
Self-igniting: >300°C
Danger of explosion: Product does not present an explosion
hazard.
Vapour pressure: <0.01 kPa
Density: 1.08 g/ml
Solubility in / Miscibility
with
water: Insoluble.
Viscosity:
Dynamic: 270 Pa.s
- Thermal decomposition / conditions to be avoided:

>250°C
Conditions to be avoided: open fire, hot spots above 250°C.
- Materials to be avoided: Strong acids, strong lye's and strong oxidising
agents.
- Dangerous reactions: No dangerous reactions known.
- Dangerous decomposition products: Thermal decomposition or
combustion can release carbon monoxide
and partly burned hydrocarbons.
- Acute toxicity:
- Primary irritant effect:
- on the skin: No irritant effect.
- on the eye: No irritating effect.
- Sensitization: No sensitizing effects known.
- Additional toxicological information:
The product is not subject to classification according to the calculation
method of the General EU Classification Guidelines for Preparations as
issued in the latest version.
When used and handled according to specifications, the product does not
have any harmful effects to our experience and the information provided to
us.
- General notes:
Water hazard class 1 (German Regulation) (Self-assessment): slightly
hazardous for water
Do not allow undiluted product or large quantities of it to reach ground
water, water course or sewage system.
- Product:
- Recommendation: Smaller quantities can be disposed of with household
waste.
- European waste catalogue:
20 01 26 oil and fat other than those mentioned in 20 01 25
- Uncleaned packaging:
- Recommendation: Disposal must be made according to official
regulations.
- Land transport ADR/RID (cross-border):

- ADR/RID class: -
- Maritime transport IMDG:
- IMDG Class: -
- Air transport ICAO-TI and IATA-DGR:
- ICAO/IATA Class: -
- Labelling according to EU guidelines:

Observe the general safety regulations when handling chemicals.
The product is not subject to identification regulations under EU Directives
and the Ordinance on Hazardous Materials (German GefStoffV).
- Special labelling of certain preparations:
Safety data sheet available for professional user on request.
- National regulations:
- Waterhazard class:
Water hazard class 1 (Self-assessment): slightly hazardous for water.
This information is based on our present knowledge. However, this shall
not constitute a guarantee for any specific product features and shall not
establish a legally valid contractual relationship.
- Department issuing MSDS: Product safety department.

- Contact:
Head Laboratory
Email: service@interflon.com
LAST UPDATE
07/01/2004
This product should be stored, handled and used in accordance with good industrial
hygiene practices and in conformity with any legal regulation. The information
contained herein is based on the present state of our knowledge and is intended to
describe our products from the point of view of safety requirements. It should not
therefore be construed as guaranteeing specific properties. We do not take on any
responsibility for any risks coming from variations or unknown effects of the
characteristics of raw materials (alone or in association), and from a different use of
the product from the one prescribed.
Seite 1 von 2
Produkt-Spezifikation
Boeson – Trennwax® fest Standard

Art.-Nr.: 93 38 88 Revision: 03
Beschreibung: Festes Formtrennmittel für Spezialanwendungen in der Kuchen-

und Dauerbackwarenindustrie. Kann bei Er-wärmung auf 60° C
verflüssigt werden.
Anwendung / Dosierung: Zugabemenge: In einem dünnen, zusammenhängenden Film auf

die Oberfläche auftragen.
Zutaten: Pflanzliche Fette, teilweise gehärtet; pflanzliches Öl, Lecithin

[E 322], Bienenwachs [E 901]
Kennzeichnung: Formtrennmittel sind Verarbeitungshilfsstoffe und brauchen nicht

(in verpackten Backwaren) gekennzeichnet zu werden.
Sensorische Daten:
ª Farbe: hellgelb
ª Struktur: feste, fettartige Masse
ª Geruch: angenehm fettartig, nach Lecithin
Chemisch / Physikalische
Daten:
ª Tropfpunkt: min. 42° C (nach Ubbelohde)

ª Jodzahl: 32 - 48 (nach Hanus)
ª Peroxidzahl: max. 3 (nach Wheeler)
ª Fettsäurespektrum: Gaschromatogramm, entsprechend Referenzmuster
Mikrobiologische Daten: Nicht spezifiziert
93 38 88
Seite 2 von 2
Produkt-Spezifikation
Boeson – Trennwax® fest Standard

Art.-Nr.: 93 38 88 Revision: 03
Anwendungstechnische Nicht spezifiziert

Prüfung:
Nährwertangaben:
(berechnete Werte in 100 g)
ª Brennwert: 3625 kJ (882 kcal)

ª Eiweiß: 0,0 g
ª Kohlenhydrate: 0,3 g
ª Fett: 97,9 g
Gebindegröße/ 8 kg Eimer
Palettengröße: 60 x 8 kg = 480 kg je Europalette
Haltbarkeit: 24 Monate in original verschlossenen Gebinden
Lagerbedingungen: Max. 25° C über einen längeren Zeitraum.
Statistische Warennr.: 1517 90 99
Sonstiges:
Erstellung Prüfung Prüfung Genehmigung

Datum/Unterschrift Datum/Unterschrift Datum/Unterschrift Datum/Unterschrift
14.05.01 18.05.01 22.06.01 26.06.01
Isabella Zintz Karl-Peter Berger Wolfram Wendler Dr. Gerald Plasch
Diese Spezifikation wurde per EDV erstellt und deshalb nicht unterschrieben.
93 38 88
c
d
Product Information
Specialty
Lubricants
MOLYKOTE® D
Paste
FEATURES Light-colored, solid lubricant paste for assembly and running-in
" High load-carrying capacity of metallic components
" Prevents stick-slip and seizure
" Good corrosion protection APPLICATIONS
" Excellent protection against galling and
" Sliding surfaces and friction contacts exposed to heavy loads, requiring "clean"
fretting corrosion
lubrication, particularly at low speeds, and as a running-in lubricant.
" Cleanness
" Used successfully, for example, on many friction contacts of electrical and
domestic appliances, packaging and office machinery, precision instruments,
COMPOSITION machinery in foodstuffs and beverages industry, as well as in textile and plastics
" Thickener processing machinery.
" Mineral oil " Wherever thin-film lubrication is impossible, the white multi-purpose grease-
" Solid lubricants paste MOLYKOTE® DX Paste is recommended. This can also be applied with a
brush or rag, and may even be applied with a grease-gun.
TYPICAL PROPERTIES
Specification writers: These values are not intended for use in preparing specifications.
Please contact your local Dow Corning sales representative prior to writing specifications on
this product.
Standard* Test Unit Result

Color Whitish
Penetration, density
ISO 2137 Unworked penetration mm/10 250-280
ISO 2811 Density at 20ºC (68ºF) g/ml 1.2
Temperature
Service temperature ºC -25 to +250
ºF -13 to +482
Load-carrying capacity, wear protection, service life
Four-ball tester (VKA)
DIN 51 350 pt.4 Weld load N 2600
DIN 51 350 pt.5 Wear scar under 800N load mm 1.08
Almen-Wieland machine
OK load N 20000
Coefficient of friction
Press-Fit test µ = 0.10, no chatter
Resistance
DIN 51 807 pt.1 Water resistance, static, evaluation 1-90
Corrosion protection
DIN 51 802 SKF-Emcor method
Degree of corrosion 0
Deyber Fretting Corrosion cycles 36x106
* DIN: Deutsche Industrie Norm.
ISO: International Standardisation Organisation.
HOW TO USE PACKAGING DOW CORNING SPECIFICALLY
How to apply This product is available in different DISCLAIMS ANY OTHER
The sliding surfaces or contact points standard container sizes. Detailed EXPRESS OR IMPLIED
should be cleaned. The paste should container size information should be WARRANTY OF FITNESS FOR A
then be applied with a brush, rag, obtained from your nearest PARTICULAR PURPOSE OR
artificial sponge or chamois leather, or Dow Corning sales office or MERCHANTABILITY.
be sprayed on with a spray can. It Dow Corning distributor.
should not be used to excess like DOW CORNING DISCLAIMS
grease lubrication. Do not mix with LIMITATIONS LIABILITY FOR ANY
greases or oils. This product is neither tested nor INCIDENTAL OR
represented as suitable for medical or CONSEQUENTIAL DAMAGES.
HANDLING PRECAUTIONS pharmaceutical uses.
Avoid contact with the eyes. Spray WE HELP YOU INVENT THE
cans: Pressurized container: protect HEALTH AND FUTURE."
from sunlight and do not expose to ENVIRONMENTAL
temperatures exceeding 50ºC (122ºF). INFORMATION www.dowcorning.com
Do not pierce or burn, even after use. To support Customers in their product
Do not spray on a naked flame or any safety needs, Dow Corning has an
incandescent material. Keep away from extensive Product Stewardship
sources of ignition - No smoking. Keep organization and a team of Product
out of the reach of children. Without Safety and Regulatory Compliance
adequate ventilation formation of (PS&RC) specialists available in each
explosive mixtures may be possible. area.
Extremely flammable. Do not breathe
spray. Avoid contact with skin and For further information, please see our
eyes. Use only in well ventilated areas. website, www.dowcorning.com or
consult your local Dow Corning
Product safety information required for representative.
safe use is not included. Before
handling, read product and safety data LIMITED WARRANTY
sheets and container labels for safe use, INFORMATION - PLEASE
physical and health hazard information. READ CAREFULLY
The material safety data sheet is The information contained herein is
available on the Dow Corning website offered in good faith and is believed to
at www.dowcorning.com. You can also be accurate. However, because
obtain a copy from your local conditions and methods of use of our
Dow Corning sales representative or products are beyond our control, this
Distributor or by calling your local information should not be used in
Dow Corning Global Connection. substitution for customers' tests to
ensure that Dow Corning's products are
USABLE LIFE AND safe, effective, and fully satisfactory
STORAGE for the intended end use. Suggestions
When stored at or below 20ºC (68ºF) in of use shall not be taken as
the original unopened containers, inducements to infringe any patent.
MOLYKOTE D Paste has a usable life
of 60 months from the date of Dow Corning's sole warranty is that the
production. product will meet the Dow Corning
sales specifications in effect at the time
of shipment.
Your exclusive remedy for breach of

such warranty is limited to refund of
purchase price or replacement of any
product shown to be other than as
warranted.
MOLYKOTE D Paste WE HELP YOU INVENT THE FUTURE. is a trademark of Dow Corning Corporation.
2 12/09/2002 Dow Corning and MOLYKOTE are registered trademarks of Dow Corning Corporation.
Ref. no. 71-0140C-01 DC 3623 ©2002 Dow Corning Corporation. All rights reserved.
Page: 1 of 8
MOLYKOTE(R) D PASTE
1. IDENTIFICATION OF THE SUBSTANCE AND OF THE COMPANY
Dow Corning Corporation 24 Hour Emergency Telephone: (989) 496-5900

South Saginaw Road Customer Service: (989) 496-6000
Midland, Michigan 48686 Product Disposal Information: (989) 496-6315
CHEMTREC: (800) 424-9300
MSDS No.: 02200970 Revision Date: 2002/02/28
Generic Description: Inorganic and organic compounds in mineral oil

Color: Off-White
Odor: Slight odor
NFPA Profile: Health 1 Flammability 1 Instability/Reactivity 0
Note: NFPA = National Fire Protection Association

2. OSHA HAZARDOUS COMPONENTS
1305-62-0 40.0 - 70.0 Calcium hydroxide
64741-96-4 7.0 - 13.0 Solvent refined heavy naphthenic distillate (petroleum)
64742-65-0 3.0 - 7.0 Solvent dewaxed heavy paraffinic petroleum distillate
64741-88-4 3.0 - 7.0 Solvent-refined heavy paraffinic petroleum distillate
64742-54-7 3.0 - 7.0 Hydrotreated heavy paraffinic petroleum distillate
The above components are hazardous as defined in 29 CFR 1910.1200.
3. EFFECTS OF OVEREXPOSURE
Acute Effects
Eye: Direct contact may cause mild irritation.
Skin: May cause mild irritation.
Inhalation: Irritates respiratory passages very slightly. Vapor overexposure may cause drowsiness.
Oral: May cause irritation to the mouth, throat and stomach.
Prolonged/Repeated Exposure Effects
Skin: Repeated or prolonged contact may cause defatting and drying of skin which may result
in skin irritation and dermatitis.
Inhalation: No known applicable information.

Page: 2 of 8
MOLYKOTE(R) D PASTE
Oral: Repeated ingestion or swallowing large amounts may injure internally.
Signs and Symptoms of Overexposure
Medical Conditions Aggravated by Exposure
The above listed potential effects of overexposure are based on actual data, results of studies performed upon similar
compositions, component data and/or expert review of the product. Please refer to Section 11 for the detailed toxicology
information.
4. FIRST AID MEASURES
Eye: Immediately flush with water for 15 minutes.
Skin: Remove from skin and wash thoroughly with soap and water or waterless cleanser. Get
medical attention if irritation or other ill effects develop or persist.
Inhalation: Remove to fresh air. Get medical attention if ill effects persist.
Oral: Get medical attention.
Comments: Treat according to person's condition and specifics of exposure.
5. FIRE FIGHTING MEASURES
Flash Point: Not applicable.
Autoignition Not determined.

Temperature:
Flammability Limits in Air: Not determined.
Extinguishing Media: On large fires use dry chemical, foam or water spray. On small fires use carbon dioxide
(CO2), dry chemical or water spray. Water can be used to cool fire exposed containers.
Fire Fighting Measures: Self-contained breathing apparatus and protective clothing should be worn in fighting
large fires involving chemicals. Determine the need to evacuate or isolate the area
according to your local emergency plan. Use water spray to keep fire exposed containers
cool.
Unusual Fire Hazards: None.
Hazardous Decomposition Products
Thermal breakdown of this product during fire or very high heat conditions may evolve the following hazardous
decomposition products: Carbon oxides and traces of incompletely burned carbon compounds. Formaldehyde.
Metal oxides. Phosphorous oxides.

Page: 3 of 8
MOLYKOTE(R) D PASTE
Containment/Clean up: Observe all personal protection equipment recommendations described in Sections 5
and 8. Wipe up or scrape up and contain for salvage or disposal. Clean area as
appropriate since some silicone materials, even in small quantities, may present a slip
hazard. Final cleaning may require use of steam, solvents or detergents. Dispose of
saturated absorbant or cleaning materials appropriately, since spontaneous heating may
occur. Local, state and federal laws and regulations may apply to releases and disposal
of this material, as well as those materials and items employed in the cleanup of releases.
You will need to determine which federal, state and local laws and regulations are
applicable. Sections 13 and 15 of this MSDS provide information regarding certain
federal and state requirements.
Note: See section 8 for Personal Protective Equipment for Spills. Call Dow Corning Corporation, (989) 496-5900, if
additional information is required.
Use with adequate ventilation. Avoid eye contact. Avoid skin contact. Avoid breathing vapor. Keep container
closed. Do not take internally.
Use reasonable care and store away from oxidizing materials.
Component Exposure Limits
CAS Number Component Name Exposure Limits
1305-62-0 Calcium hydroxide ACGIH TLV: TWA 5 mg/m3.
64742-54-7 Hydrotreated heavy paraffinic petroleum Observe oil mist limits. OSHA PEL (final rule) and
distillate ACGIH TLV: TWA 5 mg/m3; ACGIH STEL 10 mg/m3.
64742-65-0 Solvent dewaxed heavy paraffinic Observe oil mist limits. OSHA PEL (final rule) and
petroleum distillate ACGIH TLV: TWA 5 mg/m3; ACGIH STEL 10 mg/m3.
64741-88-4 Solvent-refined heavy paraffinic Observe oil mist limits. OSHA PEL (final rule) and
petroleum distillate ACGIH TLV: TWA 5 mg/m3; ACGIH STEL 10 mg/m3.
Engineering Controls
Local Ventilation: Recommended.

General Ventilation: Recommended.
Personal Protective Equipment for Routine Handling
Skin: Wash at mealtime and end of shift. Contaminated clothing and shoes should be removed
as soon as practical and thoroughly cleaned before reuse. Chemical protective gloves
are recommended.
Page: 4 of 8
MOLYKOTE(R) D PASTE
Suitable Gloves: Nitrile Rubber. Viton(R).
Inhalation: Use respiratory protection unless adequate local exhaust ventilation is provided or air
sampling data show exposures are within recommended exposure guidelines. Industrial
Hygiene Personnel can assist in judging the adequacy of existing engineering controls.
Suitable Respirator: General and local exhaust ventilation is recommended to maintain vapor exposures
below recommended limits. Where concentrations are above recommended limits as
determined by air sampling or are unknown, appropriate respiratory protection should be
worn. Follow OSHA Respirator Regulations (29 CFR 1910.134) and use NIOSH/MSHA
approved respirators.
Personal Protective Equipment for Spills
Eyes: Use full face respirator.
Skin: Wash at mealtime and end of shift. Contaminated clothing and shoes should be removed
as soon as practical and thoroughly cleaned before reuse. Chemical protective gloves
are recommended.
Inhalation/Suitable Respiratory protection recommended. Follow OSHA Respirator Regulations (29 CFR
Respirator: 1910.134) and use NIOSH/MHSA approved respirators. Protection provided by air
purifying respirators against exposure to any hazardous chemical is limited. Use a
positive pressure air supplied respirator if there is any potential for uncontrolled release,
exposure levels are unknown, or any other circumstance where air purifying respirators
may not provide adequate protection.
Precautionary Measures: Avoid eye contact. Avoid skin contact. Avoid breathing vapor. Keep container closed.
Do not take internally. Use reasonable care.
Note: These precautions are for room temperature handling. Use at elevated temperature or aerosol/spray applications may
require added precautions.

Color: Off-White
Odor: Slight odor
Specific Gravity @ 25°C: 1.27
Viscosity: Not determined.
Freezing/Melting Point: Not determined.
Boiling Point: Not determined.
Vapor Pressure @ 25°C: Not determined.
Vapor Density: Not determined.
Solubility in Water: Not determined.
pH: Not determined.
Volatile Content: Not determined.
Note: The above information is not intended for use in preparing product specifications. Contact Dow Corning before writing
specifications.

Page: 5 of 8
MOLYKOTE(R) D PASTE
Chemical Stability: Stable.
Hazardous Hazardous polymerization will not occur.

Polymerization:
Conditions to Avoid: None.
Materials to Avoid: Oxidizing material can cause a reaction.
Special Hazard Information on Components
Environmental Fate and Distribution
Environmental Effects
Fate and Effects in Waste Water Treatment Plants
Ecotoxicity Classification Criteria

Hazard Parameters (LC50 or EC50) High Medium Low
Acute Aquatic Toxicity (mg/L) <=1 >1 and <=100 >100
Acute Terrestrial Toxicity <=100 >100 and <= 2000 >2000
This table is adapted from "Environmental Toxicology and Risk Assessment", ASTM STP 1179, p.34, 1993.
This table can be used to classify the ecotoxicity of this product when ecotoxicity data is listed above. Please read the other information presented
in the section concerning the overall ecological safety of this material.
RCRA Hazard Class (40 CFR 261)
When a decision is made to discard this material, as received, is it classified as a hazardous waste? No
State or local laws may impose additional regulatory requirements regarding disposal.
Call Dow Corning Corporate Environmental Management, (989) 496-6315, if additional information is required.
DOT Road Shipment Information (49 CFR 172.101)

Page: 6 of 8
MOLYKOTE(R) D PASTE
Not subject to DOT.
Ocean Shipment (IMDG)
Not subject to IMDG code.
Air Shipment (IATA)
Not subject to IATA regulations.
Call Dow Corning Transportation, (989) 496-8577, if additional information is required.

Contents of this MSDS comply with the OSHA Hazard Communication Standard 29 CFR 1910.1200.
TSCA Status: Low Volume Exemption. One or more of the components in this product may not be listed on
the TSCA inventory of chemical substances.
EPA SARA Title III Chemical Listings
Section 302 Extremely Hazardous Substances:
None.
Section 304 CERCLA Hazardous Substances:
None.
Section 312 Hazard Class:

Acute: Yes
Chronic: No
Fire: No
Pressure: No
Reactive: No
Section 313 Toxic Chemicals:
None present or none present in regulated quantities.
Supplemental State Compliance Information
California
Warning: This product contains the following chemical(s) listed by the State of California under the Safe Drinking
Water and Toxic Enforcement Act of 1986 (Proposition 65) as being known to cause cancer, birth defects or other
reproductive harm.
None known.
Massachusetts
Page: 7 of 8
MOLYKOTE(R) D PASTE
7620-77-1 1.0 - 5.0 12-Hydroxy lithium stearate
New Jersey
8042-47-5 15.0 - 40.0 Mineral oil
Pennsylvania
8042-47-5 15.0 - 40.0 Mineral oil

Page: 8 of 8
MOLYKOTE(R) D PASTE
Prepared by: Dow Corning Corporation
These data are offered in good faith as typical values and not as product specifications. No warranty, either
expressed or implied, is hereby made. The recommended industrial hygiene and safe handling procedures are
believed to be generally applicable. However, each user should review these recommendations in the specific
context of the intended use and determine whether they are appropriate.
(R) indicates Registered Trademark

Shell Cassida Fluid GL
Gear lubricants for use in food manufacturing equipment
Shell Cassida Fluid GL 150, 220, 320, 460 and 680 are high performance, anti-wear gear oils
specially developed for the lubrication of enclosed gears in food and beverage processing
machinery.
They are based on a careful blend of synthetic fluids and selected additives chosen for their ability to
meet the stringent requirements of the food industry.
Registered by NSF (Class H1) for use where there is potential for incidental food contact. These products
meet the guidelines (1998) of, and were previously authorized by, the US Department of Agriculture Food
Safety and Inspection Service (USDA FSIS) for H1 use (lubricant with incidental food contact) and listed
in Miscellaneous Publication No 1419 “List of Proprietary Substances and Nonfood Compounds”.
Product contain only substances permitted under US 21 CFR 178.3570, 178.3620 and 182 for use in
lubricants with incidental food contact.
Applications Approvals & Recommendations

Lubrication of enclosed gearboxes used in the food This is an ongoing process, please contact your local
industry. Shell company for any updates.
Also intended for use in equipment manufacturing
food packaging David Brown: Shell Cassida GL 460 for worm gears
Lenze
Performance Features Getriebebau Nord: Shell Cassida GL 220 & 680
Flender, Krones
Resist the formation of harmful products of
SEW (GL220 for helical units & GL460 for worm
oxidation even at elevated temperatures
gear units)
Base oil has an ability to provide superior lubrication
Bonfiglioli (for parallel shaft and helical in-line
under all operating conditions
reducers; Cassida GL 460 for worm or
Excellent EP properties make Shell Cassida Fluid
worm/screw gears),
GL suitable for steel-on-steel and worm and
FMC can seamers (viscosity for different models
phosphor-bronze wheel applications
according to OEM specification).
Neutral odour and taste
FAG and Buehler recommendation
High viscosity index resulting in minimum variation
Westfalia Food Tec (Cassida GL 220)
of viscosity with change in temperature
Toyo Can Seamer type 43M (Cassida GL 150)
Stork Food and Dairy Systems (GL 150-680)
Seal and Paint Compatibility
Compatible with the elastomers, gaskets, seals and “Incidental Food contact”
paints normally used in food machinery lubrication
Registered by NSF (Class H1) and meet the USDA H1
systems.
guidelines (1998) for lubricants for use where there is a
potential for incidental food contact.
Specifications and Certificates
NSF H1 Made only from substances permitted under the US
Kosher FDA Title 21 CFR 178.3570, 178.3620 and/or those
Halal generally regarded as safe (US 21 CFR 182) for use in
ISO/DP 6743/6 food grade lubricants.
DIN 51517 CLP
DIN 51506 VBL (GL 150, 220) To comply with the requirements of US 21 CFR
DIN 51506 VCL (GL 150) 178.3570, contact with food should be avoided where
possible. In the case of incidental food contact, the
Synthetic lubricants concentration of this product in the food must not
Do not contain any natural products derived from exceed 10 parts per million (10mg/kg of foodstuff).
animals, nuts or genetically modified organisms In locations and/or applications where local legislation
(GMO). does not specify maximum concentration limits, Shell
Suitable for use where vegetarian and ‘nut-free’ recommends that this same 10 ppm limit be observed,
food is prepared. as up to this concentration Shell Cassida Fluid GL will
Biostatic; do not promote the growth of bacteria or not impart undesirable taste, odour or colour to food,
fungal organisms. nor will cause adverse health effects.
Consistent with good manufacturing practice, use only
the amount necessary to achieve correct lubrication
and take appropriate corrective action should excessive
incidental contact with food be detected.
Product Data Sheet March 2003 Version 12

Health and Safety Handling and storage
Based on information available, Shell Cassida Fluid GL All food grade lubricants, such as Shell Cassida Fluid
are unlikely to present any significant health or safety GL, should be stored separately, out of direct sunlight
hazard when properly used in the recommended or other heat sources, from other lubricants, chemical
application and good standards of industrial and substances and foodstuffs. Store between 0°C and
personal hygiene are maintained. As for all oils, 40°C. Provided that the product has been stored under
prolonged or repeated contact with the skin should be these conditions we recommend that the product be
avoided. used within 5 years from the date of manufacture.
For further information refer to the appropriate Shell Consult your local Shell Company for details.
Material Safety Data Sheet. Accept for use new Shell Cassida Fluid GL only if the
manufacturer's seal is intact.
Oil condition during use Before opening the pack ensure the area around the
closure is clean. It is recommended that it be cleaned
It is recommended that the condition of the oil and the
with Shell Cassida Fluid PL or Shell Cassida Flushing
equipment be regularly checked to ensure safe
Fluid and/or potable water and then dried with a clean
operation.
cloth before opening.
Record the date the seal was broken. To prevent
Protect the environment product contamination, always close the package after
Take used lubricants and empty packs to an authorised use. Upon opening a pack, the product must be used
collection point. Do not discharge into drains, soil or within 2 years (or within 5 years of date of manufacture,
water. whichever is the sooner).
Typical characteristics
Shell Cassida Fluid GL (x)150 220 320 460 680
Property Test method
NSF Registration No. 92534 92535 92536 92537 92538

Colour Colourless, pale yellow
Density at 15°C kg/m3 ISO 12185 845 847 852 855 858
Flashpoint °C ISO 2592 268 276 278 270 286
Pourpoint °C ISO 3016 -54 -48 -45 -45 -39
Kin. Visc. at 40°C mm2/s ISO 3104 150 220 320 460 680
Kin. Visc. at 100°C mm2/s ISO 3104 18,9 25,0 33,4 43,8 58,6
Viscosity index ISO 2909 143 143 147 148 152
FZG-Test A/8.3/90 Failure Load Stage DIN 51354 >12
These characteristics are typical for current production. Variations in these characteristics may occur.
Produced according to Shell Quality Standards, in facilities where HACCP audit and Good Manufacturing Practice
have been implemented and form part of the quality/environment management system ISO 9001/ ISO 14001.
Product Data Sheet June 2004 Version 13

ISOFLEXâ NCA 15
High-speed lubricating grease for plain and rolling bearings
Description: Pack sizes:

ISOFLEX NCA 15
ISOFLEX NCA 15 is a dynamically 400 g cartridge
light grease with good pressure 1 kg can • Rolling bearing grease
absorption properties for plain and 25 kg bucket
rolling bearings. It consists of ester • For very high speeds
oil, synthetic hydrocarbon oil, • Good pressure absorption
mineral oil and special calcium
soap. The product is resistant to • Good resistance to water
water and protects reliably against • Good wear protection
wear.
• Resistant to oxidation and
ageing
Application:
ISOFLEX NCA 15 is particularly
suitable for the lubrication of spindle
and tapered roller bearings,
threaded spindles, ball screws Product data:
subject to high loads, and for all
high-speed bearings, e.g. bearings Colour beige
in OE-spinning turbines used in the
textile industry. It is also suitable for Texture homogeneous,
tooth flanks of precision gears short-fibred
(bevel gears in milling machines). 3
Density, at 20 °C, g/cm , approx. 0.94
Application notes: Service temperature range*, °C, approx. – 50 to 120
The lubricant is applied by brush, Drop point, DIN ISO 2176, °C > 180
spatula, grease gun or grease
cartridge. Owing to the different Worked penetration, DIN ISO 2137,
compositions of elastomers and (ASTM D 217); 0.1 mm 265 to 295
plastic materials, compatibility tests
are indispensable before series Water resistance, DIN 51 807/1,
application. 3 h / 90 °c, rating 0/1 – 90
Base oil viscosity, DIN 51 562/1,

2
Minimum shelf life: at 40 °C, mm /s, approx. 23.0
2
at 100 °C, mm /s, approx. 4.7
The minimum shelf life is approx.
36 months if the product is stored in Speed factor**
the original closed container in a –1
(n x dm), mm x min , approx. 1,300,000
dry place.
Apparent dynamic viscosity***,
Klüber viscosity grade L/M
* Service temperatures are guide values which depend on the lubricant’s composition, the intended use and the applica-
tion method. Lubricants change their consistency, apparent dynamic viscosity or viscosity depending on the mechano-
dynamical loads, time, pressure and temperature. These changes in product characteristics may affect the function of a
component.
** Speed factors are guide values which depend on the type and size of the rolling bearing type and the local operating
conditions, which is why they have to be confirmed in tests carried out by the user in each individual case.
*** Klüber viscosity grades: EL = extra light lubricating grease; L = light lubricating grease; M = medium lubricating grease;
S = heavy lubricating grease; ES = extra heavy lubricating grease
Product information 5.300 e Edition 02.01

TVINT/GA
ISOFLEXâ NCA 15
Safety Data Sheet
1.1 Product name: ISOFLEX NCA 15 9. Physical and chemical properties

Code-No.: 004 180 Form paste
19.01.2001 Colour beige
Odour characteristic
Drop point > 180 °C, DIN ISO 2176
1.2 Klüber Lubrication München KG Emergency telephone no.: Flash point > 200 °C (base oil)
Geisenhausenerstraße 7 ++49 - 89 7876 - 0
Ignition temperature not applicable
D-81379 München
Tel. ++49 - 89 78 76 - 0 telephone exchange Lower explosion limit not applicable
Fax: ++49 - 89 78 76 - 333 Upper explosion limit not applicable
Vapour pressure-first not applicable
Density approx. 0.94 g/cm3, 20 °C
2. Composition / information on ingredients Water solubility insoluble
Chemical characterization (preparation): Ester oil, synthetic hydrocarbon pH value not applicable
oil, mineral oil, special calcium soap Kinematic viscosity not applicable
Further information none
3. Hazards identification
No particular hazards known
10. Stability and reactivity
Conditions to avoid: None
4. First aid measures Materials to avoid: Strong oxidizing agents
After inhalation: Not applicable Hazardous decomposition products: None under normal use
After contact with skin: Wash off with soap and plenty of water Additional information: None
After contact with eyes: Rinse with plenty of water
After ingestion: Do not induce vomiting. Obtain medical attention
Advice to doctor: Treat symptomatically 11. Toxicological information
The toxicological data has been taken from products of similar
composition
5. Fire-fighting measures Acute toxicity: LD50/oral/rat = > 2 g/kg (literature data)
Suitable extinguishing media: Water spray, foam, dry powder, Chronic toxicity: None
carbon dioxide (CO2) Human experience: Prolonged skin contact may cause skin irritation
Unsuitable extinguishing media: High volume water jet and/or dermatitis
Special Hazards: In case of fire the following can be released: Carbon
monoxide, hydrocarbons
Special protective equipment for firefighters: Standard procedure for 12. Ecological information
chemical fires Information on elimination (persistence and degradability): Product is
Additional information: Water mist may be used to cool closed insoluble in water. May be separated out mechanically in purification
containers. In the event of fire and/or explosion do not breathe fumes plants
Behaviour in environmental compartments: Ecological injuries are not
known or expected under normal use
6. Accidental release measures Ecotoxic effects: Aquatic toxicity is unlikely due to low solubility
Personal precautions: Not required Additional information: Should not be released into the environment
Environmental precautions: Do not flush into surface water or sanitary
sewer system
Methods for cleaning up / taking up: Use mechanical handling equip-
ment. Dispose of absorbed material in accordance with the regulations 13. Advice on Disposal
Disposal: Can be incinerated when in compliance with local, state and
Additional information: None federal regulations
Dispose of contaminated packaging and recommended cleaning: Offer
rinsed packaging material to local recycling facilities
7. Handling and storage
Advice on safe handling: No special handling advice required
Advice on protection against fire and explosion: No special precautions
required 14. Transport information
Requirements on storage rooms and vessels: Store at room temperature GGVS / GGVE: not applicable
in the original container ADN / ADNR: not applicable
IMDG-Code: not applicable
Incompatible materials: Incompatible with oxidizing agents. Do not store ICAO / IATA-DGR: not applicable
together with food
Further information: Not classified as dangerous in the meaning of
Further information on storage conditions: None transport regulations
8. Exposure controls / personal protection

Additional advice on system design: Not applicable 15. Regulatory information
Labelling according to EU-guidelines: The product does not require a
Ingredients and specific control parameters: None hazard warning label in accordance with EC-directives/German
Respiratory protection: No special protective equipment required regulations on dangerous substances
Hand protection: No special protective equipment required National regulations: Labelling according to the Swiss regulations: No
Eye protection: No special protective equipment required toxicological class, BAGT-no. 611500
Body protection: No special protective equipment required
Other protection measures: No special protective equipment required
General protection and hygiene measures: Avoid prolonged and/or 16. Other information
repeated contact with skin. Remove soiled or soaked clothing im- Issue-department of Safety Data Sheet: Chemical Documentation,
mediately. Clean skin thoroughly after work; apply skin cream Tel.: ++49 - 89 7876 - 564
The data in this product information is based on our general experience and knowledge at the time of printing and is intended to give information of possible applications to a
reader with technical experience. It constitutes neither an assurance of product properties nor does it release the user from the obligation of performing preliminary tests with the
selected product. We recommend contacting our Technical Consulting Staff to discuss your specific application. If required and possible we will be pleased to provide a sample
for testing. Klüber products are continually improved. Therefore, Klüber Lubrication reserves the right to change all the technical data in this product information at any time
without notice.
Klüber Lubrication München KG, a member of the Freudenberg group
Publisher and Copyright: Reprints, total or in part, are permitted if source Klüber Lubrication München KG
Klüber Lubrication München KG is indicated and voucher copy is forwarded. Postfach 70 10 47, D-81310 München
Tel. (0 89) 78 76-0, Telefax (0 89) 78 76-333
8 - 29
LUBRIPLATE "SFGO" SERIES
ISO Viscosity Grades 100, 150, 220, 320, 460 & 680
*NSF H-1 Registered
“These products are certified OU Kosher Pareve”
The LUBRIPLATE SFGO Series of synthetic hydrocarbon food grade oils have been formulated to meet
a variety of demanding applications where traditional white mineral oils may not be desirable. These
polyalphaolefin (PAO) based synthetics are outstanding lubricants for applications in which the lubricant is
subject to high temperature and high stress conditions over extended drain intervals. These fluids are all
zinc-free.
The LUBRIPLATE SFGO Series contain anti-microbial agents that retard the growth of bacteria and mold.
The LUBRIPLATE SFGO Series meets the requirements of FDA 21 CFR 178.3570 and FDA 21 CFR
172.882. All five viscosity grades are USDA H-1 authorized. *
The LUBRIPLATE SFGO Series may be recommended for bearings, gearboxes, pumps and chains
requiring ISO Viscosity Grades 150 through 680.
Advantages offered by LUBRIPLATE SFGO Series include the following:
• Excellent thermal stability resulting in longer service life.

• Superior oxidation resistance.
• Outstanding anti-wear properties providing extended equipment life.
• Exceptional demulsibility characteristics.
• Corrosion protection.
• Ηigh viscosity indexes and low pour points to ensure optimum performance
over a wide operating temperature range.
• Superior cleanliness characteristics.
• Excellent compatibility with a variety of elastomers, seals, plastics and paints.
The LUBRIPLATE SFGO Lubricants are compatible with other LUBRIPLATE products such as the
LUBRIPLATE FMO-AW Series and LUBRIPLATE SPO Series. Always consult LUBRIPLATE before
changing to an SFGO fluid from an existing lubricant that may not be compatible with polyalphaolefin
based oils.
(Over)
LUBRIPLATE “SFGO” Series – ISO Viscosity Grades 100, 150, 220, 320, 460 & 680:
Typical Properties
SFGO-100 SFGO-150 SFGO-220 SFGO-320 SFGO-460 SFGO-680
Viscosity SUS @ 100°F 570 770 1,070 1,652 2,243 3,423

SUS @ 210°F 71 87 105 130 158 197
cSt @ 40°C 102 153 219 327 445 706
cSt @ 100°C 13 16.5 21 26.5 32 41
Viscosity Index 120 115 114 107 105 97
Pour Point °F/°C -45/-43 -30/-34 -25/-31 -15/-26 -10/-23 5/-15
Flash Point °F/°C 450/232 410/210 400/204 385/196 360/182 355/179
Fire Point °F/°C 500/260 505/263 495/257 460/238 435/224 425/218
API Gravity 36.9 35.0 33.5 33.0 31.6 31.0
Color 0.0 0.0 0.0 0.0 0.0 0.0
Four-Ball Wear Test

Average Wear Scar Diameter .4 mm .38 mm .38 mm .38 mm .37 mm .37 mm
AGMA No. 3 4 5 6 7 8
ISO Viscosity Grade 100 150 220 320 460 680
LUBRIPLATE SFGO Lubricants are available in the following:
Packaging Available SFGO-100 SFGO-150 SFGO-220 SFGO-320 SFGO-460 SFGO-680
5 Gallon Pail L0918-060 L0919-060 L0920-060 L0921-060 L0922-060 L0923-060

16 Gallon Drum L0918-061 L0919-061 L0920-061 L0921-061 L0922-061 L0923-061
55 Gallon Drum L0918-060 L0919-062 L0920-062 L0921-062 L0922-062 L0923-062
*NSF H-1 Registration No’s 043673 132662 132666 132667 132668 132669
(Meets USDA 1998 Guidelines)
*Authorized by NSF for use in food processing facilities as a lubricant or anti-rust agent on equipment in which there may be incidental contact
involving the lubricated part and the edible product.
*NSF – National Sanitation Foundation
Manufactured with ingredients that comply with FDA 21 CFR 178.3570 and FDA 21 CFR 172.882.
Printed in USA
Revised 3/9/04
Page 1 of 5
MATERIAL SAFETY DATA SHEET
SECTION 1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF

THE COMPANY/UNDERTAKING
Fiske Brothers Refining Co. Emergency Telephone Number:

129 Lockwood St. 1-800-255-3924-CHEM-TEL (24 hour)
Newark, NJ 07105 Telephone Number for information:
1-973-589-9150
SUBSTANCE: LUBRIPLATE SFGO ULTRA 220

TRADE NAMES/SYNONYMS:
00229655
PRODUCT USE: lubricant
CREATION DATE: Mar 27 2003

REVISION DATE: Apr 29 2003
SECTION 2 COMPOSITION/INFORMATION ON INGREDIENTS

COMPONENT: Synthetic hydrocarbons
CAS NUMBER: 68037-01-4
EC NUMBER: Not assigned.
PERCENTAGE: 90-98
COMPONENT: Benzenamine, N-phenyl-, reaction products with 2,4,4-trimethylpentene

EC NUMBER (EINECS): 270-128-1
PERCENTAGE: 0-2
COMPONENT: Amines, C11-14-branched alkyl, monohexyl and dihexyl phosphates

PERCENTAGE: 0-2
COMPONENT: O,O,O-triphenyl phosphorothioate

PERCENTAGE: 0-2
COMPONENT: thiodiethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]

PERCENTAGE: 0-2
Page 2 of 5
COMPONENT: polyisobutylene
EC NUMBER: Not assigned.
PERCENTAGE: 0-1
COMPONENT: White mineral oil

PERCENTAGE: 0-1
SECTION 3 HAZARDS IDENTIFICATION

POTENTIAL HEALTH EFFECTS:
INHALATION:
SHORT TERM EXPOSURE: irritation
LONG TERM EXPOSURE: lack of sense of smell, headache, lung damage
SKIN CONTACT:
LONG TERM EXPOSURE: irritation, skin disorders
EYE CONTACT:
LONG TERM EXPOSURE: no information is available
INGESTION:
SHORT TERM EXPOSURE: diarrhoea, difficulty breathing
LONG TERM EXPOSURE: no information on significant adverse effects
SECTION 4 FIRST AID MEASURES

INHALATION: If adverse effects occur, remove to uncontaminated area. Give artificial respiration if
not breathing. Get immediate medical attention.
SKIN CONTACT: Wash skin with soap and water for at least 15 minutes while removing
contaminated clothing and shoes. Get medical attention, if needed. Thoroughly clean and dry
contaminated clothing and shoes before reuse.
EYE CONTACT: Flush eyes with plenty of water for at least 15 minutes. Then get immediate medical
attention.
INGESTION: If a large amount is swallowed, get medical attention.
SECTION 5 FIRE FIGHTING MEASURES

FIRE AND EXPLOSION HAZARDS: Slight fire hazard.
EXTINGUISHING MEDIA: carbon dioxide, regular dry chemical, regular foam, water
FIRE FIGHTING: Move container from fire area if it can be done without risk. Avoid inhalation of
material or combustion by-products. Stay upwind and keep out of low areas.
Page 3 of 5
HAZARDOUS COMBUSTION PRODUCTS:

Thermal decomposition products or combustion: oxides of carbon, oxides of sulphur
SECTION 6 ACCIDENTAL RELEASE MEASURES

OCCUPATIONAL RELEASE:
Stop leak if possible without personal risk. Small spills: Absorb with sand or other non-combustible
material. Collect spilled material in appropriate container for disposal.
SECTION 7 HANDLING AND STORAGE

STORAGE: Store and handle in accordance with all current regulations and standards. Keep container
tightly closed. Avoid heat, flames, sparks and other sources of ignition. See original container for
storage recommendations. Keep separated from incompatible substances.
SECTION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION

EXPOSURE LIMITS:
LUBRIPLATE SFGO ULTRA 220:
MINERAL OIL MIST:
5 mg/m3 UK OES TWA
10 mg/m3 UK OES STEL
VENTILATION: Provide local exhaust ventilation system. Ensure compliance with applicable
exposure limits.
EYE PROTECTION: Wear splash resistant safety goggles. Provide an emergency eye wash fountain
and quick drench shower in the immediate work area.
CLOTHING: Wear appropriate chemical resistant clothing.
GLOVES: Wear appropriate chemical resistant gloves.
RESPIRATOR: Consider the need for appropriate protective equipment, such as self-contained
breathing apparatus, adequate masks and filters.
SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES

PHYSICAL STATE: liquid
APPEARANCE: clear, white-water
COLOUR: colourless to white
ODOUR: odourless
BOILING POINT: >288 C
FREEZING POINT: Not available
FLASH POINT: 266 C (COC)
LOWER FLAMMABLE LIMIT: 0.9 % by volume
Page 4 of 5
UPPER FLAMMABLE LIMIT: 7.0 % by volume

AUTOIGNITION: 288 C (COC)
VAPOUR PRESSURE: <0.01 mmHg @ 20 C
VAPOUR DENSITY (air=1): >5
SPECIFIC GRAVITY (water=1): 0.840
DENSITY: 0.841 kg/m3 @ 15 C
WATER SOLUBILITY: almost insoluble
PH: Not available
VOLATILITY: Not available
ODOUR THRESHOLD: Not available
EVAPORATION RATE: <0.01 (butyl acetate=1)
VISCOSITY: 216.1 mm2/s @ 40 C
COEFFICIENT OF WATER/OIL DISTRIBUTION: Not available
SECTION 10 STABILITY AND REACTIVITY

REACTIVITY: Stable at normal temperatures and pressure.
CONDITIONS TO AVOID: Avoid heat, flames, sparks and other sources of ignition. Avoid contact
with incompatible materials.
INCOMPATIBILITIES: oxidising materials, chlorine
HAZARDOUS DECOMPOSITION:
POLYMERISATION: Will not polymerise.
SECTION 11 TOXICOLOGICAL INFORMATION

Synthetic hydrocarbons:
LOCAL EFFECTS:
Irritant: inhalation
Benzenamine, N-phenyl-, reaction products with 2,4,4-trimethylpentene:

TOXICITY DATA:
7580 mg/kg oral-rat LD50
Amines, C11-14-branched alkyl, monohexyl and dihexyl phosphates:

TOXICITY DATA:
>2000 mg/kg oral-rat LD50
thiodiethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]:
TOXICITY DATA:
>3000 mg/kg skin-rabbit LD50 (Ciba-Geigy); 6300 mg/kg oral-rat LD50
White mineral oil:

CARCINOGEN STATUS: IARC: Human Inadequate Evidence, Animal Inadequate Evidence, Group
3 (Highly refined mineral oils)
Page 5 of 5
MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: respiratory disorders
SECTION 12 ECOLOGICAL INFORMATION

Not available
SECTION 13 DISPOSAL CONSIDERATIONS

Dispose in accordance with all applicable regulations.
SECTION 14 TRANSPORT INFORMATION

LAND TRANSPORT ADR: No classification assigned.
LAND TRANSPORT RID: No classification assigned.
AIR TRANSPORT IATA: No classification assigned.
AIR TRANSPORT ICAO: No classification assigned.
MARITIME TRANSPORT IMDG: No classification assigned.
SECTION 15 REGULATORY INFORMATION

EC CLASSIFICATION (CALCULATED): Not classified as dangerous.
SECTION 16 OTHER INFORMATION

©Copyright 1984-2003 MDL Information Systems, Inc. All rights reserved.
The above information is furnished without warranty, expressed or implied, except that it is
accurate to the best knowledge of Fiske Brothers Refining Company. The data on these sheets
relates only to the specific material designated herein. Fiske Brothers Refining Company assumes
no legal responsibility for use or reliance upon this data.
8 - 20A
LUBRIPLATE Pure Flush

USDA H-1 Authorized*
LUBRIPLATE Pure Flush is a USDA H-1 authorized* flushing and cleansing lubricant which can
be used to clean and flush all types of equipment within food, beverage and pharmaceutical
processing plants. (Please see Bulletin 8-20 for additional technical data.)
The following are procedures that can be used when using LUBRIPLATE Pure Flush in gear cases,
hydraulic systems, etc., without dismantling the equipment. This of course represents a savings on
labor and downtime.
Gear Box Cleaning Procedure
Clean gear boxes in accordance with periodic maintenance schedules. Special attention should be
given to the breather seals, sight glass and fittings.
For removing water from gear boxes, please follow the tapping procedure listed below:
Open drain plug.
Drain until milky fluid and/or water or sediment stops running. At this point, clear,
non-milky oil should appear.
Replace drain plug.
Clean breather and sight glass.
Fill to required level.
The following instructions should be adhered to when periodically changing oil.
Periodic Oil Change Procedure
Drain approximately 15 to 25% by volume the existing oil currently being used in the gear box.
Add a charge of 15 to 25% by volume, LUBRIPLATE Pure Flush, one to five days prior to
a scheduled oil change. Percentage of LUBRIPLATE Pure Flush added will depend on the
severity of contamination.
After the unit has run one to five days with LUBRIPLATE Pure Flush, pull the drain plug and
drain as completely as possible. The oil will drain from the unit much more readily if drained
just after shutdown.
*Authorized by USDA for use in federally inspected meat and poultry plants. USDA H-1 authorized lubricants may be used on equipment as a
lubricant or anti-rust film in locations in which there is exposure of the lubricated part to the edible product.
(1)
Although it is not always possible, adding a small charge of new oil under pressure will
flush any remaining contaminants that may be left behind.
When the gear box is empty, remember to clean the breather, sight glass, filters and
heat exchange systems when they exist.
Recharge with new oil. Always check sight glass level.
Note: Regular use of LUBRIPLATE Pure Flush in gear boxes prior to each oil change will help
remove any carbonaceous deposits, debris or sludge that may have developed over time.
Hydraulic System Cleaning Procedures
In the cleaning of hydraulic systems, the recommended procedure will depend on both the size
and the condition of the system. On smaller systems, drain up to 50% of the hydraulic oil and
replace with LUBRIPLATE Pure Flush. This mixture should then be used for approximately
two hours of normal operation. At this time, the oil should then be drained and replaced with
new hydraulic oil. For larger hydraulic units or where it is not practical to drain as much oil
from the system, we recommend draining off enough hydraulic oil so that an addition of 10% to
30% LUBRIPLATE Pure Flush be added to the system. This mixture should then be run for a
period of two to four hours to thoroughly clean all deposits and debris. Then drain and refill
with new hydraulic oil. Frequently check all filters as this is key for the collection of any
discharged residue.
Note: If the unit is unusually dirty, your initial run may have to be without filters and an open
line to discharge chunks of thickened oil. Immediately follow this flush briefly for 30 minutes
with a mixture of LUBRIPLATE Pure Flush and clean oil to thoroughly clean lines, valves, etc.,
and then recharge with new lube. (Remember to change filters.)
Hydraulic tanks should have the following:
Venting (keep clean.)
Easy drain plug (magnetic plugs, if possible.)
Baffle to control fluid motion. Entry and exit ports should have extended piping and bias
cut close to tank bottom.
Fittings, piping, exit and entry ports should be machined (no burs control agitation.)
Filter when moisture is present. No smaller than 10 micron (filter check required
4 to 8 weeks.)
Note: Valves, gauges, pressure and most important, temperature should be

monitored regularly.
* Routine oil analysis is advisable for temperatures in excess of 150°F.
(2)
Bearing Flushing and Cleaning Procedure
Remove bottom bearing cap plug, if one exists. Prepare a grease-gun with a mixture of Pure
Flush and grease. Inject into bearing and run for approximately 2 to 4 hours. If necessary,
repeat a number of times, then try charging with new lube. Replace bottom bearing cap plug.
For severely contaminated bearings, use the following procedure: For motor bearings and other
bearing housings where there is a drain plug, apply a quantity of LUBRIPLATE Pure Flush
directly to the bearing housing (remove zerk fitting) allowing the unit to run for at least 20
minutes. Then remove the drain plug to permit the resultant mixture to be drained out. Replace
the plug. Fill the housing approximately 1/3 capacity and run again for 15 to 20 minutes and
drain. Repeat this last procedure again if the housing is unusually dirty or loaded with carbon
deposits. After the unit is thoroughly cleaned and drained, pump in new grease slowly until
grease appears at the drain plug. Replace the drain plug when the lubricant ceases to ooze from
the drain hole.
Cleaning Air Tools
LUBRIPLATE Pure Flush is excellent for cleaning air-operated tools and equipment.
LUBRIPLATE Pure Flush can be fed directly though the air line lubricators or it can be injected
into the air line by an oil pump. In many cases where air-operated equipment has become
sluggish, the introduction of LUBRIPLATE Pure Flush oil through the air line system will flush
and clean the unit, eliminating disassembly for cleaning purposes. It is recommended for
cleaning all types of air-operated impact wrenches, rotary grinders, reciprocating air tools and
other air-operated equipment. For continued good operating efficiency after the tool is cleaned,
use LUBRIPLATE FMO-85-AW which is an excellent air tool and air line oil and is also USDA
H-1 authorized*.
Cleaning Chain
For contaminated roller chain, LUBRIPLATE Pure Flush can be applied directly to the chain by
the means for which the chain lubricant is dispensed. However, if LUBRIPLATE Pure Flush is
applied under pressure, this will increase the effectiveness of the cleaning process.
LUBRIPLATE Pure Flush should not be used straight in chain applications which exceed 200°F.
These suggested flushing and cleaning procedures will always be superseded by specific flushing and
cleaning instructions that may be listed in the manufacturer's original equipment manual. We stress the
need to consult with your OEM instructions prior to the introduction of LUBRIPLATE Pure Flush.
For additional information or other possible applications for LUBRIPLATE Pure Flush,
please contact your LUBRIPLATE District Manager or
our Technical Service Staff at 1-800-347-5343
(3)
Procedure for Flushing Rotary Screw Air Compressors
with
LUBRIPLATE Pure Flush
LUBRIPLATE Pure Flush should be used where a USDA H-1 Authorized* cleaning and
flushing lubricant is required. For non-food grade applications, consider LUBRIPLATE CFL
Oil.
1. Drain compressor oil immediately after shutdown while fluid is warm. This should include
all possible drain points.
2. Check all filters as well as the separator. If in good condition, proceed to step 3. If filters or
separator is heavily contaminated, change or clean at this time as the use of LUBRIPLATE Pure
Flush may result in carbonaceous deposits and varnish being removed during use. Fill
compressor with LUBRIPLATE Pure Flush.
3. Run air compressor UNDER NO LOAD for a period of 2 hours to 24 hours. The run time will
be decided in part by the severity of contamination and the condition of the air compressor.
4. Drain Pure Flush from air compressor at all drain points as completely as possible. This
should be done immediately after shutdown.
5. Change air oil separator as well as all filters to ensure that all contaminants and oxidized oil
are removed from compressor.
6. Refill compressor with fresh LUBRIPLATE SFGO oil.
7. An initial sample should be taken after 500 hours service. Oil analysis will determine the
condition of the oil at that time and whether continued flushing is necessary. Oil samples should
then be taken at 500 hour intervals until an appropriate oil drain interval has been established.
The LUBRIPLATE Oil Analysis Program is provided at no cost to the customer. Drain intervals
may be as high as 2,000 to 4,000 hours when using LUBRIPLATE SFGO oil.
LUBRIPLATE Pure Flush is compatible with mineral oils, USP white mineral oils, other
polyalphaolefins, and many ester based synthetics. Always consult LUBRIPLATE when
converting an air compressor to LUBRIPLATE SFGO oil from an existing lubricant that may
not be compatible with polyalphaolefin synthetic oil. Many synthetics are as different from each
other as they are with petroleum products, therefore, it is always advisable to contact
LUBRIPLATE prior to changing compressor oils.
For assistance, please contact your authorized LUBRIPLATE Distributor or call LUBRIPLATE
Division Technical Services at 1-800-347-5343.
Printed in USA
Revised 2/96
(4)
Page 1 of 5
MATERIAL SAFETY DATA SHEET
SECTION 1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF

THE COMPANY/UNDERTAKING
Fiske Brothers Refining Co. Emergency Telephone Number:

129 Lockwood St. 1-800-255-3924-CHEM-TEL (24 hour)
Newark, NJ 07105 Telephone Number for information:
1-973-589-9150
SUBSTANCE: LUBRIPLATE PURE FLUSH

TRADE NAMES/SYNONYMS:
00229668
PRODUCT USE: lubricant
CREATION DATE: Mar 27 2003

REVISION DATE: Apr 29 2003
SECTION 2 COMPOSITION/INFORMATION ON INGREDIENTS

COMPONENT: Distillates (petroleum), hydrotreated light. A complex combination of hydrocarbons
obtained by treating a petroleum fraction with hydrogen in the presence of a catalyst. It consists of
hydrocarbons having carbon numbers predominantly in the range of C9 through C16 and boiling in the
range of approximately 150°C to 290°C (302°F to 554°F).
PERCENTAGE: 50
COMPONENT: White mineral oil

PERCENTAGE: 50
SECTION 3 HAZARDS IDENTIFICATION

POTENTIAL HEALTH EFFECTS:
INHALATION:
SHORT TERM EXPOSURE: irritation, nausea, loss of appetite, headache, drowsiness, dizziness,
disorientation, tremours, loss of coordination, lung damage, convulsions, coma
LONG TERM EXPOSURE: visual disturbances, lung damage
SKIN CONTACT:
SHORT TERM EXPOSURE: irritation, absorption may occur, headache, dizziness, drowsiness, loss
of coordination
LONG TERM EXPOSURE: irritation, skin disorders
Page 2 of 5
EYE CONTACT:
LONG TERM EXPOSURE: no information is available
INGESTION:
SHORT TERM EXPOSURE: diarrhoea, difficulty breathing, headache, drowsiness, dizziness, loss of
coordination, aspiration hazard
LONG TERM EXPOSURE: no information on significant adverse effects
SECTION 4 FIRST AID MEASURES

INHALATION: If adverse effects occur, remove to uncontaminated area. Give artificial respiration if
not breathing. Get immediate medical attention.
SKIN CONTACT: Wash skin with soap and water for at least 15 minutes while removing
contaminated clothing and shoes. Get medical attention, if needed. Thoroughly clean and dry
contaminated clothing and shoes before reuse. Accidental high pressure injection through the skin
requires immediate medical attention.
EYE CONTACT: Flush eyes with plenty of water for at least 15 minutes. Then get immediate medical
attention.
INGESTION: Aspiration hazard. Do not induce vomiting. If vomiting occurs, keep head lower than
hips to help prevent aspiration. Get immediate medical attention. Give artificial respiration if not
breathing.
SECTION 5 FIRE FIGHTING MEASURES

FIRE AND EXPLOSION HAZARDS: Slight fire hazard.
EXTINGUISHING MEDIA: carbon dioxide, regular dry chemical, regular foam, water
FIRE FIGHTING: Move container from fire area if it can be done without risk. Avoid inhalation of
material or combustion by-products. Stay upwind and keep out of low areas.
HAZARDOUS COMBUSTION PRODUCTS:

SECTION 6 ACCIDENTAL RELEASE MEASURES

OCCUPATIONAL RELEASE:
Stop leak if possible without personal risk. Small spills: Absorb with sand or other non-combustible
material. Collect spilled material in appropriate container for disposal.
SECTION 7 HANDLING AND STORAGE

STORAGE: Store and handle in accordance with all current regulations and standards. Avoid heat,
flames, sparks and other sources of ignition. Keep container tightly closed. See original container for
Page 3 of 5
storage recommendations. Keep separated from incompatible substances.
SECTION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION

EXPOSURE LIMITS:
Distillates (petroleum), hydrotreated light. A complex combination of hydrocarbons obtained by
treating a petroleum fraction with hydrogen in the presence of a catalyst. It consists of
hydrocarbons having carbon numbers predominantly in the range of C9 through C16 and boiling
in the range of approximately 150°C to 290°C (302°F to 554°F).:
KEROSINE (PETROLEUM):
No occupational exposure limits established.
White mineral oil:

MINERAL OIL MIST:
5 mg/m3 UK OES TWA
10 mg/m3 UK OES STEL
VENTILATION: Provide local exhaust ventilation system. Ensure compliance with applicable
exposure limits.
EYE PROTECTION: Wear splash resistant safety goggles. Provide an emergency eye wash fountain
and quick drench shower in the immediate work area.
CLOTHING: Wear appropriate chemical resistant clothing.
GLOVES: Wear appropriate chemical resistant gloves.
RESPIRATOR: Consider the need for appropriate protective equipment, such as self-contained
breathing apparatus, adequate masks and filters.
SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES

PHYSICAL STATE: liquid
APPEARANCE: transparent
COLOUR: colourless to white
PHYSICAL FORM: oil
ODOUR: petroleum odour
BOILING POINT: >288 C
FREEZING POINT: Not available
FLASH POINT: 99 C (COC)
LOWER FLAMMABLE LIMIT: 0.9 % by volume
UPPER FLAMMABLE LIMIT: 7.0 % by volume
AUTOIGNITION: 104 C (COC)
VAPOUR PRESSURE: <0.01 mmHg
VAPOUR DENSITY (air=1): >5
SPECIFIC GRAVITY (water=1): 0.825
DENSITY: 0.825 kg/m3 @ 15 C
WATER SOLUBILITY: almost insoluble
PH: Not available
Page 4 of 5
VOLATILITY: Not available

ODOUR THRESHOLD: Not available
EVAPORATION RATE: <0.01 (butyl acetate=1)
VISCOSITY: 7 mm2/s @ 40 C
COEFFICIENT OF WATER/OIL DISTRIBUTION: Not available
SECTION 10 STABILITY AND REACTIVITY

REACTIVITY: Stable at normal temperatures and pressure.
CONDITIONS TO AVOID: Avoid heat, flames, sparks and other sources of ignition. Avoid contact
with incompatible materials.
INCOMPATIBILITIES: oxidising materials, chlorine
HAZARDOUS DECOMPOSITION:
POLYMERISATION: Will not polymerise.
SECTION 11 TOXICOLOGICAL INFORMATION

Distillates (petroleum), hydrotreated light. A complex combination of hydrocarbons obtained by
treating a petroleum fraction with hydrogen in the presence of a catalyst. It consists of
hydrocarbons having carbon numbers predominantly in the range of C9 through C16 and boiling
in the range of approximately 150°C to 290°C (302°F to 554°F).:
TOXICITY DATA:
2.0-4.0 gm/kg skin-rabbit LD50; >5 gm/kg oral-rat LD50
CARCINOGEN STATUS: IARC: Human Inadequate Evidence, Group 3 (Distillate light fuel oils),
Animal Limited Evidence (Straight-run kerosene and hydrotreated kerosene)
TARGET ORGANS: central nervous system
White mineral oil:

CARCINOGEN STATUS: IARC: Human Inadequate Evidence, Animal Inadequate Evidence, Group
3 (Highly refined mineral oils)
MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: respiratory disorders
SECTION 12 ECOLOGICAL INFORMATION

Not available
SECTION 13 DISPOSAL CONSIDERATIONS

Dispose in accordance with all applicable regulations.
SECTION 14 TRANSPORT INFORMATION

Page 5 of 5
LAND TRANSPORT ADR: No classification assigned.
LAND TRANSPORT RID: No classification assigned.
AIR TRANSPORT IATA: No classification assigned.
AIR TRANSPORT ICAO: No classification assigned.
MARITIME TRANSPORT IMDG: No classification assigned.
SECTION 15 REGULATORY INFORMATION

EUROPEAN REGULATIONS:
EC CLASSIFICATION (CALCULATED):
Xn Harmful
DANGER/HAZARD SYMBOL:
EC RISK AND SAFETY PHRASES:

R Harmful: may cause lung damage if swallowed.
65
S This material and/or its container must be disposed of as hazardous waste.
60
S If swallowed, do not induce vomiting: seek medical advice immediately and show this
62 container or label.
SECTION 16 OTHER INFORMATION

©Copyright 1984-2003 MDL Information Systems, Inc. All rights reserved.
The above information is furnished without warranty, expressed or implied, except that it is
accurate to the best knowledge of Fiske Brothers Refining Company. The data on these sheets
relates only to the specific material designated herein. Fiske Brothers Refining Company assumes
no legal responsibility for use or reliance upon this data.
OKS 260 - Product Information
Fields of Application:
Assembly lubrication of sliding points where dark-coloured lubricants are

undesirable, e.g. in precision mechanics and optics, on paper and textile -processing
machines or packaging machines in the pharmaceutical industry, food and beverage
industry, for office machines and household appliances etc. Prevents frictional
OKS 260 corrosion on joint connections of steel parts of all kinds subject to vibration loading
White Assembly Paste under damp-room and aggressive operating conditions.
Advantages and Benefits:
Excellently suited for dirt-free assembly lubrication. Highly effective against fretting.
Low consumption due to thin-film lubrication. Completely waterproof. Excellent
lubricating and separating effect, good corrosion protection behaviour.
Application:
For best adhesion, clean the surfaces from dirt and other lubricants. Best way is to
clean mechanically first and then with OKS 2610 or OKS 2611 universal cleaner.
Apply paste evenly thin with brush, spatula, etc. Remove excessing paste. Do not
use paste instead of grease and only mix with appropriate lubricants. For further
questions please contact our Technical Department.
Additional Information:
Packaging (Article number):

- 100 g Tube (00260012)
- 250 g Tin (00260030)
- 1 kg Tin (00260034)
- 5 kg Hobbock (00260050)
- 25 kg Hobbock (00260062)
Version
E-11.2/07
The data in this brochure are the result of extensive testing and experience and meet the latest stage of engineering.
Due to the diversity of application possibilities and technical realities they can only be recommendations and are not
arbitratily transferable; thus no obligations, liability or warranty claims can be derived herefrom. We accept liability for the
fitness of our products for particular purposes and accept such liability in writing in the individual case. In any event any
justified warranty claims shall be limited to the delivery of replacement goods which are free from defect or, in the event
that such subsequent improvement fails, to reimburesement of the purchase price. Any and all further claims, in
particular but without limitation any liability for consequent damage, shall be excluded. Prior to use own testing must be
done to prove suitability. The data are subject to change for the sake of technical progress. ® = Registered Trademark
OKS 260
White Assembly Paste
Technical Data
Norm Conditions Unit Value

Base Oil
Type White oil
40 °C mm ²/s 17
Viscosity DIN 51 562-1
100 °C mm ²/s 4
Flash point DIN ISO 2592 °C 195
Thickener
Type Lithiumhydroxystearate
Unworked
DIN ISO 2137 no shear stress 0,1 mm 250 - 280
penetration
Drop point DIN ISO 2176 °C 195
Additives
Solid
lubricants, White solid lubricants
type
Application Data
Density DIN EN ISO 3838 +20°C g/cm³ 1,25
Colour light-coloured
Service Temperatures
Minimum
service °C - 25
temperature
Maximum
service
°C 150
temperature
- lubrication
Water
DIN 51 807-1 +90°C Grade 1-3 0 - 90
resistance
Wear Protection Tests
VBT - weld
load (Four DIN 51 350-4 N 2.600
ball test rig)
Friction Values
Press -Fit-
E DIN 51 833 µ 0,09, chatterfree
Test
Thread
Screw: ISO 4017 M10x55-8.8 plain
friction DIN EN ISO 16047 µ 0,08
Nut: ISO 4032 M10-10 plain
value
The data in this brochure are the result of extensive testing and experience and meet the latest stage of engineering.
Due to the diversity of application possibilities and technical realities they can only be recommendations and are not
arbitratily transferable; thus no obligations, liability or warranty claims can be derived herefrom. We accept liability for the
fitness of our products for particular purposes and accept such liability in writing in the individual case. In any event any
justified warranty claims shall be limited to the delivery of replacement goods which are free from defect or, in the event
that such subsequent improvement fails, to reimburesement of the purchase price. Any and all further claims, in
particular but without limitation any liability for consequent damage, shall be excluded. Prior to use own testing must be
done to prove suitability. The data are subject to change for the sake of technical progress. ® = Registered Trademark
Page 1/4
Safety Data Sheet
according to 1907/2006/EC, Article 31
Printing date 07.01.2008 Revision: 31.10.2007
* 1 Identification of substance:
· Product details:
· Trade name: OKS 260
· Application of the substance / the preparation Lubricant
· Manufacturer/Supplier:
OKS Spezialschmierstoffe GmbH
Triebstrasse 9
D-80993 München
Phone (+49)-89-149892-0
Fax. (+49) 089-1419219
E-Mail: mcm@oks-germany.com
· Emergency information: (+49)89-149892-17
* 2 Hazards identification
· Hazard designation:
Xi Irritant
· Information pertaining to particular dangers for man and environment

R 38 Irritating to skin.
R 41 Risk of serious damage to eyes.
· Classification system
The classification is in line with current EC lists. It is expanded, however, by information from
technical literature and by information furnished by supplier companies.
* 3 Composition/information on ingredients
· Chemical characterization
· Description: Mixture of the substances listed below with harmless additions.
· Dangerous components:
CAS: 1305-62-0 calcium dihydroxide 25-50%
EINECS: 215-137-3 Xi; R 38-41
4 First aid measures

· General information No special measures required.
· After inhalation Supply fresh air; consult doctor in case of symptoms.
· After skin contact Wash with water and soap and rinse thoroughly.
· After eye contact
Rinse opened eye for several minutes under running water. Then consult doctor.
· After swallowing Drink copious amounts of water and provide fresh air. Instantly call for doctor.
5 Fire fighting measures

· Suitable extinguishing agents
CO2, extinguishing powder or water jet. Fight larger fires with water jet or alcohol-resistant foam.
· For safety reasons unsuitable extinguishing agents Water with a full water jet.
(Contd. on page 2)
GB
DR
Page 2/4
Safety Data Sheet
Trade name: OKS 260
(Contd. of page 1)
· Special hazards caused by the material, its products of combustion or flue gases:
Carbon monoxide (CO) and carbon dioxide ( CO2 )
6 Accidental release measures

· Person-related safety precautions: Wear protective equipment. Keep unprotected persons away.
· Measures for environmental protection:
Do not allow to enter drainage system, surface or ground water.
Do not allow to enter the ground/soil.
· Measures for cleaning/collecting:
Collect mechanically.
Dispose of contaminated material as waste according to item 13.
· Additional information: No dangerous materials are released.
7 Handling and storage

· Handling
· Information for safe handling: No special measures required.
· Information about protection against explosions and fires: No special measures required.
· Storage
· Requirements to be met by storerooms and containers: Store in cool location.
· Information about storage in one common storage facility: Not required.
· Further information about storage conditions: None.
8 Exposure controls and personal protection

· Additional information about design of technical systems: No further data; see item 7.
· Components with critical values that require monitoring at the workplace:
The product does not contain any relevant quantities of materials with critical values that have to be
monitored at the workplace.
· Additional information:
The currently valid safety information database was used to compile this data sheet.
· Personal protective equipment
· General protective and hygienic measures
Instantly remove any soiled and impregnated garments.
Avoid contact with the eyes and skin.
Wash hands during breaks and at the end of the work.
Do not eat, drink or smoke while working.
· Breathing equipment: Not required.
· Protection of hands: Protective gloves and protective skin cream.
· Material of gloves Nitrile rubber, NBR
· Penetration time of glove material
The exact break trough time has to be found out by the manufacturer of the protective gloves and
has to be observed.
· Eye protection: Safety glasses
9 Physical and chemical properties:

· General Information
Form: Paste
(Contd. on page 3)
GB
DR
Page 3/4
Safety Data Sheet
Trade name: OKS 260
(Contd. of page 2)
Colour: White
Smell: Odourless
· Change in condition
Melting point/Melting range: Not determined
Boiling point/Boiling range: Not determined
· Flash point: 195°C (ISO 2592)
· Self-inflammability: Product is not self igniting.
· Danger of explosion: Product is not explosive.
· Density at 20°C 1.25 g/cm3 (DIN ISO 3838)
· Solubility in / Miscibility with
Water: insoluble
10 Stability and reactivity

· Thermal decomposition / conditions to be avoided:
No decomposition if used according to specifications.
· Dangerous reactions No dangerous reactions known
· Dangerous products of decomposition: No dangerous decomposition products known
11 Toxicological information
· Acute toxicity:
· Primary irritant effect:
· on the skin: Irritant for skin and mucous membranes.
· on the eye: Irritant effect.
· Sensitization: No sensitizing effect known.
· Additional toxicological information:
When used and handled according to specifications, the product does not have any harmful effects
according to our experience and the information provided to us.
12 Ecological information:
· General notes: Water hazard class 1 (Self-assessment): slightly hazardous for water.
13 Disposal considerations
· Product:
· Recommendation
Must not be disposed of together with household garbage. Do not allow product to reach sewage
system.
· European waste catalogue
12 01 12 spent waxes and fats
13 06 01 oil waste not otherwise specified
· Uncleaned packagings:
· Recommendation: Disposal must be made according to official regulations.
GB
(Contd. on page 4)
DR
Page 4/4
Safety Data Sheet
Trade name: OKS 260
(Contd. of page 3)
14 Transport information
· Transport/Additional information: Not dangerous according to the above specifications.
15 Regulatory information
· Designation according to EC guidelines:
· Code letter and hazard designation of product:
Xi Irritant
· Risk phrases:
38 Irritating to skin.
41 Risk of serious damage to eyes.
· Safety phrases:
23 Do not breathe fumes.
24 Avoid contact with skin.
26 In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.
37/39 Wear suitable gloves and eye/face protection.
60 This material and its container must be disposed of as hazardous waste.
· National regulations
· Water hazard class: Water hazard class 1 (Self-assessment): slightly hazardous for water.
16 Other information:
This data is based on our present knowledge. However, it shall not constitute a guarantee for any
specific product features and shall not establish a legally valid contractual relationship.
· Relevant R-phrases
38 Irritating to skin.
41 Risk of serious damage to eyes.
· Department issuing data specification sheet: Technical departement
· Contact: Technical departement
GB
DR
EXTRUDER PLANT
4.14.) VARIOUS DOCUMENTATION
TAE- Operating & M aintenance i nstructions an d s pare p arts l ist o f D C-

Motors (brushless)
ELEKTROR- Operating & Maintenance instructions and spare parts list of blower
for main drive
SIT - Mounting instructions of V-belt pulley/TAPER bushing
GEMÜ- Operating instructions for water flow control
BÜRKERT- Operating instructions for magnetic valve
BAIER+KÖPPEL- Operating & M aintenance instructions a nd s pare pa rts l ist of

Lubrication Unit
K-TRON-SODER- Operating & Maintenance instructions and spare parts list of Dosing
Units
EMOD- Operating & Maintenance instructions and spare parts list of 3-phase
motor
Dietz-motoren- Operating & M aintenance in structions and s pare p arts l ist o f Radial
Ventilator
IWAKI (LDT)- Operating & M aintenance instructions a nd s pare pa rts l ist of

Membrane dosing pump
Getriebebau NORD Operating & Maintenance instruction of Worm Gear box motors
IFM- Adjusting instruction of capacitive sensor& pressure switch
Endress+Hauser Adjusting instruction of Level Limit Switch
157

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Schaaf Technologie GmbH

Switch board with built-in

Additional Dosing unit T20

EXTRUDER PEPSICO STANDARD 9250A

If you need help, please do not hesitate to contact us:

Schaaf Technologie GmbH Telephone: +49 (0) 6434/91 72 0

Before you will contact us ...

 Have you alarm signals ?

 Did you change anything at the plant (e.g. raw materials,

Prepared and written

EQUIPMENT/ACCESSORIES / TOOLS ........................................................................................................................... 1

4. OPERATING INSTRUCTION - EXTRUDER ........................................................................................................... 63

Extruder Special design / right hand operation flap

flange safety screw D 11703 Extruder accessory assembled

Screw cleaning rollers device C 00230

Pressure plates cleaning ring C 00200

Sleeve centering ring / screw D 11501

Draw out device for inlet sleeve C 12004

Drawing-in device for screw C 51004

Ejection device for screw C 50004

Sleeve cleaning brush C 12076

Cleaning tool for screw W 84955

wrench for TURBO (D16) D 14092

freewheel ratchet with ring KR16-30 W 80152

Flat wrench SW46 W 85750

Socket wrench W 85307

2x V 50760 R 16041 + R 16073

Precision cotter pin driver ∅ 3,9mm W 85007 1x

Reingungswerkzeug "pick-Set“ W 84940

auxiliary tool for adjusting the cutting D 13367

Tool box/Werkzeugkiste 600 x 200 x 200 W 80991

Trennwax fest /Dose 2 kg N 02404 Einfetten von Düsenteilen und

Klübersynth U H1 64 -62, Ka rtusche W 00171 Cutting device etc.

1.1 DUTIES OF THE USER

 Make s ure, th at o nly trained a nd pr operly i nstructed pe rsonnel w ork o n t he pl ant.

 Ensure, t hat t he p ersonnel h ave r ead an d u nderstood t he o perating in structions f or

IT CONCERNS YOUR SAFETY!

 The u ser is r esponsible f or t he o bservation o f t he l aid-down an d v alid ac cident

1.2 PURPOSEFUL USAGE

 Ensure, that no foreign bodies are able to enter the process

 In cas e o f p rocessing of dan gerous m aterials, al so f ollow addi tionally t he s afety in -

 Operate t he e xtruder only as p er t he s pecified t echnical dat a. A ll m anipulations f or

ATTENTION Proper o bservation o f the o perating in structions a nd t he m aintenance

It is absolutely forbidden to switch on the continuous moisturiser

1.3 ORGANISATIONAL MEASURES

 Always ha ve t he o perating in structions a vailable a t t he p roduction s ite. E nsure t hat

 Follow special safety instructions regarding electrical fittings

1.4 SAFETY-CONSCIOUS WORKING

 To t his a lso b elongs t he r eading a nd p roper u nderstanding of the O perating

ATTENTION AT EXTRUDER MAIN OPERATING PANEL!

1.5 SAFETY FITTINGS

 physical and mortal for the user or for third parties.

 of damage to the extruder or other things of material value

 Do not open or remove any covers or safety lids during operation.

 During exchange use only the specified fuse types.

ATTENTION AFTER END OF PRODUCTION:

High Temperatures and high pressure still continue to be in existence in the

Use only suitable tools to proceed with the dismounting.

1.6 ADDITIONAL FITTINGS

 Introduction of changes is prohibited

1.7 HIGH VOLTAGE

 Activities in the electrical f ittings o f t he E xtruder a re t o be u ndertaken

 Activities in t he el ectrical f ittings m ust b e undertaken ex clusively u nder