Soya Training

9 10 June 2010
VinaSoy

Plant Maintenance
By: Seah Chong Meng
Tetra Pak Dairy, Beverage & Prepared Food Soya & Tea Centre

PERFORATED DISC MILL

Working Principle

Working Principle

Mashing Pulping Grinding Emulsifying

Maintenance & Operation cooling liquid

Pressure Gauge

Pressure Regulator Regulating Valve

The pressure of the cooling / sealing liquid must be 0.5 to 1 bar higher than product outlet pressure. Flow is about 1 to 4 liters/min. Check and clean filter monthly

Maintenance Greasing of Main Motors

Greasing Nipples

New Disc, Knife and Cam ring The disc can be turn over when it is worn on one side

After >2000 hours of operation, the knife, disc and cam-ring worn out

DONT WAIT FOR THIS TO HAPPEN

COLLOID MILL
WITH FINE CUT STATOR/ROTOR

Working Principle

STATOR

FINE CROSSCUT ROTOR

Working Principle

Grinding Homogenizing Dispersing Emulsifying

Maintenance & Operation cooling liquid

The pressure of the cooling / sealing liquid must be 0.5 to 1 bar higher than product outlet pressure. Flow is about 1 to 4 liters/min. Check and clean filter monthly

Adjusting the grinding Gap

Gap 150~200 micron

Adjusting the grinding Gap

Scale

Decrease Gap Hand Wheel Increase Gap

Holding Handle

Maintenance Stator & Rotor and Lubrication

Stator/Rotor will be worn after long usage. Can be sent back to factory for re-sharpening. Stator/Rotor to be changed when worn out. Yield will decrease due to bigger particle size from worn rotor and stator

New Fine Cut Rotor & Stator

THE SMALL EDGES ARE PUPOSELY CHIPPED OFF TO PREVENT IT FROM BREAKING DURING NORMAL OPERATION

DONT WAIT FOR THIS TO HAPPEN

Vibrations In the Mills

Causes: -Cavitations worn stator of M2, wrong M4 gap -Overloading too much beans, small gap -Over pressure wrong back pressure setting, system design

Remedy: -Cavitations - ensure sufficient feed or increase system backpressure -Overloading - reduce beans capacity, increase gap -Over pressure - reduce system back pressure

DETAILED MAINTENANCE INSTRUCTIONS FOR BOTH MILLS CAN BE FOUND IN THE OPERATION AND MAINTENANCE MANUAL
PLEASE READ IT - BEFORE YOU CARRYOUT ANY MAINTENANCE WORK

NETZSCH MOHNO PUMPS

Working Principle

Maintenance - General

The Rotors are Reduced Rotors The motor and gearbox ALSO need maintenance Before you carryout any maintenance work, READ the instructions found in Section 7 to 10 of the O&M Manual

FLASH COOLER

Working Principle

Cooling Water Inlet

Cooling water To vacuum pump Outlet

Product

Maintenance Change O ring

De-scaling of Condenser is necessary if the cooling water is Hard

STEAM INJECTOR

Working Principle

Maintenance Optimization
Steam injector Optimizing running time and temperature control by gap setting using spacer 7, 8, 9 10 and11

S7 T=2.0 mm S8 T=2.5 mm S9 T=3.0 mm S10 T=3.5 mm S11 T=4.0 mm

Instruments

Tetra Alwin Soy Instruments

Check for Correct Function Quarterly Calibrate Annually

Calibration of Pressure Transmitter

Do not attempt to calibrate the sensor on site. The PLC program is set according to its calibrated range The pressure transmitters for the flash cooler has a range from -1 to 1 bar so YOU MUST NOT ZERO IT.

Decanter

Maintenance & Operational Guide

Daily Operational Checkpoints

Cleanliness. Look for oil spills, grease spots, liquid spills etc Check machine vibration Check bearing and general machine noise Look for loose nuts, bolts or screws etc. Tighten if necessary Check temperature of grease lubricated main bearings Look for oil leaks from gearbox Check conveyor torque Check flexible connections for deterioration and leaks Check general condition of vibration isolators

Weekly - Check the CIP Nozzles

Ensure that there is no blockage

SAFETY FIRST
1. ENSURE ELECTRIC POWER IS CUTOFF TO MACHINE

2. ENSURE MACHINE HAS COME TO A STANDSTILL BEFORE OPENING COVER

3. LOCATE GREASING POINT BY LOOKING OUT FOR THIS SYMBOL

LUBRICATION SCHEDULE
ACCORDING TO SERVICE BULLETIN SB_9807_3 Main Bearings Standard time interval for lubrication of main bearings is 300 operating hours for operation temperatures less then 70 degrees C and 150 operating hours for higher then 70 degrees C. Foodec 310T it is 12 grams or 8 strokes per lubrication (1.5gm/stroke with standard Alfa Laval grease gun) Conveyor Bearings The conveyor bearings should be lubricated after every CIP cycle. Foodec 310T it is 2.4 grams or ~2 strokes per lubrication (1.5gm/stroke with standard Alfa Laval grease gun) PLEASE REFER TO SERVICE BULLETIN FOR COMPLETE LUBRICATION GUIDE

Lubricate Main & Conveyor Bearings

Main Bearing Grease: SKF LGHP2 Lubricate when bearing temperature is below 80 degrees C and at low speed

Conveyor Bearing Grease: Texaco Lubricate when machine at standstill

Always use the recommended lubricants

Lubricate Main & Conveyor Bearings

Main Bearing Grease: SKF LGHP2 Lubricate when bearing temperature is below 80 degrees C and at low speed

Conveyor Bearing Grease: Texaco Lubricate when machine at standstill

Always use the recommended lubricants

3.5 kNm DD Gearbox Ratio 1:52

Consult your local Alfa Laval Service Centre for service & repair of gearbox

Monthly - Remove feed tube and check for clogging in feed inlet and cleanliness

Venting is Important

CAUSE

EFFECT

Other Important Checkpoints

Check V Belt Tensions every 2000 Hrs Change V Belts every 16000 Hrs Check Seating Torque of Main Bearing Pillow Block Bolts 4000 Hrs Check for Corrosion Inside Casing and Bowl Exterior 1000 Hrs Check Bushings at Solid Discharge for Wear 1000 Hrs Check Function of Emergency Stop 2000 Hrs Check Function of Vibration Switch 2000 Hrs Check Function of Cover Switch 2000 Hrs Change Gearbox Oil 2000 Hrs Plan for Intermediate and Major Service Remember the Motors Also Needs Servicing 2000 Hrs

REFER TO OM FOR COMPLETE MAINTENANCE INSTRUCTIONS

Thank You