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I Didacta Italia
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TA98D
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Pasteurizing Cooling Tunnel
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I User's Manual
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I Didacta Italia

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I TA98D

I Pasteurizing Cooling Tunnel

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User's Manual
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I This manual illustrates the technical characteristics and operating instructions of
the system Didacta TA98D Pasteurizing Cooling Tunnel, giving the instructor or

I the student a specific knowledge of the unit and its applications.

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I Didacta Italia Srl- Strada del Cascinotto, 139/30 - 10156 Torino

Tel. +39011 273,17,08 273,18,23 - Fax +39 011 273,30,88

I http://www.didacta.it - e-mail: [email protected]

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The Information contained In this manual has been selected and verified with the I
greatest care. However, no responsibilitystemming from its use can be ascribed to the
Authors or to Didacta Italia or any person or company involved in itspreparation.

The information contained in this manual can be modified at any time and without
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warning on account of technical or educational needs.

Copyright © Didacta Italla 2004

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Reproduction by any means, including photocopying of this test or parts thereof, or the
figures contained therein, Isstrictly prohibited. I
Printed in Italy - 19/02/04

Code o 1454E0204- Edition 01 - Revision02

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I Chapter 1.

I 1. General
The shower-tunnel pasteurizer cooler, made of AISI 304 stainless steel, allows
I continuous processing of packaged products. The packages are carried through the
tunnel by a conveyor belt made of food-compatible plastics.

I The unit includes three main sections, which perform the following functions:

I • Pasteurizing
The process is carried out by means of nebulized water heated up to 95-98°C by
steam. The water is contained in a suitable collection reservoir and is pumped to
I the nebulizers by a centrifugal pump. Temperature control is achieved through a
regulating valve driven by an electronic controller.

I • Pre-cooling
This operation is implemented by means of nebulized water heated up to about
I 60°C by steam, with manual regulation. This step is needed in order to avoid
damages to the glass containers due to large temperature drops. The water,

I contained in a suitable collection reservoir, is pumped to the nebulizers by a

centrifugal pump.

I • Final cooling

This function is carried out by means of cold water from the mains.

I The average capability of the unit which depends on the capacity of the
containers to be processed, is about 150 bottles of 0.7 Icapacity per hour.

I The various operating steps are managed through an electrical control panel.

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I TA98D - User's Manual

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I Chapter 2.

I 2. Description, Start-up, and Maintenance

I 2.1 Technical data

I 2. 1. 1 Description

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I Fig. 2.1-Pasteurizateur and cooling

1. Belt conveyor
I 2. Tank

I 3. Cloak of aspiration smokes

4. Frame

I 5. Pasteurization pomp

6. Pasteurization water small tank

I 7. Water small tank on pre-cooling

I 8. Pomp of pre-cooling

9. Motogear

I 10. Counter of inspection

I 11. Panel control

I TA98D - User's Manual 3

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 Description,Start-up,and Maintenance
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Fig. 2.2 - Frame and conveyor

1.

2.
Tank of pasteurization-cooling

Cover
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3.

4.
Cover

Counter of tank inspection on pre-cooling

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5. Counter of tank inspection of pasteurization

6. Protection I
7. Motogear

8. Support I
9. Belt to modular chain

10. Pinion
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11. Draft device I
12. Support

13. Support
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4 Didacta Italia
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 Description, Start-up, and Maintenance
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2.1.2 Weight and dimensions (fig. 2.1)

• Net weight: 530 kg. I

• Maxim lenght: LT= 3200 mm
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• Lenght of pasteurization: LV = 2200mm

• Maxim width: B = 830mm I

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Width usable belt conveyor: A= 335 mm

High: H= 1100 mm± 50

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2. 1.3 Required services
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The Didacta Italia TA98D unit requires the following services:
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• power supply: 380V three phase, 50 Hz, 2.4 kW;

• water supply: 0.12 m3/h - from mains; I

• steam supply: 15 kg/h at 3 bar.
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2.1.4 Tunnel belt and pumps

• Moto gear: worm gearboxes

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• Power: 0.12 Kw I
• Transmission ratio: i = 2800
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• Min speed: 36.6mm1min

• Max speed: 110 mmlmin I

• Time of pasteurization: 20+60 minutes

• Belt: modular chain

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• Width belt: 381 mm
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• Pasteurization pump: 80 l/min at 3 bar 1.5kW

• Cooling pump: 40 l/min at 3 bar 0.75 kW I

• Diffusive water: brass
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• Frame and pipelines: stainless steel

• Net weight: 530 kg I

8 Didacta Italia
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I Chapter 2.

2.2 Preliminary operations

I Each operation to handle, install, start up and maintain the equipment must be carried
out in compliance with safety laws currently in force and by adopting any practical
I measures aiming to prevent occupational accidents and ensure safety in the workplace
by implementing all those good practises of workmanship generally known to skilled
operators.
I On positioning, check that there is sufficient space around the machine (1.5 meters)
to allow for safe use and maintenance operations.
I Position the machine levelled on a steady surface suitable for bearing its weight. In
order to favour this operation, the feet resting on the floor are fitted with adjustment
I screws. Once the levelled position is reached, the lock-nut on the fixed part must be
locked on each foot, so that the foot does not move. If necessary, foot flanges must be
fixed on the floor by means of expansion plugs, to prevent the machine from moving
I while in operation.

I 2.2. 1 Electric connection

1. check whether the section of the supplying line is adequate, taking in

I consideration the total in-stalled power and that the voltage drop must not be
superior to 5%;

I 2. check whether the ratings of the unit are correct and correspond to the electric
supply;

I 3. check whether there is a circuit breaker and verify its correct operation;

4. check that all the safety devices are connected;

I 5. connect the unit to the electric mains;

I 2.2.2 Pipe connection

• Inlet of water into the line (fig. 2.5 rif. 1). External thread 1" GAS.
I Maximum temperature 18°C.

I • Steam inlet (fig. 2.5 rif. 2). External thread %" GAS.

I Note
Steam pressure at machine pipe inlet must be MAX.3 bar.

I 2.2.3 Drainage

I • Pasteurization water drainage/outlet (fig.2.5 rif.5). Internal thread 1" GAS

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 •
Description,Start-up,and Maintenance

Pre-cooling water drainage/outlet (fig. 2.5 rif. 4). Internal thread I" GAS.
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• Pasteurization water overflow drainage/outlet (fig. 2.5 rif. 7). Pipe 1"114. I
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Pre-cooling water overflow drainage/outlet (fig. 2.5 rif. 6). Pipe 1"1/4.

Vapours and fume suction (fig. 2.5 rif. 3). Pipe 0 154 mm
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Fig. 2.5 - Connections

1. Water inlet
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2. Steam inlet
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3. Vapours outlet

4. Pre-cooling water outlet I

5.

6.
Pasteurization water outlet

Pre-cooling water overflow

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7. Pasteurization water overflow I
8. Electric panel
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2.3 Safety devices

2.3. 1 Safety warnings

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• Do not remove the protections I
• Do not use the machine with its safety devices deactivated or damaged.
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10 Didacta Italia

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I Chapter 2.

• Do not put inside the machine hands, arms, head and legs when it is operating.
I The machine must be non working and disconnected from the electric feed.

• Do not open the terminal board of the electric motors. The general switch has to
I been disconnected.

2.3.2 Fire risk

I The product that will be processed by the machines, is not dangerous as far as the fire
risk, but there are some electric parts and therefore there is the possibility that through
I carelessness, damaging or insufficient maintenance , the operators can run into
dangerous conditions; In this cases, take away tension disconnecting immediately the

I machines from the electric line.

Do not use water to extinguish the fire.

I Use these extinguishing substances:

• Carbon dioxide (C02)

I • Dust

I 2.3.3 Emergency button

I In case of emergency, the machine has to be stopped, press the emergency stop push-
burton located on the machine or on the electric board.

I Please remember that the above mentioned devices have to be used only in case of
real emergency and not to stop the machine during regular functioning operations.

I At the end of the emergency, when you are sure no part of the machine is failing,
reset the emergency stop push-burton by turning it counter clockwise, and start up the
machine.
I 2.4 Maintenance
I 2.4.1 Maintenance procedures

I • Machine cleaning

Machine cleaning is necessary for the correct operation of the machine and its
I life.

In order to keep it clean and efficient and protect it from contamination it is

I necessary to clean all the parts that touch the product and surrounding areas. Use
detergents that can be used when dealing with food (non toxic).

I Electric parts must not be washed with water.

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 Description, Start-up, and Maintenance

NOTE: The steam filter (fig.3.2 rif.3) must be cleaned after 3-4 hours after starting, and
subsequently checked every 50 hours.

This operation must be carried out when the machine is at a standstill and cold, after closing
the steam on-Of/valves (fig. 3.2 rif. 1, 4, 5).
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• Tank filter cleaning

Within the pump suction tanks, there are two filters that are to be regularly
checked and cleaned. For this operation it is necessary to lift the covers and pull
the grid-filters out.
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• Lubrication

Shaft bearings must be greased every 50 work hours or when you start the I
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machine after a not using period. Use Litium soap grease (base oil: Silicone oil)
only. Do not use oil.

• Motor reducer lubrication

The variable-speed drive consist of metal moving parts, it therefore needs

constant lubrication. Drive lubrication takes place by means of oil flutter. The
drive has a "lifelong" lubrication system (synthetic oil ROTOLIFE 511) and is
supplied by the manufacturer already filled with oil. Before starting, make sure
that there is oil in the reducer/drive by checking that it appears in the sight-glass.

The reducer is fitted with synthetic oil permanent lubrication and does not need
maintenance.

• Elimination of the pollutant materials

Pay attention to get rid oil and grease: they are polluting substances. Oils and
greases must not be dispersed on the ground because they could contaminate
water beds.

2.4.2 Schedule periodic maintenances

Motogear
Detail

Variable speed motor

Type of
Intervention

NOONE
NOONE
Characteristics
Materials
Maintenance
Oil 0.50 It
Oil 0.250 It
Maintenance

lubrific. for ever

lubrific.for ever
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Supports with ball bearings Grasing fat to the soap of lithium every 50 h
Steam filter Cleaning every 50 h
Tank filter Cleaning every 50 h

12 Dldacta Itolla
I Chapter 3.

I 3. Operating Procedure

I 3.1 General
Pasteurization is a heat treatment at atmospheric pressure with a maximum
I temperature lower than 10oce. It is used to remove pathogens or enzymes from food
thus enhancing food keeping properties.

I During pasteurization, heat-sensitive microorganisms are inactivated (non-spore

forming bacteria, yeasts and mildew). Pasteurization causes little changes in the
organoleptic characteristics or the nutritional value of food.
I The different conditions of heat treatment and the resulting degree of preservability
are mainly determined by the pH value of food.
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Fig. 3.1 - Operating principle
I 1. First section

I 2. Second section

3. Third section

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 Operating Procedure

3.2 Operating procedure

The product is loaded manually on a modular-chain conveyor belt which carries the
vessels into the pasteurizer.

The machine is subdivided into three sections (see fig. 3.1) in which the temperature
of the water diffused on the vessels is different.

3.2. 1 Firstsection
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Pasteurization treatment with water kept circulating by means of a centrifugal pump.
Water is heated to a maximum temperature of 95°C by means of direct injection of
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steam and diffused on the product with the appropriate spray nozzles.

The operator sets the desired water temperature on the governing equipment. A probe
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(PT100) - located on the pump delivery - measures the temperature and opens or closes
the injection of steam into the tank accordingly. Replenishment of water is carried out I
by drawing, taking the water from the 2nd section (pre-cooling), this adjustment must be
carried out manually, making sure that during operation the level of water does not
decrease. I
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Fig. 3.2 - Steam inlet

1. Steam valve to the second section

2. On-off solenoid valve

3. Steam filter

4. On-off valve

5. By-pass valve

14 Didacta Italia
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I Chapter 3.

The inlet of steam is governed by an electrically-operated on-off valve (fig. 3.2 rif.
I 3); this may be disabled by closing the on-off valve (fig. 3.2 rif. 4) and opening the
manual BY-PASS valve (fig. 3.2 rif. 5).

I Steam and fumes created during pasteurization are collected by an intake hood"
located in the area of vessel inlet.

I Hood: to be connected to a pipe to convey steam (not included in the supply)

towards the outside.

I 3.2.2 Second section

Pre-cooling treatment with the water kept circulating by a centrifugal pump.

I When the machine starts with the pump in operation, we suggest you open the steam
valve of this section (fig. 3.2 rif. 1) until a temperature of about 60+65°C is reached: this
I will prevent vessels from breaking due to temperature decrease. This valve must be
closed during the processing stage. Part of the exceeding water is used to compensate

I losses from the first section (pasteurization).

Cooling in this section takes place by means of the water coming from the third and

I last section.

The water in excess is discharged from the overflow pipe.

I 3.2.3 Third section

I Cooling treatment carried out with line water which must have a maximum
temperature of 18°C.

I The water to be used must be drinkable water.

The water used is collected in the pre-cooling tank.

I 3.2.4 Start up

I When the machine is to be started, a senes of operations must be carried out

following this sequence:

I 1. Make sure that all valves are closed.

2. Make the all connections (water, steam, exhaust)

I 3. Tank filling:

I Open the loading valves (fig. 3.3 rif. 2 and rif. 8) until the water comes out of the
overflow exhausts (fig. 3.3 rif. 12 and rif. 13) and close them again

I 4. Start the machine (making sure that all selectors are on "0") by pressing the
"start" button.

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 Operating Procedure
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Fig. 3.3 - Start up
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1. Cooling water valve I
2. By-pass valve

3. Pump delivery valve

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4. Pump
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5. Temperature

6. Loading valve I
7.

8.
Temperature

Loading valve
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9. By-pass valve I
10. Pump delivery valve

11. Pump
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12. Overflow

13. Overflow
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5. Set up temperature of pasteurization water by pressing _., 'f' (fig. 3.4). I
6. Open the pump delivery valves (fig.3.3 rif.3 and rif.10).

7. Pre-cooling water temperature must be set manually by acting on the steam on-
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offvalve (fig.3.2 rif.1). We recommend that you bring the water to a temperature
of about 60-65 °C to prevent the vessels from breaking. I
16 DidactaItalia
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I Chapter 3.

This valve must be closed in the processing stage

I 8. Open the cooling water valve (fig.3.3 rif.1).

I 9. Open the valve for water replenishment in the pasteurization section (fig.3.3
rif.6), adjusting it according to the quantity of water to be added.

I 10. Slowly open the steam on-off valve (fig.3.2 rif.4 ).

11. Start the conveyor.

I 12. Adjust pasteurization time by rotating the handwheel located on the variable-
speed drive.

I NOTE

The handwheel of the variable-speed drive must be operate only if the motor reducer is
I working. Operating the witeel with the motor at a standstill may cause damage or breakdown
within the drive and reducer.

I 13. Switch on the pump 1 (pasteurization)

14. Switch on the pump 2 (pre-cooling)

I 15. Switch on the solenoid valve

I 16. Pasteurization water will automatically and gradually go to the set temperature
(check the actual temperature on the thermometer).

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Fig. 3.4 - Control board
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3.3 Trouble shooting
Operating Procedure ,
PROBLEM POSSIBLE CAUSE SOLUTION
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TEMPERATURE OF
PASTEURIZATION WATER
Missing or not sufficient steam
injection
Check that manual steam on-off
valve is open.
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DIFFERENT FROM SET UP
TEMPERATURE Check filter and if necessary
clean it.
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Check operation of steam on-off
solenoid valve, in case of 1
malfunctioning, replace it.

Changes in the set up of Calibrate the equipment again.

temperature governing equipment See attached manual
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Malfunctioning of temperature Replace probe ~
probe (PT100)

PRODUCT SPRAYING Pump filters dirty Clean filters. ~

INSUFFICIENT
Nozzles clogged Clean nozzles.
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Malfunctioning of pumps Replace pumps.

PRODUCT DOES NOT MOVE Malfunctioning of motor reducer Replace motor reducer. ~
FORWARD
Pinions do not inmesh belt due to Tighten chain again by removing
excessive extension of chain modules from mat.
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