FBL Training
FBL Training
1
Procedure Protocol:
Adress:
Purkersdorferstraße 58 (3100 St. Pölten, Austria)
E-mail: [email protected]
Type: Manual de encendido y apagado de la línea de envasado de
mermelada.
Manufacturer:
F.B.L. FOOD MACHINERY S.r.l.
www.fbl-it.i
GF
INDEX
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2
Procedure Protocol:
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3
Procedure Protocol:
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4
Procedure Protocol:
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5
Procedure Protocol:
● Make sure that the line and depalletizer are completely empty, must be stopped and
with no alarms.
● Access the “MAIN MENU” page via the Touch Screen panel. [1].
● Enter “RECIPES” [2].
● Select the format to be processed via the “+” or “-” commands. [3].
● Select the work cycle in “AUTOMATIC” and start running [4]. The machine will now
position itself for the processing of the selected format.
● Check that the grippers are in the correct position [53], if not, adjust them manually
[54].
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6
Procedure Protocol:
● If the luminous push button “ALARM RESET” [6] does not turn off, check for the
presence of any alarms on the control panel. In case of alarms, access the
“ALARMS” page in the touch-screen panel and check out the problem. Act
accordingly to solve the problem. After having eliminated the causes, press the
“ALARM RESET” pushbutton once again.
● Select the desired machine operating cycle, either MANUAL or AUTOMATIC using
the relevant controls found in the “MAIN PAGE” of the touch-screen panel.
● By selecting the MANUAL MODE [5] ,(cycle to be used for the first installation, during
maintenance operations and during the manual handling of the machine
apparatuses), it is possible to move the various machine applications independently.
Attention to the operations being carried out.
○ Press reset if it is illuminated.
○ Press manual.
○ Choose what you want to move.
○ Press manual command (if you release the button it stops. To be able to
move something the sensors must be green, to ensure that the position is
correct).
● By selecting the AUTOMATIC MODE [4] (cycle to be used during regular production)
○ Select the recipe.
○ Select automatic mode.
○ Press start (the depalletizer will rise to the highest position).
○ Put the pallet (the alarm will go on).
○ Press reset.
○ Press start.
○ Press start conveyors.
● The first conveyor did not work in automatic mode, we discovered that the problem
was the exit photocell, it had moved from its place, therefore the sensor detects that
it is full of jars and the conveyor stops [57].
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7
Procedure Protocol:
● The pallet of 720ml jars was too tall to fit into the depalletizer, so we had to remove
the first layer [58]. The maximum height of the pallet must be approximately 202,5cm
[59].
1.9. Images:
image [1]
image [2]
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8
Procedure Protocol:
image [3]
image [4]
image [5]
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9
Procedure Protocol:
image [6]
image [7]
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10
Procedure Protocol:
image [8]
image [53]
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11
Procedure Protocol:
imagen [54]
image [55]
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12
Procedure Protocol:
image [56]
image[57]
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13
Procedure Protocol:
image[58]
image [59]
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14
Procedure Protocol:
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15
Procedure Protocol:
● The side guides of the container conveyor are correctly adjusted according to the
new container format to be processed.
● All parts requiring lubrication are lubricated.
● The width of the pads is correctly adjusted according to the new container format to
be processed.
● There are no tools, free machine components or other objects in the machine.
● Make sure that the emergency buttons are not pressed down. If they are, release
them.
● Make sure that all safety guards are present, closed and properly secured.
● Turn the main switch on the electrical panel to the ON position [9].
● Acknowledge the various alarms by pressing the corresponding button on the touch
screen [10].
● Press the "RESET" button [11].
● Check that none of the lamps used to signal faults or alarms on the machine are lit.
● Check that the "RESET" button is pressed on the electrical panel.
● Press the ALARMS button on the display to verify that there are no active alarms
[10]. If present, identify the problem and resolve it.
● On the touch screen panel, press the "MENU" command [12].
● Press the "MANUALS" button [13].
● Select the part or parts to be moved manually. The commands of the selected part(s)
are highlighted in green.
● Press the "START" button [14]: this starts flashing. During the start-up of the part, the
buzzer lights up. After two seconds, the "START" button light is fixed and the
selected part starts.
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16
Procedure Protocol:
● Stop the supply of containers at the machine head, and completely empty the
machine at the end of production.
● Stop the line using the appropriate functions on the control panel.
● Turn off the machine power supply by setting the master switch to 0 [9].
● Thoroughly clean the machine following the instructions in chapter 5 of the manual.
2.5. Sensors:
● Entry photocell: If it does not detect any jars, it stops the blowers and the tapes that
grab the jars to save energy. When a jar is detected again, they start up again.
● Exit photocell: if it detects many jugs, it stops the grippers for safety. when it is
released they start up again.
● Middle photocell: if the exit photocell does not work and the jars accumulate, they fall
to the side platform and this sensor, detecting it, stops the machine for safety.
● To change the format of the jars you only have to enter the new diameter in the
recipe and the grippers adjust automatically when changing the recipe.
● If the jugs are very tall, the height of the blowers must be manually adjusted. They
are adjusted by raising or lowering the level of the bars on the sides of the machine.
2.7. Alarms:
● High pressure/ dirty filter: If the filter is dirty, it is more difficult for the machine to take
in air and the pressure increases. When this is detected, the alarm sounds and the
machine stops. It is solved by cleaning or changing the filter.
● Wrong position: This alarm sounds when it detects that the diameter of the grippers
is different from that of the recipe.
● When many jars accumulate at the outlet of the grippers, jars can fall into a side tray
of the machine [60]. When this happens, a sensor detects these jugs and an alarm is
activated, which stops the machine as well as warning.
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17
Procedure Protocol:
2.8. Images:
Image [9]
Image [10]
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18
Procedure Protocol:
Image [11]
Image [12]
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19
Procedure Protocol:
Image [13]
Image [14]
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20
Procedure Protocol:
Image [15]
Image [16]
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21
Procedure Protocol:
Image [17]
Image [60]
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22
Procedure Protocol:
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23
Procedure Protocol:
● Check that the photocells and sensors on the machine are functioning.
● Check that the side guides of the containers, installed on the conveyor belt, are
correctly adjusted to the new format of the containers to be filled.
● Check that the height of the valve unit is suitable for the format to be handled.
● Check that the recipe selected on the panel is correct for the format to be processed.
● Check if the product level probe inside the tank is functioning.
● Check that there are no pieces of equipment, unanchored machine components or
other objects on the machine.
● Check that the interchangeable components are correct for the jar size, if not, replace
them with the correct ones. The components with a red sticker are for the small and
medium-sized jars. Components with a blue sticker are for large jars.
● If we want the piston filler tank to be completely emptied when product stops arriving
from the buffer tank, we must set "EMPTYNG" to "ON".
● Check that the button on the screen that activates the door that allows the jars to
enter is activated.
● Check that in the "SET UP" section the "Infeed block", "No can no fill" and "Product
calling" sections are in "AUT". If we want the Buffer Tank product to stop being
called, we must set the "Product calling" to "STOP". If our product has many solid
traces and requires stirring, we must set the "Stirrer" section to "AUT".
● Check that the capping machine is working. If the capping machine is not running,
the piston filler stops.
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24
Procedure Protocol:
● If the illuminated “RESET” button does not go out, check if the alarm message is
present on the control panel [20].
● Select manual or automatic cycle on the MAIN PAGE menu by pressing either the
“MANUAL CYCLE” or “AUTOMATIC CYCLE” button [21].
● If automatic mode is selected, check that:
○ The selected recipe is the one required [22]. if not, select the correct recipe.
○ Size change and position screw presence photocell conform to the size to be
processed.
● In the MACHINE SET-UP menu the devices [23]: product call, stirrer are in “AUT”
mode.
● Press the “START” button to start the machine [24].
3.6. CIP
● 1. Automatic
● 2. Star number 8 comes out (a drawing with a water tap).
● 3. CIP [67]
● 4. There are several parameters 3 and 4 are for cleaning with soda.
● 5. Start
● When the capping machine is not working or there is a problem with a sensor, the
white gate does not open [69].
● If the entry photocell detects that there are not enough jars, it does not open the gate
[70].
● If the exit photocell detects that there are too many jars, it does not open the gate
[71].
● It is very important that the tank temperature does not drop below 85ºC.
3.8. Images:
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25
Procedure Protocol:
Image [18]
Image [19]
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26
Procedure Protocol:
Image [20]
Image [21]
Image [22]
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27
Procedure Protocol:
Image [23]
Image [24]
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28
Procedure Protocol:
Image [25]
image [65]
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29
Procedure Protocol:
image [66]
image [67]
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30
Procedure Protocol:
image [68]
image [69]
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31
Procedure Protocol:
image [70]
image [71]
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32
Procedure Protocol:
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33
Procedure Protocol:
● The tension of the conveyor belt installed on the vertical cap sorter-feeder. If
necessary, act on the tensioner of the idler pulley (at the upper end of the belt).
● The stacked cap detection photocell and the cap position detection unit are correctly
adjusted according to the new format of the caps to be processed.
● The overflow sensor located in the inclined chute of the downstream chute is
correctly adjusted according to the new format of the caps to be processed.
● The container travels in the adjacent hinged chains are correct.
● No one is in a dangerous position in the vicinity of the machine.
● There are no tools, rags or other items used during cleaning or maintenance of the
equipment on the machine.
● All protective panels/grids are in place and properly fastened.
● All emergency mushroom buttons are reset.
● All safety sensors and photocells are functioning properly.
● The main valve of the pneumatic circuit is open.
● The pneumatic circuit pressure is between 4.5 Bar and 6 Bar.
● Press the blue "RESET" button [26] to reset the safety devices.
● Select the manual mode on the touch screen panel [29] and check the process
recipe (if necessary).
● Select the part(s) to be moved manually. The commands for the selected part(s) are
highlighted in green.
● Start the production cycle by holding down the illuminated "START" button for
approx. two seconds [28]. During part start-up, the buzzer lights up. After two
seconds, the light of the "START" button lights up and the machine starts.
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34
Procedure Protocol:
● On some occasions the caps would stop due to the steam and the sensor would
detect that it was full, therefore it would not send new caps, the solution was to go up
with a ladder to push the caps and dry them a little [75].
● The jars were stuck at the exit and in order to remove them to undo the jam, the
width of the lane was adjusted and then put back into place [76].
4.6. Images:
Image [26]
Image [27]
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35
Procedure Protocol:
Image [28]
Image [29]
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36
Procedure Protocol:
image [72]
image [73]
image [74]
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37
Procedure Protocol:
image [75]
image [76]
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38
Procedure Protocol:
● Make sure that the emergency buttons are not pressed. If they are, release them.
● Make sure all safety guards are present, closed and properly secured.
● Turn the main switch on the electric panel to the ON position [30].
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39
Procedure Protocol:
● Check that the “RESET” button [31] is pressed on the electric switchboard.
● Press the ALARMS button [32] on the display to verify that there are no active
alarms. If present, identify the issue and resolve it.
● On the touchscreen panel, press the command "MENU” [33].
● Press the “MANUALS” button [34].
● Press the “START” button [35].
● Check that the “RESET” button [31] is pressed on the electric switchboard.
● Press the ALARMS button [32] on the display to verify that there are no active
alarms. If present, identify the issue and resolve it.
● Select automatic mode on the Touch Screen panel and check the process recipe.
[36].
● Press the "START" button [35].
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40
Procedure Protocol:
5.6. Images:
Image [30]
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41
Procedure Protocol:
Image [31]
Image [32]
Image [33]
Image [34]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
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42
Procedure Protocol:
Image [35]
Image [36]
Image [37]
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43
Procedure Protocol:
Image [61]
Image [62]
Image [63]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
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44
Procedure Protocol:
Image [64]
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45
Procedure Protocol:
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46
Procedure Protocol:
● The side guides of the container conveyor (not included), installed on the conveyor
belt, are correctly adjusted according to the new format of the container to be
processed.
● There are no tools, detached machine components or other objects in the machine.
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
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47
Procedure Protocol:
● Cut off the voltage to the machine by setting the master switch to position 0 [42].
● Thoroughly clean the machine following the instructions given in the manual.
6.5. Images:
Image [38]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
48
Procedure Protocol:
Image [39]
Image [40]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
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49
Procedure Protocol:
Image [41]
Image [42]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
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50
Procedure Protocol:
● Place a container you wish to process at the entrance of the drying tunnel and adjust
the lateral guides of the conveyor belt.
● Align the first air blade to remove water droplets from the top of the cap, adjusting
and securing it in place [43].
● Adjust the blade's inclination by loosening the bolt [44] and retightening it after
adjustment.
● Position the container under the first two blades, ensuring the blade starts at the
same or slightly higher height than the container and ends below the container mid-
height.
● Adjust the lateral blades used for drying by loosening the locking handles [45] and
using the graduated scales on the supports for proper positioning. Adjust the blade
inclination by loosening the bolt [46] and retightening it after adjustment.
● Repeat these adjustments for all blades on the machine.
7.2. Images:
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
51
Procedure Protocol:
Image [43]
Image [44]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
52
Procedure Protocol:
Image [45]
Image [46]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
53
Procedure Protocol:
● All points of the machine are well lubricated as prescribed in the Maintenance
chapter of the manual.
● All safety devices are correctly installed and perfectly operable.
● The installed equipment corresponds in each of its components to the format to be
processed.
● All equipment has been correctly installed in accordance with the data in the format
changeover tables in the manual.
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
54
Procedure Protocol:
● The devices of the labeler are correctly positioned according to the data of the format
changeover tables in the manual.
● The head is adjusted according to the height of the container to be processed.
● No objects have been inadvertently left in the machine.
● All photocells and reflectors are clean.
● Compressed air pressure is adequate (min. 5 bar).
8.4. Images:
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
55
Procedure Protocol:
Image [47]
Image [48]
Image [49]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
56
Procedure Protocol:
Image [50]
Image [51]
Image [52]
© [2024] [Aprosell Frucht GmbH]. All rights reserved. This document is confidential and may contain privileged information. It is intended solely for the use of the individual
or entity to which it is addressed. If you are not the intended recipient, please notify the sender immediately and delete this document from your system. Any review,
dissemination, distribution, or unauthorized copying of this document is strictly prohibited.
57