Operation of Machine
Sub-Assemblies Introduction
1. Infeed Conveyor Assembly
1.1.3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - MS, RAL 7045
Infeed Conveyor Assembly
1.2 Infeed Conveyor Assembly
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The infeed conveyor assembly receives the butter packs from the Customer Machine Assembly.
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The conveyor is driven by an induction motor for continuous product movement.
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The conveyor transfers the butter packs towards the Collation Assembly.
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The assembly provides smooth and continuous feeding of butter packs for further processing.
1.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Infeed Conveyor Assembly.
1.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
1.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
1.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
2
1
2
2
2. Collation Unit
2.1.3D Model
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Collation Unit
2.2 Collation Unit
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The collation assembly receives the butter packs from the Infeed Conveyor Assembly.
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The butter packs are side-shifted and arranged into a matrix of 5 × 3 using a pneumatic assembly.
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Once the complete matrix is formed, the products are released towards the Stacker Assembly.
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The assembly forms the required product arrangement for stacking operation.
2.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Collation Unit
2.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
2.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
2.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
1
1
2
2
1
1
2
3. Stacker Unit
1.1.3D Model
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Stacker Unit
3.2 Stacker Unit
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The stacker assembly receives the 5 × 3 matrix from the Collation Assembly.
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Each completed matrix is stacked one by one on the stacker unit using a servo mechanism.
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The stacking operation continues until a total of 10 layers is formed.
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Once the full stack is completed, a signal is given to the Pusher Assembly.
3.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Stacker Unit.
3.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
3.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
4. Pusher Assembly
4.1.3D Model
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Pusher Assembly
4.2 Pusher Assembly
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The pusher assembly receives the stack completion signal from the Stacker Assembly.
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The completed product stack is pushed from the stacker unit onto the Tilting Assembly using a pneumatic assembly.
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The transfer is carried out after confirmation that the full stack is ready.
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The assembly moves the stacked butter packs for shipper loading operation.
4.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Pusher Assembly
4.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
4.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
4.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
1
1
1
2
1
5. Tilting Unit
5.1.3D Model
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Tilting Unit
5.2 Tilting Unit
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The tilting assembly receives the completed product stack from the Pusher Assembly.
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The operator manually places an empty shipper with bottom tapping completed at the defined position.
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Once shipper placement confirmation is received, the shipper is tilted with the help of an induction motor towards the Roller Conveyor Assembly.
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The stacked butter packs are transferred into the shipper during the tilting operation.
5.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Tilting Unit
5.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
5.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
5.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
1
2
2
2
6. Roller Conveyor Assembly
6.1.3D Model
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Roller Conveyor Assembly
6.2 Roller Conveyor Assembly
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The roller conveyor assembly receives the filled shipper from the Tilting Assembly.
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The conveyor transfers the filled shipper forward after product loading is completed.
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The shipper is moved in a straight path towards the next station.
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The assembly passes the filled shipper to the Tapping Assembly for sealing operation.
6.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Roller Conveyor Assembly
6.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
6.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
6.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
2
2
2
2
7. Tapping Unit
7.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Tapping Unit
7.2 Tapping Unit
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The roller conveyor assembly receives the filled shipper from the Tilting Assembly.
-
The conveyor transfers the filled shipper forward after product loading is completed.
-
The shipper is moved in a straight path towards the next station.
-
The assembly passes the filled shipper to the Tapping Assembly for sealing operation.
7.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Tapping Unit
7.4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
7.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
7.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
2
4
2
4
2
7.
2
8.
9.
2
1
10.
4