1.0 Purpose of line
The line is used for packaging of UF white cheese.
It was designed so that through the technological process of filling mixture, coagulation, and vessel closure gets a product of the required quality
Contents:
2.0 Technical description..............................................................................
2.1 Filling module – FILLER ..............................................................
2.2 Coagulation module...........................................................................
2.3 Closing module – MONOSER ...........................................................
3.0 Line management functions.................................................................
2.0 TECHNICAL DESCRIPTION
Line FESER 1500 is automatic machine composed of three modules, capacity of 1500 pcs per hour, volume to 1l.
The concept of this line is such that in the automatic cycle there are few synchronized functions performed: a picking up of the vessels from the magazine and placing them on the conveyor, UV disinfection of vessels, dosing of non-adhesive, concentrate and rennet dosing, dosing of anti-foaming agent (optional), transfer of vessel to an endless line where the filled vessels travel 30 minutes (coagulation), ejection of vessels from endless line to output line, placing to the MONOSER 1500 stepping lath, where in the tact mode operate: cutting, putting the parchment paper, salting (optional), taking aluminum lids with pre-welding, thermo-welding, taking and putting snap-on lids, ink-jet dating and putting closed vessels to the rotating table. All modules are protected with clean air through HEPA filters.
2.1. Module for mixture filling
2.1.1. Input conveyor
This is a tact conveyor, which carries vessels through filling module and it is ending at the end of the input of chamber for coagulation.
2.1.2. Placement of vessels on the conveyor
Pneumatic driven handle accepts vessels from the charge and puts them on the conveyor line
2.1.3. UV lamp
It is located on the chamber above half closed conveyor, and acts with UV rays
on vessels, which are moving under
2.1.4. Module for dispensing of Anti-Sticking coating
Thin-film of Anti-Sticking coating is sprayed on the inside of the vessel by using atomic nozzles. The agent against sticking is carried under a pressure from the vessel in a volume of 10 liters.
2.1.5. Module for mixture dosing into vessels
It consists of separate vessels for retentate - 40 lit. and rennet - 15 lt., which with separate paths goes to a static mixer and then to the two heads filling two vessels at the same time. Heads for charger are equipped against dripping after filling of vessel.
2.1.6. Module for spraying of anti-foaming agent
Performs injection of a fluid with anti-foaming agent, using atomic nozzles. Agent against the foam is brought under the pressure from a vessel in
a volume of 8liters.
2.1.7. HEPA filter
HEPA filter is located on the armature that covers the volume where nozzles for application of anti-sticking coating are located, as well as filling heads, nozzles for applying anti-foaming agent and a part of the input conveyor to the entrance to the chamber.
2.2 MODULE FOR COAGULATION
2.2.1 Pusher of filled vessels at the input of the chamber
Transfers filled vessels from the input conveyor to the conveyor through the chamber, using a pneumatic drive fixed on the frame structure of the chamber avoiding any obtrusion of air flow.
2.2.2 Chamber
The chamber is an enclosed structure that enables clean air overpressure created by HEPA filters. Frame structure is designed to allow the installation of conveyor, HEPA filter, transfer module assembly on the entrance and exit of the chamber and other equipment
2.2.3 Conveyor through the chamber
Continuous conveyor with endless tape through a chamber carries vessels from input to output, during the time needed for coagulation of the mixture in vessels
2.2.4 Pusher of filled vessels at the output of chamber
Transfers filled vessels from conveyor tape through a chamber on the conveyor that carries containers to the station where they are transferred to the conveyor module for closing. Transfer module drive is automatic - fixed on the frame structure of the chamber avoiding any obtrusion of air flow.
2.2.5 Conveyor from the output of the chamber to the closing module
Tact conveyor which brings vessels to the station for transferring them to the conveyor of a closing module
2.2.6 HEPA filters
Three HEPA filters are arranged above the conveyor, on the chamber enclosure and provide overpressure of clean air in the overall volume of the chamber
2.2.7 Chamber heaters (optional)
are placed inside the chamber and maintain the temperature required for the coagulation of the mixture in the vessels
2.3 CLOSING MODULE
2.3.1 Module for a transfer of vessels to the conveyor of closing module.
Pneumatic handle takes vessels from the conveyer and puts them on the conveyor of closing module
2.3.2 Conveyor of closing module
Tact conveyor with the openings for the vessels in conveyor tape transfers the vessels through closing module
2.3.3 Module for cheese cutting
Cutting is done with highly polished knives which do not need cleaning during the process. Movement of the blade is achieved by pneumatic cylinder.
2.3.4 Module for putting parchment paper
Rotary head with the vacuum effect takes food parchment paper from the container and puts it on the vessel.
2.3.5 Module for salting
Device for salting dosage dispenses predetermined amount of salt on the parchment paper; dispersion of the salt outside of the vessel is prevented by design solutions
2.3.6 Module for putting aluminum lids
Rotary head by using vacuum effect takes al-lid from container and puts it on the vessel
2.3.7 Module for pre-welding aluminum lids
Performs partial welding of aluminum lid on the vessel
2.3.8 Module for welding aluminum lids
Performs final welding of aluminum lid on the vessel
2.3.9 Module for putting and impacting of pop-up lids
Rotary head using vacuum effect takes aluminum lid from the container and places it on the vessel. Pneumatic driven presser is doing lid stamping
2.3.10 Ink jet printing of the date
Ink jet printer prints date on the side of the vessel
2.3.11 Lifting of vessels and output on the conveyor of final products line
By synchronized action of a device for lifting vessels and ejector, vessels are placed on the conveyor of the final product
2.3.12 HEPA filter
Is located on the frame that covers the volume of the chamber to the pop-up lid station
2.3.13 Conveyor of final product
Transports vessels from the closing module to the rotating table
2.3.14 Output on rotating table
Closed vessels are transferred from the output conveyor on the rotating table
3.0 LINE MANAGEMENT FUNCTIONS
The line is fully automated and equipped with PLC (programabile logic controler) and HMI (human-machine interface). As a cost-efective solution equipment of Taiwan manufacturers FATEK is selected - http://www.fatek.com/.
Equipment from other manufacturers (Omron or Schneider Electric) is also available, as a cost quality solution
According to the mode, the line is automatic and depends on all of its components, so that all operations are controlled and adjusted to the input parameters. On the output side is controlled by inverters for conveyors and coordinates the work of the tumbler so that conveyors are always optimally filled, and each container with the product retains the same time as the previous one. In this way it ensures equal treatment temperature of each vessel in the chamber for coagulation.
The end of the line is managed by an array of mechanical and pneumatic components which are strictly controlled by probes end positions, so that seals the product as quickly as possible, and puts it on the output conveyor.
The whole control mechanism is controlled by the terminal (touch screen 10.1 ") for interaction with processes on the line:
• user's choice of recipes,
• diagnostic alarms and events,
• directly manage the production process -
• speed control,
• temperature control,
• intervals,
• the ability to communicate with other participants in the production
• proces statistics,
• labor statistics,
delay statistics and alarms, etc..
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