Buhler SnackFix User manual

Operating Instructions
SnackFix
Issue-date: 2016-08-V1.0
Translation of original document (German)
German version is binding.
Read the instructions carefully
prior to any installations!

2 SnackFix 2016-08
Bühler GmbH
Daimlerstrasse 8
74211 Leingarten
Germany
T [phone]
F [phone]
[e-mail]
buhlergroup.com/countlines
© Bühler GmbH 2016

Supplemental instructions
SnackFix2016-08 3
Supplemental instructions
This manual enables the safe and efficient handling of the machine.
The manual is part of the machine and must be kept in immediate
proximity to the machine so that it is accessible for the staff at any
time. The personnel must have carefully read and understood this
manual before starting any work. Basic requirement for safe operation
is the compliance with all safety information and handling instructions
stated in this manual. In addition, the local accident prevention regula-
tions and general safety rules apply for the area of application of the
machine. Illustrations in this manual only serve the purpose of provid-
ing a conceptual understanding and may differ from the actual design.
No claims may be derived from any potential deviations. Besides this
manual, the manuals of the installed components shall apply that can
be found in the annex.
Liability limitations
All information and notices in this manual have been compiled in con-
sideration of the applicable standards and regulations, state-of-
technology as well as our findings and experiences that have been
gained over many years. The manufacturer does not assume any
liability for damage caused by:
Non-observance of any information in this manual
Any use that is not in accordance with the intended purpose
Deployment of untrained staff
Unauthorized retooling or technical modifications that have not
been approved by the manufacturer
Use of unapproved replacement parts
The obligations agreed to in the delivery contract, the General Terms
and Conditions as well as the delivery conditions of the manufacturer
shall apply in addition to the respective legal regulations that are ap-
plicable at the time the contract becomes effective.

4 SnackFix 2016-08
Copyright
This manual is protected by copyright. The surrender of this manual to
third parties, reproduction in any way or form - including excerpts - as
well as the exploitation and/or conveyance of the content without writ-
ten authorization of the manufacturer is not permitted with the excep-
tion of the use for internal purposes. Violations are subject to com-
pensation for damages. The manufacturer reserves the right to make
additional claims.
The manufacturer owns the copyright.

Table of Contents
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Table of Contents
1Overview ......................................................................................8
1.1 Overview.............................................................................8
1.2 Short description.................................................................9
1.3 Other applicable documents.............................................10
2Safety..........................................................................................11
2.1 Symbol declaration ...........................................................11
2.2 Intended Use.....................................................................13
2.3 Responsibility of the operator ...........................................14
2.4 Employee requirements....................................................15
2.4.1 Qualifications.....................................................15
2.4.2 Unauthorized individuals ...................................16
2.4.3 Training..............................................................17
2.4.4 Hygiene requirements .......................................17
2.5 Personal safety gear.........................................................17
2.6 Basic hazards....................................................................20
2.6.1 General hazards at the work station..................20
2.6.2 Hazards from electric powers............................21
2.6.3 Hazards from mechanics...................................22
2.6.4 Hazards from lacking hygiene...........................23
2.6.5 Hazards from high temperatures.......................24
2.6.6 Hazards from noise ...........................................25
2.7 Safety installations............................................................25
2.7.1 Position of safety installations ...........................26
2.7.2 Description of the installed safety installations..27
2.8 Secure against restarting..................................................29
2.9 Stopping in Case of Emergency.......................................31
2.10 Labeling 32
2.11 Environmental Protection..................................................35
3Technical Data...........................................................................36
3.1 General Data.....................................................................36
3.3 Connection Values............................................................38
3.3.1 Electricity ...........................................................38
3.4 Capacity Values................................................................39
3.5 Operating Conditions ........................................................39
3.6 Noise Emission .................................................................39
3.7 Name Plate .......................................................................40

Table of Contents
6 SnackFix 2016-08
4Design and Function.................................................................41
4.1 Overview...........................................................................41
4.2 Component Description ....................................................42
4.2.1 15l vessel...........................................................42
4.2.2 Pump .................................................................42
4.2.3 Mass preparation unit........................................42
4.2.4 Equalizing roller EGW 180 ................................44
4.2.5 Cutting machine SZ 100 M/TB..........................45
4.2.6 Control Panels...................................................48
4.2.7 Operating elements...........................................49
4.3 Connections......................................................................51
4.3.1 Connection for power supply.............................51
4.4 Workplace.........................................................................51
5Transport, packaging and storage..........................................52
5.1 Safety instructions for transport........................................52
5.2 Symbols on the packaging................................................53
5.3 Transport inspection .........................................................54
5.4 Transport...........................................................................54
5.5 Packaging .........................................................................56
5.6 Storage..............................................................................57
6Installation and First Start-Up..................................................58
6.1 Safety................................................................................58
6.2 Requirements at the Installation Site................................58
7Operation ...................................................................................59
7.1 Safety................................................................................59
7.2 Switching on and off..........................................................60
7.3 Stopping in Case of Emergency.......................................60
7.4 Adjustments and preparations..........................................61
7.4.1 Set-Up Vessel HM520.......................................61
7.4.2 Adusting the vibration unit.................................62
7.4.3 Adjusting the working position at the EGW.......62
7.4.4 Adjusting the scrapers at the EGW ...................63
7.4.5 Adjust the Belt Tension at the TB......................64
7.4.6 Adjusting the knife height at the SZ...................65
7.4.7 Adjusting the downholder at the CU..................66
7.5 Adjusting the Knife Follow Movement with Eccentric
Control...............................................................................68
7.6 Actions after usage ...........................................................69

Table of Contents
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8Maintenance...............................................................................70
8.1 Safety................................................................................70
8.2 Maintenance Plan .............................................................74
8.2.1 Clean the machine.............................................76
9Lubricate the machine..............................................................85
9.1.1 Changing the knife at the QS ............................91
9.1.2 Change scrapers at the downholder of the SZ..92
9.1.3 Measures after Carried Out Maintenance.........93
10 Malfunctions ..............................................................................94
10.1 Safety 94
10.2 Behavior in Case of Malfunction.......................................97
10.3 Malfunction signal .............................................................97
10.5 Malfunction Chart..............................................................98
10.5.1 Cutting unit ........................................................98
10.5.2 Equalizing roller EGW 180-100.........................99
10.6 Measures after Malfunction Removal ...............................99
11 Dissassembly and Disposal...................................................100
11.1 Safety 100
11.2 Disassembly....................................................................102
11.3 Disposal 102
11.4 Disassambly Pump .........................................................103
11.5 Disassambly Contimix.....................................................103
11.6 Disassambly Side guiding plates....................................103
12 Spare Parts ..............................................................................104
13 Index..........................................Fehler! Textmarke nicht definiert.
14 Appendix..................................................................................105

Overview
Overview
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1 Overview
1.1 Overview
Fig. 1: Overview
1
Vessel 15l
2
Pump
3
Hopper 40l
4
Vibration feeder
5
Contimix
6
Conveyor belt I TB
7
Equalizing Roller I EGW 180
8
Equalizing Roller II EGW 180
9
Conveyor belt I TB
10
Cutting machine SZ 100 M/TB
11
12
Control cabinet, preparation unit
13
Control cabinet, cutting unit
Mass Preparation Unit
2
3
5
9
10
8
7
12
13
1
Cutting Unit
6
4

Overview
Short description
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1.2 Short description
Detailed description   Chapter „Design and Function“
on page 41.
The line serves for producing confectionery products such as granola
bars on a small scale. For this, the ingredients are mixed, formed,
cooled and cut.

Overview
Other applicable documents
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1.3 Other applicable documents
In addition to this instruction following documents are applicable:
Operating instructions of the control panels “Operator manual”
Instructions of integrated components (Documentation file)

Safety
Symbol declaration
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2 Safety
This section gives an overview on all important safety aspects for the
optimal protection of the personnel as well as for a safe and trouble-
free operation.
Nonobservance of the guidelines and safety instructions given in this
manual can lead to serious hazards.
2.1 Symbol declaration
Safety instructions are labelled in this manual with symbols. The safe-
ty instructions are prefaced by signal words which express the extent
of the hazard.
In order to prevent accidents, personal injury or material damage, the
safety instructions must be complied with and carefully carried out.
DANGER
This combination of a symbol and signal word indicates an imme-
diate hazardous situation which could lead to death or serious inju-
ries if it is not prevented.
WARNING
This combination of a symbol and signal word indicates a possible
hazardous situation which could lead to death or serious injuries if
it is not prevented.
CAUTION
This combination of a symbol and signal word indicates a possible
hazardous situation which could lead to slight or moderate injuries
if it is not prevented.
NOTICE
This combination of a symbol and signal word indicates a possible
hazardous situation which could lead to material or environmental
damage if it is not prevented.
Safety instructions

Safety
Symbol declaration
12 SnackFix 2016-08
This symbol highlights useful tips and recommendations
for an efficient and problem-free operation.
For the labeling of instructions, result descriptions, enumerations,
references and other elements, the following symbols and highlighting
are used in the text:
1.
Identifies step-by-step instructions.
Identifies a condition or an automatic sequence as a result of
an action.
Identifies enumerations and list entries with a specific sequence.
Identifies references to chapters in this manual.
[BUTTON] Identifies designations of buttons and other controls.
Tips and recommendations
Symbols in this manual

Safety
Intended Use
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2.2 Intended Use
The machine is excluively laid out and designed for the intended use
that is described here.
The line serves for producing confectionery products such
as granola bars on a small scale.
Sich_Fehlgeb
Intended use does amongst others mean to adhere to all instructions
in this manual.
Any use that exceeds or differs from the intended use is regarded as
misuse.
WARNING
Danger from misuse!
Misusing the machine can lead to dangerous situations.
Do not use the machine in explosive atmospheres.
Do not operate the machine outdoors.
Do not operate the machine beyond the values specified in the
technical details and on the name plates.
Do not rebuild, retool or modify the machine or single compo-
nents.
Any claims for to damages caused by misuse are excluded.
The machine is designed for being used in the food industry.
Installation site

Safety
Responsibility of the operator
14 SnackFix 2016-08
2.3 Responsibility of the operator
The operator is that person who either operates the machine
him/herself or allows use by a third party for industrial or commercial
purposes and during the operation, bears the legal product responsi-
bility for the protection of the user, the employees or the third party.
The machine is only to be used in industrial areas. The operator of the
machine is subject to the legal obligations regarding work safety.
In addition to the safety guidelines in this manual, the valid safety,
accident prevention and environmental regulations for the application
area of the machine must be complied with.
This applies particularly in the following situations:
The operator must keep informed regarding the prevailing indus-
trial safety regulations and determine in a risk assessment addi-
tional hazards which result from the special working conditions at
the machine’s place of use. This must be in the form of operating
instructions for the operation of the machine.
The operator must check to see if the operating instructions
he/she prepared correspond to the current status of the regula-
tions during the machine’s entire operating time and, if neces-
sary, adjust them.
The operator must clearly establish and check the responsibilities
for the installation, operation, error clearance, maintenance and
cleaning.
The operator must ensure that all employees who are involved
with the machine have read these guidelines and understood
them. Additionally, he must train the employees in regular inter-
vals and inform them of the hazards.
The operator must provide the required protective equipment to
the employees and mandate its use.
Furthermore, the operator is responsible for making sure that the ma-
chine is always in technically perfect condition. The following applies
here:
The operator must ensure that the maintenance intervals listed in
this manual are adhered to.
The operator must observe the interfaces to the neighboring ma-
chine sections during the machine operation in a separate risk
assessment (interface analysis) and, if necessary, check the in-
tegration in an emergency stop chain.
The operator must have all the safety equipment checked regu-
larly for functionality and completeness.
Operator
Operator responsibilities

Safety
Employee requirements
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2.4 Employee requirements
2.4.1 Qualifications
WARNING
Danger of injury if employee is not adequately qualified!
If unqualified employees work on the machine or stay in the area of
the hazard zone, hazards exist which could cause severe injuries
and substantial damage.
Allow only employees qualified for those operations to use the
machinery.
Keep unqualified employees away from the hazard zones.
In this manual, the employee qualifications for the different areas of
operations are listed as follows:
The electrician is able to carry out work on electrical plants and rec-
ognize and avoid possible hazards due to his/her training, skills and
experience as well as knowledge of the relevant standards and regu-
lations.
The electrician is specially trained for the work environment in which
he/she works and recognizes the relevant standards and regulations.
The electrician must comply with the regulations and conditions of the
currently valid legal guidelines on accident prevention.
A technical employee is able to carry out the work assigned to him/her
and independently avoid possible hazards due to his/her training,
skills and experience as well as knowledge of the relevant standards
and regulations.
The trained person has been trained in a training session carried out
or allocated by the operator on the assigned job responsibilities and
possible hazards in the case of improper use/behavior.
Only those individuals from whom it can be expected that they will do
their job reliably are permitted as employees. People whose respon-
siveness is affected by e.g., drugs, alcohol or medication are not au-
thorized.
When choosing the employees, the applicable age and job-specific
regulations for the production site must be observed.
Electrician
Technical employee
Trained employee

Safety
Employee requirements
16 SnackFix 2016-08
2.4.2 Unauthorized individuals
WARNING
Danger to life for unauthorized individuals from hazards in the
hazard and working area!
Unauthorized individuals who do not meet the requirements de-
scribed here, do not know the hazards in the workshop area. For
this reason, there is a possibility of serious injury or death for this
unauthorized individual.
Keep unauthorized individuals away from hazard and working
areas.
When in doubt, speak to the individual and remove him/her from
the hazard and working area.
Stop the work on the machine as long as the unauthorized indi-
vidual is in the hazard and working area.

Safety
Personal safety gear
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2.4.3 Training
The employees must be trained by the operator on a regular basis. To
improve tracking, the implementation of the training must be logged.
Date
Name
Type of training
Training was
done by
Signature
2.4.4 Hygiene requirements
The personnel must know and adhere to the respective regulations,
hygiene requirements and prevailing operating methods of the food
industry.
PSA_Allg
2.5 Personal safety gear
Personal safety gear is used to protect employees against hazards
which could affect their safety or health when working.
When carrying out the various work on and with the machine, the em-
ployees must wear personal safety gear. Special remarks regarding
this gear are noted in the individual chapters of this manual. In the
following, this personal safety gear is explained:
Put on the personal safety gear required in the various chapters
of this manual before beginning work –no exceptions.
Follow the directions posted in the working area for personal
safety gear.

Safety
Personal safety gear
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Description of the personal safe-
ty gear
Wear strictly
PSA_Hyg_Haube
Hygienic protective cap
The hygienic protective cap is used to maintain hygiene requirements
and protect the hair from being pulled into the machine through the
rotating and moving parts.
PSA_Hoeren
Ear protection
Ear protection is used to protect against hearing damage.
PSA_Hyg_Kleid
Hygienic protective clothing
Hygienic protective clothing is tight-fitting work clothes with low tearing
strength, with close-fitted sleeves and without any protruding parts. It
is used to protect the employee against being caught in the machine
through moving parts and to maintain the hygiene requirements.
Rings, chains and other jewellery may not be worn.
PSA_Schuhe
Safety shoes
Safety shoes serve to protect from heavy falling parts and slipping on
slippery floors.
PSA_Helm
Protective helmet
Protective helmet is used to protect against falling and flying parts and
materials.
PSA_Brille

Safety
Personal safety gear
SnackFix2016-08 19
Protection goggles
Protection goggles are used to protect the eyes against flying parts
and liquid splashes.
Hygienic protective gloves
Hygienic protective gloves serve for adhering to the hygiene require-
ments and for protecting the hands from friction, abrasion, cuts or
deeper injuries as well as from contact with hot surfaces.
Wear when doing special work
PSA_Atem
Light breathing protection
Breathing protection is used to protect the respiratory organs from
health-threatening particles and dust.

Safety
Basic hazards
20 SnackFix 2016-08
2.6 Basic hazards
The following section describes residual dangers that may be caused
by the machine and that have been determined in the course of risk
evaluation.
In order to reduce heath hazards and to prevent from dangerous sit-
uations, pay attention to the safety advices given in the present sec-
tion and in any other chapters in this instruction.
2.6.1 General hazards at the work station
AllG_1_Schmutz
Dirt and leaking products
CAUTION
Danger of injury from falling due to dirt or the product leaking
from the machine!
Contamination and leaking products create slippery areas. A fall
can lead to injuries.
Always keep the working area clean.
Wear non-slip safety shoes.