Bulteh 2000 EKOMILK mini DAIRY Plant 120L User manual

BULTEH 2000 Ltd.
Industrial Area 19, STARA ZAGORATel./Fax:[phone], 603 449; Tel. [phone];
1
AUTOMATIC
MINI DAIRY
PLANT
EKOMILK mini Dairy Plant 120L
TECHNICAL MANUAL
2016

BULTEH 2000 Ltd.
Industrial Area 19, STARA ZAGORATel./Fax:[phone], 603 449; Tel. [phone];
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TABLE OF CONTENTS
1. GENERAL 3
1.1 Terms of use of the present technical manual 3
1.2 Structure of safety instructions 3
1.3 Warranty terms 3
1.4 Liability limitation 4
2. 2. SAFETY DATA AND LABOR PROTECTION 4
2.1 Characteristics of operator and maintenance personnel 4
2.2 Preliminary checks 4
2.3 General requirements for safety 4
2.4 Appropriate application of the plant 5
3. INSTALLATION OF THE PLANT 5
3.1 Installation site requirements 5
3.2 Plumbing fixtures assembly 6
3.3 Assembly diagram to power source 8
3.4 Diagram of waste water drainage from the upper board 9
4. TECHNICAL DESCRIPTION OF THE PLANT 9
4.1 Purpose and area of application 9
4.2 Parts of the Plant 9
4.2.1 Main operation module 9
4.2.1.1 Metal vat with water jacket for dairy products’ processing 9
4.2.1.2 Metal vat cover with mixer 10
4.2.1.3 Horizontal centrifugal pump 11
4.2.1.4 Dosing system 11
4.2.1.5 Electric box 11
4.2.1.6 Control panel 12
4.2.1.7 Electric heaters 4 pcs. х 5kW 13
4.2.1.8 Hydraulic accumulator 8L, plumbing fixtures and protection 13
4.2.2 Tools & accessories for dairy product processing 14
5. TECHNICAL DATA 15
6. OPERATION PRINCIPLE OF DAIRY PRODUCT PROCESSING PLANT 16
6.1 Initial start-up of the plant and start-up after a prolonged stay 16
7. CLEANING OF DAIRY PRODUCT PROCESSING PLANT 20
8. TRANSPORTING OF DAIRY PRODUCT PROCESSING PLANT 21
9. FAULTS 21
10. CONTROLS 24
11. RECIPES 25
12. QUALITY CERTIFICATE 27
13. SALES SERVICE 28
14. ATTACHMENTS 29
Read the manual before installing and starting the plant!
Keep this document carefully!

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1.GENERAL
1.1 Terms of use of the present technical manual:
This technical manual is included into the complete set of the plant for
processing of dairy products and contains important instructions for its operation
and maintenance. It is designed for all professionals involved in the installation,
commissioning, maintenance and daily operation with the device.
The manual should always be available to servicing personnel of the product.
1.2 Structure of safety instructions:
Attention! - Important.
Attention! - Danger of electrical shock.
Information! –Useful information or recommendation.
1.3 Warrany terms:
The warranty period of the plant for processing of dairy products is 12 months
from the date of receipt but not more than 13 months from the date of sale.
The assembly of the plant for processing of dairy products is
carried out by the manufacturer or by organization authorized thereof!
The company manufacturer / the authorized organization is obliged to remove
all defects arising in the course of operation during the warranty period.
The manufacturer is not liable in the following cases:
damage caused during transportation of the equipment;
damage due to incorrect installation by unauthorized for this purpose
persons;
when it was attempted to remove damage by unauthorized for this
purpose persons;
failure to comply with the operation instructions of the equipment
which are given in this manual;
in case of damage by electrical shock, natural disasters and accidents
which are not related to the operation of the machine.
After expiration of the warranty period, the user can conclude a contract with
the manufacturer or his authorized organization for service support of the device
after sales.

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1.4 Liability limitation:
Comply with the technical guidance - this is a necessary condition for
safe operation of the plant for processing of dairy products and achieving the
technical parameters of the product.
Company BULTEH-2000 is not responsible for injuries of personnel,
material and pecuniary loss resulting from failure to follow the instructions in
this manual.
2.SAFETY DATA AND LABOR PROTECTION
The purpose of the following instructions on operational safety is to prevent
injuries to personnel and avoid damage to property.
User is obliged to ensure strict compliance with these guidelines. Ensure that
personnel responsible for the condition of the device and its operation, as well as
staff who will operate the equipment have completely read and mastered what is
written in the technical manual.
2.1 Characteritics of operator and service personnel:
The automatic mini dairy plant can be operated only by an operator who has
received training for working with this equipment.
Connection of the plant to drains system and maintenance of drains system
should be carried out only by a licensed plumbing technician familiar with this
manual.
Electrical connection and electric maintenance of the plant should be carried
out only by a qualified electrician who has been trained.
The operator must have everything needed to work in safe mode.
2.2 Preliminary checks:
It must be checked for:
absence of by-products in and on the machine;
proper connection of all the hydraulic and electric links must be checked.
2.3 General requirements for safety:
It is forbidden to use the plant in explosive environments.
It is forbidden to use the plant in an environment with harmful oils, acids,
dust, radiation, etc.
Starting the machine should be allowed only when safe working conditions
are provided.
It is forbidden to approach the parts found in the movement for a person not
working with the machine.
The operator should always use protection means prescribed by safety
standards of the user country.
It is forbidden to remove or isolate safety devices and emergency
indicators.
In case of detection of unusual noises or symptoms of the machine, the
operator shall disconnect it from the power supply and notify the relevant
technical persons.
It is forbidden to perform actions which are not within the operator’s
competence, and thus may endanger his safety or that of others.

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2.4 Appropriate application of the plant:
This plant is designed for processing of liquid dairy products in small
quantities.
Inappropriate application of the plant is not allowed.
3.INSTALLATION OF THE PLANT
The dairy product processing plant is supplied in two parts:
a main frame including a vessel for heat processing of milk products;
gearbox and electrical equipment. It is affixed with four studs on a special
transport wooden pallet;
a metal vat; a curd separator / dispenser with a cover; plastic cheese molds
(optional).
3.1 Installation site requirements:
The dairy product plant is to be operated in closed premises with normal
climatic conditions:
Air temperature –5˚С to 35˚С;
Relative air humidity –40% to 85%;
Temperature of the cold feed water should be at least by 20°C lower than
that of the dairy product fermenting.
The place of installation should be leveled - up to 5 mm per 1000 mm and
equipped with the energy and water resources, as follows:
Power supply - 380V ±10% industrial three-phase current with frequency
of 50÷60 Hz or 220V ±10% monophasic current with frequency of 50÷60 Hz
and a minimum installed power of 21 kW.
Power supply network, plug and terminal connections must meet
obligatory requirements / standards of the user country.
Attention:
Obligatory!
Use five-wire mains power supply;
The power supply can be provided by a separate circuit in the electrical
switchboard, secured with four wire leakage protection installed in the
electrical panel with:
- Rated current –minimum 35А per phase;
- Rated current of activation 30mA;
- Class А;

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Principle diagram of connecting the four-wire residual current device
protection:
After the residual current device protection the zero and protective
conductors must not be connected anywhere between themselves;
If the cable route from the power distribution panel to the plant is long, we
recommend to install an extra electrical switchboard in the vicinity in which
to embed the residual current device;
The fitness of the residual current device protection must be periodically
checked by an authorized person or organization;
It is not recommended to use residual current devices, operation of which is
influenced by the power supply voltage;
The control unit monitors the value of the rated voltage and turns
off the plant automatically, if the supply power exceeds the exposure
limits.
Water drains system: W&S drains system for cold drinking water should
be at a pressure of 0,3 ÷ 0,6mРa equipped with a valve to stop and drain
water
- hot and cold water equipment / drains system.
It is recommended that before the cold water inlet of the plant should be
mounted an additional filter. It is not allowed in the water content of solid
particles > 25μn.
This installation does not require a special foundation
Premises where the Plant will be installed must have equipment for washing,
cleaning and aspiration.

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Pic.1
2
3
3.2 Diagram of assembly for plumbing fixtures: (pic.1/pos.1), (pic.2/pos.1÷3)
Plumbing fixtures assembly must be performed by an authorized technician
who is pre-trained and familiar with the technical characteristics of the plant and its
peculiarities.
After the equipment is placed on the work site, a specialized technician will
perform a connection to the existing water supply network for supplying clean
drinking water (pic.1/pos.1).
- connection of the plant for
dairy product processing to the water
supply network
A shut-off valve must be installed between the plant for processing of
dairy products and water network!
Hot and waste water draining system should be ensured (the pipes from the
two water leads should have a separate connection) (pic.2).
Right Wrong
pic.2
1
1
1

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In case that the user has the possibility to use the processed hot water for
other purposes (washing, irrigation, watering of livestock, etc.), water storage tanks
have to be connected in the fitting (pic.3/pos.1).
Processed hot / cold water has the same properties as input drinking
water.
- connection of the pipe of
the processed hot water to the
fitting
- connection of the short
pipe of the emergency safety
valve to the fitting
The short hose that is connected to the emergency safety valve
(pic.3/pos.2), must be inserted into drains or placed under the plant
(pic.3/pos.3) - in case of activation to prevent burning of operating
personnel.
The hydraulic block diagram is given in (attach. 1 on p.28)to this technical
Manual.
3.3 Assembly diagram to power source:
The electric assembly must be performed by an authorized technician who is
pre-trained and familiar with the technical characteristics of the plant and its
peculiarities.
Due to different national standards and user requirements the dairy
product Plant is offered without power cable and plug.
For proper and safe operation of the unit, power cord that will be
mounted by user must be five-core with cross-section of 5х6mm²,
flexible, with insulation meeting the conditions in which it will work.
Connection of the power cable to the plant should be done by an
approved circuitry included in the set of the product (annex 2).
Pic.3
1
3
2
4
1
2

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Power cable must pass through the fitting of the electric cabinet installed in the
plant (pic.4/pos.1), and fitting on the rear center column of the unit - when
transported this fitting is removed and attached on the inside of the column
(pic.5/pos.1).
pic.4 pic.5
After mounting the power cable the plant grounding must be done,
according to the standards of the user country.
Fitness of the grounding must be periodically checked by an
authorized specialist or a specialized organization, according to the
standards of the user country.
3.4 Diagram of waste water drainage from upper board: (pic.6/pos.1), (pic.7/pos.1)
For draining water obtained as a result of condensation in heating milk product
or cleaning the upper board it is provided with a fitting hole on the bottom side. A
pipe is mounted at the fitting through which this water is drained into the drains
system.
от горен
4.TECHNICAL DESCRIPTION OF THE PLANT:
4.1 Purpose and area of application:
The Plant is designed for processing of up to 120L of dairy products.
Function of the plant includes :
4.1.1Automatic or manual processing of dairy products:
Automatic or manual processing of dairy products through thermal cycles of
heating and cooling, pasteurization and subsequent coagulation.
4.1.2 Operation in thermostatic mode:
The processing vat can operate as a thermostatic chamber with manually set
up of temperature and time by the operator.
Pic.7
1
Pic.6
1
2

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4.2 Parts of the installation and their design:
The installation for dairy products’ processing consists of the following main
parts:
4.2.1Main processing device, comprising :
4.2.1.1 Metal vat with water jacket for heating & cooling of processed milk:
(pic.8/pos.1),(pic.9/pos.1÷2)
Made of stainless steel with maximum working volume of 135L. The vat design
is a typical heat exchanger with indirect heating. Externally it is covered by a belt
that serves as a water jacket. To reduce heat losses and protect the operating
personnel from burns, the outer surface of the vat and the jacket is covered with
insulating wool. The heating of the processed dairy product is done with water
heated to a maximum of 110˚C. Automatically it is maintained ΔT processed
product / water in the jacket at 15÷20˚С. Circulation is provided by a centrifugal
pump included in the hydraulic system.
Cooling is carried out with water, the temperature of which is lower by at least
20°C than the temperature to which the processed product is cooled by providing a
free flow through the water jacket due to the water source pressure. To reduce the
cooling time of the processed products ice-cold water may be used.
The temperature of the processed dairy product is measured by the
temperature sensor mounted in the hull of the vessel - (pic.8/pos.1).
The water temperature in the jacket is measured by the temperature sensor
mounted in the heat exchanger - (pic.9/pos.2).
To avoid emergency from overheating in case of refusal of the control device a
two-stage protection is provided for consisting of - a temperature sensor of
automatically unrecoverable type - (pic.9/pos.1) and safety hydraulic-overflow valve
- (pic.3/pos.4).
Restarting of the emergency temperature sensor is performed only
after removal of the accident by authorized specialist!
Operation of the safety hydraulic-overflow valve should be checked
periodically by an authorized specialist, not rarer than twice a year, by forcibly
increasing the pressure in the hydraulic system between 3 and 5 bars when the
hydraulic system is filled with cold water by pressure controller - (pic.1/pos.2)
before water runs out from the valve.
At a smooth increase in pressure the safety overflow valve should be
enabled at 3 ÷ 4 bar.

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After checking the safety hydraulic-overflow valve the system
pressure must be restored to its normal working value of 1.5 bar.
4.2.1.2 Metal vat cover with mixer: (pic.10/pos.1÷3), (pic.11)
The vat is closed with stainless steel cover (pic.10/pos.1). There is a U-
shaped profile with a handle (pic.10/pos.2) mounted on the cover plate, and a
hinge limiter on the opposite side. A gearbox (pic.10/pos.3) is placed on the plate.
A stirrer of blade type with bayonet connection (pic.11) for convenient and quick
assembly and disassembly is mounted on gearbox’s axis.
The gearbox rotates at speed varying from 0 ÷ 30 rev / min.
Changing the rotation speed is set by the control panel as a percentage
fulfillment.
The blade shaped stirrer provides intensive mixing of dairy products and
improves heat transfer.
4.2.1.3 Horizontal centrifugal pump:
It is designed for the transportation of clean water which temperature shouldn’t
exceed 110°C. It is made of stainless steel.
Pic.11
Pic.9
1
2
Pic.8
1
Pic.10
0
2
3
1

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4.2.1.4 Dosing system:
It includes the following:
- Dosing pump,
- dosing pistol,
- dosing pistol trigger.
The dosing pump’s rotation speed can be set up between 33% and 100%. In
practice this speed determines its flow.
"Hold" - the dosing pump is running while the button is pressed;
"Trigger" - pressed and released button (start) and trigger pressed and
button released (end of execution);
"Automatic" - button pressed for a dose (at set speed / flow of the dosing
pump and time set for duty cycle)
When automatic dosing quantity (a dose) is proportional to the pump rotation
speed and time of dosing.
Dosing is autonomous and it is possible in all operation modes (of the plant) if
the product temperature is 55°C.
The operating time of the dosing pump is programmable within the range of 3
÷ 60sec.
4.2.1.5 Еlectric box: (pic.12/pos.1÷7)
- Frequency inverter for dosing pump control
- Frequency inverter for mixer control
- Controller board MDAIRY2
- CK switch for turning on one or both power
circuits
(10kW/20kW)
- Contactors
- Electrical fuses
- Transformer
1
2
3
4
5
6
7
pic.12
1
2
3
4
5
6
7

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pic.1
3
1
2
5
8
1
0
7
6
4
3
9
1
1
4.2.1.6 Control Panel: (pic.13/pos.1÷11)
DIGITAL DISPLAY (on the control panel):
- LED indication : for product temperature
- LED indication : for elapsed time
- LCD: symbolic indicator of specific functions : for parameters’ setting up, values
and messages
CONTROLS:
- Keyboard : 6 keys with auto repeat upon arrest (hold). Used to set modes,
parameters and values for operation of the installation
- - Key Power: for the installation
- Key "Start - Stop" for control of the installation : for Start/Stop of the process
(recipe/step)
- - Key "MIXER": start/stop stirrer in the container: only by the operator
LIGHT AND SOUND INDICATORS:
- Green light : the installation process has started
- Red light : fault in the installation
- - Emergency stop
- Sound signaling: siren
1
2
4
5
6
7
8
10
9
3
11

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- Continuous Sound signaling: failure of the installation
- Beep (1 second) might indicate : the end of the step (if preset by the
operator) signal for an interruption which requires operator’s intervention.
The system works in automatic and manual mode, which is set up and
monitored by the operator via the control panel.
4.2.1.6 Electric heaters 4 pcs. x 5kW:
Electric heaters (pic.15) are included in two heating circuits / collectors of
10Kw each (pic.14/pos.1 and 2).
Pic.14 pic.15
Electric heaters are fitted in two U-shaped collectors (pic.14/pos.1 and 2),
made of stainless steel. Each collector has a drainage outlet closed by a cap. Each
collector has two heaters with installed power of 5kW. If necessary (when a
consumer of 21 kW cannot be included in the network) two of the heaters are
switched off, and the installed power of the plant becomes 11kW. The configuration
of electric heaters that will work two or four in a circuit is done using switch
(pic.12/pos.4), mounted in the electric box of the plant.
4.2.1.7 Expansion vessel with 8L volume:
For compensation of the increased water volume during the heating an 8L
hydraulic accumulator is installed in the hydraulic system. The vessel has rubber
membrane that divides the vessel into two parts - the part where the working fluid of
the hydraulic system (water) is and the part that is filled with inert gas. The pressure
of the inert gas should be 2.4 to 3 bar and is set by the manufacturer.
Protection
The hydraulic system of the plant is automatically filled with water under
pressure between 1.3 and 1.5 bar. To create and maintain this pressure a reducing
valve is used (pic.1/pos.2). When the water pressure in the hydraulic system is
lower than the rated pressure, the pressure sensor (pic.1/pos.3) provides a signal
to the control panel. Control panel terminates the program. To prevent the plant of
heating of working fluid up to inadmissible temperature (higher than 110°C), if the
control panel fails to work, an emergency temperature sensor of automatically
unrecoverable type is provided - (pic.9/pos.1).
To protect the hydraulic system of the plant from pressure higher than
permissible a safety overflow valve (pic.3/pos.4) is included in the hydraulic
system.
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1

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4.2.2 Tools & accessories for dairy product processing.
Tools and accessories include the following parts:
1. Curd separator
2. Receptacle for making curd
3. Legs for preparing cheese
4. Stand for washing of curd separator
5. Lira-knife for cutting the curd vertical
6. Lira-knife for cutting the curd horizontal
7. Circle stand for thermostatic mode
8. Metal plate for breaking the curd
9. Cover with handle for cheese making
10. Plastic cheese mold cylindrical shape 800 gr. –Ø 120/H 135
mm (optional)
11.Plastic cheese mold conic shape 300 gr. –Ø 120/Ø83/H 63
mm (optional)

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5.TECHNICAL DATA:
PARAMETERS:
Measuring
Units
VALUE
1. Rated working volume
L
120
2. Minimum working volume
L
45
3. Maximum working volume
L
135
4. Installed power (optional)
kW
10 / 20
5. Cold water flow / consumption
L/min
15÷40
6. Temperature of cold water -
recommended
ºС
12 ÷18ºС
7. Stirrer speed –controllable from
control panel
rev/min
up to 30
8. Dimensions:
- Length
- Width
- Height with control panel
- Height without control panel
mm
mm
mm
mm
1180
800
1500
1000
9. Net Weight
kg
275
6. OPERATION PRINCIPLE OF THE DAIRY PRODUCTS PROCESSING PLANT
The plant is designed for industrial processing of dairy products in small
quantities.
The main part of the plant is the vessel / vat in which liquid milk product is
processed. It is filled manually, in accordance with the limits of volumes given in the
„Technical Data“on p. 15.
Before each filling of the vat with liquid dairy product it must be
cleaned (see „Technical Manual“item 7).
6.1 Initial start-up of the plant and start-up after a prolonged stay:
Remove from the plant anything that is not necessary for work.
6.1.1 Wash the internal and external surfaces;
6.1.2 Connect the input (pic.1/pos.1) to the water source at the required pressure, flow
and water quality;
6.1.3 Connect the output (pic.3/pos.1) to the drains system or vessels for storing hot
water;
6.1.4 Connect the outlets of flexible pipeline (pic.3/pos.3) to the drains system or
under the unit;

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6.1.5 Connect the flexible pipeline that discharges the waste water from the upper
board to the sewerage;
6.1.6 Supply water to the Plant for processing dairy products from the water source;
6.1.7 Check the reading on the pressure gauge outflow of the pressure reducing valve
(pic.1/pos.2). Normal pressure should be 0.15mPa. Carefully adjust the rated
pressure using the rotary knob; turning the knob in increases the pressure,
turning the knob out decreases the pressure.
6.1.8 Open the valve for free outflow (pic.16/pos.1), until it starts to pour out only
water without being mixed with air;
6.1.9 Unscrew the two end caps (pic.17/pos.1) on the electrical heat exchangers by ½
÷1 turns successively, until air stops to come out of them.
Pic.16 Pic.17
Screw the end caps in until they stop leaking;
6.1.10 Unscrew the lid of the automatic air vent (pic.18/pos.1);
Pic.18
6.1.11 If during the performing of the above operations leakage from some of the
hydraulic connections are noticed, tighten carefully the respective connection to
remove the leak. If the leak still persists, dismount the connection and re-do the
assembly, using the best practices for the implementation of plumbing systems;
6.1.12 Fill up the vessel with water for pasteurization, as the water level should be about
10 cm above the temperature sensor;
6.1.13 Connect the power supply cable of the plant, according to the Attached
schematic diagram –Attachment 2;
6.1.14 Check electric phases on the metal surface of the plant;
6.1.15 Turn off the emergency stop (if it is ON) (pic.13/pos.10);
6.1.16 Check if the emergency stop button works –Press it;
6.1.17 Switch the power supply on, using Power Button (pic.13/pos.5);
6.1.18 Digital panel (pic.13/pos.1) indicates the temperature of the processed product
(in this case the temperature of the water which is filled up in the vessel for
pasteurization). Press the UP arrow on the keyboard (pic.13/pos.4). It indicates
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the temperature of the water in the heat exchanger - in this case the temperature
of the cooling water.
6.1.19 Select any program from freely programmable ones –5 to 9 inclusive;
6.1.20 Edit the program, as follows:
6.1.20.1 The heating t°should be 20°С higher than the water temperature in the
vessel for pasteurization;
6.1.20.2 Pasteurization time should be set in the range of 5 to 15 minutes;
6.1.20.3 Cooling –the cooling t°should be 10°С lower than the water temperature in
the heat exchanger;
6.1.21 Select step „Cooling”from the program created in item 6.1.20.
6.1.22 Start the program using key pos.6/pic.13 –turn the key clockwise and release it;
6.1.23 Pull out the end of the flexible pipe (pic.3/pos.3) which is placed in the drains
system. It shall drain from 15 to 40 liters of water per minute. If the water runs out
with the air, wait until it starts to drain only water;
6.1.24 Stop running the program using key pos.6/pic.13 –turn the key
counterclockwise and release it;
6.1.25 The outflow of cooling water from the end of the flexible pipe (pic.3/pos.3) should
be stopped;
6.1.26 To control, start and stop running the program. Starting the program shall start
discharging the cooling water, and stopping the program shall stop discharging
the cooling water;
6.1.27 Stop running the program.
6.1.28 Place the end of the flexible pipe again into the drains system;
6.1.29 Add up to 100 –120 litres of water in the vessel for pasteurization.
6.1.30 Put the blade on the stirrer;
6.1.31 Close the cover on the vessel for pasteurization. When the stirrer turns on, the
pasteurization vessel must be closed. It is inadmissible for the Operator or other
specialists working with the plant to be in the area of the moving parts of the
stirrer.
6.1.32 Using the key (pos.7/pic.13)turn on the Stirrer. Check if the Stirrer moves
uniformly.
6.1.33 Turn off the Stirrer;
6.1.34 Go to the edit mode of the control device and edit the percentage execution of
the Stirrer speed;
6.1.35 Check the work of the stirrer at a different speed of percentage execution;
6.1.36 Turn off the Stirrer;
6.1.37 Mount the flexible pipe with the dosing pistol using the holender connection. Be
careful as not to damage the O-ring.Place the end of the dosing pistol through
the gap in the cover for thermal processing of dairy products, so that dosing
product flows back into the vessel.
6.1.38 Mount the plug connector on the dosing Trigger.
6.1.39 Unscrew the holender connection (pos.2/pic.6). Take the nut aside and pour a
5% solution of liquid soap in the suction pipeline of the dosing pump to fill the
suction and discharge piping. Wait a minute, if necessary fill up the suction
pipeline. This procedure is performed only when the dosing pump is not filled with
process product or water that it does not run dry.
6.1.40 !!! It is forbidden to run the dosing pump dry. This leads to unrecoverable
damage.
6.1.41 When pumping products processed, stop working with the dosing pump before it
starts to suck air with the processed product –the surface of the treated product

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is about 15-20 mm above the top end of the suction pipe in the vessel for thermal
processing of dairy products.
6.1.42 Reassemble the holender connection.
6.1.43 Using the dosing Trigger check the work of the Dosing system in all modes –see
the Manual.
6.1.44 If there is a leak from the holender connections, tighten them carefully.
6.1.45 Monitor the dosed product flow in the flexible pipe. If after one or two minutes of
the dosing pump work it is still seen movement of air inclusions in the dosed
product, it is necessary to check tightness of all the hydraulic connections in the
dosing system.
6.1.46 !!! The dosing system works only if the processed product has temperature lower
than 55°С.
6.1.47 From the control panel, Select Recipe 2 - Cow / Goat white brine cheese.
6.1.48 Using the switch (pic.12/pos.4), select power of 10kW of the Plant operation;
6.1.49 Turn ON the mixer to run at 100% speed;
6.1.50 Change to the automatic operation mode of the program;
6.1.51 Start the operation of the program - Recipe 2. When the program starts the
centrifugal pump (pic.19/pos.1) and heaters in the heat exchanger
(pic.19/pos.2) get started automatically. The centrifugal pump drives the water
through the electric heat exchanger in which it is heated. The heated working
fluid flows around the temperature sensor (pic.9/pos.2) and emergency
temperature sensor (pic.9/pos.1), and then it enters the heat exchanger jacket in
the pasteurization vat - in the bottom of the heat exchange jacket. From the outlet
of the latter the working fluid returns to the intake manifold of the centrifugal
pump;
Pic.19
6.1.52 Follow the change of the product temperature (the water in the pasteurization
vessel) and the working fluid (press the UP arrow (pic.13/pos.4), by reading the
display for temperature (pic.13/pos.1);
6.1.53 After heating the product at 10°C above the original temperature, the heaters can
be switched to power of 20kW using a switch (pic.12/pos.4), if the electrical
system allows to work with such power;
6.1.54 Follow the work of the plant. Upon execution of each step of the program you will
hear a beep. It will automatically start the next step.
6.1.55 If during the execution of the program when the processed product temperature
increases a ringing sound is heard, it is due to the cavitation process in the
centrifugal pump. Quickly switch to cooling mode and wait until the drains pour
1
2

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Industrial Area 19, STARA ZAGORATel./Fax:[phone], 603 449; Tel. [phone];
20
about 15 to 20 liters of cooling water. Go back to heating mode. If the ringing
sound does not disappear, repeat the procedure.
6.1.56 Wait for the program to terminate.
6.1.57 The Plant is ready to implement the manufacturing process.
7.CLEANING OF THE DAIRY PRODUCT PROCESSING PLANT
To clean the Plant remove everything that interferes with the procedure.
Fill the multifunction vessel for dairy products processing with washing solution
(water and soap) at 40 ÷ 45°C. If there is no source of hot water, use the plant
facilities to heat the washing solution. Dosing pump and piping input and output are
washed in the "Dosage" mode lasting at least for five minutes, as the effluent
washing solution is poured into a multipurpose vessel.
For washing use only soft plastic brushes. Metallic brushes
scratch the surfaces and damage them beyond repair.
Rinse with clean water after washing with washing solution. To protect
surfaces from deposits of salts wipe dry the wet surfaces. To avoid bacterial
contamination at the end of the working day wash the Plant and dosing system with
a sodium hydroxide solution with a concentration of 2÷3% and a temperature of
45÷50°C for 10÷15 minutes.
If necessary, wash the plant with sodium hydroxide as well when changing the
processed products.
At the end of the working day wash the Plant inside and outside. To prevent
buildup of "Milk stone" once a week wash the Plant and with a solution of Citric or
Acetic acid at a concentration of 2÷3% and a temperature of 45÷50°C for 10÷15
minutes.
When working with alkalis and acids, personal protective equipment must be
used "working spectacles", "rubber gloves", "rubber apron" etc. These procedures
are performed only by an operator or person from personnel who attended courses
and training for working with aggressive detergents. In an eventual contact with
such substances, comply with all the procedures described by the manufacturer and
seek medical attention.
When washing be careful not to get water jet directly on the electrical, boilers
and engines.
During the set operation cycles the dosing pistol must be placed
so as to pour into the vat.
Then rinse the vat with hot water (70-75˚С) and finally with cold mains water.
8. TRANSPORTING THE PLANT FOR PROCESSING OF DAIRY
PRODUCTS