Comtec 2200 User manual

COMTEC INDUSTRIES, LTD.
Pie and Tart Dough Presses
Model 2200
Operator’s Manual
2200

www.comtecltd.com r.03JA13
COMTEC INDUSTRIES, LTD.
Model 2200 Operator’s Manual
Comtec Industries, Ltd.
10210 Werch Drive, Ste 204
Woodridge, IL 60517
Phone [phone] • Fax [phone]
[e-mail]
www.comtecltd.com
WARNING
Read and understand operator’s
manual before using this machine.
Failure to follow operating instructions
could result in serious injury.

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ii
Read Before Operating This Machine
The following symbols are used on the machine and in this manual. Do not operate the
machine until you understand the meaning of these symbols
WARNING
Disconnect Power Supply
Before Servicing Machine
Dangerous Voltages
Potential lethal voltages and currents are present
within the machine. Service should only be done
by qualified personnel after disconnecting the
machines power source.
WARNING
Serious Physical Injury Possible
Keep All Body Parts Away From
Dies While Pressing
Crushing Force Warning
This warning is used near moving parts of the
machine that move with sufficient force to crush
or damage body parts. Never operate the
machine when any body parts are inside of these
areas.
CAUTION
HOT!
Hot Areas
This warning is on areas of the machine that
have a lot of heat associated with it. Serious
burns may result if personnel come in contact
with these areas.

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Product Description
The Model 2200 is a hydraulic machine that uses custom dies to form dough. Each size
and type of crust requires a separate, custom die. Dies that form bottom crusts are
manufactured to work with a specific pan, chosen by the customer.
To form a crust, a dough portion is placed in the center of the pan to be used. The pan is
then placed in the lower die half. USING TWO HANDS, ONE HAND ON EACH LEVER,
PRESS BOTH LEVERS to bring the lower die half up against the upper stationary heated
die half.
After a short dwell (for example, 2 seconds) the levers are released, bringing the lower die
half down. The formed crust is then removed from the die. ONLY THE OPERATOR OF
THE HANDLES IS TO LOAD THE PAN WITH DOUGH PORTION INTO, AND REMOVE
THE FINISHED CRUST FROM THE PRESS.
There are no user serviceable hydraulic components on the Model 2200. Any questions
about the hydraulic should be directed to Comtec or Comtec’s authorized representative.
The Model 2200 does not have a dedicated neutral.
Heater Block
with temperature control
Travel Plates
Press Activation Handles
Electric Motor
Hydraulic Cylinder
Hydraulic Reservoir
On/Off Switch

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SAFETY FIRST
READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO OPERATE THE PRESS.
COMTEC HAS INSPECTED THIS PRESS. OTHER THAN TRANSIT DAMAGE, NO
MODIFICATION IS NECESSARY.
THE PRESS OPERATOR MUST USE TWO HANDS (ONE ON EACH HANDLE), TO
CYCLE THE PRESS. UNDER NO CIRCUMSTANCES SHOULD A SECOND PERSON
BE INVOLVED IN LOADING OR UNLOADING THE DIE AREA OF THE PRESS.
PRECAUTION SHOULD BE TAKEN TO PREVENT A PRESS OPERATOR FROM
CIRCUMVENTING THE DUAL SAFETY HANDLES.
THE PRESS MUST BE DISCONNECTED FROM ELECTRICAL POWER BEFORE ANY
ELECTRICAL SERVICE IS ATTEMPTED. PLEASE NOTE WARNING LABEL ON TOP
COVER OF PRESS.
ELECTRICAL POWER MUST BE TURNED OFF BEFORE ATTEMPTING TO CHANGE A
DIE.
MISINSTALLATION OF A DIE MAY CAUSE MINOR DAMAGE THAT PREVENTS LOW
PRESSURE SAFETY RETRACTION FORCE FROM FULLY RETRACTING THE
HYDRAULIC RAM. DO NOT OPERATE PRESS IN THIS CONDITION. CONTACT
FACTORY FOR RECOMMENDATION.
WARNING
ONLY OPERATOR OF
PRESS HANDLES IS TO LOAD
AND UNLOAD DIE AREA

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IMPORTANT
Hydraulic Oil Specifications
BEFORE OPERATING THIS MACHINE, FILL THE
RESERVOIR WITH EITHER:
FIVE (5) GALLONS (18.9 LITERS) OF MINERAL
BASE “LIGHT” #32 HYDRAULIC OIL, 150 S.S.U.
VISCOSITY (EQUAL TO 10 WT. ENGINE OIL).
USE ONE OF THE NAME BRANDS (ARCO, ENCO,
STANDARD, SHELL, ETC) EQUAL TO CITGO
PACEMAKER #32.
OR
USE FIVE (5) GALLONS (20 QUARTS/18.9 LITERS)
OF S.A.E. 10 WEIGHT, AUTOMOTIVE ENGINE OIL,
FOR NON-DETERGENT SERVICE.
THE MOTOR STARTER SWITCH (LOCATED ON
THE MACHINE CROWN COVER) SHOULD BE IN
THE “OFF” POSITION BEFORE PLUGGING THE
MACHINE INTO THE APPROPRIATELY RATED
SINGLE PHASE, AC SERVICE OUTLET.
REFERENCE THE MACHINE’S NAME PLATE
INFORMATION FOR THE APPROPRIATE
ELECTRICAL OPERATING VOLTAGE.

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IMPORTANT SANITATION INFORMATION
Compliance with sanitation specifications requires that the bottom of each Comtec crust
forming machine's base be completely sealed to the surface or structure on which it rests.
To guarantee a smooth, airtight seal between the machine and the mounting surface,
perform the following steps:
1. Thoroughly clean and dry the mounting surface and the bottom of the machine's
base.
2. Remove the four glide feet (one at each corner) from the bottom of the machine.
To remove, twist each glide foot counterclockwise (unscrew it).
3. Use only a clear sealant/adhesive that is completely suitable for use in a food
processing environment; i.e. nonflammable, nonhazardous when fully cured, etc.
IMPORTANT: read and understand the product and material
data safety sheets before handling.
4. Position the machine properly.
5. Apply the sealant around the base of the machine as instructed in the product
information. The applied sealant must prevent foreign matter or fluid from
accumulating underneath the machine.
6. Allow the sealant to dry and cure completely.
7. Wash the sealant.

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viii
GENERAL NOTES
You should be familiar with the following information before setting up and operating the
equipment described in this manual.
1. NO ONE OTHER THAN THE OPERATOR SHOULD LOAD AND UNLOAD THE DIE
AREA DURING PRODUCTION. Hundreds of pounds of force is generated in the Comtec
2200 Press during its upward forming motion. Fingers, hands, or arms should never be
placed in the die area while the motor is running. The Press is equipped with a low force
retraction circuit. This limits the downward force of the Press. This downward force is high
enough to cause injury, but not of the permanent nature that would occur from the
hundreds of pounds of upward force. Also, always disconnect the plug before making any
electrical adjustment or alteration. A double lever, requiring two hands to cycle the Press is
provided. Care should be taken not to modify or allow an employee to devise any method
of circumventing this safety feature.
2. PANS AND DIES.
Be certain the upper and lower die halves match and are for the pan to be used. All
Comtec dies are marked with an identifier of the pan for which they were manufactured.
On upper die halves, the pan identifier is marked on the top surface. On lower die halves,
the pan identifier is marked on the inside horizontal surface. Comtec dies are precision
manufactured to match the pan supplied with your order. Generally speaking, pans, other
than those for which the dies were manufactured, may not be substituted. The pressed
crust may look good, but in most instances, the die halves may be damaged and/or the
crust will bake up with problems.
3. DOUGH FORMULA. The Comtec 2200 does not require a special type of dough. In
most cases, your present formula will work satisfactorily, if you bear in mind the following
points:
A. With the Comtec 2200 Press, you should not be rolling or sheeting your dough,
hence toughening it. A "flaking" additive is not necessary or recommended.
B. A pie or pastry flour should be used.
C. You will not need to dust your dough with flour as in a sheeting or rolling operation.
You will not be reworking scrap trimmings. For these two reasons, it is recommended
that you reduce the amount of water used in you formula to be no more than 25% of
the weight of the flour.
D. Comtec recommends using a cake paddle when mixing your dough. Dough hooks
and similar devices can very easily overwork the dough, resulting in pressing
problems.
In operating the Press, keep these things in mind:
1. Don't use dough that is too cold. The best temperature is about 60 degrees. If it is too
cold, it will prevent the dough from flowing.
2. Proper temperature of the upper die: On some of the richer pie crust formulas, you will
find it better to use less heat.

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IMPORTANT DOUGH MIXING INFORMATION
COMTEC equipment forms crust exactly to size. Dough mixing errors may result in deformed
shells.
BE CAREFUL WHEN USING ALL PURPOSE, BREAD FLOUR (H & R FLOUR), INSTEAD OF
PASTRY FLOUR. Bread flour is stronger-it has more gluten. If bread flour is used, the shortening
should be raised to 75% to 80% of the weight of the flour. Do not rest the dough for more than an
hour. Do not store the dough; use all of it in crust production. If stored, the dough gets stronger
and increases the possibility of crust shrinkage.
BEWARE OF EXCESS WATER IN PIE DOUGH. Pie dough formula for rolled and sheeted crust
include extra water to cope with dusting flour and scrap dough recovery. The Comtec crusts
system includes neither scrap dough recovery nor dusting flour, so excess water leads to tougher
dough and shrinkage problems. Water should be no more than 25% of the weight of the flour. A
typical recipe: 24 lb. Pastry Flour
16 lb. Shortening
6 lb Water
1 lb Sugar
½ lb Salt
PIE DOUGH SHOULD BE "SHORT TIME DOUGH"- BEWARE OF OVERMIXING.
COMTEC RECOMMENDS USING ONE OF THE FOLLOWING TWO MIXING METHODS:
METHOD A:
1. Place 1/2 of the flour in the bottom of the mixer bowl. Add all the shortening, broken into a
number of pieces.
2. Use the cake paddle or flat beater at #1 speed setting on a "Hobart" type mixer. Start the mixer.
Mix until shortening and flour are thoroughly blended smooth. Stop the mixer and add the balance
of the flour. Start the mixer and blend until white of new flour can no longer be seen (15 seconds
max). Stop mixer.
3. Add the water, with the balance of the ingredients (sugar, salt, conditioner, etc. in solution)
directly into the middle of the mixer bowl.
4. Start the mixer and count the turns of the socket or orbiter the paddle is inserted into. Twenty
(20) turns. Stop the mixer, feel dough. If slimy, give an additional 3 to 5 turns. Stop the mixer.
5. Rest the dough mixture on a sheet pan at room temperature for at least one half (1/2) hour.
Additional rest time can be done under refrigeration. Dough is ready when a handful can be
gripped and released cleanly without any sticking to hand.
METHOD B
1. All ingredients at room temperature. Place all the flour in the bottom of the mixer bowl. Salt and
sugar can be worked in at this time or added to the water. Add all the shortening, broken into a
number of pieces.
2. Use a cake paddle at the #1 speed on a "Hobart" type mixer. Start the mixer. Mix until
shortening is broken down to "Streusel" size, just before the mix goes from white to gray in color.
Stop the mixer. Add water as described in Method A, follow steps 3, 4, and 5.

Table of Contents
Read Before Operating This Machine ii
Product Description iii
SAFETY iv
Hydraulic Oil Specifications v
GENERAL NOTES viii
DOUGH MIXING ix
CHAPTERS
INTRODUCTION 1
INITIAL INSTALLATION 2
INSTALLATION OF DIES 4
Tapped Air System 10
TEMPERATURE ADJUSTMENT OF DIE 11
USING THE MODEL 2200 13
SERVICING THE PRESS 15
TROUBLESHOOTING 19
Electrical Schematic 34
Maintenance Schedule 35

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INTRODUCTION
he COMTEC Model 2200 Press forms pie, cheesecake, hors d’oeuvres and
other specialty crusts in round and non-round containers. This Press can
form bottom crusts ranging in size from 1-1/2 inches (38 mm) to 12 inches
(300 mm) diameter; top crusts to 11-5/8 inches (295 mm) diameter. The
quality of the crusts formed with this Press exceeds that obtained with sheeted
methods.
The Model 2200 is a hydraulic machine that uses custom dies to form dough. Each size
and type of crust requires a separate, custom die. Dies that form bottom crusts are
manufactured to work with a specific pan, chosen by the customer.
To form a crust, a dough portion is placed in the
center of the pan to be used. The pan is then
placed in the lower die half. USING TWO
HANDS, ONE HAND ON EACH LEVER, PRESS
BOTH LEVERS to bring the lower die half up
against the upper stationary heated die half.
After a short dwell (for example, 2 seconds) the
levers are released, bringing the lower die half
down. The formed crust is then removed from
the die. ONLY THE OPERATOR OF THE
HANDLES IS TO LOAD THE PAN WITH DOUGH
PORTION INTO, AND REMOVE THE FINISHED
CRUST FROM THE PRESS.
T
Figure 1Front View of Machine

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INITIAL INSTALLATION
he following procedure should be followed when the COMTEC 2200 Press
is initially installed. The Press has been carefully checked, adjusted and preset
at the factory for optimum performance.
NOTE: Do not run the Press without the required amount of hydraulic oil in the
reservoir-tank. Do not adjust hydraulic system. Adjusting the hydraulic system without
first contacting Comtec may seriously compromise the safe operation of the machine.
BEFORE ATTEMPTING ANY MODIFICATION OF THE PRESS OR DIE, CONTACT
THE FACTORY FOR APPROVAL.
1. Uncrate carefully and inspect for any possible damage that may have occurred in
transit. If you notice any damage to the equipment, immediately report this damage to
the carrier.
2. The CE Marked version of the Model 2200 is shipped without a plug. It is the end
user’s responsibility to attach the appropriate grounded plug that conforms to EN
60309-1 and EN 60309-2. The power plug is the Model 2200’s mains disconnect and
must always be accessible.
3. Position the Press so that it is within six (6) feet (2 meters) of an appropriately rated
single phase, AC service outlet. Reference the machine’s name plate information for
the appropriate electrical operating voltage and amperage. Position the Press so that it
is reasonably level. Arrange the area so that the work can be handled smoothly and
efficiently.
4. Fill the reservoir with five (5) gallons, (20 quarts/18.9
liters), of a light mineral base #32 hydraulic oil
(equivalent-CITGO Pacemaker 32), with a viscosity not
to exceed 150 S.S.U. Remove the fill cap at the left side
of the reservoir and add oil. (See Figure 2).
In an extreme emergency, an SAE 10 weight
automotive engine oil FOR NON-DETERGENT
SERVICE may be substituted. While the machine will
operate using 10 weight oil, it may shorten the
operational life of the machine.
5. Plug the power line of the press into an appropriately
rated outlet. Turn on the machine’s power switch which
is located on the top of the machine.
T
Figure 2 Removing Fill Cap

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6. USING TWO HANDS, ONE HAND ON EACH LEVER, push both control levers
down. This will move the travel plate to the full UP position. Remove both hands from
the control levers and travel plate will come down to original position.
7. You should hear no noise except the standard operating sounds of the motor and
hydraulic pump.
8. The travel plates should only stop moving at the top and bottom of the machine’s
cycle.
This completes the initial test of the Model 2200.

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INSTALLATION OF DIES
NEVER INSTALL DIES WITH THE MACHINE TURNED ON AND THE MOTOR
RUNNING !
For single-pressing round dies, follow the installation procedure below (Single-Pressing
Round Die Installation). For non-round and multi-pressing dies, follow the installation
procedure on page 6 (Non-round and Multi-Pressing Die Installation).
Single-Pressing Round Die Installation
he following procedures can be used to install all sizes and types of round
single-pressing dies, and tooling, supplied by COMTEC for your Press. We
will assume the Press does not have a set of dies installed at this time.
1. Switch Power Off. Use the power switch at the control panel on top of the
Press.
CAUTION: MAKE SURE THAT THE POWER TO THE PRESS IS OFF BEFORE
ATTEMPTING TO INSTALL A DIE.
2. Examine your dies. Make sure that both hubs are clean. While both hubs should
be clean, be especially certain that the upper die is clean. If the hub of the upper die
is coated with dough or other foreign material, the die may not heat properly (See
Figure 13).
3. Make sure that the circular hub on the heater assembly and all locating holes on
the rectangular travel plate are clean.
4. Fit the tail of the lower die half into its hole in the center of the rectangular travel
plate. (See Figure 3)
T

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5. Turn thumb screw on the right side of the travel plate clockwise to lock the
lower die half in position.
6. Insert pocket of upper die half into hub at heater assembly. Using the supplied
hex head wrench, turn wrench to secure die. The hex head wrench fits into the
opening located in the panel on top of Press. The die must be “snug” but not
overly tight to assure good heat conduction. (See Figure 4)
Figure 4Installing Upper Die Half
7. Switch Power On.
8. USING TWO HANDS, ONE HAND ON EACH LEVER, push both levers
down simultaneously to bring the travel plate up. Check to see if the dies close
fully. When the dies close fully, the damming ring on the upper die half will move
1/8 inch (3 mm) or more. If the dies do not close fully, bring the travel plate down
Figure 3Installing Lower Die Half

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(release both levers) and carry out the procedures on page 9 (If The Dies Do Not
Close Fully).
If the dies DO close fully, the installation procedure is done.
Non-round and Multi-Pressing Die Installation
he following procedures can be used to install all sizes and types of non-
round and multi-pressing dies, and tooling, supplied by COMTEC for your
Press. We will assume the Press does not have a set of dies installed at this
time.
1. Switch Power Off. Use the power switch at the control panel on top of the
Press.
CAUTION: MAKE SURE THAT THE POWER TO THE PRESS IS OFF BEFORE
ATTEMPTING TO INSTALL A DIE.
2. Examine your dies. Make sure that both hubs are clean. While both hubs should
be clean, be especially certain that the upper die is clean. If the hub of the upper die
is coated with dough or other foreign material, the die may not heat properly (See
Figure 13).
3. Make sure that the circular hub on the heater assembly and all locating holes on
the rectangular travel plate are clean.
4. Feed die alignment bolt through the hole in the bottom of the lower die half.
5. Fit tail of lower die half into travel plate. (See Figure 5)
T
Figure 5Installing Lower Die Half

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6. DO NOT turn the thumb screw below the lower die half clockwise to lock die
half in position, yet.
7. Insert pocket of upper die half into hub at heater assembly. Using the supplied
hex head wrench, turn wrench to secure die so that it is approximately aligned with
the lower die half. The hex head wrench fits into the opening located in the panel
on top of Press. The die must be “snug” but not overly tight to assure good heat
conduction. (See Figure 6)
Figure 6Installing Upper Die Half
8. Thread the die alignment bolt into the corresponding hole on upper die half.
Tighten the die alignment bolt until it is completely threaded into the upper die
half.
9. Switch Power On.
10. USING TWO HANDS, ONE HAND ON EACH LEVER, push both levers
down simultaneously to bring the travel plate up. Repeat 3 or 4 times to allow the
die alignment bolt to align the two die halves. If the lower die half binds on the
alignment bolt, release the press handles immediately and check that the alignment
bolt is not bent and that it is completely seated in the upper die half. Check to see if
the dies close fully. If your die is equipped with a damming ring on the upper die
half, the damming ring on the upper die half will move 1/8 inch (3 mm) or more
when the dies close fully. If the dies do not close fully, bring the travel plate down
(release both levers) and carry out the procedures on page 9 (If The Dies Do Not
Close Fully).

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11. If the dies DO close fully, turn thumb screw below the lower die half clockwise
to lock the die half in position. This installation procedure is done.

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9
If The Dies Do Not Close Fully.
Carry out the following steps:
1. Switch Power Off
2. Measure the distance from the bottom edge of the rectangular travel
plate which supports the bottom die half (also known as a travel plate) to
the top edge of the flange plate directly below the middle of the travel plate
(See Figure 7). The factory sets this distance to 2-3/4 inches (70 mm). The
distance can be safely reduced to 2-1/4 (57 mm) inches if needed.
3. If the measured distance is less than 2-3/4 inches (70 mm), adjust the
cylinder ram. The cylinder ram is located underneath the rectangular travel
plate. Release tension on lock nut at top of cylinder ram under the travel
plate. Take care to place wrenches only on the wrench-flat on top of ram
and hex surface of lock nut. Rotate hydraulic ram clockwise two full turns;
retighten lock nut.
4. Check Closing of Dies. Repeat this procedure if the dies still do not
close properly.
Figure 7 Model 2200 Press
Travel Plate
Flange Plate