GEA ONE 11TS Specification sheet

Instructions for use and maintenance
MODEL:
ONE11TS
SERIAL NUMBER:
9146
YEAR:
2011
LANGUAGE:
English
REVISION:
0
Translation of the original instructions

GEA Niro Soavi S.p.A.
COVER02.DOC
REV. DESCRIPTION DATE SIGN
0 1 EDITION 05/07/2011 ANC
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ONE 7TS – General Information
page 1.1
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.
TABLE OF CONTENTS PAG.
1.1 Declaration of Conformity.......................................................................................................1.2
1.2 Introduction ..............................................................................................................................1.4
1.3 Warranty and general test.......................................................................................................1.5
1.3.1 Warranty...................................................................................................................................1.5
1.3.1.1 Warranty period........................................................................................................................1.5
1.3.1.2 Application method...................................................................................................................1.5
1.3.1.3 Exclusions and limitations ........................................................................................................1.6
1.3.1.4 Returned material.....................................................................................................................1.6
1.3.2 General test..............................................................................................................................1.6
1.4 Preliminary remarks ................................................................................................................1.7
1.5 How to use this manual...........................................................................................................1.7
1.6 Reproduction limits and copyright........................................................................................1.7
1.7 Revisions..................................................................................................................................1.7
1.8 Retaining manual.....................................................................................................................1.8
1.9 Aspects to be arranged by the customer..............................................................................1.8
1.10 Instructions for requesting technical support......................................................................1.8
1.11 Instructions for ordering spare parts ....................................................................................1.9
1.12 Characteristics of operators and language used ..............................................................1.10

ONE 7TS – General Information
1.1 Declaration of Conformity
The document shown below is a FACSIMILE of the “Declaration of Conformity”. The official copy will be
completed and delivered with the machine.
FACSIMILE OF CE DECLARATION OF CONFORMITY
page 1.2
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – General Information
GEA Niro Soavi S.p.A. is also certified to UNI EN ISO 9001 regulations for the Design, Construction and
Servicing of High Pressure Piston Pumps and Homogenizers, therefore the machines supplied are designed
and constructed in compliance with the approved quality procedures.
The following figure shows the UNI EN ISO 9001 Quality System Certificate.
page 1.3
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – General Information
1.2 Introduction
This manual is addressed to operators and specialized staff to enable correct use of the machine.
The manual provides instructions and indications regarding:
- correct machine installation
- functional description of the machine and of each part of it
- adjustments during setting up and startup
- correct scheduled maintenance
- basic safety and accident prevention rules
This will enable operators to find information about any problems connected with the machine and the proc-
essed product.
For better comprehension of this manual, some basic terms are described below:
- DANGER ZONE:
Any zone within or around the machine in which an exposed person is subject to a risk to his health or
safety.
- EXPOSED PERSON:
Any person wholly or partially in a danger zone.
- OPERATOR:
Person in charge of installing, operating, adjusting, cleaning the machine and performing ordinary main-
tenance procedures.
- QUALIFIED TECHNICIAN:
Qualified person who has been specifically trained and authorized to perform extraordinary maintenance
procedures or repair hob requiring particular knowledge of the machine, its operation, safety systems
and triggering conditions.
ATTENTION:Accident prevention rule for operators
WARNING:Possibile damage to machine and/or machine components.
PRECAUTION: Additional information about current operation.
NOTE: Provides useful information.
page 1.4
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – General Information
page 1.5
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.
1.3 Warranty e general test
Unless otherwise specified in the order confirmation, the warranty will be governed by the following terms
and conditions:
1.3.1 Warranty
GEA Niro Soavi S.p.A. guarantee the good quality and workmanship of their machines and undertake, for
the period specified by the warranty, to repair or repair free of charge any parts whose failure or early wear is
caused by bad material quality, manufacturing defects or imperfect assembly.
The warranty will not cover parts whose failure or wearing out results from:
- user negligence with respect to level checks, filter cleaning, auxiliary services, insufficient feed pressure;
- use of the machine outside the conditions specified in the contract, in particular with respect to maximum
pressure, capacity, product treated, operating and washing temperature, feed pressure, specifications of
utilities
- use of inadequate tool for ordinary and extraordinary maintenance;
- failed or incorrect maintenance;
- tampering or alterations performed without specific approval from GEA Niro Soavi S.p.A.;
- failure to comply with the instructions contained in the OPERATION AND MAINTENANCE INSTRUC-
TIONS;
- improper use of the machine, incorrect operating conditions and procedures
- incorrect installation of the machine or inadequate feed line design
- use of inadequate components upstream and downstream of the machine, and in particular use of in-
adequate feed pump.
For this reason it is fundamental to become familiar with the instructions contained in this manual and to im-
plement them in order to ensure correct and efficient machine use.
Use of the machine and reading of the OPERATION AND MAINTENANCE INSTRUCTIONS imply integral
acceptance of Warranty conditions.
For further information about application of the Warranty, please refer to the General Sales Conditions.
1.3.1.1 Warranty period
The warranty is valid for 12 MONTHS starting from the date of delivery, unless otherwise specificed in the
order confirmation.
This term is fixed and may not be extended following the replacement of components or repairs during that
period.
1.3.1.2 Application method
In order to determine the cause of the problem and applicability of the warranty, it is indispensable for GEA
Niro Soavi S.p.A. to receive the parts for which replacement under warranty is requested.
Shipping costs shall be borne by the customer.
Repair work or replacement under warranty shall be carried out, at the discretion of GEA Niro Soavi S.p.A,
either in their own workshop, in other workshops or on site.
The costs of shipping materials to the site shall be borne by the customer, especially in the case of urgent
shipment of materials and spare parts.
For work performed on site the customer shall provide energy sources, extraordinary equipment, any auxil-
iary personnel needed and shall bear the costs for travel, meals and accommodation of GEA Niro Soavi
S.p.A staff.

ONE 7TS – General Information
page 1.6
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.
1.3.1.3 Exclusions and limitations
The warranty shall not cover materials and parts that are subject to normal wear such as, for example, all the
gaskets used on the machine, transmission belts, plunger gaskets and associated anti-extrusion washers
and support washers, safety valve seat, filters, etc., and the parts whose lifetime cannot be determined be-
forehand, such as lamps, fuses, plunger pistons and their coating, plunger valves and their seats, homoge-
nizing valve, pressure gauges.
For components and accessories purchased from external suppliers, GEA Niro Soavi S.p.A shall apply to
the Customer the same warranty conditions granted to them by the manufacturer.
1.3.1.4 Returned material
Before returning to GEA Niro Soavi S.p.A. the parts for which you request replacement or repairing under
warranty, you must send a written notice to the Spare Parts Department for approval.
The parts must be properly packaged to prevent damage during transport and they must be accompanied
by:
- reference to purchase order;
- serial number of machine;
- spare part code number;
- accurate description of fault and of the way in which it occurred.
The parts accepted in warranty are delivered ex-origin; the parts replaced become the property of GEA Niro
Soavi S.p.A. and must be delivered ex your factory.
1.3.2 General test
This machine has been accurately inspected in the premises of GEA Niro Soavi S.p.A. before shipment,
with operating test simulating normal working conditions.
The test was performed with cold water to verify match between machine characteristics and design charac-
teristics, calibration of safety, regulation and control systems, efficiency of seals and general operation with
no abnormal noise or vibrations, parametrization of any instruments or programmable equipment.
Testing of machine performance (flow rate at the maximum operating pressure, noise level, power absorp-
tion) was carried out with water at 20 °C approx., so it was possible to verify that the deviation of actual ma-
chine flow rate with respect to the rated value is ± 5% depending on the different temperatures and viscosity
values of the product treated.
After installation, at the time of startup, it is still necessary to run a final general test on site with the presence
of technicians from GEA Niro Soavi S.p.A

ONE 7TS – General Information
1.4 Preliminary remarks
The employer must inform personnel about the following safety-related issues in the use of the machine:
- Risks of injury.
- Devices designed for operator safety.
- General safety rules or regulations laid down by international directives and by the laws of the country
where the machine is installed.
Operators, maintenance staff, cleaning staff, etc. are required to strictly comply with the safety regulations in
force in the country where the machine is installed.
WARNING:
Before operating the machine, the operator must be familiar with the position and operation of the
customized controls and with the characteristics of the machine, and must have read every part of
this manual.
The instructions, warnings and general safety rule contained in this manual must be complied with.
Alteration or replacement of machine parts without the prior authorization of GEA Niro Soavi S.p.A.
can create risk of injury and relieves GEA Niro Soavi S.p.A. from all legal responsibility.
1.5 How to use this manual
A list of contents has been included in the first page for easier reference and to quickly find the subject that
you are interested in. The chapters are organized with a special structure to facilitate the search for informa-
tion. Each chapter starts with an index. A statement at the beginning of the chapter indicates that the chapter
deals with topics and contains information of specific interest for the operaton.
1.6 Reproduction limits and copyright
All rights reserved to GEA Niro Soavi S.p.A
No part of this manual or of its structure may be reproduced unless expressly authorized by GEA Niro
Soavi S.p.A. It is also prohibited to store the information on any type of support (magnetic, magnetic-
optical, microfilm, photocopies, ecc.).
1.7 Revisions
Subsequent revisions of this manual will be issued following alterations or functional replacement in the ma-
chine.
page 1.7
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – General Information
1.8 Retaining manual
Compulsory conservation
Retain this manual and all attached publications in an easily accessible place, near the machine and inform
all users (operators and maintenance personnel) of its location.
In every situation operators and maintenance technicians must be able to quickly access the manuals and
attachments for easy reference.
WARNING:
The manual is an integral part of the machine for safety purposes.
Therefore this manual:
- must be kept in good condition (in every part);
- must be left with the machine until decommissioning (even in case of moves, sale, hire, etc.);
- must be updated and any alteration must be indicated.
1.9 Aspects to be arranged by the customer
The customer must prepare, at his expense, the installation site and provide all the electrical and pneumatic
supplies required for operating the machine as detailed below:
- Prepare premises.
- Provide power supply up to machine inlet in accordance with current regulations.
- Provide auxiliary services required by the machine (e.g. air mains).
- Any safety devices upstream and downstream of the power supply lines (such as switches, leakage
breaker, earthing system, etc.) as may be required by current regulations.
- Adequate hoisting means for handling the machine
ATTENTION:
All the above aspects, even when not indicated, must comply with the regulations in force in the
country where the machine is installed.
1.10 Instructions for requesting technical support
Requests for assistance from the Technical Support Department should be sent by fax to the following ad-
dress: GEA Niro Soavi S.p.A. Via Da Erba Edoari, 29/A - 43100 - PARMA (Italy) – Phone no. +39 0521
965411,Fax [phone], e-mail: [email protected], http//www.niro-soavi.it, indicating:
- machine type, serial number, year of installation
- reported defects
- exact address of factory where the machine is installed
page 1.8
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – General Information
1.11 Instructions for ordering spare parts
All requests for spare parts should be sent by fax to the following address:
GEA Niro Soavi S.p.A. Via Da Erba Edoari, 29/A - 43100 - PARMA (Italy) – Phone no. +39 0521
965411,Fax [phone], e-mail: [email protected], http//www.niro-soavi.it
For quick, reliable identification of spare parts please include the following information:
- machine type and serial number
- description of part
- components code
- quantity required
If you are sending an executive order for spare parts, you should also indicate the required delivery date, the ad-
dress for shipment and address for invoicing and any special shipping instructions.
Please include name, telephone number and fax number of person normally in charge of all aspects relating to
spare parts.
After receiving the order, GEA Niro Soavi S.p.A. will send an order confirmation with an indication of
prices, final delivery date and sales conditions.
ATTENTION:
We wish to point out that the Customer is required to purchase original spare parts. Removal and fit-
ting of parts must be performed by qualified technicians.
The use of non-original spare parts and incorrect fitting will relieve the manufacture of all responsi-
bility.
ATTENTION:
Particular care should be taken with the replacement of safety components where it is important to
match the safety class of the original part and any calibration requirements.
page 1.9
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – General Information
1.12 Characteristics of operators and language used
To understand the instructions in this operation manual (text and illustrations) machine operators must have
(or acquire, through adequate training) at least the following characteristics:
- Sufficient general and technical knowledge to allow them to reand and understand the parts of this op-
eration manual that concern them and to correctly interpret drawings and diagrams.
- Ability to understand and interpret symbols, pictograms and video messages.
- Familiarity with basic safety, hygienic and technological rules.
ATTENTION:
THE SAFETY MANAGER in the customer’s factory must:
- verify that operators actually have sufficient knowledge to read and fully understand the manual;
- provide adequate practical training and test the operators to ensure that they are able to correctly
and safely operate the machine, both under normal conditions and in emergency situations.
ATTENTION:
Operators must not perform any of the procedures reserved to maintenance staff or qualified techni-
cians.
The manufacturer shall not be liable for damage resulting from the failure to comply with this re-
quirement.
page 1.10
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – Description of the machine and technical data
page 2.1
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.
CHAPTER 2
Machine description and technical data Pag.
2.1 General description........................................................................................................... 2.2
2.1.1 Operating principle ............................................................................................................. 2.2
2.2 Main machine components............................................................................................... 2.3
2.2.1 Monoblock compression head............................................................................................ 2.5
2.2.2 Homogenizer assembly...................................................................................................... 2.6
2.2.3 Pressure gauge.................................................................................................................. 2.8
2.2.4 Compression head safety valve......................................................................................... 2.10
2.2.5 Manifold assemblies........................................................................................................... 2.11
2.2.6 Water system for sanitary machine.................................................................................... 2.12
2.2.7 Pneumatic system............................................................................................................. 2.13
2.2.8 Transmission body ............................................................................................................ 2.18
2.2.9 Motordrive.......................................................................................................................... 2.19
2.2.10 Casing................................................................................................................................ 2.20
2.2.11 Operator control panel........................................................................................................ 2.21
2.2.12 Electrical system................................................................................................................. 2.22
2.3 Technical specifications of the machine......................................................................... 2.25
2.4 Regulations, certifications, limits of use, ergonomics, ecology .................................. 2.26
2.4.1 Applicable technical regulations......................................................................................... 2.26
2.5 Environmental conditions ................................................................................................ 2.27
2.6 Atmosphere with risk of explosion and/or fire............................................................... 2.27
2.7 Lighting............................................................................................................................... 2.27
2.8 Vibrations ........................................................................................................................... 2.27
2.9 Noise ................................................................................................................................... 2.27
2.10 Residues and environmental contamination.................................................................. 2.28
2.11 Dismantling and disposal of materials............................................................................ 2.28
2.12 Disposal.............................................................................................................................. 2.29

ONE 7TS – Description of the machine and technical data
2.1 General description
The GEA Niro Soavi S.p.A. homogenizer consists of a positive-displacement piston pump, with automatic
suction and delivery spring-loaded valves, and a homogenizing section connected to it where the product
undergoes high-pressure micronization to reduce the size of the particles suspended in the fluid and achieve
homogeneous dimensional distribution.
This process can be applied to a great variety of products, with different viscosity, making it possible to ob-
tain stable suspensions through micronization and particle dispersion, depending on the pressure applied.
As regards specific machine configuration, model, technical data, accessories and optional features, please
refer to the TECHNICAL SPECIFICATIONS enclosed in chapter 11 of this manual.
ATTENTION
The machine should not be used for purposes other than those indicated in chapter 3.1 of this man-
ual. The manufacturer shall not be liable for damage or injury caused by improper machine use.
2.1.1 Operating principle
The operating principle of the Machine is shown in the diagram below.
2 STAGES
HOMOGENIZING
PUMP PRODUCT OUTLET
PRODUCT
INLET
OPERATING PRINCIPLE
FIG. 2- 1
page 2.2
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – Description of the machine and technical data
2.2 Main machine components
The main components of the machine are shown in the figures below, for “Homogenizer” type machine
(standard and optional versions)
COMPONENTS OF HOMOGENIZER TYPE MACHINE (STANDARD VERSION/ GREEN – OPTIONAL
VERSION/RED)
FIG. 2- 2
NOTE: The asterisk (*) in the figure indicates some components in the standard and optional ver-
sions that are not shown in the drawing
page 2.3
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – Description of the machine and technical data
page 2.4
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.
List of machine components shown in Figure 2.2 ( Homogenizer type)
STANDARD LAYOUT
Assembly
HOMOGENIZER
1) Compression head std
2) Homogenizing assembly 1st Stage std
3) Head Pressure gauge 1st Stage std
4) Head safety valve std
5) Manifold assembly std
6) Water system std
7) Pneumatic system std
8) Transmission body std
9) Motordrive std
10) Casing std
11) Control panel std
OPTIONS
12) Electrical system on machine opt
13) Homogenizer assembly 2nd stage opt
14) Suction pressure gauge opt
15) Suction pulsation damper opt
16) Delivery pulsation damper opt
17) Head transmitter Opt
18) Tri-clamp connectors Opt
19) Lubrication water circuit on-off solenoid Opt
20) Pneumatic circuit air intake on/off solenoid Opt

ONE 7TS – Description of the machine and technical data
2.2.1 Monoblock compression head
The Head (1) is the main part of the machine, where the product is pumped at high pressure, i.e. first sucked
up and then forced out by the pistons, which are driven by the crank gear system, with connection rods and
crankshaft.
The product enters the compression chamber of the Head, pushed by a special external pump, initially at
low pressure around 5 / 6 Bar; according to the operating pressure for which the machine is designed, pres-
sure is gradually increased until it reaches 250 bar. In the first processing phase, the product enters the
compression chamber through the opening suction valves (2) located inside the head, and then the pressure
generated by the action of the piston (6), pushes out the product so the suction valves close while the deliv-
ery valves (3) open to let the product out towards the Homogenizer assembly.
The head is also equipped with pressure gauge whose function is to measure head pressure.
FIG. 2- 3
1) Full forged block – cross section
2) Suction pump valve assembly
3) Delivery pump valve assembly
4) Plunger gasket
5) Removable bottom and top flanges
6) Plungers
page 2.5
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – Description of the machine and technical data
2.2.2 Homogenizer assembly
The Homogenizer assembly (1) has the function of homogenizing the product, i.e. reducing the size of parti-
cles with the high pressure applied by a special valve.
The homogenizing valve is the central element of the process. Thanks to this adjustable high-pressure valve,
the product is transformed by a combination of the following effects:
- turbulence
- local cavitation
- shear stress
- high velocity
This ensures uniform particle size distribution after the micronization obtained thanks to the high pressure
in constantly dynamic conditions.
To create the pressure, it is necessary to apply a force “F” in order to partially close the passage of the liquid
flow through the homogenizing valve.The valve is never completely closed, a small gap is left where the flow
goes through: under the same flow conditions, the higher the pressure the smaller the gap will be.
NOTE : the type of valve installed on the machine described in this manual, is indicated in detail in the tech-
nical data sheet enclosed in chapter 11.
HOMOGENIZING UNITS
FIG. 2- 4
page 2.6
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – Description of the machine and technical data ONE 7TS – Description of the machine and technical data
page 2.7
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.
page 2.7
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.

ONE 7TS – Description of the machine and technical data
2.2.3 Pressure gauge
page 2.8
This manual is property of GEA Niro Soavi S.p.A. and no part of it may be reproduced.