Gildewerk ZXM-05000 User manual

Instruction manual
EN 1
CONTENTS
1 Introduction 1
1.1 Points of interest
1.2 Safety guidelines
1.3 Operating environment
2 Construction 2
2.1 Motor housing
2.2 Control panels
2.3 Screw
2.4 Screw housing
2.5 Filling feeder
2.6 Heating of press head unit
2.7 Extrusion plates
3 Operation 2
3.1 Start-up
3.2 Short-term deactivation
3.3 Long-term deactivation
4 Transport and
installation 4
4.1 Transport
4.2 Installation
5 Maintenance 4
5.1 Cleaning
6 Extruder specifications 5
Chapter 1
Introduction
This soap extruder has been designed
to produce staves of soap from soap
granulate, which is a semi-processed
product. This is made possible by
means of extrusion. The machine is
equipped with a three-speed
revolution control and an electronic
temperature regulator. The various
other functions of the machine are
controlled by a PLC. By using assorted
shape plates, it’s possible to produce
differently shaped staves of soap.
Please note: Read this instruction
manual carefully before use. Only use
the soap extruder if the ambient
temperature is at least 18 °C.
1.1 Points of interest
This machine was tested prior to
delivery. However, you should still do
the following:
1 Check the machine for apparent
damage.
2 Make sure that the electrical
specifications on the model plaque
correspond to the available
current.
3 Because the press screw and
the screw housing - when new -
must hone one another to create
a perfect fit, some miniscule metal
particles may be released.
This is not in any way a problem.
In case of malfunctions, transport
damage and/or deficiencies, please
notify Gildewerk immediately.
1.2 Safety guidelines
● 
This machine has been designed
to be splash proof and is intended
for indoor use.
● 
The operation and maintenance of
this machine must only be perfor-
med under the constant supervisi-
on of a capable person.
● 
This machine is only suitable for
the extrusion of soap granulate
supplied by Gildewerk and using
Gildewerk fragrances and
colourants.
Please note: If ingredients not men-
tioned above are used, the guaran tee
becomes null and void and Gildewerk
will not be liable for injury and/or
damage. This also applies to possible
modifications which could influence
the functioning of machine, and
to use in an area with an ambient
temperature below 18 °C!
1.3 Operating environment
In order to guarantee the reliable
functioning and long useful life of
the machine, the below conditions
must be met:
1 Ambient temperature:
18 °C to 25 °C
2 Relative humidity: max 90 %
3 Vibration: max 0,5 g
4 No aggressive fumes or gases
present.
5 No excessive dust, sand, etc.
6 Adequate ventilation.
Soap
extruder
GW1101HL-44
©2011 Gildewerk NL
Subject to changes. The conditions held at
the county court in Haarlem apply to all services
and goods supplied by Gildewerk.
www.gildewerk.com
The Netherlands
Gildewerk B.V.
Jan van Geunsweg 10 A
NL-2031 BD Haarlem
Pays-Bas
T 31
–
(0)23
– 532 22 55
F 31
–
(0)23
– 534 09 65
E [e-mail]25
ZXM-05000

Chapter 2
Construction
The soap extruder consists of
a number of basic components.
1 Motor housing-
2 Control panels
3 Press screw
4 Screw housing with the mixing
plate
5 Filling feeder with lid
6 Press head-
7 Shape plates are attached
2.1 Motor housing
This is the large purple case on top
of which the ‘Emergency Stop’ button
is mounted. The motor housing is
supported by four adjustable feet
which can be set to stabilise
the machine using a no. 17 spanner.
The opening in the underside of
the machine ensures that the motor
receives adequate ventilation.
It’s important that this opening is not
obstructed. A cable with a round
connector is also attached to the
motor housing. This is for the heating
of the press head.
2.2 Control panels
The two control panels are located
on the sides of the motor housing:
Depending on the configuration,
the locations of these panels may
differ (left- or right handed machines).
This is not significant to the rest of
the operation instructions.
The Power panel featuring:
● Main switch
(on /off)
● 
Fuse holder with 20 mm 16 A fuse.
Please note! When replacing the
fuse, make sure that it is replaced
with the abovementioned type!
● Electricity supply cable
● 
Indicator lamp which shows that
the machine is live.
●
‘Remote’ operating pedal connec-
tion.
The Command panel featuring:
● 
the ‘ZX’ section with ‘ready /
error’
indicator
The
‘heating’ section with:
● 
On /off button with ‘active’
indicator
The
‘remote ’ section with:
● 
On /off button and ‘active / stand-
by’
indicator
The
‘feeder’ section with:
●
‘closed’ indicator
The
‘motor’ section with
● button and
‘stop’ indicator
● button and
‘speed 1’ indicator
● button and
‘speed 2’ indicator
● button and
‘speed 3’ indicator
The display is also located here. This
provides the user with all necessary
information, including the state of
the machine, the temperature of
the press head, the motor capacity
and the elapsed running time. It is also
used to provide instructions in case
of errors. Certain settings can be
changed by the user with the buttons
next to this display.
2.3 Press screw
The press screw, which becomes
visible when the screw housing is dis-
assembled, is attached to the motor
in the motor housing. The soap is
pushed forward by the movement of
the screw. It’s important that this
screw is kept as clean as is possible.
The smoother the screw, the more
efficient the extrusion process
becomes.
2.4 Screw housing
The screw housing is a stainless steel
tube into which the screw is placed.
It is fixed to the motor housing by
means of three hex bolts. As the
screw rotates, soap is extruded via
this tube – which leads to the press
head - through the large mixing plate.
2.5 Filling feeder
The filling feeder is fixed to the screw
housing and is fitted with a lid to
ensure safety. The lid is equipped
with a grid, and soap granulate can be
added from above. If the lid is opened
while the machine is active, the press
screw will stop immediately. Never
insert any objects into the feeder with
the intention of, perhaps, pushing the
soap down. This can cause irre parable
damage to the screw and screw
housing.
2.6 Press head
The press head is mounted on
the end of the press tube by means
of three hex bolts. Various inter-
changeable shape plates can be fixed
to this head. For optimum perfor-
mance during the extrusion of soap,
the press head is heated. This heating
system is connected to the machine’s
electricity supply cord.
2.7 Shape plate
The shape of this plate determines
the style of the extruded stave of
soap. The plate is fixed to the press
head with four crosshead screws.
Chapter 3
Operation
Please note: Before the machine is
used, make sure that all the hex bolts
are fitted and have been tightened
using the hex key provided!
3.1 Start-up
● 
Makes sure that the main switch is
in the
‘off’ position.
● 
Connect the electricity supply cord
to the machine and insert the plug
into an earthed wall socket.
Please note: To ensure safety and to
prevent damage to the machine, it is
absolutely essential that the machine
is connected to a suitably earthed
socket. If you are in doubt, ask your
technical department to check.

● 
Attach the plug on the press heater
cable to the connector on the
press head and make sure that it
fits properly: Push the plug onto
the connector (
please note! It only
fits when inserted in a certain way)
and carefully turn the ring on the
plug in a clockwise direction.
● 
Make sure that the ‘emergency
stop’
button is in its upward
position and deactivated. If this
is not the case, the machine won’t
start!
● 
Please note! If the ‘emergency
stop’
button is used while the
machine is working, it cannot
simply be turned on again.
Obviously something has gone
wrong and must be checked by
someone capable of doing so.
This is also indicated on the display.
In order to reactivate the machine,
the main switch must first be
placed in the
‘off’ position and,
after a few minutes, returned to
the
‘on’ position.
● 
The ‘main switch’ activates the
machine. When it is turned on,
the yellow
‘power’ indicator lamp
next to this switch will illuminate.
● 
The machine will first test a
number of functions and display its
software version. During start-up,
you do not need to pay attention
to what is displayed. After two
seconds, the machine will start
and the display will indicate its
processes.
EN 2

● 
Now, the machine will start
heating the press head. If the
heating is ‘on’, the
‘active’ indicator
will illuminate. The display will read
ZX=Warming up and will also
indicate the temperature. If the
heating cord is not connected,
the display will read ‘Connect
Heater! Or outside temp too cold’.
The machine cannot be used if
the ambient temperature is below
10 degrees. If, for some reason,
you would not like to use the press
head heating, you can deactivate
it by pressing the
‘heating on / off’
button. To later reactivate the
heating, press the
‘heating on / off’
button a second time.
● 
Once the press head has reached
its temperature, the green
‘ready’
indicator lamp will illuminate,
indicating that the machine is
ready. The display will read ZX =
Ready. The machine is now ready
for use.
● 
Using the ‘1, 2 and 3’ buttons,
you can set the machine to run at
a predetermined speed. The
indicator lamp in the chosen
button will illuminate. The
‘stop’
button will turn off the motor.
● 
The display indicates the selected
‘speed’ and motor capacity in
Amperes. It’s essential that you
keep an eye on this value. If it rises
above 8A, we recommend that you
select a lower speed. If the motor
capacity remains higher than 8A
for more than 20 seconds (over-
load), the motor will automatically
shut off and you will have to select
a different, lower speed. If
the motor reaches a state of
‘Overload’ three times, it will shut
itself down and you will have to
restart the machine once you’ve
removed the cause of the block-
age. This will rarely happen in
practice, where the machine
efficiently functions at 3 to 4A.
If the meter indicates values above
6,5A when it is not heavily loaded,
the soap in the screw housing has
probably dried out and you will
have to detach the press head and
remove the old soap from it.
Also beware against running the
machine at a low speed for too
long. This affects the quality of
the soap, while the motor also
doesn’t receive enough ventilation,
causing it to overheat and auto-
matically shut down. If this hap-
pens, you should turn off the
machine and allow it to cool for at
least an hour before starting it
again.
● 
The ‘emergency stop’ function
speaks for itself and should only be
used if something threatens to go
wrong. To restart the machine,
refer to the start-up instructions
above.
3.2 Opening the feeder
● 
If you open the feeder lid while the
machine is running, the machine
will immediately stop and the
green
‘feeder closed’ indicator
lamp will go out. This indicator
also specifies whether or not the
lid is well-closed. It is not always
necessary to open the lid to fill
the feeder. The grid openings are
large enough to allow soap
granulate to pass through the grid.
● 
When you replace the lid, you once
again must select a speed in order
to activate the motor.
3.3 Using the remote
● 
To use the ‘remote’ pedal, first
plug it into the
‘remote’ connector
on the power panel.
● 
By pressing the ‘remote on’ button
(of the
feeder open indicator)
once, you can activate remote
operation.
● 
Now, when the feeder is closed,
the
remote on indicator lamp will
flash, indicating that the machine
is awaiting use of the pedal.
● 
A speed can now be selected.
When you now depress the pedal,
the motor will start and the lamp
will illuminate continuously. If you
release the pedal, the motor will
stop. Depress the pedal and
the motor will start again (this
depends on the PLC settings, see
page 11). This function is especially
useful for emptying the machine.
Please note: If you open the feeder,
you will have to reset the motor
speed.
● 
By pressing the ‘remote off’
button, you deactivate remote
operation.
3.4 Turning off the machine
● 
After use, place the machine in
‘stop’ mode.
● 
After intensive use, allow the
machine to cool down for a while
(you’ll be able to hear the fan
running) before turning it off using
the
‘power on’ switch. This
procedure will increase the useful
life of the machine.
Please note: If necessary, the
machine can be turned off at any time
without following specific procedures.
EN 3
3.5 Changing various functions
When the machine is not in operation,
you can use the display to view and
change various functions. You can do
this by briefly pressing the button
with the arrow pointing to the right.
Using the up and down arrow button,
you can then browse the various
menus. These are, in order:
● 
Locking the machine
This function is handy if you would
like to prevent the buttons from
being tampered with (e.g. in
a store). Press the right-arrow
button to select this function.
When the ‘Code’ is zero, all the
buttons are active. Using the ‘plus’
button, you can change the code
to a number of your choice,
thereby deactivating the buttons.
You must confirm your choice
by pressing the ‘OK’ button.
By pressing the ‘Esc’ button, you
will return to the main screen.
The display will indicate that the
machine is locked (ZX=locked).
You can reset this function by
zeroing the ‘Code’ again using
the ‘min’ button and confirming
this with the ‘OK’ button.
● 
Checking the number of
‘session hours’
This function allows you to
determine the number of hours
during which you have made soap
in a week, for instance. This is
the ‘Session’ time. The time
indicated is the actual time during
which the motor has been active.
You can reset this counter by
pressing the left-arrow and right-
arrow buttons simultaneously
for 10 seconds.
● Checking the total number
of hours
This function allows you to
determine the total number of
hours during which the machine
has been ‘On’ and in operation.
This is important with respect to
the maintenance of the machine.
This counter cannot be reset.
● Setting the press head
temperature
You can use this function to set
the temperature of the press head.
The default temperature is 42 °C.
Using the ‘plus’ and ‘min’ buttons,
you can adjust the temperature.
Once the desired temperature has
been set, you must press the
‘ok’
button to save this temperature.
Press ‘Esc’ to return to the main
screen.

EN 4
● 
Use a wooden palette knife to
remove the rest of the soap stuck
to the press head.
● 
Clean the mixing- and spaghetti
plates using water and a brush.
You could also use our handy aids
(item nos. ZXB-01002 or
ZXB-01003) to clean the mixing
plate.
● 
Now undo the three bolts fixing
the screw housing to the motor
housing.
● 
Carefully slide the screw housing
off the screw.
● 
Clean the screw housing with
a damp cloth.
● 
Clean the screw with a wooden
palette knife and/or a damp cloth.
We recommend that you lubricate
the screw’s rubber sealing ring
with acid-free Vaseline. Once you
have finished cleaning the machine,
it can be reassembled.
Do the following:
● 
Carefully slide the screw housing
onto the screw.
● 
Make sure that the screw housing
edge fits into the recess in the
motor housing and that the bolt
holes line up. Tighten the bolts
with the hex key.
● 
Fix the ‘large mixing plate’ to
the front of the screw housing
with the larger sides of the holes
towards the screw.
● 
Attach the press head to the screw
housing and make sure that
the electrical connection on the
press head is pointed sideways.
Tighten the bolts with the hex key.
● 
Place the small spaghetti plate in
position and attach it evenly using
the four crosshead screws. Use
a no. 2 screwdriver to do this.
● 
Reconnect the press head heating.
Warning: Unattached and/or
insufficiently tightened bolts or screws
can cause irreparable damage to
the machine during operation.
The soap extruder is now ready for
further use. If it is regularly cleaned
following the above mentioned
procedures, the machine will remain
in an excellent condition.
● 
Avoid damage to the electricity
supply cord during transport.
● 
Make sure that the main switch on
the side of the motor housing is
in the off position before inserting
the plug into a socket.
● 
Never connect the machine to
an unearthed socket!
Chapter 5
Maintenance
1.1 Cleaning
Warning: Place the main switch
in the ‘0’ position and unplug
the machine before removing any
components!
Warning: Never rinse or submerge
any components in water, detergents,
etc. unless you are specifically
instructed to do so!
The machine must be cleaned under
the following circumstances:
1. When changing the soap colourant.
2. When deactivating the machine for
a long period of time.
Do the following:
● 
Allow the machine to empty
almost completely. The machine
is almost empty when virtually
no more soap exits through
the extrusion plate while the
motor is running.
● 
Turn off the heating and disconnect
the cord from the press head.
● 
Undo the four crosshead screws
from the shape plate and place
these in a safe place. If one of these
screws were to end up in the
machine, it could cause irreparable
damage!
● 
Turn the motor back on (Speed 1)
and allow the pressure to push the
shape plate from the press head.
● 
Using the hex key provided, undo
the three hex bolts on the press
head and, once again, allow
the pressure of the soap to push
the press head off. Make sure that
it doesn’t drop off suddenly!
● 
Turn off the machine and unplug it.
● 
When removing the press head,
the ‘large mixing plate’ will detach
along with it. From the front,
push the remaining soap from
the press head. This is done more
easily once the press head has
cooled somewhat. A handy tool
(item no. ZXB-01001) is available
to assist you in doing this.
● Adjusting remote pedal
operation
You can use this function to adjust
the operation of the remote pedal.
Press the right-arrow button to set
the pedal. If the ‘code’ = 1,
the pedal will function as a ‘pulse’
switch. The motor will then start
when you depress the pedal and
stop when you release it. If you
change the code to zero using
the ‘min’ button, the pedal will
function as a ‘latch’ switch.
The motor will then start when
you depress and release the pedal,
and will stop when you once again
depress and release the pedal.
You must confirm your selection
using the
‘ok’ button.
If you don’t press any buttons for a
period of 100 seconds, the display
will revert to the main screen.
Chapter 4
Transport and installation
4.1 Transport
Warning: Before moving the
machine, always make sure that it is
unplugged!
When moving the machine, always
take the following into account:
● 
Never lift or move the machine by
its cables, knobs, switches or other
fragile components. The machine
is provided with two handles at
the front and one at the back.
● 
Place a flat object underneath
the machine when it is being
moved using a pallet mover or
forklift. This is due to the ‘open
bottom’ of the motor housing.
● 
Avoid severe vibration during
transport of the machine.
● 
Avoid movement of the machine
due to vibration.
● 
Only move the machine horizon-
tally and vertically.
4.2 Installation
● 
Place the machine on a level
surface which can comfortably
support 104 kg and which has
sufficient sideways stability
(e.g. a worktable / -bench).
● 
The area in which the machine
is placed must be adequately
ventilated.
● 
Set up the machine in such a way
that all the controls are easily
accessible.
● 
Make sure that all its feet touch the
surface. The feet can be adjusted
by screwing them in or out.

5 EN
Chapter 6
Specifications of ZXM-
05000 extruder and subse-
quent models
● 
Voltage: 220V-240V / 50 Hz
● 
Motor capacity: 1,5 kW
● 
Revolutions: 15 – 30 – 45 rpm
● 
Heating: 80 W
● 
Max recorded capacity: 1,8 kW
● 
Length x breadth x height:
105 x 35 x 52 cm
● 
Weight: 104 kg
● 
Production capacity:
5 kg soap products
● 
PLC:Mitsubishi ALS-24-MR-D
EC Declaration
of conformity
Manufacturer:
Gildewerk BV
Adress:
Jan van Geunsweg 10A
2031 BD Haarlem
The Netherlands
Hereby declares that,
ZXM-05000 Extruder
comply with the stipulations
found in the following EC
directives, these being the
most recently amended:
● 
EMC-Richtlinien 89/336/
EEG, 91/263/EEG, 92/31/
EEG en 93/68/EEG
● 
Niederspannungs-
richtlinien 73/23/EEG en
93/68/EEG
and that the following
standards have been met:
● 
EN 55014 (1995)
● 
EN 55104 (1995)
● 
EN 61000-3-3 (1995)
● 
EN 60335
Finalised in Haarlem on
17 Januari 2010
M.L.J. Teunissen
Directeur