IDD Processing & Packaging SQUIRE PLUS 2 User manual

PROCESS &PACKAGING, INC.
Address: 5450 Tech Circle, Moorpark, CA 93021 Tel: [phone] Fax: [phone]
CREATED: May 29, 2015
REVISION: 1.3
SQUIRE “PLUS 2”
2-HEAD WASHER /FILLER
OPERATIONS MANUAL
(Image shows Fill-by-Weight and Double-Doser options)

SQUIRE PLUS 2OPERATIONS MANUAL
TABLE OF CONTENTS
INTRODUCTORY STATEMENTS
1. PREFACE .......................................................................................................................... 4
2. DISCLAIMER ..................................................................................................................... 4
3. CONFIDENTIALITY AND COPYRIGHTS .......................................................................... 4
SAFETY
4. OPERATIONAL SAFETY NOTES ..................................................................................... 5
SYSTEM PROCEDURES & OPERATIONS
5. SERVICES ......................................................................................................................... 6
SQUIRE “PLUS 2” SERVICES ............................................................................................................. 6
SQUIRE “PLUS 2” DRAINAGE ............................................................................................................. 7
DOUBLE DOSER UNIT OPTION .......................................................................................................... 9
SUGGESTED COMPONENTS .............................................................................................................. 10
6. SPECIFICATIONS ............................................................................................................. 14
7. CYCLE TIMES ................................................................................................................... 15
8. SIMPLIFIED START–UP AND SHUT–DOWN PROCEDURES ......................................... 16
9. KEG WASHING & FILLING PROCEDURES ..................................................................... 17
KEG WASHING .................................................................................................................................. 17
END OF DAY CLEANING ................................................................................................................... 25
KEG FILLING .................................................................................................................................... 26
10. CLEANING IN PLACE (CIP) PROCEDURE ...................................................................... 35
CIP SEQUENCE –PRODUCT FILLING SIDE ......................................................................................... 35
EXTERIOR CLEANUP ........................................................................................................................ 36
11. PLANNED MAINTENANCE ............................................................................................... 37
12. QUALITY CONTROL ......................................................................................................... 38
KEG LINE QUALITY ASSURANCE ....................................................................................................... 40
13. OXINE CLEANING/SANITIZING ....................................................................................... 41
OXINE DILUTION AND USE ................................................................................................................ 41
OXINE &PUROGENE SANITIZER SUGGESTED USES ........................................................................... 42
CIO2ACTIVATION ............................................................................................................................ 45
OXINE MATERIAL SAFETY DATA SHEET ............................................................................................. 46
SYSTEM DETAIL INFORMATION
14. PLANT LAYOUT ............................................................................................................... 52
15. FLOW DIAGRAM ............................................................................................................... 53
16. ELECTRICAL .................................................................................................................... 54

SQUIRE PLUS 2OPERATIONS MANUAL
17. MECHANICAL ................................................................................................................... 56
EURO &AMERICAN SANKEY KEG VALVE FLOWS ............................................................................... 56
ARES VALVE –INSTALLATION &MAINTENANCE MANUAL ................................................................... 57
PROCESS VALVE ............................................................................................................................. 60
SOLENOID VALVE ............................................................................................................................. 61
PINCH VALVE .................................................................................................................................. 62
TANK DOSING UNIT .......................................................................................................................... 63
FLOAT VALVE WITH PROPORTIONER ................................................................................................. 65
ADJUSTABLE SINGLE STAGE INJECTORS ........................................................................................... 68
DETERGENT PUMP –NPE/NPE-F INSTRUCTION MANUAL................................................................... 69
PRODUCT PUMP –OPERATION MAINTENANCE,&PARTS LIST ............................................................ 77
18. PNEUMATICS .................................................................................................................. 108
19. DIMENSIONS ................................................................................................................... 109
20. I/O LISTING ....................................................................................................................... 110
GENERAL INFORMATION
21. APPENDICES .................................................................................................................... 112
Appx. A IDENTIFYING AND ANALYZING PROBLEMS .............................................................. 112
Appx. B COMPLETE KEG WASHING & FILLING SEQUENCE CONTROL PROCESSES ....... 118
Appx. C SPARE PARTS ................................................................................................................ 122
Appx. D PROGRAM LISTING ....................................................................................................... 125
Appx. E TRAINING ........................................................................................................................ 125
Appx. F WHICH MASK SHOULD I WEAR? .................................................................................. 125

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 4OF 125
www.iddeas.com
INTRODUCTORY STATEMENTS
1. PREFACE
This system has been designed as a self-contained and reliable automatic keg processing
machine. Although kegs are loaded and unloaded manually, all washing, sanitizing, and filling
operations are fully automatic for consistent high quality results.
The information, instructions, and warnings contained in this document have been prepared to
clarify operational and maintenance procedures. If followed carefully, they should provide safe,
long, and reliable service from the machine.
Proper maintenance and the use of approved spare parts will extend the life of the system and
its reliability, while the use of any non-approved spare parts may void any warranties or
guarantees; actual or implied.
2. DISCLAIMER
The customer assumes all responsibility for the system, once delivered. The system is tried and
tested equipment, and as such, IDD Processing & Packaging will not be held responsible for
alterations and modifications carried out by anyone, without the written approval of IDD
Processing & Packaging.
3. CONFIDENTIALITY AND COPYRIGHTS
All information contained within this document is confidential and the copyright of IDD Process
& Packaging, Inc. No portion of this data shall be released, disclosed, used, or duplicated for
use in procurement or manufacturing, without the express written permission from IDD Process
& Packaging, Inc.
Back To TOC

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 5OF 125
www.iddeas.com
SAFETY
4. OPERATIONAL SAFETY NOTES
EMERGENCY STOP / MANUAL PROCESS STOPS
To STOP the process sequence at any time for each of the process heads, use the Manual
Stop Process Buttons, located on the system Control Panel.
VENTILATION
The work area should have adequate ventilation approved for use by your Safety and
Operational Procedures Committees. Respirators should be used during cleaning and other
operations where fumes are present.
Refer to APPENDIX F–WHICH MASK SHOULD IWEAR?
WEAR SAFETY GOGGLES
Wear Safety Goggles approved for use by your Safety and Operational Procedures Committees
when operating or observing this system.
WEAR CHEMICAL RESISTANT GLOVES & APRON
Wear Chemical Resistant Gloves and Apron approved for use by your Safety and Operational
Procedures Committee.
WEAR BACK SUPPORT EQUIPMENT
Wear Back Support Equipment and use proper lifting technique as approved by your Safety
and Operational Procedures Committees.
Note: Use only the proper lifting equipment for full kegs, as they weigh up to 165 lbs.
Back To TOC

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 6OF 125
www.iddeas.com
SYSTEM PROCEDURES &OPERATIONS
5. SERVICES
SQUIRE “PLUS 2” SERVICES
LINE SUPPLY PRESSURE FLOW RATE CONSUMPTION CONNECTION
1
*
CO2/N230 PSIG 20 SCFM 1.75 SCFM 3/4" N/B Hose
2
*
AIR PURGE 22.23 PSIG
20 SCFM 1.25 SCFM 3/4" N/B Hose
3 (Ambient) WATER 55 PSIG 15 GPM 1.5 SCFM 3/4" N/B Hose
4 (Ambient) WATER 55 PSIG 15 GPM Top Up 1/2" NPTM
5
*
AIR 80 PSIG 2.5 SCFM 0.25 SCFM 1/4" NPTM
6 ELECT. -- -- 208V-240V-1PH-50/60Hz-35A --
7 CAUSTIC -- -- Dosing at 2% V/V 1/4" OD Tubing
8 PRODUCT 15 PSIG 20 GPM 7.5 GPM 1-1/2" TC
9 OXINE -- -- Dosing Nominal 50 ppm 1/4" OD Tubing
10 (Option) ACID -- -- Dosing at 0.5% V/V 1/4" OD Tubing
11 CIP RETURN -- 10 GPM -- 3/4" N/B Hose
12 FILL DRAIN -- -- -- 3/4" N/B Hose
6
3
9
2
1
8
10
74
5
12
11
Back To TOC
*
Customer to provide suggested
components. Refer to Page 8,
Suggested Components
.

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 7OF 125
www.iddeas.com
SQUIRE “PLUS 2” DRAINAGE
Page 8

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 8OF 125
www.iddeas.com
PREVENTING BACK PRESSURE IN DRAIN LINES
The following model is the IDD suggested method of process and packaging plant drainage for designated non-wet area locations to
prevent back pressure within the drain lines. This method allows enough air-behind-water to prevent backups with 3/4" drain pipes to
enter a 2” PVC drain.
Back To TOC

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 9OF 125
www.iddeas.com
DOUBLE DOSER UNIT OPTION
DOUBLE DOSER UNIT OPTION #: MS 50030
DETERGENT TANK LOWER BLEED VALVE :
LEAK RATE: 3 GAL. (11.4 LITERS) PER HOUR
ALLOWS FOR THE AUTOMATIC REFRESHING
OF CAUSTIC OR ACID DOSING.
-
-
DOSERS TO DOSE ACID AND CAUSTIC INTO
THE DETERGENT TANK FOR ALTERNATING
-
YOUR KEG WASHING REGIME IN ORDER TO
RID KEGS OF HEAVY PROTEINS AND CALCIUM
BUILD UP.
ISOLATING VALVE (CHANGEOVER BY OPENING
AND CLOSING FROM CAUSTIC AND ACID)
NOTE:
SQUIRE "PLUS 2" SYSTEM SHOWN.
Back To TOC

SQUIRE PLUS 2OPERATIONS MANUAL
PROCESS & PACKAGING, INC. PAGE 10 OF 125
www.iddeas.com
SUGGESTED COMPONENTS
Water, oil, and random particles are the natural enemies of perfectly prepared compressed air. They will
have an adverse effect on components and cost additional energy. In order to improve process reliability
and machine availability, start by first analyzing the compressed air supply in detail from source.
IDD suggests the following equipment be included in your Purge Air and Inert Gas Regulator
configurations. They are available at www.Grainger.com.
1” NPT AIR REGULATOR
(1 ea. For Air Purge & CO2/N2)
Grainger Item # 4ZM10
•1” NPT
•Adjustment Range 5 to 125 PSI
(Set to 30 PSI, 2 Bar for CO2/N2)
(Set to 22-23 PSI, 1.55 Bar for Air)
•¼” NPT (Female) Gauge Port
PRESSURE GAUGE
(1 ea. For Air Purge & CO2/N2)
Grainger Item # 33HP99
•0 to 60 PSI
•2” Dial
•¼” (Male) NPT Inlet, Back
RELIEF (SAFETY VALVE)
(1 ea. For Air Purge & CO2/N2)
Grainger Item # 15X911
•60 PSI Preset Setting
•½” (Male) NPT Inlet
¼” NPT AIR REGULATOR
(1 ea. For Control Air)
Grainger Item # 4ZM18
•¼” NPT
•Adjustment Range 5 to 150 PSI
(Set to 80 PSI, 5.8 Bar)
•¼” NPT (Female) Gauge Port
PRESSURE GAUGE
(1 ea. For Air)
Grainger Item # 33HR23
•0 to 100 PSI
•2 ½” Dial
•¼” (Male) NPT Inlet, Back
AIR SUPPLY (AIR COMPRESSOR)
Grainger Item # 4ME99
•Electric
•175 PSI Max. Pressure
•5 HP
•2 Stage
•208-230/460V / 3Phase / 60 Hz
/ 13.4-13.2 A
•60 Gallon Tank (Vertical)
•¾” NPT (Female) Outlet