Moffat Sottoriva 60 Installation guide

Safe Operating Procedures
TRAINING MANUAL
SOTTORIVA
MIXERS 60/90/130
Current January 2004 Contains 22 pages

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©MOFFAT JAN-2004
• About this instruction manual
• User liability
• Safety precautions
• Before you start
• Name of parts
• Hazard risk analysis
• Safe operating procedures
• Operations checklist
• Operations overview
• Daily cleaning procedure
• Operations competency
• Daily cleaning competency
• Trouble shooting
• Risk assessment
Moffat's policy is one of
continual improvement and
development. We therefore
reserve the right to amend the
information given in this booklet
without prior notice. All sales will
be subject to the company's
conditions of sale.
©MOFFAT 2004
CONTENTS
Owners and operators of Moffat equipment please note:
The risk ratings and control measures as outlined in this manual must be incorporated
into your safety management systems and procedures. Ensure effective risk control
by reinforcing these procedures with staff.

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This manual contains all the necessary information for the use, cleaning and maintenance of the
machine. The purpose of this booklet is to allow the user to take all measures and set up all the human
and material resources needed for safe and long-lasting use of the machine.
This manual should be available for all staff and maintenance personnel authorised to use the machine.
Do not attempt to use this machine in any other way that is not in compliance with the instructions
supplied.
Firstly
Please read the instruction book carefully and follow the directions given.
Secondly
If you are unsure of any aspect of the instructions or performance of this equipment, contact your dealer
promptly.
About this instruction manual
The bakery must be fitted with an electrical system complying with current electrical regulations, in particular
the earth connection system and electrical control board must be protected against overload currents and short
circuiting. The rated power of the machine is shown on the machine plate. Electrical plant must be properly
installed throughout, maintained and regularly inspected by trained electricians issuing certificates of
compliance for all jobs carried out, guaranteeing compliance with current Australian legislation and Standards.
The electric power supply

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User liability
The manufacturer declines all direct and indirect liability deriving from:
•Use by untrained personnel.
•Non-observance of the instructions contained in this booklet.
•Unauthorised modifications and/or repairs carried out on the machine.
•The use of accessories and parts that are not genuine.
•Exceptional events.
Working Safety
The machine must be used only by personnel suitably trained for the purpose and who have been trained
in the contents of this publication.
To ensure safe work, comply with the following instructions:
•Install the machine in compliance with workplace safe work requirements.
•Install the machine in an area out of reach of the personnel not authorised to operate it and especially
out of the reach of minors.
•Use the machine with great care and never be distracted.
•Do not wear loose fitting clothing or clothing with wide and open sleeves.
•Do not let anyone approach the machine during use.
•Do not remove, cover or modify the identification plates placed on the machine body.
•Work on the products permitted and not on other types.
•Do not use the machine as a working top and do not place any objects on it that are not required for
normal working operations.
•Do not use the machine with temporary electrical connections or non-insulated cables.
•Periodically check the state of the power cable and the cable clamp on the machine body. If defective
replace immediately by qualified personnel.
•Stop the machine immediately there is defective or abnormal operation, a breakage is
suspected, there are incorrect movements or unusual noises.
•Before cleaning or carrying out maintenance, disconnect the machine from the electricity mains.
•Use protective working gloves for cleaning and maintenance.
•For all extraordinary maintenance consult the manufacturer or qualified or authorised personnel.
•Do not aim high-pressure jets of water at the machine.
•When sharp accessories are manipulated, use cut-resistant gloves.
•Never insert hands or other objects into the product inlet or outlet.
Summary safety notes for owners/operators of this machine
Always operate within the limits of use of the machine.
Always carry out constant and diligent maintenance.
Have the machine used by a single trained person.
Avoid distractions while operating the machine.

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User instructions and precautions
The manufacturer declines all responsibility for any injury to persons or animals or damage to objects
resulting from the failure to observe any of the previous or following information and instructions on the
use or maintenance of the machine:
•Do not use the equipment for any purposes and / or loads different to those stated by the
manufacturer;
•Every day, check the safety devices and general state of the equipment;
•Every day clean the equipment thoroughly;
•Take all the necessary precautions and safety measures when loading, adjusting, changing parts or
carrying out repair or maintenance work on the machine, to make sure that the machine or any parts
of it are not accidentally started up by other persons;
•Do not tamper with the guards and safety devices on the machine;
•Do not remove the guards and safety devices on the machine unless actually necessary for work
purposes and without adopting the measures designed to reduce the risk to the minimum possible, as
described fully and frequently in this manual;
•Put back all the guards and safety devices as soon as the reason for their temporary removal no
longer exists;
•All operators must comply with applicable workplace safety procedures.
Definitions
According to this manual, the following definitions are used:
1. "Danger area" any area inside or near a machine which might be dangerous for a bystander.
2. "Bystander" any person entirely or partly situated in a danger area.
3. "Operator" the person or persons installing, running, adjusting, cleaning, repairing, transporting or
performing maintenance work on a machine.
To ensure maximum safety and optimum
performance from this machine it is essential
that you or any other operator of the machine
read and understand the contents of this
manual before the machine is ever started.
Pay particular attention to the SAFETY
INSTRUCTIONS highlighted by these symbols.
These safety alert symbols mean CAUTION,
WARNING or STOP/DANGER - a personal
safety instruction. Failure to comply with the
instruction may result in personal injury or
death.
WARNING: ELECTRICITY CAN KILL
Test and tag electrical cables to workplace
safety standards.
CAUTION
Serious injury possible
STOP
DANGER
WARNING
Electric shock
Safety precautions

Before starting undertake a General Safety check
•Area clean and free from obstructions, e.g. nothing placed on top of the machine such as a dough knife, etc.
•Operator not wearing loose fitting clothing etc.
The key safety and hygiene features are:
Safety:
1Emergency stop button. A red mushroom safety switch.
2Inbuilt safety microswitch into the lid hinge mechanism.
3Gas assisted struts to assist lid lift and to hold lid in open position.
4Two lock down feet for extra stability and levelling.
Hygiene:
1Bearings below the bowl are enclosed to ensure no water etc. affects the machine during the cleaning
process and to allow easier cleaning.
2The guard over the bowl is enclosed to reduce any possibility of foreign matter being able to fall into
the bowl and transparent for quality and contamination checks during operation.
3The top cover is an industrial plastic moulding and not fibreglass to reduce potential contamination
issues.
4 All areas around the spiral hook are stainless steel for easy cleaning and sanitation.
Machine in use:
Please note when using the following functions of the Control Panel:
1. Slow Bowl will rotate anti clockwise
Dough Hook will rotate clockwise - direction of arrow
Auto start in these directions
Operator can choose to reverse this direction.
2. High Bowl will rotate clockwise
Dough Hook will rotate clockwise
3. Bowl Jog Rotates the bowl only either way in order to enable dough to be pulled out - Dough Hook
does not rotate.
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Before you start the SOTTORIVA 60/90/130

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Names of parts
Sottoriva 90 pictured above.
Emergency Stop Control Panel
Mixing Bowl
Safety Skirt
Levelling Feet
Power On
Indicator
Power Switch
Safety Guard
Rest
Micro Switch
Safety Shut Off
inside of
machine
Safety Guard

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Hazard Risk Analysis
Installation:
Daily checks:
Machine in use:
2Cleaning machine should only
be carried out with a damp
cloth. Buckets of water or a
hose should not be used
3The internal microswitch on
lid mechanism should
never be removed or
tampered with in any way.
4Electrical isolation switch
should be fully accessible to
the operator.
1.5 metres above the floor is
a recommended height.
1The stabilising screw at the
front of the machine should
be used to level the machine.
2The safety guard microswitch
should be checked for
correct operation.
3No more than 60kg on 90,
75kg on 130 and 30kg on
60 of flour should ever be
placed within the bowl at one
time.
4 Minimum dough capacity 5kg.
Maximum dough capacity
60kg, 90kg and 130kg.
Note: Overloading of the
machine will void warranty.
1Guard should be raised and
pushed back fully against
stops to avoid injury. Do not
throw guard back against
the stops.
✓
✗
11
2
4

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Hazard Risk Analysis
6The safety guard should not
be removed.
5Hands or arms should not be
placed behind bowl whilst
machine is in operation.
10 Thermal overloads within the
SOTTORIVA 60/90/130
electrical circuitry should not
be tampered with or changed
from original manufacturer’s
setting.
11The machine must be
connected to the correct
designated power outlet.
8Hands should never be
placed near Dough Hook
whilst in motion (only
possible if lid is opened
quickly with no product in
the bowl).
9Cleaning of machine should
not take place whilst it is in
operation
7Service panels should not be
removed whilst the machine
is in operation. The machine
must not be operated with
any service access panel
removed.
511
8

©MOFFAT JAN-2004
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Safe Operating Procedures
1Check the machine is
clear of all objects, all
switches are off and any
danger area clear of all
bystanders.
NOTE:
It is recommended that the
following procedure is
carried out before starting
work to ensure that all
safety features are working.
WARNING:
The operator should never
tamper with or make repairs
to this machine. All
maintenance other than
approved cleaning operations
to be carried out by trained
technicians only.
OFF
4 Test red safety emergency
stop button by pushing the
mushroom button in.
(See below)
The machine must stop
operating immediately. If not,
do not use the machine,call
supervisor and advise Moffat
service agent.
The machine must stop
operating immediately. If not,
do not use the machine,call
supervisor and advise Moffat
service agent.
3Push start button with both
timers off zero to start the
mixer.
2Check or place the electrical
cord in the appropriate
socket and turn power on.
5Test the micro switch on the
guard by restarting the
machine (with both timers off
zero) and lifting the guard.
6During normal mixing
operation, do not place any
instruments or fingers
under the guard into the
bowl section (danger area).
7Mix dough according to
workplace procedures.
(see Operations Overview
pages 12, 13 and 14)
OFF
6
5
3
2
4
MOFFAT SUGGESTS —Use this form to train staff, copy and laminate for your workplace.

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Standard Operations Checklist
✓
Lift mixing bowl safety guard
OPERATION INSTRUCTIONS
Add ingredients - flour, premix,
yeast, water, etc
By lifting the Safety Guard, the dough mix can be checked
for consistency and development. To avoid injury wait until
the Mixer Bowl and the Spiral Dough Hook have stopped.
Avoid breathing dust—use a face mask.
Add water using a bucket or water meter.
Follow standard workplace procedures.
If additional mixing time is required, set appropriate timer.
Guard should be raised and pushed back fully.
against stops to avoid injury.
Lower mixing bowl safety guard
Set "low speed" timer
Set "fast speed" timer
Press "start"
Check dough quality visually
during mid mix (optional)
Mixer will automatically change
from low speed to high speed.
Mixer will "stop" automatically
when both timers have timed
out
Check final dough quality, e.g.,
development, extensibility etc.
Remove dough from mixing
bowl
"Bowl Jog" mixing bowl
(optional)
MOFFAT SUGGESTS —Use this form to train staff, copy and laminate for your workplace.
Use the ‘Bowl Jog”button (with Bowl Guard
lowered) to assist in removal of dough.

2 Ingredient Check
Complete ingredient check to
ensure accuracy in scaling.
3 Add Ingredients
for example for a Soft White
mixture you could use the
following:
Premix 60 kg
Water 29.5 Litres
Yeast 600 g
For a final dough yield 90 kg.
Note: Operators should
check and use their own
workplace recipes.
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Operations Overview
1 Lift bowl safety guard
Safety guard should be raised
and pushed back fully against
stops to avoid injury.
Mixer has safety interlocks to
prevent mixer operation when
guard is lifted.
4 Lower the safety guard
SET TIMING:
5 To set timing:
Turn the Timer Dials to set the
slow or fast mix times.
The red LED indicators around
the knob will illuminate and the
corresponding numeral will be
displayed in the two-digit
display directly above the
knob.
Pressing the START button will
initiate the mixing process in
low speed, reverse direction
assuming the mix time
incorporates slow mixing.
If the preset value in the low
display is zero, the mixer will
automatically start mixing in
high speed providing time has
been entered in the fast speed
display. The mixer will not start
if both timers are set to zero.
For example; as guide only:
3 minutes for Soft White mix.
Note: Bowl Reverse is
possible on Slow Speed only.
Note: Mixing time will vary
depending on flour quality
and workplace procedures.
6 Set the High Speed timer
For example; as guide only:
9 minutes for Soft White mix.
Note: Mixing time will vary
depending on flour quality
and workplace procedures.
PREPARATION:
1
3
water
premix
yeast
5
6

Operations Overview
7 Bowl Reverse
Use only when rapid or
comprehensive blending of
ingredients is desired.
Bowl Reverse
The ‘Bowl Reverse’option only
works on “Low Speed’. The
mixing bowl is driven in the
opposite direction of rotation to
the spiral dough hook. This
facilitates the rapid and
complete incorporation of the
ingredients. Standard or
correct bowl direction is
resumed when the ‘Fast
Speed’timer commences.
USES:
The bowl reverse action is very
useful when blending fruit etc.
into fruit bread dough at the
end of a mix.
7
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STARTING:
8 Press Start
The SOTTORIVA 60/90/130
will commence to blend all
ingredients on ‘Slow Speed’.
When the mixer commences
the ‘Fast Speed’cycle, the
mixing bowl will change
direction and proceed to
develop the dough.
10 Finish
The mixer will stop
automatically when the pre-set
mix cycle is complete.
11 Check final dough quality
Check the key elements in
dough quality ie:
•Development.
•Extensibility.
•Consistency.
•Final dough temperatures.
Additional mixing may be
required to enhance final
dough quality: If so, re-set
timers for estimated additional
mixing times then press ‘Start’.
12 Prior to removing the dough
Food grade oil can be added
between the dough and the
mixing bowl just prior to the
finish of the mix cycle.
This will aid in the removal of
the dough from the mixing bowl.
9 Mid mix check
At any time during the mix
cycle (Slow or Fast Speed) the
mixer can be stopped by lifting
the Guard, and the dough mix
checked for consistency and
development.
Mix cycle times will not be
cancelled and will resume at
the time at which they were
interrupted.
WARNING
The SOTTORIVA 60/90/130
is equipped with an overload
mechanism.
If the bread dough is too
tight/tough/stiff the Overload
switch will activate.
The
SOTTORIVA 60/90/130
will automatically re-set within
10 minutes.
Refer to Trouble Shooting
section pages 19 and 20 if
correction is necessary.
12
8

14 Inch bowl
Use the “ Bowl Jog ”button to
assist in removal of dough.
Pressing the Bowl Jog rotates
the bowl either way in order to
enable dough to be pulled out.
Note: the Dough Hook does not
rotate.
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Operations Overview
13 Removing the dough
Wait until Mixer Bowl stops
turning.
Use care when cutting the
dough.
Observe appropriate workplace
manual handling procedures
when removing dough from
Mixer Bowl.
DANGER
Make sure the Mixing Bowl and
Dough Hook have
stopped before lifting the
Safety Guard.
14
OPERATIONAL ISSUES:
•Pressing the STOP button
during a mix pauses the
mixer and the LED indicators
will flash.
Pressing the start button at
this stage will restart the
mixer at the mix time
remaining when it was
paused. Pressing the STOP
button a second time will
reset the timers and the LEDs
will stop flashing.
•Extra time may be added to
the mix times in either the
paused state or the fully
stopped state.
•At the end of the mix, the
timers will reset to the initial
set time, disregarding any
extra time that may have
been added if the mixer was
paused.
•Pressing the BOWL
REVERSE button changes the
direction of the bowl while
the mixer is operating in slow
speed. It will have no effect
at any other time.
STOP BUTTON:
Pressing the STOP BUTTON
or lifting the guard while the
mixer is running stops the
mixer and places it into the
paused state, with the LED
indicators flashing.
To restart the mixer, lower the
guard and press Start Button.
EMERGENCY STOP
If the EMERGENCY STOP is
pressed, the machine stops
immediately. The Timers need
to be reset.
Note:
There is no Re-set Button to
reset times to original position.
Let the Timers time out.

1Brush off all external surfaces
Use a bannister brush and
work from top to bottom.
2Remove all old dough/built
up deposits using a plastic
scraper.
3Scrape the Mixing Bowl, the
Breaker Bar, the Dough Hook,
the upper inside mixing bowl
cowling and behind the
mixing bowl.
(see illustrations 3 and 4)
5Wipe all surfaces with warm
water.
6Apply a detergent/sanitiser
and leave on all surfaces
(for length of time specified
by the supplier and/or
manufacturer).
7Scrub to loosen and remove
residues.
8Rinse Bowl and Dough Hook
thoroughly with hot water.
9Remove excess moisture with
clean squeegee or paper
towels. Dry all surfaces.
10 Re-examine all surfaces to
evaluate whether cleaning
has been effective.
11 If further cleaning required,
start from step 3.
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WARNING
Electrically isolate
Dough Mixer.
Daily Cleaning Procedure
7
1
4
3
5
MOFFAT SUGGESTS —Use this form to train staff, copy and laminate for your workplace.
2

SOTTORIVA MIXERS 60/90/130
GUIDE SHEETS
for Staff Training
Pages in the following section of this manual should be copied and used
when training staff to operate the SOTTORIVA 60/90/130
MOFFAT suggests that competency assessment check lists be completed,
signed and a copy kept in the personnel files for future reference.
SUPERVISORS TO ENSURE
• competency check lists are copied and completed as part of the training of staff
• correct training of staff to the required competency expectations
• the verification section of the competency check list is signed off
• a copy of the completed and signed competency check list is placed in personnel
records as evidence of operator competence
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OPERATIONS COMPETENCY CHECKLIST
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Comments
To gain competency in the use of the Sottoriva 60/90/130 , the assessor must be satisfied that
the operator has consistently applied the knowledge and skills in all of the above elements.
✓
Assessment Criteria
“Can the operator”
Identify the purpose and use of:
•Equipment guards;
•Warning signs;
•Safety features;
related to this machinery?
Identify:
•Machine related health and safety risks of this equipment?
•Emergency procedures to be used with this equipment?
Operate this equipment correctly in normal and emergency situations?
Identify:
•OH&S reporting procedures related to hazard reporting for this machine?
Element Implement safe work procedures for the SOTTORIVA 60/90/130
Assessor’s signature Date / /
Applicant’s signature Date / /
This form should be signed off only when the assessor is satisfied that the
employee/trainee is competent to carry out all of the tasks described above.
MOFFAT SUGGESTS—Use this form to train staff, and place a copy in personnel file.

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DAILY CLEANING COMPETENCY CHECKLIST
Element
Implement essential hygiene and sanitation procedures for the SOTTORIVA 60/90/130
Comments
To gain competency in the use of the SOTTORIVA 60/90/130, the assessor must be satisfied that
the operator has consistently applied the knowledge and skills in all of the above elements.
✓
Assessment Criteria
“Can the operator”
Maintain sound personal hygiene at all times when working with the SOTTORIVA 60/90/130?
Use appropriate protective and work clothing while working with the SOTTORIVA 60/90/130?
Identify:
•Product handling requirements during production process ?
•Critical points in the process where contamination can be introduced ?
•Why it is important to monitor hygiene and sanitation performance ?
•The effect of poorly maintained equipment on the control of contamination and spoilage ?
•Company policies and procedures regarding hygiene and sanitation ?
•Actual and potential contamination and spoilage hazards ?
•Solutions to rectify contamination and spoilage problems ?
Use work practices and methods that reduce the risk of product contamination ?
Remove contamination where appropriate in accordance with
•Workplace hygiene and sanitation procedures ?
•Procedures specific to the SOTTORIVA 60/90/130?
Assessor’s signature Date / /
Applicant’s signature Date / /
This form should be signed off only when the assessor is satisfied that the
employee/trainee is competent to carry out all of the tasks described above.
MOFFAT SUGGESTS—Use this form to train staff, and place a copy in personnel file.

Machine Based Trouble Shooting
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The Sottoriva 60/90/130 does not
operate/start.
The Sottoriva 60/90/130 starts and
then stops.
The Sottoriva Sottoriva 60/90/130
labours under load.
The Sottoriva Sottoriva 60/90/130
moves or rocks during operation.
Excessive flour dust coming from
mixer.
The Sottoriva Sottoriva 60/90/130
does not stop.
The Sottoriva Sottoriva 60/90/130
mixer bowl and dough hook operate
in wrong direction.
Gas struts on Safety Guard not
providing full assistance.
Plug in and switch on.
Turn on.
Place in down position.
Contact supervisor/Moffat Service
Agent.
Resets automatically (10 min).
Release by rotating and pulling.
Reset mix cycle on both timers.
Resets automatically (10 min)
If overload occurs repeatedly
Contact supervisor/Moffat Service
Agent.
Contact supervisor/Moffat Service
Agent.
Review and adjust dough
consistency, eg: add more liquid.
Contact supervisor/Moffat Service
Agent.
Re-adjust level and stablise by
means of adjustable foot.
Extend first speed mix/blending
cycle.
Switch off power at main switch.
Isolate mixer by removing wall plug.
Attach danger tag to machine.
Contact Moffat Service Agent.
Return to correct position.
Consult authorised electrical service
to rewire 20 amp 3 phase plug.
Contact supervisor/Moffat Service
Agent.
Not plugged in to socket at main
switch.
The main switch is "off".
The bowl safety guard is open.
Fuse overload at the power board.
The mixer overload has been
activated.
Stop button still locked in down
position.
Both high and low speed timers on
zero.
The mixer overload has been
activated.
Fuse overload at the power board.
Dough too stiff/tight.
Mechanical malfunction.
Floor not level or the adjustable feet
located incorrectly.
First speed timer set too short.
Electrical/mechanical malfunction.
Inserting the Sottoriva 60/90/130
electrical plug into non compatible
socket after cleaning.
Relocating mixer in another position
after maintenance.
Leaking or worn gas struts.
Problem Remedy Possible cause

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Problem Remedy Possible cause
Product Based Trouble Shooting
Review recipe and adjust dough
consistency.
Contact authorised maintenance.
Review/check/change mix cycle.
Reduce water temperature.
Shorten mix cycle.
Increase water temperature.
Increase mix cycle.
Thoroughly scrape and check
between dough. Review cleaning
instructions.
Contact ingredient supplier.
Review and reinforce correct
procedures.
Remove from bowl earlier.
Refer - dough too soft.
Run food grade oil between dough
and bowl at end of mix cycle to stop
dough sticking.
Excessive water used in dough
(human error).
Incorrectly metered/measured
through water meter (Equipment
error).
Overmixed dough.
Water temperature too warm.
Dough mixed too long.
Water temperature too cold.
Dough mix too short.
Mixer not cleaned as per cleaning
instructions.
Poor ingredient quality.
Poor personal/bakery hygiene.
Dough left in bowl too long.
Dough too soft.
Dough overmixed.
Bread dough too soft.
Final dough temperature too hot.
Final dough temperature too cold.
Foreign matter found/seen in dough.
Dough is difficult to remove from the
mixing bowl.