Staalkat Farmpacker 40 User manual

Translation of original user’s manual
Document version:
Reprint date: 22-06-10
Machine order no: .......................................
Year of manufacture: .......................................
Article no:
a
Copyright © 2010 Staalkat International B.V. Document: SFP40 user eng.fm
User’s Manual
STAALKAT INTERNATIONAL B.V. Telephone: [phone]
Fax: [phone]
Ambachtsstraat 4 · P.O. Box 70 www.staalkat.com - [e-mail]
7120 AB Aalten · Holland Banker: ABN AMRO · nr. 52.69.70.790
Trade register Arnhem, No. 09102326 BTW/VAT nr. NL807264714B01
The Global Supplier for
Egg Handling and Processing
*TD0108203010*
Staalkat
Farmpacker 40
FP102TB001

2
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1 Using this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Other documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1 Tray stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2 Parts catalogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Presence of children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.3 Before starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.4 Cleaning, inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.5 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.6 Working on the electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.7 Adjustments and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.8 Dismantling, moving and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.9 Decommissioning and the environment . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Guards and warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1 Names of major parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.1 Denester (1 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.2 Carton transport lane (6 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.3 Peak absorber (2 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.4 Packer (5 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.5 Incline conveyor (7 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.6 Control box (4 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.7 Identification plate/CE-marking (3 in diag. 8) . . . . . . . . . . . . . . . . . . 15
3.3 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6.1 Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.1 Work positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents
User’s Manual Staalkat Farmpacker 40
3
4.4.1 Normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.2 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Setting for type of cartons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5.1 Denester, changing accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.2 Carton transport lane, changing steps cam . . . . . . . . . . . . . . . . . . . 24
4.5.3 Carton transport lane, setting side guides . . . . . . . . . . . . . . . . . . . . 25
4.5.4 Packer, insert pitch adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Very small or very large eggs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.6.1 Leaf springs in gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.6.2 Clip-on gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.1 Maintenance routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Safety during maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.1 Before starting maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.2 At the end of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.1 Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.2 Bearings with grease nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.3 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.4 Guides in denester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.5 Egg holder shafts in packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.6 Memory pins of packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.1 Cleaning in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.2 Removing drip trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.3 Tipping the packer gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5.4 Removing the spin roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6 Greasing of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.6.1 Flange bearings with grease nipple . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.7 Lubrication and tensioning of chains . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.7.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.7.2 Tensioning in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.8 Motor and reduction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.8.1 Checking reduction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9 Denester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9.1 Tensioning belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9.2 Greasing the gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.10 Peak absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.10.1 Tensioning of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.10.2 Tensioning of extended belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.11 Packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.11.1 Lubrication of egg holder shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.11.2 Greasing the memory pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.12 Incline conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.12.1 Tensioning the conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents
User’s Manual Staalkat Farmpacker 40
4
6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.1 Peak absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.1.1 Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.2 Denester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2.1 Mechanical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2.2 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.2.3 Drive clutch release pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.2.4 Start moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2.5 Drive Staalkat Farmpacker 40 right hand model . . . . . . . . . . . . . . . 48
6.2.6 Drive Staalkat Farmpacker 40 left hand model . . . . . . . . . . . . . . . . 49
6.2.7 Wedge holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.2.8 Gripper cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2.9 Gripper levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2.10 Grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2.11 Hinge pins for auxiliary grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2.12 Auxiliary gripper rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2.13 Auxiliary grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3 Carton transport lane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3.1 Mechanical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3.2 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3.3 Drive clutch release pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.4 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.4 Packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.4.1 Mechanical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.4.2 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.3 Clearance of fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.4 Locking star in locked position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.4.5 Lock pawl play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.4.6 Using gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.4.7 Transfer strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4.8 Starwheels in locked position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.4.9 Position of fingers between starwheels . . . . . . . . . . . . . . . . . . . . . . 66
6.4.10 Start starwheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.4.11 Friction clutch starwheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.4.12 Ejector height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.4.13 Tipping plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4.14 Distance between egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.4.15 Pitch of egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.4.16 Height of egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.4.17 Opening of egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.4.18 Catch flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.4.19 Start moment of carton transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.4.20 Cam for egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.4.21 Cams for ejectors, tipping plates and gate movement . . . . . . . . . . 78
6.4.22 Cam for insert mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Contents
User’s Manual Staalkat Farmpacker 40
5
7 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.1 Error messages general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.2 Fuses and thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
8.1 Using the Parts Catalogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.1 Order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.2 Finding the right page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.3 Type of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.4 Right hand and left hand machines . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.1.5 Before/after a certain date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.1.6 Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.1.7 Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.1.8 Assembled units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1.9 Non-standard parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1.10 Machine-order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2 Other documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2.1 Other equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9 List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
10 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

6
1 Introduction
1.1 Using this manual
This manual provides a guideline for the safe and effective operation and
maintenance of the Staalkat Farmpacker 40. We recommend that you read this
manual carefully before operating the machine, and also before carrying out any
maintenance works in a later stage. This will ensure that the Farmpacker is
used optimally and above all safely.
Warning:
It is important that everyone working on the machine is thoroughly acquainted
with the contents of this manual, and particularly with the safety regulations in
the next chapter.
1.2 Other documentation
1.2.1 Tray stacker
A tray stacker is available as an option. When installed the User's Manual for it
can be found behind its own divider in this book.
1.2.2 Parts catalogue
The Parts Catalogue can be found behind its own divider in this book.
Note:
nTake notice of the chapter ‘Ordering spare parts’ on page 81 before using the
Parts Catalogue and ordering spare parts.
1.2.3 Electrical installation
A set of diagrams is included in a separate file.
!

7
2 Safety
2.1 Safety regulations
2.1.1 Warnings
The machine has rotating parts that can be dangerous if maintenance and/or
inspection work is carried out during operations.
Always follow the safety instructions in the User’s Manual and on the machine,
and take heed of the following warnings:
The machine must always be
switched off before any work is
carried out on it!
Switch off the power supply before
carrying out work on the machine,
and make sure that nobody can
switch it on again!
Never allow children near the
machine, even when it is switched
off!
Beware of the risk of electric shock
when opening the cabinet!

Safety
User’s Manual Staalkat Farmpacker 40
Safety regulations
8
2.1.2 Presence of children
Moving parts have been covered to protect persons 14 years and older.
However, there are also moving parts in areas that must remain accessible
while the machine is in operation. Children must therefore never be allowed to
come near the machine.
Large warning stickers, which have been supplied with the machine, must be
attached to the access door. Additional stickers can be supplied on request.
2.1.3 Before starting the machine
Check that all protective screens, covers and drip trays are in place, before
starting the machine, especially after carrying out maintenance or repair work.
Wherever possible, warning stickers have been attached on or near safety
screens, covers, drip trays, or parts that are under dangerous voltage, the
removal or opening of which may give access to components that can cause
injury. Please check that all the relevant stickers are in place.
2.1.4 Cleaning, inspection and maintenance
Always switch off the machine for cleaning, inspections or maintenance work.
This applies in particular, if covers or safety screens have to be opened or
removed, and when drip trays are removed. After switching off the machine,
disconnect the power supply. To do this, use the main switch and secure it with
the padlock that is provided, to prevent someone inadvertently switching the
machine on again.
2.1.5 Periodic inspections
It is not necessary to carry out periodic inspections or to replace parts for safety
reasons. However, regular maintenance in accordance with the Maintenance
Schedule is required to keep the machine in good working order.
2.1.6 Working on the electrical installation
Work on the electrical installation must only be carried out by authorised
personnel. Alterations or additions may only be carried out by the manufacturer.
2.1.7 Adjustments and repairs
Adjustments and repairs, as far as not described in this User’s Manual, must be
carried out by Staalkat service engineers, so as to prevent damage to the
machine or injury to persons. Our service technicians dispose over the
necessary expertise and equipment.

Safety
User’s Manual Staalkat Farmpacker 40
Safety regulations
9
2.1.8 Dismantling, moving and installing
The machine should only be moved by Staalkat service engineers, to prevent
any damage occurring to the machine while it is moved, and to ensure that it is
safe for subsequent operation.
2.1.9 Decommissioning and the environment
The machine can be dismantled, after the power supply has been disconnected
by an authorized person. See the chapter ‘Technology’ for the utilised materials,
and the chapter ‘Maintenance’ for the utilised lubricants. These must be
discarded in accordance with local regulations.

Safety
User’s Manual Staalkat Farmpacker 40
Guards and warning stickers
10
2.2 Guards and warning stickers
Warning stickers have been applied, wherever possible, at or near the safety
screens, covers and drip trays, which, when removed or opened, give access to
moving parts that can be dangerous or to parts under dangerous voltage.
See the diagrams below for the location of the various safety screens and
warning stickers.
.
Fig. 1 Guards and warning stickers on Staalkat Farmpacker 40 right hand
Fig. 2 Guards and warning stickers on Staalkat Farmpacker 40 right hand
STAALKAT170132
FP102VS001
STAALKAT170132
FP102VS002

Safety
User’s Manual Staalkat Farmpacker 40
Guards and warning stickers
11
Fig. 3 Guards and warning stickers on Staalkat Farmpacker 40 left hand
Fig. 4 Guards and warning stickers on Staalkat Farmpacker 40 left hand
STAALKAT170132
FP102VS003
STAALKAT170132
FP102VS004

Safety
User’s Manual Staalkat Farmpacker 40
Main switch
12
2.3 Main switch
Fig. 5 Guards and warning stickers on egg stamping unit (optional)
FP102VS005
Fig. 6 Position of main switch
FP102HS001

Safety
User’s Manual Staalkat Farmpacker 40
Emergency stop
13
2.4 Emergency stop
In emergencies the machine can be stopped immediately by pressing the button
once. This emergency stop button is located in top of the Farmpacker frame.
The button is red with a yellow background.
Danger:
Check why the emergency stop has been used. The machine may only be
started once it is certain that everything has been made safe.
Fig. 7 Position of emergency stop button
FP102NS001

14
3 Technology
3.1 Names of major parts
3.2 Description
3.2.1 Denester (1 in diag. 8)
The Staalkat denester denests fully automatically stacks of egg trays. The
denester has a set of accessories for 17 lbs trays fitted as standard. Sets for
different trays are available on request.
3.2.2 Carton transport lane (6 in diag. 8)
The carton transport lane is fitted with bars that move the cartons step by step
underneath the packer. The lane is driven through a clutch with a cam that
determines the size of the steps. The lane has a steps cam for 17 lbs trays fitted
as standard. Steps cams for different trays can be fitted on request.
Fig. 8 Major parts
1 Denester
2 Peak absorber
3 Identification plate/CE-marking
4 Control box
5 Packer
6 Carton transport lane
7 Incline conveyor
FP102OZ009
1 23456 7

Technology
User’s Manual Staalkat Farmpacker 40
Description
15
3.2.3 Peak absorber (2 in diag. 8)
The peak absorber divides the stream of supplied eggs to the packer. Moving
gates take care that the packer will receive six eggs at once each time.
With the standard, short model peak absorber egg supply is possible from the
end. With the extended peak absorber (optional) supply is also possible from
both sides. The Staalkat Farmpacker 40 can be used with supply belts of a
height between 900 and 1000 mm.
The control box contains a relay to which the supply belts can be connected.
When used the belts will stop when the Staalkat Farmpacker 40 stops. A
pressure control, fitted on the peak absorber, will stop the supply belts
temporarily when too many eggs are supplied.
3.2.4 Packer (5 in diag. 8)
The Staalkat packer inserts the eggs accurately, points down, in the tray. The
pitch of the insert mechanism can be easily adjusted to the pitch of the tray.
3.2.5 Incline conveyor (7 in diag. 8)
The incline conveyor brings the trays on the correct height for taking them away.
A take away table is fitted to the end of the conveyor. The conveyor has
sufficient accumulation length for 5 filled trays. A jam indicator stops the
Farmpacker automatically when the incline conveyor is getting filled up.
3.2.6 Control box (4 in diag. 8)
The control box of the Staalkat Farmpacker 40 is built in at the left hand side of
the peak absorber. The box contains the power supply and the Farmpacker
control.
The relay for switching off the egg supply belt(s) is also found in this control box.
3.2.7 Identification plate/CE-marking (3 in diag. 8)
The identification plate shows the type of machine and the machine/order
number. The CE-marking is also found on this plate. The EC Declaration of
Conformity is included in this manual.

Technology
User’s Manual Staalkat Farmpacker 40
Use
16
3.3 Use
The Staalkat Staalkat Farmpacker 40 is intended for the packing of eggs on egg
trays.
3.4 Ambient conditions
The machine is suitable for use in ambient temperatures of between 0º and
+35ºC and a relative humidity of between 40% and 85%. Sharp fluctuations in
temperature and the accumulation of condensation must be avoided.
3.5 Capacity
The gross capacity of the Staalkat Farmpacker 40 is 40 cases (14.400 eggs) per
hour.
3.6 Energy
3.6.1 Electricity
The needed mains supply is 230 V (± 10%), 1 phase, 50 Hz.
On request the Staalkat Farmpacker 40 can be supplied for 230 V, 1 phase, 60
Hz.
The connection rating is 0,3 kVA.
3.7 Sound level
The sound level of a Staalkat Farmpacker 40 is 70 dB(A), measured on the
work positions at the denester, the take away table and the peak absorber.
Measurements are conform EN-ISO 11201.

Technology
User’s Manual Staalkat Farmpacker 40
Materials
17
3.8 Materials
The frame sheet metal of the denester, the carton transport lane and the incline
conveyor is made of stainless steel.
The frame of the packer is of cast aluminium.
The guards are made of stainless steel sheet metal.
The perforated steel guard is powder-coated.
Stainless steel has been used for the deck plate of the carton transport lane and
the take away table.
The shafts are made of stainless steel.
The conveyor belts of the peak absorber and incline conveyor are made of
nylon material.
The incline conveyor rollers are of aluminium.
The various mechanical parts, when not made of stainless steel, aluminium or
plastic, are zinc plated.

18
4 Operation
4.1 Work positions
The following work positions may be used by the staff:
1 at the denester for filling stacks of trays
2 at the take away table for removing the filled trays
3 at the peak absorber for inspection of the arriving eggs
Fig. 9 Work positions Staalkat Farmpacker 40 right hand
model
Fig. 10 Work positions Staalkat Farmpacker 40 right
hand model
1
2
3
FP102OZ002
1
2
3FP102OZ003

Operation
User’s Manual Staalkat Farmpacker 40
Starting
19
4.2 Starting
Danger:
Check before starting the Farmpacker if all guards, covers, drip trays and
warning stickers are (back) in place.
When trays are present in the denester and on the carton transport lane till
underneath the packer the Staalkat Farmpacker 40 can be started as follows:
1 Plug in the mains lead.
2 Turn the main switch (4) to on (I).
3 Turn the on/off switch (2) to on.
4 Press the reset button (3). The warning light in the button will come on and
the Farmpacker starts running.
The machine will not start when:
•the guard with safety switch (6) is not (entirely) closed
•the emergency stop button (1) has been pressed
•the jam indicator (5) signals a filled up incline conveyor
In these situations the warning light in the reset button (3) will flash. See
‘Warning light’ on page 20 for an explanation of the warning light functions and
how to act.
Fig. 11 Controls
1 Emergency stop button
2 On/off switch
3 Reset button with warning light
4 Main switch
5 Jam indicator
6 Guard with safety switch
Staalkat
OFF ON
123 4
65
FP102BP001

Operation
User’s Manual Staalkat Farmpacker 40
Warning light
20
4.3 Warning light
When the Staalkat Farmpacker 40 does not start or has stopped automatically
the cause is indicated by the warning light in the reset button.
Light Situation Cause How to start (again)
Off Farmpacker is not
running On/off switch is off Turn switch to on and press reset button
Lead not plugged in Plug in mains lead and press reset
button
On Farmpacker is running
Flashing
slowly Farmpacker has stopped Guard with safety switch not (entirely) closed Close the guard and press reset button
Emergency stop button
has been used Check why the emergency stop has
been used. The machine may only
be started once it is certain that
everything has been made safe.
Release the emergency stop button
by turning it, then press the reset
button
The main supply has
been interrupted Press the reset button
No trays in denester Fill denester, put a tray in front of
photocell and press reset button
Trays jammed in
denester Separate trays, put a tray in front of photocell and press reset button
Flashing
rapidly Farmpacker is running Pressure control activated, too many eggs
supplied
Egg supply starts automatically
when surplus on peak absorber is
away
Farmpacker has stopped Jam indicator signals
filled up incline conveyor Farmpacker starts automatically after taking away trays from incline
conveyor
Flashing very
rapidly Farmpacker is in service- mode On/off switch has been turned to on while reset
button was pressed
Press reset button to move
Farmpacker in small steps
(“inching”)
Turn the switch to off and start
again for normal use