TPCD 66242 1 en 0006

Bühler AG
CH-9240 Uzwil, Switzerland

Phone ++41 71 955 11 11
Fax ++41 71 955 33 79
www.buhlergroup.com
Operating instructions
66242-1-en
0006
Pasta extrusion press TPCD

with extrusion screw 210/LW
handling device
2 Pasta extrusion press TPCD
Preface
These operating instructions document the pasta extrusion press TPCD.
The operating instructions have to be handed over to those persons who are
responsible for the operation and the supervision of these devices.
These operating instructions contain the information required for the user regarding
installation, operation and maintenance.
Description of activities that do not require any special knowledge have been
omitted.
Repair instructions that exceed the normal maintenance work are not provided.
The machine meets all acknowledged safety regulations. However, improper use
can involve physical danger for the user.
Highest priority, therefore, has been given to safety.
The symbols below are used to highlight specific information regarding safety:
Danger Caution Note
Important information
• Procedures upon receipt
Inspect the equipment visually in accordance with the delivery contract as soon
as it has been received.
• Storage
Equipment that is not installed immediately must be stored protected against
weather and other influences.
• Installation
The assembly and installation of the machine and machine equipment must
only be carried out by observing all installation instructions supplied.
• Design versions
If different designs are described in the documentation provided, only the infor-
mation concerning the version supplied will apply. We reserve the right to make
modifications due to technical progress up to the time of delivery.
• Duty of instruction
Commissioning and maintenance must only be done by trained specialists.
Prior to the initial start-up the operating personnel must familiarize themselves
with the documentation provided.
66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

Pasta extrusion press TPCD Table of contents 3
Table of contents
1 Safety .......................................................................................................... 1-1
1.1 Safety of persons ......................................................................................................... 1-1
1.2 Explosion protection ..................................................................................................... 1-1
1.3 Safety concept for the control units .............................................................................. 1-1
1.3.1 Connecting to the electrical mains .................................................................... 1-1
1.4 Safety concept ............................................................................................................. 1-2
1.5 Designated use ............................................................................................................ 1-2
1.6 Safety precautions ....................................................................................................... 1-2
1.6.1 Sectional switch pasta extrusion press ............................................................. 1-2
1.6.2 Safety switches mixer section .......................................................................... 1-2
1.6.3 Locations of the emergency-OFF push buttons ................................................ 1-2
1.6.4 Limit switches for the protection of persons ...................................................... 1-2
1.7 Bayonet lock at the diffusor .......................................................................................... 1-3
1.8 Dough pressure gauge ................................................................................................. 1-3
2 Description ................................................................................................. 2-1
2.1 Design features ............................................................................................................ 2-1
2.1.1 Twin-shaft high-speed mixer (TCMD) ............................................................... 2-1
2.1.2 Main mixer ....................................................................................................... 2-1
2.1.3 Vacuum airlock (TPSD) .................................................................................... 2-1
2.1.4 Vacuum mixer .................................................................................................. 2-1
2.1.5 Press line ......................................................................................................... 2-2
2.1.6 Diffusor with temperature control ...................................................................... 2-2
2.1.7 Hydraulic system .............................................................................................. 2-2
2.1.8 Slewing hoist .................................................................................................... 2-2
2.2 Function ....................................................................................................................... 2-2
2.2.1 Main mixer/vacuum mixer ................................................................................ 2-3
2.2.2 Function of the dough pressure gauge ............................................................. 2-4
2.2.3 Function of the level probe ............................................................................... 2-4
2.2.4 Cylinder cooling by circulation system .............................................................. 2-5
2.2.5 Vacuum system with vacuum pump ................................................................. 2-5
2.2.6 Vacuum line with double filter unit .................................................................... 2-6
2.2.7 Vacuum generation by water ring pump ........................................................... 2-6
2.2.8 Vacuum generation by sliding vane pump ........................................................ 2-7
2.2.9 Pneumatic diagram .......................................................................................... 2-7
2.2.10 Hydraulic diagram ............................................................................................ 2-8
2.3 Technical data .............................................................................................................. 2-9
2.3.1 Type key .......................................................................................................... 2-9
2.4 Noise data .................................................................................................................... 2-9
© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

4 Table of contents Pasta extrusion press TPCD
3 Transport..................................................................................................... 3-1
3.1 Handling with a crane ................................................................................................... 3-1
3.2 Transport weights and volumes .................................................................................... 3-1
4 Installation .................................................................................................. 4-1
4.1 Setting up the extrusion press ...................................................................................... 4-1
4.2 Electrical installation ..................................................................................................... 4-1
4.3 Water connections ........................................................................................................ 4-1
5 Commissioning .......................................................................................... 5-1
5.1 Preparations before the initial start-up .......................................................................... 5-1
5.2 Insertion of the extrusion screws and dough deflection units ........................................ 5-1
5.3 Cooling system ............................................................................................................. 5-1
6 Operation .................................................................................................... 6-1
6.1 Operating modes .......................................................................................................... 6-1
6.1.1 Unverriegelt/Verriegelt ...................................................................................... 6-1
6.1.2 Preparing the dough ......................................................................................... 6-1
6.1.3 Pre-extrusion without die .................................................................................. 6-2
6.1.4 Pre-extrusion with die ....................................................................................... 6-2
6.1.5 Normal operation .............................................................................................. 6-2
6.1.6 Emptying of the pasta extrusion press at the end of production ....................... 6-3
6.2 Control desk ................................................................................................................. 6-4
6.2.1 Individual operation on the mixer control panel ................................................ 6-4
6.2.2 Individual operation on the pasta extrusion press control panel ....................... 6-5
6.3 Instructions for the die change device .......................................................................... 6-5
6.3.1 Installation of the long-goods die ...................................................................... 6-6
6.3.2 Removal of the long-goods die ......................................................................... 6-6
6.3.3 Die change ....................................................................................................... 6-6
6.4 Instructions for the bayonet lock (left and right) ............................................................ 6-8
6.5 Removal of the extrusion screw seal pack ................................................................... 6-9
6.6 Temperature control of the diffusor ............................................................................. 6-10
6.7 Instructions for the extrusion screws handling device ................................................. 6-10
6.7.1 Removal of the dough deflection unit and the extrusion screw ....................... 6-12
6.7.2 Installation of the extrusion screw and the dough deflection unit .................... 6-14
6.7.3 Specifications to the control system ............................................................... 6-14
6.8 Troubleshooting in the case of faults .......................................................................... 6-15

Pasta extrusion press TPCD Table of contents 5
7 Maintenance ............................................................................................... 7-1

7.1 Safety during maintenance and cleaning ...................................................................... 7-1
7.1.1 Lock main switch .............................................................................................. 7-1
7.1.2 Instruction of the personnel .............................................................................. 7-1
7.1.3 Sanitation ......................................................................................................... 7-1
7.2 Cleaning ....................................................................................................................... 7-2
7.2.1 Cleaning during production .............................................................................. 7-2
7.2.2 Cleaning after completion of production ........................................................... 7-2
7.3 Maintenance schedule ................................................................................................. 7-3
7.3.1 Maintenance and checking work after 1 week .................................................. 7-3
7.3.2 Maintenance and checking work after 1 month ................................................ 7-4
7.3.3 Maintenance and checking work after 3 months .............................................. 7-4
7.3.4 Maintenance and checking work after 1 year ................................................... 7-4
7.3.5 Maintenance and checking work after 4 years ................................................. 7-5
7.4 Lubricants ..................................................................................................................... 7-5
7.5 Lubrication schedule .................................................................................................... 7-6
7.5.1 Lubrication after 1 week ................................................................................... 7-6
7.5.2 Lubrication after 1 month .................................................................................. 7-6
7.5.3 Lubrication after 1 year ..................................................................................... 7-7
7.5.4 Lubrication after 4 years ................................................................................... 7-7
8 After-sales service ..................................................................................... 8-1
8.1 Spare parts................................................................................................................... 8-1
8.2 Address ........................................................................................................................ 8-1

6 Table of contents Pasta extrusion press TPCD

Pasta extrusion press TPCD Safety 1-1
1 Safety
1.1 Safety of persons
• Protective guards must always be installed and closed. Open or removed pro-
tective guards are extremely dangerous and can cause accidents involving seri-
ous personal injuries.
• Always keep safety devices in good working condition. Safety devices must not
be bridged over or put out of operation.
• Maintenance work at the machine or parts thereof must only take place with the
installation at a standstill. It is absolutely important that the installation is
switched off and that the switch is locked!
• When taking out material samples, make sure that this is done safely.
1.2 Explosion protection

(Safety precautions for the prevention of dust fires or dust explosions)
• Smoking is generally prohibited in plants for food and animal feed products.
• Repair and installation work using welding equipment, blow torches etc. must be
carried out in special workshops or at locations designed for such activities.
• For exceptional cases, where welding or similar work must be carried out direct-
ly at the production facility, special safety precautions must be taken. For exam-
ple, the immediate surroundings have to be covered with wet or special canvas
hoods and fire extinguishers have to be on hand immediately at the worksite.
• Electrical installations and appliances have to be checked at regular intervals.
Special attention must be given to the following:
– do not use hand lamps and light fittings without covers or protective glass.
• In order to reduce electrostatic sparks, the machines have to be earthed. The
leakage resistance to ground must be less than 106 ohms at all parts.
1.3 Safety concept for the control units

The control unit supplied by Buhler is an integrated part of the safety concept for the
prevention of accidents. Prior to initial operation, the control unit must be checked
by a Buhler expert in accordance with a checklist.
If a control unit for Buhler machines is delivered by third parties it must be built ac-
cording to Buhler specifications. Prior to commissioning it must be checked thor-
oughly by trained experts according to the specifications in the documentation sup-
plied and released with a signature.
1.3.1 Connecting to the electrical mains

• Observe the regulations of the local safety authorities.
• The power supply has to be fuse-protected according to the local regulations.
• Check wether the operating voltage and frequency correspond to the specifica-
tions given on the identification plate and in the control cabinet.
• All electrical connections to the control systems must be done according to the
wiring diagram to ensure that the phase conductors are really switched in the
case of single-phase power supplies.

1-2 Safety Pasta extrusion press TPCD
1.4 Safety concept

The pasta extrusion press TPCD is normally part of an installation and therefore
integrated into the safety concept of the installation.
If the pasta extrusion press TPCD is not used within this safety concept, the user
has to redefine the risk estimation of the dangers involved and has to take suitable
measures.
The design and construction of the machine comply with EC regulations and USA-
FDA regulations with respect to safety and hygiene.
The CE mark can be attached and the EC declaration of conformity issued after
commissioning and safety inspection.
1.5 Designated use

The pasta extrusion press TPCD is designed only to process the products in the
contractually agreed field of application. Any use beyond that is considered contrary
to its designated use.
1.6 Safety precautions
1.6.1 Sectional switch pasta extrusion press

Due to safety reasons a sectional switch which switches off the entire extrusion
press has to be installed into the high-voltage cabinet! This will de-energize the
electric, hydraulic and pneumatic drives.
(lockable maintenance switch)
1.6.2 Safety switches mixer section

The safety switches, which disconnect all phases, allow the relevant motors to be
individually switched off and secured with a personal padlock before service and
maintenance work can begin.
1.6.3 Locations of the emergency-OFF push buttons

• Control panel mixer (on the platform of the extrusion press)
• Control panel line (at the foot of the extrusion press)
• Control panel extrusion press operating platform
The entire production line can be shut down with these emergency-OFF push
buttons.
1.6.4 Limit switches for the protection of persons

• Twin-shaft high-speed mixer
– The safety at the mixer shaft and cover ensures that the motor is switched
off when the mixer shaft thrust bearing and the upper housing section are
opened (See separate operating instructions TCMD).
• Main mixer lid interlock
– The limit switch ensures that the four mixer lids are closed and locked pneu-
matically.
• Airlock channel lid
– The airlock lid at the outlet of the main mixer is electrically monitored. The
main mixer drive and the airlock drive are switched off when the airlock lid is
opened.

Pasta extrusion press TPCD Safety 1-3
• Vacuum mixer lid interlock

– The limit switches ensure that the two mixer lids are closed and locked
pneumatically.
• Extrusion screw interlock
– The two lids of the vacuum mixers are electrically monitored. This ensures
that both drives of the extrusion screws are switched off when the lid is
opened.
1.7 Bayonet lock at the diffusor

The diffusor is equipped with two hydraulically actuated bayonet locks which allow a
quick and easy removal and installation of the dough deflection units and of the
extrusion screws.
• When the bayonet lock is openend the drives of the extrusion screws cannot be
started and on the other hand the bayonet lock cannot be opened as long as
the extrusion press is running.
• The two position limit switches (Fig. 7.1) indicate to the operator in the corre-
sponding operating mode (e.g automatic, manual or cleaning) whether the bay-
onet lock is
– unlocked, i.e. opened or
– locked, i.e. closed.
1.8 Dough pressure gauge

Pressure gauges for dough pressure 1 + 2
• release an alarm at approx. 20 bar above operating pressure (dependent on
product and dough moisture) via the contact 1 and stop the pasta extrusion
press at approx. 40 bar above operating pressure via the contact 2.

1-4 Safety Pasta extrusion press TPCD

Pasta extrusion press TPCD Description 2-1
2 Description
2.1 Design features
5 4 3 2 1
8 6 7
Fig. 2.1
(1) Twin-shaft high-speed mixer (5) Press line

(2) Main mixer (6) Diffusor with temperature control
(3) Vacuum airlock (7) Hydraulic system
(4) Vacuum mixer (8) Slewing hoist
2.1.1 Twin-shaft high-speed mixer (TCMD)

For the dampening and intensive mixing of the raw materials fed into the line. This
mixer is always heated for the production of egg pasta in order to ensure optimum
product control.
Can be opened up for cleaning.
2.1.2 Main mixer

For further mixing, for a homogeneous dough mixture.
2.1.3 Vacuum airlock (TPSD)

For the feeding of the product into the vacuum trough. The airlock is equipped with
teflon-coated feeding pockets.
2.1.4 Vacuum mixer

For the evacuation of air from the dough mixture and for an uniform distribution of
the dough between both extrusion screws. This is done with a corresponding pad-
dle position and with the spiral efffect by the mixing paddles to both sides.

2-2 Description Pasta extrusion press TPCD
2.1.5 Press line

• The extrusion screws generate a gentle pressure build-up and at the same time
convey the dough via the diffusor to the die.
• Extrusion cylinder with cylinder cooling for the elimination of the excessive heat
of the dough.
2.1.6 Diffusor with temperature control

The diffusor is provided with bores for the dough temperature control, which allow
the diffusor to be quickly preheated before the production start and which enable a
quick setting to new nominal values or temperatures during production.
2.1.7 Hydraulic system

The hydraulic system consists of the hydraulic unit and the necessary valves, hy-
draulic cylinders, etc. for following movements:
• Opening and closing of the bayonet lock
• Installation and removal of the dough deflection units and extrusion screws;
provided the handling device for the extrusion screws is installed.
• Die ejection
2.1.8 Slewing hoist

The slewing hoist is used for the handling of the:
• Long-goods die
• Dough deflection units
• Extrusion screws
• Extrusion screws handling device
Caution!
Maximum load £ 500 kg
2.2 Function
The raw material ingredients received from the feeder are intensively dampened
and premixed with the feedwater and/or other liquid components in the twin-shaft
high-speed mixer.
From the twin-shaft high-speed mixer the material is transferred to the main mixer.
Once the material has been sufficiently mixed in the main mixer it is then trans-
ferred through the vacuum airlock to the vacuum mixer.
In the vacuum mixer and in the subsequent extrusion screws the air is extracted
from the dough with the help of a vacuum pump.
The negative pressure is - 0,8 bis - 0,9 bar.
The dough pressure of approx. 80...130 bar required for the extrusion is generated
with the extrusion screws.
The two pressure gauges for the dough pressure located in the area of the diffusor,
show the current dough pressure and indicate to the operating personnel whether
more or less liquid must be added to the material via the feeder.

2.2.1 Main mixer/vacuum mixer

• The drive of the main mixer can only be started if all the mixer lids are closed
and if the coupling is interlocked.
The mixer lids and the coupling can only be opened once the drive has been
stopped. (audible click of pneumatic cylinder, monitoring with speed monitor)
• The opened lids are retained by a catch.
When closing the lids the catch has to be released first by pressing the rubber
push buttons.
• By disengaging the coupling the drive and the mixer shafts are separated. This
will allow for the mixer shafts to be turned by hand during the cleaning opera-
tion.
• The enagaging can take place gently and without the use of force by a simulta-
neous movement of the mixer shafts and the coupling (synchronisation). (during
engaging the toothed rings of the coupling must not knock against each other)
Main mixer:
Electrical Drive Drive Condition

Object Function
element main mixer vacuum airlock Y 303
Main switch switched on 1 1
Q 290
main mixer switched off 0 1
locked 1 1 1
Lid main mixer B 292
unlocked 0 1 0
Coupling mixer engaged 1 1 1
B 302
shaft disengaged 0 1 0
Speed monitor rotating 1
B 297
mixer shaft stopped 0
Lid airlock closed 1 1
B 296
channel open 0 0
1 = enabled 0 = disabled

Vacuum mixer:
Drive Drive Drive Drive

Electrical Condition
Object Function main vacuum vacuum extrusion
element Y 324
mixer airlock mixer screws
Main switch switched on 1 1
Q 315
vacuum mixer switched off 0 0
Lid vacuum locked B 319 1 1 1 1 1

mixer left/right unlocked B 320 0 0 0 0 0
Coupling mixer engaged 1 1 1 1 1

B 321
shaft disengaged 0 0 0 1 0
Speed monitor rotating 1
B 322
mixer shaft stopped 0
Lid airlock closed 1 1 1 1
B 296
channel open 0 0 1 1
Vacuum airlock blocked B 299 0 0 1 1
1 = enabled 0 = disabled
2.2.2 Function of the dough pressure gauge

The pressure gauge with the analog output (4...20 mA) is installed on the left-hand
extrusion screw (No. 1). The pressure gauge is equipped with 2 contacts.
The output signal is registered by the recorder.
Two limiting values release the following in the PLC:
• Alarm (working pressure + approx. 20 bar) at the first contact
• Extrusion press stop (working pressure + approx. 40 bar) at the second contact
Addition of feedwater results in a lower dough pressure.
Removal of feedwater results in a higher dough pressure.
• Wait for response time (approx. 20 minutes).
The pressure gauge installed on the right-hand screw is used for display only and
has no electrical connections.
2.2.3 Function of the level probe

The level of the material in the vacuum mixer is automatically controlled with the
level probe installed in the mixer.
A special program is used to request a bigger or smaller amount of material from
the feeder.
The feedwater volume is automatically adjusted to the quantity of semolina.

2.2.4 Cylinder cooling by circulation system

• The extrusion cylinders are provided with a cylinder bush with circumferential
channels for the cooling water.
• The heat transfer takes place from the pressurized dough through the cylinder
bush into the cooling water of the secondary circuit.
• The extrusion press cylinder cooling is fed with circulation water from the cold-
water circuit (primary circuit) and is equipped with a separate circulation pump
in the secondary circuit.
• The circulation pump is started automatically as soon as one of the two drives
of the extrusion screws is switched on, .
• At the same time the control valve and the I/P converter are fed with an air pres-
sure of 1,4 bar via the solenoid valve and the pressure reducing unit.
• In the I/P converter the electrical output signal is converted to a pneumatic
signal which then activates the control valve.
• The control is done with a control circuit in the PLC, whereby the PT-100 ther-
mocouple measures the actual value of the return water in the secondary
circuit.
• The temperature of the return water is displayed on the screen.
2.2.5 Vacuum system with vacuum pump

• The vacuum pump is connected to the vacuum mixer with a vacuum line.
• The vacuum line with a double filter unit connected to the vacuum trough allows
the exchange of cartridges during operation by means of a manual switch-over.
• The negative pressure generated in the vacuum mixer (normal operation ap-
prox. - 0,8 bar) is measured with the vacuum probe and displayed on the
screen.
• The generated negative pressure is monitored with the limiting value alarm
«Alarm low» (approx. - 0,7 bar).
• The extrusion press is stopped with the alarm «Vacuum too low» (approx. -
0,6 bar), because a production of a sufficient quality can no longer be guaran-
teed (air enclosures in the product).
• The ON / OFF keyboard for the manual operation of the vacuum pump is locat-
ed on the mixer control panel.
• In normal operation the pump is started and stopped with the PLC as follows:
Starting (interlocking sequence)
1. Extrusion screws 1 and 2
2. Vacuum mixer
3. Vacuum pump
4. Vacuum airlock
Stopping (interlocking sequence)
1. Vacuum airlock
2. Vacuum pump
3. Vacuum mixer
4. Extrusion screws 1 and 2

2.2.6 Vacuum line with double filter unit

The ball valve position is marked with the square.
Normal operation Bypass opera-

tion
Fig. 2.2
123456
123456
123456
123456
123456 Filter not in operation, i.e.
123456
123456
123456
123456 filter can be cleaned
123456 Filter in operation
123456
123456
123456 during production.
123456
123456
2.2.7 Vacuum generation by water ring pump

• This type of pump works on the basis of «Fresh water operation with circulation
tank».
• The water used for operating the water ring pump is taken from the mains.
• A vent valve installed in the vacuum line limits the negative pressure in order to
prevent the pump from operating in the cavitation range and therefore will not
be damaged.
• The ball check valve prevents water from being drawn into the vacuum mixer
when the pump is stopped.
• The return water temperature is controlled by the water saving valve.
• The nominal value is set manually with the handwheel on the valve body.
• The actual value is measured by the sensor in the circulation tank.
• At the same time the return water temperature is indicated on the thermometer .
• The pump is designed for a return water temperature of 35...40 °C, ensuring a
minimum return water volume.
• The solenoid valve (24 V DC) shuts off the operating water supply as soon as
the pump has been stopped and opens the supply when the pump is running.

2.2.8 Vacuum generation by sliding vane pump

The operation of this pump type is based on the principle of rotating vanes that slide
radially in grooves.
The pump is oil-flooded with the emerging air being passed through an oil trap.
The oil supply serves mainly for lubrication and sealing as well as for the elimination
of compression heat, i.e. for the cooling of the pump.
Caution!
The ambient temperature must not exceed 40 °C.
With higher temperatures Buhler must be consulted.
Caution!
The extracted air is allowed to contain water vapour but no water and no other liq-
uids.
Aggressive gases or vapours must not be extracted.
2.2.9 Pneumatic diagram
B 302 B 292 B 321 B320 B 319

disengaged locked disengaged unlocked unlocked
Limit switch
symbol
Coupling main Lid interlock main Coupling vacuum Lid interlock Lid interlock vacuum
mixer mixer mixer vacuum mixer left mixer right
Compressed air
connection
p = 5...7 bar
dia. 8/6 mm
Fig. 2.3

2-8
2 hydraulic cylinders 2 hydraulic cylinders Hydraulic cylinder ø 38,1/24,4 x 90

ø 100/55 x 1970 for ø 63/32 x 1100 for bayonet lock open and close
long-goods die ejection for handling device
Fig. 2.4
open close open close
66242-1-en-0006
Description
Screw
Die ejection entering
2.2.10 Hydraulic diagram
extraction
Idle stroke
Pasta extrusion press TPCD
© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

2.3 Technical data

Mixer volumes:
• Twin-shaft high-speed mixer: ca. 10 dm3
• Main mixer: ca. 980 dm3
• Vacuum mixer: ca. 387 dm3
Connections for infrastructure:
feedwater connection 2 x G½" per rotary inlet
• Twin-shaft high-speed mixer heating 2 x G¾"
• Cooling of press cylinder 2 x G1" per press line
• Temperature control of diffusor 1 x G¾" per side
• Vacuum connection 1 x G2“
Power Speed
Unit
at 50 Hz at 50 Hz
Twin-shaft high-speed mixer TCMD 5,5 kW 955 U/min.
Main mixer TPCD 22 kW 50 U/min.
Vacuum airlock TPSD 1,1 kW 58,2 U/min.
Vacuum mixer 11 kW 60 U/min.
Press line (2x) 2 x 75 kW 23 U/min.
Diffusor with temperature control ---- ----
Hydraulic system 1,5 kW ----
Slewing hoist 0,4 kW ----
2.3.1 Type key

TPCD-210/LW
Long-goods die
Extrusion screws ø 210 mm
Twin-screw press
2.4 Noise data
Measured values
1
) Equivalent sound pressure level in the area around the Leq = 79,5 dB (A)
machine
2
) Acoustic power level Lw = 103,1 dB (A)
1)
Measuring method: according to ISO 6081
2)
sound intensity in conformity with ISO 9614

2 - 10 Description Pasta extrusion press TPCD

Pasta extrusion press TPCD Transport 3-1
3 Transport
Note:
The transport must only be handled by persons who are familiar with and trained for
this task.
3.1 Handling with a crane

A crane can be used to unload and transport the equipment.
Caution!
Check the lifting gear for the required design and the permissible load capacity.
3.2 Transport weights and volumes
Note:
Generally the transport weights in the shipping papers apply and have to be
observed!

3-2 Transport Pasta extrusion press TPCD

Pasta extrusion press TPCD Installation 4-1
4 Installation
4.1 Setting up the extrusion press
The following has to be considered when setting up the extrusion press:
• The setting up of the extrusion press is done by our specialists.
• The machine has to be bolted to the floor.
4.2 Electrical installation

The electrical installation for the extrusion press has to be done according to the
electrical diagram and by observing the local regulations.
Caution!
Due to safety reasons a sectional switch has to be installed in the high-voltage
cabinet. (lockable maintenance switch)
4.3 Water connections

The connections for the cylinder cooling and the temperature control of the diffusor
have to be done according to the diagrams of Buhler Uzwil.
The extrusion press is supplied with the water lines installed up to the foot of the
press. The inlet and outlet lines have to be determined on site.

4-2 Installation Pasta extrusion press TPCD

Pasta extrusion press TPCD Commissioning 5-1
5 Commissioning
Danger!
For all control work which requires the stoppage of the machine due to
safety reasons, the mains supply switch of the control system has to be
switched off and the key withdrawn. In addition all the main switches have
to be switched off and locked with a personal padlock.
5.1 Preparations before the initial start-up

• Use the lubricants specified in the lubrication schedule for the gear units of the
following machines.
– Main mixer
– Vacuum airlock
– Vacuum mixer
– Press line
– Hydraulic unit
• Only use lubricants that have the specified properties.
• The use of food-compatible oil is mandatory for the hydraulic system.
• Selection of the lubricants for all points of lubrication according to chapter 7.5.
• Check that all gearboxes are filled with oil.
• Briefly start all motors and check the direction of rotation.
5.2 Insertion of the extrusion screws and dough deflection units

Before inserting the screws clean the following parts and oil them lightly with
edible oil:
• Dough deflection units with O-rings
• Extrusion press cylinder
• Intermediate piece
• Diffusor
Additionally:
• Fill the rotary shaft seals of the seal packs with grease.
• Slide the seal packs into the coupling housing and turn them clockwise into the
bayonet anchoring up to the stop.
• Insert the extrusion screws and check if they are properly engaged.
• Insert the dough deflection units with the O-rings in place and close the bayonet
lock hydraulically.
• Fill the lines leading to the dough pressure gauges with Vaseline.
5.3 Cooling system

The entire cooling system has to be vented carefully.

5-2 Commissioning Pasta extrusion press TPCD

Pasta extrusion press TPCD Operation 6-1
6 Operation
6.1 Operating modes
The following three operating modes are selected with the «ON/OFF» key:
• Dough preparation
• Pre-extrusion with and without die
• Normal operation
Dough preparation and pre-extrusion are taking place with the selector switch in the
locked position.
When normal operation is started the selector switch must also be set to «locked».
• Emptying
The operating mode «emptying» can only be started from the mixer control panel
with the selector switch set to «locked».
6.1.1 Unverriegelt/Verriegelt
• With the selector switch at position 1 «unlocked» all elements of the extrusion
press can be individually started and stopped.
• The main mixer und the twin-shaft high-speed mixer remain firmly locked at all
times.
• On position 2 «locked» the extrusion press is interlocked with all the interlinked
elements from the spreader to the feed system.
• The extrusion press can now only be started with the key «Normal operation»,
provided the extrusion press has been preselected with the key «ON».
6.1.2 Preparing the dough

Dough preparation and pre-extrusion are taking place with the selector switch at the
locked position, i.e.: the elements about to be started are interlocked.
Once all the peripheral equipment is operating and the diffusor is preheated the
dough is prepared in the mixing troughs according to the product formula.
For the dough preparation the outlet opening to the airlock has to be closed with the
manually actuated gate.
Raw ingredients such as: semolina or flour, water, salt water or egg additives are
automatically specified as nominal values for the individual controllers according to
the preselected product formula.
When the key «Dough preparation» is pressed, the equipment starts in the following
sequence:
1. Vacuum mixer
2. Vacuum airlock
3. Main mixer
4. Twin-shaft high-speed mixer
5. Feed system
provided that the appropriate selector switches for the raw ingredients were prese-
lected on the feed system panel.
As soon as a certain material level (approx. middle of mixer shaft) has been
reached in the vacuum mixer, the operation is automatically stopped.
The operation can also be stopped with the OFF-key on the control elements.
If required the dough preparation can be selected any number of times, provided
that the material level in the vacuum mixer was lowered by rotating the extrusion
screws.

6-2 Operation Pasta extrusion press TPCD
6.1.3 Pre-extrusion without die

With the key «Pre-extrusion» all elements of the «Dough preparation» are
operating.
In addition, the two extrusion screws run at reduced speed.
This process continues until the emerging dough strands have the required consist-
ency to enable a subsequent extrusion through the die.
The vacuum pump, the cooling water pump, the temperature control for the cooling
water return and the diffusor temperature control are already in operation in this
mode.
The alarms «Vacuum low» or «Vacuum too low» are suppressed during the pre-
extrusion without die.
The process can be stopped with the stop key.
6.1.4 Pre-extrusion with die

The process is restarted with the key «Pre-extrusion» as soon as the die has been
inserted with the help of the die change device.
Once the dough strings are running evenly and the dough pressure has almost
been reached, the process is stopped with the stop key.
As a guideline this process should not take longer than 2 minutes.
Caution!
The vacuum airlock and the mixer shafts of the twin-shaft high-speed mixers will
continue to run for approx. 10 seconds after the stop key is pressed.
The pasta extrusion press is now ready for normal operation.
Note:
If the pre-extrusion process is disturbed by a malfunctioning element, the extrusion
press will automatically stop, starting at the source of the fault and progressing
backward until the feed system.
Once the minimum dough level has been reached in the vacuum mixer the pre-
extrusion process of the entire extrusion press is stopped.
With the start of the dough preparation the extrusion press is returned back to the
original operating condition again.
6.1.5 Normal operation

Once the:
• Stick return conveyor
• Stacker
• Dryer
• Spreader
have been started mechanically, the extrusion press is started in the operation
mode «Normal operation».
First the spreader is set to Pos. 3 (loaded) and the selector switch for the dryer and
the extrusion press is set to «Locked».
In normal operation the extrusion press automatically starts in the following se-
quence:
1. Die ventilation of spreader
2. Extrusion screws 1+ 2 (water circuits for cylinder cooling and diffusor tempera-
ture control start automatically)

3. Vacuum mixer
4. Vacuum pump
5. Vacuum airlock
6. Main mixer
7. Twin-shaft high-speed mixer
8. Feed system
Note:
If normal operation is disturbed by a malfunctioning element, the extrusion press will
automatically stop, starting at the source of the fault and progressing backward until
the feed system.
6.1.6 Emptying of the pasta extrusion press at the end of production

The operating mode «Empty extrusion press» can only be started from the mixer
control panel with the selector switch on the control panel of the extrusion press set
to «Locked».
The emptying process can be interrupted at any time with the «Stop» key on the
mixer or extrusion press control panel.
After the key «Empty extrusion press» is pressed the emptying process proceeds
according to the following sequence:
• Regardless of the level in the semolina feed hopper the feed system stops im-
mediately.
• At the same time the extrusion screw speeds are reduced by 30 %.
The dryer speed is also reduced to the same extent.
• The twin-shaft high-speed mixer stops with a time delay in relation to the feed
system after a slowing-down time of approx. 30 seconds. This ensures an al-
most complete self-emptying of the twin-shaft high-speed mixer.
For the complete cleaning of the twin-shaft high-speed mixers TCMD, please
refer to the separate operating instructions.
• Now the material level in the main mixer starts to drop.
In order to ensure that the main mixer empties itself as complete as possible,
the lower gate in the airlock channel has to be opened, i.e. the lever has to be
turned to the top position and engaged.
As soon as the remaining material in the main mixer consists to a large extent
of «Rework» only (cut off, reusable dough strings), the direction of travel of the
dough return conveyor belt of the spreader has to be reversed with the key
«Reverse dough return belt» located on the panel «Operation mixer». At the
same time the shredder fan and the double separator are stopped.
• Now the drive of the main mixer is stopped with the key «Main mixer stop».
The stoppage monitor ensures that the mixing trough lids can only be opened
once the mixer shafts have come to a stop.
The pneumatic cylinders unlock the mixing trough lids.
Now both mixer lids can be opened and the material can be pushed out by
hand.
In order to ensure that the mixers are emptied as complete as possible the vac-
uum airlock has to run.
Under no circumstances, therefore, must the safety device above the airlock
channel be bypassed.

Danger!
The rotating rotor of the vacuum airlock is a danger zone.
Never reach with the hands into the rotor area.
• Now the material level starts to drop in the vacuum trough as well.
As soon as the flights of the extrusion screws become visible the key «Extru-
sion press stop» on the extrusion press control panel has to be actuated.
However, this must only take place after the upper knife of the spreader has
performed the cut.
With «Extrusion press stop» the vacuum airlock, the vacuum mixer, the vacuum
pump and the drives of the extrusion screws are stopped.
The spreader stops automatically after the end of the cycle.
Now the shutdown program of the dryers has to be selected manually.
The dryer drive now again continues to run with the original operating stick fre-
quency.
6.2 Control desk

(installed in the control room or in front of the line)
All other extrusion press functions with regard to a current product formula can be
carried out and monitored at the control desk:
• Semolina quantity (and possibly additives)
• Volume control of the feed water
• Temperature control of the feed water
• Speed control of the extrusion screws with frequency converters
• Temperature control of the cylinder cooling
• Dough level monitoring in the vacuum trough
• Vacuum monitoring
• Dough pressure monitoring
• Dough temperature monitoring
6.2.1 Individual operation on the mixer control panel

On the mixer control panel individual control is provided for the following elements
(ON/OFF):
• Metering pump
• Feed system
• Main mixer
• Vacuum airlock
• Vacuum mixer
• Vacuum pump
• Forward and return movements of the dough return conveyor at the spreader

6.2.2 Individual operation on the pasta extrusion press control panel

On the control panel of the extrusion press operating platform the following ON/OFF
keys are available for the individual operation of the extrusion press:
• Feed system • Die ventilation of spreader
• Temperature control of the diffusor • Lifting and lowering of the
• Hydraulic unit ventilation hood
• Extrusion screw No.1 • Cutter knife of spreader top knife
• Extrusion screw No.2 to the left
• Bayonet lock No.1 • Cutter knife of spreader top knife
• Bayonet lock No.2 to the right
• Die change
6.3 Instructions for the die change device

• The hydraulic unit is basically not interlocked with the extrusion press.
• The keyboard for the operation of all hydraulic movements is located at the con-
trol panel on the spreader platform.
• The following applies for the operation:
– It is always possible to extend the piston rods.
– Retraction of the piston rods, i.e. the ejection of the inserted long-goods die
is only possible with the extrusion screw drives stopped.
– The piston rods may remain in the retracted position after the first die instal-
lation or die change.
This protects the long piston rods against contamination and damage.
– The end position after the completed working stroke, i.e. the initial instal-
lation of the long-goods die or die change, indicates at the same time that
the long-goods die is installed at the correct position.
– The fact that the piston rods have reached an end position can be heard by
the change in sound as a result of the additional load on the hydraulic unit.
– The hydraulic unit is automatically stopped after 10 min if the die change
device is not actuated for a longer period.

6.3.1 Installation of the long-goods die

The die bearing surfaces (friction surfaces) have to be cleaned well and greased
lightly with Vaseline before the die installation and die change.
Insertion of the die:
1. Switch on the hydraulic unit and extend the die changing device all the way to
the stop.
2. Grease the rubber seal with Vaseline and place it in the circular round groove of
the seal plate.
3. Push the seal plate by hand into the diffusor.
4. Lift the seal plate into the recess of the diffusor by using the two supports.
5. Place the cleaned and preheated die (50 °C) with the wire mesh inserted (die
protection) between the diffusor and the extended die changing device onto the
die carrier (2000 mm long).
6. Push in the die with the die changing device, making sure that the correct end
position is reached by moving it all the way to the stop.
Caution!
The two supports have to be removed once the die is approx. 15 cm from the
support.
6.3.2 Removal of the long-goods die

the stop.
2. Insert the die ejection bar included in the supply and hook it into the cross-mem-
ber.
3. Eject the die and lift it off using the hoist and special gripper.
4. Extend the piston rod again together with the die ejection bar.
5. Briefly start the main motors (approx. 10 seconds) and use the remaining dough
to press the seal plate completely down.
6. Eject the seal plate in the same way as the die.
7. Place the die and the seal plate into warm water immediately after the removal.
8. Extend the die changing device again together with the die ejection bar and
remove the die ejection bar.
9. Retract the die changing device to protect the piston rods.
6.3.3 Die change

With every die change or die removal make sure that there is only a residual pres-
sure of approx. 10 bar before the ejection of the die (check dough pressure gauge).
Procedure:
1. Switch off all drives at the extrusion press, with the exception of the hydraulic
unit.
the stop.

3. Place the new, cleaned and preheated die with the wire mesh inserted between
the outer edge of the diffusor and the cross-member onto the die carrier
(2000 mm long) (The seal plate with the rubber seal remains installed in the
diffusor).
4. Let the extrusion pressure drop to approx. 10 bar, then cut the dough strings off
the inserted die.
5. Push in the preheated die.
6. For pre-extrusion with die, see chapter. 6.1.4
7. Normal operation, see chapter. 6.1.5
8. Lift off the ejected die with the slewing hoist.
7, 8, 9, 10
2 3, 5 1 6 2
11 a b
4
Fig. 6.1
(a) Hydraulic die change device, position «retracted»

(b) Hydraulic die change device, position «extended»
(1) Diffusor
(2) Die carrier
(3) Dough deflection unit
(4) Bayonet lock
(5) Bayonet disk
(6) Bayonet ring
(7) Rubber seal of the seal plate
(8) Seal plate
(9) Die
(10) Die protection
(11) Extrusion screw

6.4 Instructions for the bayonet lock (left and right)

The bayonet lock is driven by the same hydraulic unit which also supplies the die
changing device with oil. The keyboard is also located on the control panel «Line».
For the operation the following applies:
• Normal operation:
During the normal operation the bayonet lock is closed, i.e. the piston rod of the
hydraulic cylinder is retracted and the four lugs of the bayonet ring and the bay-
onet disk overlap.
(The notches on the nodular cast iron housing of the diffusor and the bayonet
ring are positioned vertically below each other).
It is impossible to open the bayonet lock during the normal operation, because
the pasta extrusion press is under pressure and the end position «Bayonet lock
locked» is electrically interlocked with the drives of the extrusion screws.
• Cleaning mode:
If cleaning is necessary the extrusion press is changed from normal operation
to cleaning mode.
Once the drives of the extrusion screws have stopped and have been secured
with the safety switch and once the pressure of the extrusion press has dropped
to almost 0 bar (check dough pressure gauge), the bayonet lock can be hydrau-
lically opened by pushing the button with the function «Unlock bayonet lock».
If necessary the dough deflection unit and the extrusion screw can now be re-
moved with the help of the handling device, provided it has been installed.
For the operation of the handling device please refer to the instructions under
chapter 6.7.
• Restart of the extrusion press:
The cleaned extrusion screw and the cleaned dough deflection unit are placed
next to the extrusion press ready for installation.
Conduct a visual check to ensure that there are no foreign objects in the
areas of the drive square of the gear transmisssion, the entire press line and the
extrusion press head. To prevent damaging the seal rings in the seal pack the
seal pack has to be removed when cleaning the press line.
Note:
The sections marked in Fig. 6.2 with – - –, the drive square, the seal pack, the diffu-
sor head area, especially the areas of the seal rings and of the the bayonet ring,
must be entirely free of dirt and dough residues. Grease these areas with some
grease according to the specifications in the lubrication chart.
Now the extrusion screw and the dough deflection unit can be installed with the help
of the handling device.
When installing the dough deflection unit make sure the sides are correct, left/right!
For the installation of the extrusion screw we recommend to install always the same
extrusion screw into the same press line.
Now perform a visual check to verify the axial installation position of the dough de-
flection unit.
The pressure edges of the bayonet disk, when viewed in an axial direction, must be
located behind the pressure edges of the bayonet ring (Fig 6.3).
Now close the bayonet lock hydraulically with the push-button. Perform a visual
check of the overlap of the four lugs, bayonet disk/bayonet ring and the position of
the notches.
The extrusion press is now ready for operation again.

Diffusor Press cylinder Drive square
Fig. 6.2 Press line
Dough deflection
unit
Bayonet ring
Bayonet disk
Fig. 6.3 Installation positon of the dough deflection unit
Danger!
Never get near the rotating extrusion screw! With this design it is possible
to install the extrusion screw only without the dough deflection unit and
still be able to close the bayonet lock!
This will greatly increase the danger of someone reaching right into the
rotating extrusion screw.
6.5 Removal of the extrusion screw seal pack

1. Use the lever to turn the seal pack out of the bayonet anchoring.
2. Now withdraw the seal pack in an axial direction out of the guide of the interme-
diate plate toward the planetary gear.
3. The seal pack can now be lifted or lowered out of the coupling housing.
4. The seal pack should be removed every time the extrusion cylinder and the
intermediate piece are cleaned to prevent the shaft seals from being damaged.
5. Every time the seal pack is removed the condition of the sealing lips of the shaft
seals has to be checked.

6 - 10 Operation Pasta extrusion press TPCD
6.6 Temperature control of the diffusor

There are two operation modes for the diffusors.
• Preheating to the required temperature before production start:
– With the auxiliary heating system the diffusor is heated for approx. 20 minu-
tes to the preselected nominal temperature of approx. 45 °C.
– Once the nominal temperature has been reached the heating valve is clo-
sed automatically.
– This will ensure a homogeneous temperature distribution throughout the
entire diffusor, already during the stages of dough preparation and pre-ex-
trusion with or without a die installed.
• Maintaining the temperature during the production:
– During the production the diffusor is cooled under normal operation with the
cooling water of the secondary circuit until the nominal temperature has
been reached.
– Depending on temperature fluctuations (caused by fluctuations in through-
put or production interruptions) the auxiliary heating system is heating again
until the nominal temperature has been reached.
– The control of the nominal temperature (heating or cooling) is done with a
temperature sensor which measures the water temperature in the return line
of the secondary circuit.
– The temperature of the return water is displayed on the screen.
6.7 Instructions for the extrusion screws handling device

The subsequently described device ensures a safe handling during the daily, week-
ly or monthly cleaning of the entire extrusion press and especially of the dough de-
flection units and the extrusion screws.
1. The horizontal reciprocating movements of the dough deflection units and the
extrusion screws are done hydraulically with two hydraulic cylinders situated
parallel alongside the extrusion screw.
2. Manual operations:
– The coupling and uncoupling of the dough deflection units (16) and the
extrusion screws (17)
– The separation and joining of the tension rod (3, 4, 5)
– The up and down movement of the yoke (2)
– The attachment of the dough deflection units and the extrusion screws
– The withdrawal of the extrusion screw to the extended end position
– The insertion of the extrusion screw after the cleaning
3. The attachment and detachment, the lifting and lowering of the dough deflection
units and the extrusion screws is done with a slewing hoist attached to the ex-
trusion press.
4. The control of the hydraulically actuated movements is done with a push-button
(18), which is attached to the support (1) of the handling device.
5. We recommend to wear gloves for all manual work, especially when moving the
extrusion screw because of the sharp edges of the screw flights.
Caution!
Danger of personal injury!

Pasta extrusion press TPCD Operation 6 - 11
Caution!
For the operation the operator must stand always outside of the installation, i.e. on
the extrusion press operator platform.
6. The speed of the yoke moving in and out is set in such a way that the permitted
maximum speed of Vmax. = 1 m/min. is not exceeded.
Note:
The readjustment of the speed by the operating personnel is not allowed under any
circumstances!
7. The maximum space requirement from the center of the diffusor or cylinder
head to the end of the extended extrusion screw is approx. 4000 mm.
8. We recommend to transport the extrusion screw on the floor
– by using a sufficiently long hand cart
– by using wooden supports to protect the flights of the screw.
9. For load reasons never lift or lower the handling device together with the extru-
sion screw.
Y
2 6 3 1 4 18 5 8 15 16 12
X X
B A C D
7 14 13 17
1 8 9
Detail Y
7
10
Fig. 6.4

6.7.1 Removal of the dough deflection unit and the extrusion screw
1. The handling device (1) is attached to the cylinder head by means of the ta-
pered pivot (7). The vertical position and the lateral inclination are adjusted at
the pivots with the cap screws (8) and the set screws (9) to the correct height in
relation to the extrusion press center line (X-X) (see detail Y).
The yoke (2) is closed at the horizontal position and the tension rod assembly
(3, 4, 5) L=2020 mm is installed.
Caution!
The handling device (1) must be secured on both sides with the clamping screws
(10) before it is connected to the hydraulic system of the extrusion press!
The two flexible hydraulic hoses are connected by quick-action couplings to the
hydraulic system of the extrusion press. The extrusion screw has been emptied as
completely as possible.
Now the hydraulically actuated bayonet lock is opened by pushing the button. (see
chapter 6.4 «Instructions for the bayonet lock-cleaning mode»)
Caution!
The pressure P of the extrusion press must be 0 bar!
2. Retract the yoke (2) hydraulically all the way to the stop.
3. Insert the tension rod assembly (item 3, 4, 5) L = 2020 mm and screw it into the
dough deflection unit and tighten (M36 thread).
4. Push down the lock bolt (6) at position «A» of the tension rod.
5. Extend the dough deflection unit by a stroke of 1150 mm.
6. Pull up the lock bolt and unscrew the tension rod from the dough deflection unit.
7. Screw eyebolt (M16 thread) in to the dough deflection unit and lower the dough
deflection unit to the floor with the slewing hoist.
8. Remove dough residues
– in the cylinder head
– before the end of the extrusion screws
9. Remove cap (12) with wrench (SW 55) from the threaded plug in the extrusion
screw.
10. Insert the tension rod and screw it onto the M36 thread of the threaded plug
(13) in the extrusion screw and tighten.
11. Retract the hydraulic cylinder all the way to the stop, push down the lock bolt at
position «B» of the tension rod.
12. Extend the extrusion screw by a stroke of 1100 mm, all the way to the stop.
13. Pull up the lock bolt, retract the hydraulic cylinder all the way to the stop and
push down the lock bolt at position «C» of the tension rod.
14. Remove item (3) of the tension rod and put aside.
15. Extend the extrusion screw by a stroke of 1100 mm.
16. Pull up the lock bolt, retract the hydraulic cylinder by approx. 650 mm and push
down the lock bolt at position «D» in adapter (5).

17. Remove item (4) of the tension rod and put aside.
18. Extend the extrusion screw by a stroke of 650 mm, all the way to the stop.
19. Pull up the lock bolt, unscrew the adapter (5) at the threaded plug in the extru-
sion screw.
20. Open the yoke with the adapter (5) of the tension rod by 270°. The yoke now
hangs downward from the piston rod of the lifting cylinder.
21. Completely withdraw the extrusion screw by hand on the guide trough until the
square becomes visible. Attach the screw by rope to the slewing crane 1,4 m
from the front and lower it onto the cart provided with wooden supports.
22. After cleaning the components take this opportunity to check the condition:
– of the extrusion cylinder
– of the intermediate piece
– of the seal pack
Y
2 6 3 1 4 18 5 8 15 16 12
X X
B A C D
7 14 13 17
1 8 9
Detail Y
7
10
Fig. 6.4

6.7.2 Installation of the extrusion screw and the dough deflection unit
1. Lift the cleaned extrusion screw with the slewing crane and lower it with mini-
mum speed into the handling device.
2. Before inserting the extrusion screw align the square of the extrusion screw as
good as possible with the square in the planetary gear.
3. Insert the extrusion screw either by hand or with the help of the hydraulics. Pro-
ceed with the hydraulic assembly in the reverse sequence as described in
chapter 6.7.1. While doing this note the original assembly of the tension rod
according to the sketch.
Caution!
When inserting the extrusion screw hydraulically for the last 200 mm the square of
the extrusion screw must be aligned exactly with the square in the planetary gear.
This will prevent the squares in the planetary gear and at the extrusion screw from
being damaged and at the same time will protect the handling device from an un-
necessary overload.
4. Lift the cleaned dough deflection unit with the slewing crane and lower it careful-
ly onto the guides (19) of the handling device.
5. Reinsert the dough deflection unit with the help of the hydraulics all the way to
the stop. Note the correct position of the four lugs at the bayonet disk (14). (see
Fig. 7.1)
6. Now close the hydraulically actuated bayonet lock with the push-button.
(see chapter 6.4)
7. Remove the two quick-action couplings from the hydraulic system of the extru-
sion press.
8. Restart the production of the extrusion press.
6.7.3 Specifications to the control system
Caution!
Before the handling device is hydraulically acutated the main switch of the extrusion
press has to be switched off first.
This will deactivate the following drives:
• Main mixer
• Vacuum airlock
• Vacuum mixer
• Extrusion screw
Push-button control for the retraction and extension of the hydraulic cylinder.
The push-button control has following function keys:
• No. 1: Parallel retraction of the hydraulic cylinder
• No. 2: Parallel extension of the hydraulic cylinder
If the 4/3-way valve is not actuated it will remain at the middle position, i.e. the hy-
draulic system of the handling device is not pressurized.
To ensure interruption-free work with the handling device the switch-off relay of the
hydraulic pump should be set in such a way that the switch-off time is longer than
the operating time between any two hydraulic movements.

6.8 Troubleshooting in the case of faults

Refer to the separate instruction manual for information on the trouble-shooting at
the twin-shaft high-speed mixer.
Note:
Contact the specialists at Buhler Ltd. if there are faults at the extrusion press which
you are unable to eliminate yourself. This concerns mechanical faults as well as
faults at the control system.
Symptom Cause Remedy

Paddle positions set
Select flatter paddle pitch
Dough level in main mixer too excessively for conveying
low Lower gate in airlock Turn lever of the gate to lower
channel is open position and engage
Dough level in main mixer too Paddle positions not set
Select steeper paddle pitch
high sufficiently for conveying
Condensation at the mixer lids Dough mixture too moist Set correct dough moisture
of the main and vacuum Ambient temperature of the Adjust ambient temperature of the
mixers extrusion press too low extrusion press
Dough mixture too moist Set correct dough moisture
Blockage in airlock channel Condensation with material Adjust ambient temperature of the
build-up extrusion press
Feed system is conveying Increase conveying rate of the feed
Dough level in vacuum mixer insufficient semolina system
too low Conveying rate of the Reduce conveying rate of the
extrusion screws is too high extrusion screws
Feed system is conveying Reduce conveying rate of the feed
Dough level in vacuum mixer too much semolina system
too high Conveying rate of the Increase conveying rate of the
extrusion screws is too low extrusion screws
Filter cartridge clogged Replace filter cartridge
See separate operating instructions
Vacuum pump
for the vacuum pump
Check all connections of the
Vacuum line is leaking vacuum line, possibly also the
Required vacuum is not vacuum lines of the customer
reached Gaskets at the mixer lids are
Replace gaskets
leaking
Shaft seals of the mixer
Replace shaft seals
shafts are leaking
Seal pack at the extrusion
Replace shaft seals
screw is leaking

Symptom Cause Remedy

Reduce volume of feed water,
Dough mixture too moist possibly reduce feed volume of
Dough pressure too low further liquid ingredients
Feed water temperature too
Reduce feed water temperature
high
Increase volume of feed water,
Dough mixture too dry possibly increase feed volume of
Dough pressure too high further liquid ingredients
Feed water temperature too
Increase feed water temperature
low
Extrusion press head not
Preheat extrusion press head
Dough pressure too high sufficiently preheated
when starting Die is too cold Preheat die
Dough is too dry Increase liquid addition rate
Incorrect and/or unequal Fill grease into the feed line of the
indication of the two dough Hardened dough residues in pressure gauge and the bore in the
pressure gauges the pressure lines dough deflection unit until the hard
Minor pressure differences dough residues are removed
(between 6...8 bar) may occur Pressure gauge defective Replace pressure gauge
Check inlet temperature of cylinder
Cylinder cooling system
cooling control circuit
Temperature of feed water Control circuit or mixing valve
Die protection device
blocked or incorrectly Check die protection device
installed
Wear of extrusion screw Check screw clearance
Poor discharge from die Extrusion press head
Check shutoff valve
heating not turned off
Screw speed too high Check extrusion screw speed
Die not properly washed Wash die again
Die inserts defective Replace die inserts
Dough pressure incorrect See above
Extrusion press head Reduce time for extrusion press
excessively preheated head heating

Pasta extrusion press TPCD Maintenance 7-1
7 Maintenance
Danger!
Perform all maintenance, cleaning and inspection work with the machine at
a standstill only (all machine movements have to be stopped).
The service or the local switch must be set to «0» and locked.
7.1 Safety during maintenance and cleaning
7.1.1 Lock main switch
Caution!
For all maintenance or cleaning work on machines switch off and lock the relevant
safety switch.
Note:
Electrically protected doors and covers cannot be relied on to offer full personal
protection.
The safety devices must be checked regularly (e.g. every 2 months) and any
necessary repairs must be done immediately.
7.1.2 Instruction of the personnel
Caution!
Personnel carrying out maintenance and cleaning work are exposed to higher risks.
Therefore, only trained persons must be used for such work.
Note:
The training of maintenance personnel is the responsibility of the plant operator.
7.1.3 Sanitation
When designing the pasta extrusion press TPCD-210/LW much attention was given
to allow easy access to all machine components requiring maintenance and
cleaning.
The mixer lids can be opened up for cleaning. In the open position the mixer lid
catches engage automatically.
Dough deflection units and extrusion screws can be removed and reinstalled with
the hydraulically actuated handling device.
Note:
Machine components in direct contact with the product must not be treated with
grease and oil, or, if lubrication is necessary only lubricants approved by the food
laws must be used.

7-2 Maintenance Pasta extrusion press TPCD
7.2 Cleaning
7.2.1 Cleaning during production

All surfaces of all extrusion press units including the feeding system can be cleaned
during the production.
This is recommended due to the following reasons:
• Excessive product buildup must be prevented especially in the area of the feed-
ing system and of the units installed underneath it.
• Avoiding bacteria contamination resulting in pasta of a high hygienic standard.
• Inspection of the product in the main and vacuum mixer ensuring a continuous
control of the product.
• Constant process control resulting in constant product quality.
• All walk-on areas on the extrusion press leave a clean impression.
• Safety for the operating personnel.
Note:
We recommend to do this cleaning work once a week.
If necessary, the filter cartridges of the vacuum line can be removed during the pro-
duction. (see chapter 2.2.6)
7.2.2 Cleaning after completion of production

The emptying procedure of the pasta extrusion press is described in the chapter
6.1.6.
Once the emptying has been completed the following cleaning work has to be car-
ried out at the extrusion press for hygienic reasons.
• Clean and recalibrate the feeding system.
• Twin-shaft high-speed mixer (see separate operating instructions)
• The main mixer and vacuum mixer must be cleaned with hot water and dried.
• The rotor of the vacuum airlock must be removed, cleaned with hot water, dried
and greased before reinstallation.
• For the purpose of sanitation, the dough deflection units and extrusion screws
must be removed, cleaned with hot water and dried. The seal area and the
square end of the extrusion screw have to be greased before installation.
• Using the special groove cleaner the dough residues must be ejected from the
grooves of the extrusion cylinder and of the intermediate piece and these parts
must be greased.
• Clean and grease the bayonet locks at the diffusor.
• Clean the dies and filter plates in the die rinsing machine.
• Clean the filter cartridges in the vacuum line. Replace the cartridges in the case
of heavy contamination and/or insufficient vacuum.
• If the press units are too heavily contaminated an external cleaning may be
necessary.
Caution!
Do not flood the pasta extrusion press because of the 4-stick spreader
underneath it.

Note:
Never clean teflonized components with a sharp-edged tool.
7.3 Maintenance schedule
Interval Operating hours Chapter

1 week --- 7.3.1
1 month approx. 500 7.3.2
3 months approx. 1500 7.3.3
1 year approx. 6000 7.3.4
4 years approx. 24000 7.4.5
7.3.1 Maintenance and checking work after 1 week

• The rotor of the vacuum airlock must be removed, cleaned with hot water, dried
and greased before reinstallation.
• For the purpose of sanitation, the dough deflection units and extrusion screws
must be removed, cleaned with hot water and dried. The seal area and the
square end of the extrusion screw have to be greased before installation.
• Lubricate the seal packs on the extrusion screws at the lubrication points pro-
vided for this purpose.
• Using the special groove cleaner the dough residues must be ejected from the
grooves of the extrusion cylinder and of the intermediate piece and these parts
must be greased.
• Clean the filter cartridges in the vacuum line. Replace the cartridges in the case
of heavy contamination and/or insufficient vacuum.
• Clean the bayonet locks at the diffusor and grease at the lubrication points pro-
vided. (see Fig. 7.1)
• Press in additional grease at the pressure gauge for the pressure of the extru-
sion press until the hard dough residues are removed from the line.
Note:
The maintenance at the presssure gauge must only be done after the die and the
dough pads have been ejected.
Position limit switch
Lubrication nipple
Bayonet ring Bayonet disk Notch bayonet ring
Fig. 7.1

7.3.2 Maintenance and checking work after 1 month

Check the sealing lips (for mechanical damage) of the rotary shaft seals in the seal
pack.
1. Remove dough deflection unit and push out extrusion screw approx. 300 mm .
(see chapter 6.7.1)
2. Turn the seal pack (viewed in the direction of production of the extrusion screw)
counterclockwise out of its anchoring, shift it slightly in an axial direction toward
the planetary gear and lift it vertically out of the coupling housing. Lubricate the
oil seals before reassembly. (Fig. 7.2)
Schmiernippel
Fig. 7.2
7.3.3 Maintenance and checking work after 3 months

Clean electric motors and clear ventilation intake.
7.3.4 Maintenance and checking work after 1 year

• Main mixer
– Check for noise at the mixer shaft bearings
– Check stuffing box packings at the mixer shaft bearings for leaks and tigh-
ten if necessary. (Fig. 7.3)
• Vacuum mixer
– Check for noise at the mixer shaft bearings
– Check stuffing box packings at the mixer shafts for leaks and tighten if ne-
cessary. (Fig. 7.4)
• Vacuum airlock
– Remove airlock bearing and lubricate
• Vacuum pump
– See separate instructions

• Press line
– Remove seal pack and lubricate. (see chapter 6.5)
– Slip-on screw/bearing bush: Check the diameter.
If clearance exceeds 1.5 mm, replace or repair.
– Extrusion cylinder/extrusion screw: Check the diameter and grooves.
If clearance exceeds 2 mm, replace or repair.
• Electric chain block
– Check oil level
Main mixer Vacuum mixer
Fig. 7.3 Fig. 7.4
7.3.5 Maintenance and checking work after 4 years

• Hydraulic unit
– Replace exchange filter insert
7.4 Lubricants
Danger!
Use physiologically safe lubricants only in the food-processing industry.
Caution!
For the relubrication of the different units always use the same lubricant as was
used for the initial filling, because the lubrication properties can be effected if vari-
ous types of lubricants are mixed.
If in doubt about the compatibility of the lubricants the previously used lubricant has
to be removed completely for safety reasons.
Gear units which are lubricated with synthetic oil have an oil change interval of
20'000 hours or 4 years.
In the case of gear units with a mineral oil filling the oil change is due after approx.
10'000 hours, in these operating instructions, however, the interval given is 1 year.

7.5 Lubrication schedule
Interval Operating hours Chapter

1 week --- 7.5.1
1 month approx. 500 7.5.2
1 year approx. 6000 7.5.3
4 years approx. 24000 7.5.4
7.5.1 Lubrication after 1 week

• Lubricate the seal packs on the extrusion screws at the lubrication points
provided. (Fig. 7.2)
7.5.2 Lubrication after 1 month

• Planetary gear of extrusion press drive (Fig. 7.6)
– Check oil level and refill if required.
• Planetary gear «Redex» at main mixer (type H 80,6), vacuum airlock (type
H 25,6), and vacuum mixer (type H 65,5)
– check oil level and top up if required. (Mobilgear 629)
Thrust bearing section Gear unit section

Mobilgear SHC XMP 460 Mobilgear SHC XMP 320
Oil filling screw Dip-stick

Oil filling screw
Oil-level glass
Oil-level glass Oil drain screw
Fig. 7.5 Fig. 7.6

7.5.3 Lubrication after 1 year

• Main mixer
– Oil change, reduction gear type H 80,6: Mobilgear 629 / 7 litre (Fig. 7.5)
– Oil change, oil bath mixer shaft transmission: Mobilgear SHC XMP 320 /
14 litre (Fig. 7.7)
• Vacuum airlock
– Oil change, reduction gear type H 25,6: Mobilgear 629 / 0,35 litre (Fig. 7.5)
• Vacuum mixer
– Oil change, reduction gear type H 65,5: Mobilgear 629 / 4,0 litre (Fig. 7.5)
– Oil change, oil bath mixer shaft transmission: Mobilgear SHC XMP 320 / 3,5
litre (Fig. 7.8)
• Press line
– Three-phase motor: recommended lubricant, Alvania G3 (Shell) / 30 g
– Oil change planetary gear type EK-1212.2-U:
=> Gear section: Mobilgear SHC XMP 320 / 2 x 7,6 litre
=> Thrust bearing section: Mobilgear SHC XMP 460 / 2 x 14,5 litre
(for further information refer to the separate operating and maintenance
instructions)
7.5.4 Lubrication after 4 years

• Hydraulic unit
– Oil change, if required by the result of an oil examination.
Specified lubricant: Klüber Summit Hysyn FG 68 / 53 litre
• Electric chain block
– Oil change gear unit: Mobilgear SHC XMP 320 / 0,3 litre
– Grease chain: Recommended lubricant, flow-grease DG 68 (Demag), or
LUCA 20/5 (Shell).
Oil-level glass Oil-level glass Oil drain screw
Fig. 7.7 Fig. 7.8


Pasta extrusion press TPCD After-sales service 8-1
8 After-sales service
8.1 Spare parts
When ordering spare parts please refer to the spare parts catalog and its relevant
illustrations.
8.2 Address
Bühler AG
Ersatzteildienst Processed Food
CH-9240 Uzwil, Switzerland
Fax ++41 (0)71 955 36 60
Note:
The information on the machine identification plate is to be used to identify the ma-
chine when making any inquiries at Bühler AG.

8-2 After-sales service Pasta extrusion press TPCD

TPCD 66242 1 en 0006

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Bühler AG

CH-9240 Uzwil, Switzerland

Pasta extrusion press TPCD

Danger Caution Note

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

7 Maintenance ............................................................................................... 7-1

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

1.2 Explosion protection

1.3 Safety concept for the control units

1.3.1 Connecting to the electrical mains

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

1.4 Safety concept

1.5 Designated use

1.6 Safety precautions

1.6.1 Sectional switch pasta extrusion press

1.6.2 Safety switches mixer section

1.6.3 Locations of the emergency-OFF push buttons

1.6.4 Limit switches for the protection of persons

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

• Vacuum mixer lid interlock

1.7 Bayonet lock at the diffusor

1.8 Dough pressure gauge

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

(1) Twin-shaft high-speed mixer (5) Press line

2.1.1 Twin-shaft high-speed mixer (TCMD)

2.1.2 Main mixer

2.1.3 Vacuum airlock (TPSD)

2.1.4 Vacuum mixer

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

2.1.5 Press line

2.1.6 Diffusor with temperature control

2.1.7 Hydraulic system

2.1.8 Slewing hoist

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

2.2.1 Main mixer/vacuum mixer

Electrical Drive Drive Condition

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

Drive Drive Drive Drive

Lid vacuum locked B 319 1 1 1 1 1

Coupling mixer engaged 1 1 1 1 1

2.2.2 Function of the dough pressure gauge

2.2.3 Function of the level probe

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

2.2.4 Cylinder cooling by circulation system

2.2.5 Vacuum system with vacuum pump

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

2.2.6 Vacuum line with double filter unit

Normal operation Bypass opera-

2.2.7 Vacuum generation by water ring pump

66242-1-en-0006 © Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

2.2.8 Vacuum generation by sliding vane pump

2.2.9 Pneumatic diagram

B 302 B 292 B 321 B320 B 319

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz 66242-1-en-0006

2 hydraulic cylinders 2 hydraulic cylinders Hydraulic cylinder ø 38,1/24,4 x 90

© Copyright 1996 Bühler AG, CH-9240 Uzwil, Schweiz

2.3 Technical data

2.3.1 Type key

2.4 Noise data