Manual Master MaxxD EN

Customer Service and ProTec
Profit from our full array of services: every one of our customers is unique. That’s why FrymaKoruma offers you comprehensive,
individual consulting and support before, during and after your machine purchase. You can also gain valuable, detailed insights into a
variety of topics in the modern rooms of ProTec, our process technology and training centre.
Classic Services
Installation Repair
Enhance the efficiency of your investment from the very first We provide reliable and prompt support if ever your machine
day! Your new FrymaKoruma technology is carefully assembled needs to be repaired.
and installed by our specialists. Faulty parts and / or bugs in the software are replaced or removed
expertly and promptly, so that costly downtime is reduced to a
Commissioning minimum.
You make sure your new machine and your staff are ready to go
fully operational. We connect the mechanical and electrical Retrofit
components for you and test the software features. Our products are continuously developed to bring you into line
with the latest state of the art. We make sure you stay up to date
Inspection – and we listen to you if you have any suggestions of your own or
Our technicians can carry out an as-is analysis of the machine’s if new legislation requires your machine to be extended. We boost
condition on request. You can have this done on your premises your productivity by upgrading existing features or implementing
or, if you prefer, ship the machine to us. We provide you with new ones.
recommendations regarding next steps, for example repair,
maintenance or replacement. Spare parts
Our high quality machines are shipped to you in top condition. We
Maintenance want you to be successful in the marketplace for many years to
Maintenance takes place either on-site on your premises or at come, which is why we supply you with original spare parts as well
our ProTec centre at a time chosen by you. We inspect, test and as all the certificates and attestations you need to manufacture
care for your FrymaKoruma technology and do our best to rule quality products.
out any unexpected disruptions to your production process.
High Value Services (HVS)
HelpLine % Energy and resource
Is there a problem with your application, your engineering or management
your software? Just give us a call and we’ll provide prompt We would be pleased to review your production processes and
expert support! advise you on more effective resource management, energy
saving strategies and sustainable manufacturing.
Feasibility studies
We will gladly carry out feasibility studies on your behalf – after Seminars
all, you want to be certain of achieving the desired result with ProTec, our process technology and training centre, is the venue
our processes and technologies. for numerous events dealing with specific issues in cooperation
with experienced experts from research, science and industry.
Scale-ups Take advantage of this opportunity to broaden your expertise
We reduce your technical and financial risks to a minimum by with an informative mix of theory and practice that casts a
scaling up your manufacturing processes to a larger machine of spotlight on selected applications in the food, pharmaceutical,
identical design. cosmetics and chemical markets.
Product transfer 1 2 3 Training

We transfer an existing product from old to new technology We offer you customer-specific training in theory and practice
without compromising quality. We do this through a targeted designed to deepen your staff’s product and process know-how,
adaptation of your processes and parameters. either on-site on your premises or in the modern seminar rooms at
our ProTec centre. Please contact us directly to discuss the
Start-up topics and content. We look forward to hearing from you!
To get you onto the market as quickly as possible with our
FrymaKoruma technology, we provide you with start-up support IQ/OQ support
during the first product run, for example by defining setpoints for After your machine has been installed, please do not hesitate to
optimal production results or arranging training for operators. ask for support with the installation qualification (IQ) and the
operational qualification (OQ). We can provide you with all relevant
Product analysis forms. We also help you conduct the actual IQ of machine
and evaluation components in accordance with the P&ID and layout documents
Profit from product sample tests focusing on specific parameters as well as the OQ of machine functions in accordance with the
such as pH, viscosity, temperature and particle size. FS (functional specification).
Optimisation of existing Calibration service

processes/products The initial or recalibration for the measuring circuits of your
To help strengthen your competitiveness, we analyse and assess machines can be carried out by our technicians. Numerous
your manufacturing processes or products on request. Drawing parameters such as pressure, temperature, speed, flow rate, fill
on the results, we then suggest possible measures for optimising level, conductivity and pH are calibrated precisely using our
© FrymaKoruma
your processes, for instance, as well as your performance, high-tech instruments. This is essential in order to comply with
formulations and use of raw materials. specific requirements or standards in the framework of certification
procedures.
Development of new
processes/products
FRY_EN_CS_0414
Our aim: to support your innovation efforts! Bespoke production

processes or products are developed especially for you, taking
account of your workflows, parameters, technologies, formulations
and raw materials.
FrymaKoruma AG FrymaKoruma GmbH info@frymakoruma.com

Theodorshofweg Sales / ProTec www.frymakoruma.com
4310 Rheinfelden / Switzerland Fischerstraße 10
phone +41 61 8364-141 79395 Neuenburg / Germany
fax +41 61 8312-000 phone +49 7631 7067-0
fax +49 7631 7067-29
WHEN ALL ELSE IS THE SAME,
IT‘S THE DIFFERENCE THAT COUNTS!
H E L P!
T H ER E TO
WE‘R E
6 4 2 2 2
) 61 8 3 m a . c o m
+ 41 ( 0 @fr ymakor u
e l p l i n e
h
m ber
On e n u
s u p p or t !
ied
– unif
FK-HelpLine:
■ Expertise to protect your productivity
■ Efficient troubleshooting support
■ Emergency operating and process help
Benefits for you:

single, central contact
access to expert know-how
prompt, efficient support
less downtime
effective productivity safeguards
worldwide availability
All free of charge throughout the warranty period! www.frymakoruma.com
Spare parts
□ Inquiry No.
□ Order No..
Customer Invoice
Address:
VAT no.
Delivery
Address:
Your reference
Phone no.
Machine
Typ of machine Serial No. Year of construction
Specification of spare parts

Part no. Quant. Drawing/Pos. No. Description
FrymaKoruma AG, CH-4310 Rheinfelden

Fax: +41 61 836 41 69
Description of the Machine
Technical Data, Equipment 1
Data Sheets, Layout Plan, P + I Diagram
Safety Regulations
Risk and Hazards, General Safety Recommendations 2
Qualification and Requirements to the Staff
•
TABLE OF CONTENTS • PART 1
Structure and Functions

Principle / Description of the Machine and Main Process 3
Functions of individual Units and Parts
Operating Modes and Controls

Controls for Operating and Primary Set-up,
Operating Modes
4
Commissioning
Instruction for Assembly and Primary Set-up 5
Wiring Diagram
Operation
Operating and Possibilities. Data Input / Run of Programs / 6
Trouble Shooting, Operating Instructions of the Operating Panel
Maintenance
Service Plan, Supplies and Accessories
Service Operations, Cleaning
7
•
Repairs
Recognising of Troubles, Judging and Trouble Shooting 8
Instruction of Repairs
Recycling 9
Transport 10
Operating Manual
1 Description of the Machine

Aim: To provide the user with basic information about the machine and its appropriate use.
TABLE OF CONTENTS
1 DESCRIPTION OF THE MACHINE�� 1

1.1 Machine layout�� 2
1.1.1 Designated use�� 3
1.1.2 Misuse�� 4
1.1.3 Safety measures�� 6
1.1.4 Conformity in relation to safety�� 6
1.2 Technical Data �� 7
1.2.1 Performance characteristics�� 7
1.2.2 Power supply and infrastructure requirements�� 7
1.2.3 Interfaces �� 8
1.2.4 Environment�� 9
1.3 Equipment�� 9
1.3.1 Accessory�� 9
1.3.2 Optional extra�� 9
Annexe 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data sheets

Annexe 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout
Annexe 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P+I - diagram
Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 1 of 9

Operating Manual
1.1 Machine layout

10
1-3 Product feed
4 Spray head (optional)
4 5 Process vessel, optional with heatable
double jacket
6 6 Scraper agitator (slow running)
9 6a with scraper blades
6a Stationary vortex breaker
7 Homogenizer (quick rotating
5
8 crushing element)
7a *Colloid head (Delmix)
7a *Toothed rotor/stator elements (DisHo)
1-3
8 Circulating pipe
7 9 Product outlet
10 Vacuum pump
7a 7b
Fig. 1-1 Cross-sectional view
Short description of the system

The machine allows carrying out the following operations of process engineering:
• Sucking in of products owing enough liquidity (dry, liquid)
• Mixing of liquid and pasty products of low viscosity
• Dispersing powders, granules, pigments and agglomerates in liquids
• Manufacturing emulsions
• Improving heat transmission
• Deaeration
The machine has been developed to produce viscous emulsions, dispersion or suspensions.

Operating Manual
Main components
• Vessel with or without double jacket for heating or cooling.

• Slowly running scraper agitator with scraper blades with spring contact pressure.
• Fast running homogenizer* with specifically toothed homogenizing element *(alternatively with
colloid head or toothed rotor/stator system).
• Vacuum pump.
The auxiliary aggregates are integrated in the equipment cabinet. All models have a lid opening
system and a control panel.
Design in accordance with actually GMP- and hygiene directives. Therefore the machine meets
the „CIP“-requirement (Cleaning In Place) i.e. the machine can following a cleaning programme be
cleaned on the spot, if it is furnished correspondingly.
1.1.1 Designated use

The machine may only be used for the designated purpose!
The contractual agreements are valid as designated use.
• It is designed for use in manufacturing emulsions, dispersions or suspensions. To do this, the

design data of the system must be observed (operating limits of pressure, temperature, filling
quantity, current consumption of the processing aggregates and scraper, product viscosity).
• The substances used for processing and cleaning must be compatible with the substances used
in the machine system.
• The mixing tank is designed for intended use only.
• The machine shall only be used with the programs delivered by FrymaKoruma and for the
designated processes.
The written consent of FrymaKoruma is necessary for applications that are not mentioned
in this document.

Operating Manual
1.1.2 Misuse
Any use other than those agreed upon in the contract or any use of the machine extending beyond
the agreement will be considered as unintended.
Danger!
It is forbidden:
to use substances that are flammable or explosive, or that could create a

flammable or explosive mix when in use. This also includes the use of detergents.
Note: For machines without explosion protection, the electric circuits and equipment are not designed for an operation
with such substances.
to use substances which are harmful or toxic and which can leak out of the
system into the environment.
to use substances which could release harmful or toxic substances during

processing, and which could do harm to people or the environment. (Examples:
lead, chlorine, mercury, tin, zinc).
Note: The system has got no such device, which could prevent the release of
such substances.
Warning against incorrect and misuse!
Note: Apart from uncontrollable reactions which could under certain circumstances severely injure people, material
damage could happen to the system too such as overloading or breaking bearing components, damage to the scraping
system, the sliding ring seal, the homogenizer and pumps, scratches on the vessels, etc..

Operating Manual
Predictable misuse
The machine may never be subjected to the following:
• Permissible operational limit pressure being exceeded, or
• Process settings being made in which an excessive vapour formation occurs.
By exceeding the operational limit pressures on the vessel or double jacket, the safety valve is activated. Excessive
vapour formation can lead to an increase of pressure, the vacuum pump could then become overloaded and sustain
cavitation damages due to condensed vapour.
• Permissible level in vessel being exceeded.
The product lands in the vacuum system, causing product backlogs in the vacuum line. The vacuum pump can become
damaged because of hammer-blows in the pipes (breaks of bucket wheel, for example). The standard execution level is
not monitored.
• Carrying out chemical reactions that lead to excess temperature or pressure levels of permissible
operational data’s.
• The intermediate and end products of chemical reactions causing damage to used materials
(elastomere, synthetic material or metals).
• The given process limiting values* such as temperature, pressure, level, not being observed.
* The monitoring of the process parameter and limiting values is the responsibility of the operator. The standard
execution is not equipped with redundant components, which provide an automatic emergency disconnection in the
event of technical faults. If the lack of redundant components leads to unacceptable risks, suitable measures are
provided to eliminate risks.

Operating Manual
1.1.3 Safety measures
When using wax/grease or other similar substances, their point of ignition should
not be exceeded.
The monitoring of the process limiting temperature is the responsibility of the operator. The standard execution is not
equipped with redundant components, which provide for an automatic emergency disconnection in the event of technical
faults. If by exceeding the limiting temperature, unacceptable risks are taken, suitable measures are provided to
eliminate risks.
• Safety data sheets are necessary for all used substances.
Danger areas
Constant or unexpected threats are listed in the danger area plan in chapter 2.5.2.
Product purity
The product ingredients which are processed in the machine must not contain
foreign substances. Possible foreign substances must be removed or restrained
by suitable means (such as filters, checks, for example), before they can enter
the system.
Note: Foreign substances or material particles which enter the machine are grinded to product fineness by the
homogenizer depending on their quality. Metal parts or stones, etc. can damage the processing aggregates, the vessel
or the fittings.
System Operation:
Control panel on machine, switch gear with emergency stop.
1.1.4 Conformity in relation to safety

See CE-conformity declaration.

Operating Manual
1.2 Technical Data
1.2.1 Performance characteristics

Data sheets are to be found as attachments to this chapter.
1.2.2 Power supply and infrastructure requirements

Note: For a trouble-free operation the following power and utility supplies are to be supplied in
quantity and qualities.
Electrical
Information regarding the electric equipment and the standards applied to, are
found in the wiring diagram in the chapter 5.
Infrastructure / Operating media

Information regarding to the required media as: cooling- and hot water, steam, CIP-water, operating
media for the vacuum pump, pressurized air are to be found in the P+I diagram.
Water
For personal hygiene and cleanliness during the process, cold and hot water
should be available to the staff on the operation site.
Hot- and cooling water, steam
Quality of water: To maintain a good working of the machine we recommend the

water specification as follows:
The water is chloride free and the electric conductivity should be max. 500 µS/
cm. This will reduce electrolytic metal erosion and corrosion.
Keep the pH-value of the water neutral, i.e., between 7.5-8.
To avoid lime deposition, the hardness of the water should not exceed 6°dH.
(1° dH corresponds 17.8 ppm CaCO3).
Water must be free from contamination and solid matters.

Operating Manual
Compressed air (Option)
Used for pneumatic control/valves and drives. Please observe the requirements
of the suppliers regarding compressed air.
Compressed air for control (optional)
Used for pneumatic logics. A lower dew point and enhanced purity are required
as will be delivered from compressed air.
Lubricating oil and grease
Specifications for lubricating oils and greases used for the machine are listed in
the “Lubricating schedule” in chapter 7 of the manual.
Information’s to components originating by suppliers (gears, motors a.s.o.) are

found in the supplier’s manuals, see volume 2.
1.2.3 Interfaces
The branch connections and dimensions of linking’s and interfaces can be found on the machine
dimensional drawing. Quantities, temperatures and operating pressures of medias are to be found
on the data sheet.

Operating Manual
1.2.4 Environment
Following table shall be adapted according the customers need. Please mind notes in 2.4.1.
MESURE TO BE
PARTICULAR HAZARDS WHERE ABOUT /WHAT DOCUMENT
TAKEN
- Inflammable materials - -
- Explosible materials - -
Materials being a danger to health
- Chem./biolog. effects -
- Dust -
- Gases / danger of suffocation -
Protection against water and touching All equipment Motors IP 54
- Explosion-proofness of motors
- Switchgear
- Control and electric circuits
Ambient temperatures and humidity

The room temperatures should be kept between 18 °C and 27 °C, with a relative humidity of less
than 70%.
The ventilating system of the electrical gear is related to an ambient temperature of maximal
30° Celsius at sea level.
The ambient and compressed air temperature for the rotary drives in the
ex-protected zone must not exceed 68°C.
Lighting
The average flux density in the working area shall be 600 Lux/m2.
1.3 Equipment
1.3.1 Accessory
• Tools
1.3.2 Optional extra
• Optional extra according to the order specification.

Operating Manual
Safety Regulations
2 Safety Regulations
Aim: Inform the users about the remaining risks and the dangers in case of appropriate use.
TABLE OF CONTENTS
2 SAFETY REGULATIONS �� 1

2.1 Layout�� 2
2.2 Basic Principles�� 3
2.3 General�� 3
2.3.1 Warning signal �� 3
2.3.2 Safety instructions for use in potentially explosive areas�� 3
2.4 Organization/Personnel �� 4
2.4.1 Duty of the operating company�� 4
2.4.2 Qualifications and training requirements of the operators �� 5
2.5 Additional dangers �� 5
2.5.1 Transportation of the machine �� 5
2.5.2 Danger zones operating / danger warnings and sign-boards�� 6
2.5.2.1 Lab �� 6
2.5.2.2 From 200 - 3500 l�� 7
2.5.3 Danger zones service/maintenance / Danger warnings and sign boards�� 8
2.5.3.1 Lab �� 8
2.5.3.2 From 200 - 3500 l�� 9

Operating Manual
Safety Regulations
2.1 Layout
The level of danger resulting from a situation or action will be displayed with signal words.
DANGER WARNING CAUTION NOTICE*
Immediate threats which Possible dangerous Possible dangerous Possible critical or

can lead to grievous situation, which could situation which could lead dangerous situation
lead to serious injury or to slight bodily injuries. whereby the product or
bodily harm or death.
SIGNAL WORD
death. Also used to warn about property could be damaged.
property damages.
RISK
MORE HAZARD LESS
HAZARD FROM MACHINE

Dangerous voltage Risk of scalding Hot surface
Jamming Squeezing Do not switch on Wear ear defenders

HAZARD FROM PROCESS AND
Explosive material Flammable material No source of ignition Wear gloves

PRODUCT
Poisonous/caustic
Danger of suffocation products Wear protection mask Wear safety goggles
*“IMPORTANT“ Operational messages for and other useful information, but not intended to warn of dangerous or critical
situations.
Note: DANGER, WARNING, CAUTION, NOTICE are within the United States of America mandatory signal words.

Operating Manual
Safety Regulations
2.2 Basic Principles

The machine has been designed and manufactured to meet and exceed all safety requirements.
Nevertheless in order to prevent dangers, machine:
• needs to be installed properly.

• is operated by well trained and authorized persons only. Due to specific use of the machine and,
in particular, a strict hygiene standard applied, only dully qualified personnel is authorized to its
check-out and maintenance.
• shall be used for the intended use only. Permissible use is specified in Chapter 1.1 of the
Operating Manual.
• is serviced and maintained in accordance with the requirements in this manual. No inadmissibly
alterations shall be made.
• Not to pursue in explosion-endangered surroundings.
• Check proper and safe functioning all protective equipment regularly. Dismantle protective covers
only after disconnection of machine supply. Provide protection against accidental energizing.
Upon completion of work activities and before re-commissioning, a proper condition of the
machine shall be recovered.
• the regulations of this Operating Manual must be observed.
• operator or external personnel shall mind the warning signs on the unit.
2.3 General
2.3.1 Warning signal
No alarming occurs in the standard version. Engines or aggregates with thermal-

or overload protection are switched off in the case of overload.
Emergency power-off functions and shut-down procedure

If an incident requires the immediate shutdown of the machine, it can be switched OFF with the
emergency switch. The emergency switch is accessible to everyone.
In the operating mode, the functions of the display are used for switching the unit on/off.
A summary of the warning signals, the emergency power-off and the shut-down procedures are
found in Chapter 4.2 of this manual.
2.3.2 Safety instructions for use in potentially explosive areas
Pay attention to the instructions in the relevant sections as well as to the

instructions issued by the respective suppliers in Volume 2 of the operating
manual.

Operating Manual
Safety Regulations
2.4 Organization/Personnel
2.4.1 Duty of the operating company

The operating company shall be liable to provide the following safety instructions are available, and
that the operating personnel receives proper instruction about.
• Guidelines on how to handle chemicals used for the process and cleaning.
• First aid measures in case of accidents with chemicals and electric shocks
• Use of personal protective equipment.
Note: These operating manual of FrymaKoruma does not deal with the aspect of dangerous material used in the clients
premise. In most cases, these are not known to FrymaKoruma (professional secret).
According EC-general guidelines 89/391 “Protection of workers” it is the responsibility of the

operating company to prevent of danger:
• As measure to prevent of danger an analysis of all hazards related to professional risk have to be
executed.
• All personnel must be informed and trained in occupational safety and correct operation of the
machine on a regular basis. In particular, care shall be taken to avoid contact with hot surfaces.
• All personnel have to be informed and instructed accordingly. *(High voltage, steam, hot water,
pressurized air, handling of loads a.s.o.).
According EC- guidelines 2009/104 “Use of working material” it is the responsibility of the operating
company to:
• Inform the employee about all dangers related to them and the working material available in their
environment.
• If trained workers are entrusted to perform simple control activities, they should fully acknowledge
residual risks related to machine operation.
• If dangerous machinery or equipment and agents are being used, an operating manual has to
be established!
• Generally, the operator shall provide suitable platforms and steps. Design of stationary
scaffolding must be in line with harmonized standard EN ISO 14122-1 to 4. If stationary
scaffolding cannot be used, the owner should investigate possibility of safe using ladders or
similar means within a general assessment of risks at workplaces.

Operating Manual
Safety Regulations
2.4.2 Qualifications and training requirements of the operators

The machine is only to be operated by well trained persons.
If your operators need training, please ask for at the FrymaKoruma customer service.
User profile/qualification and permitted activities in dealing the machine

The users of the machine should own a professional requirements profile with the following
qualities:
Party responsible for the machine / machine manager

Is responsible for the total process, including the use of permissible products, safe process
parameters according the machine specification and safety data sheets.
Determination: of batching, thresholds of the alarms, product recipes, purity and hygiene, ecology.
Specific task: Responsible for the conversion of the guidelines 2009/104/EC regarding the use of
equipment. Instruction of all machine users in the procurement of safety, avoidance of risks and
arranging of protective measures.
User / operator
Is responsible for the correct use and operating of the machine. Conversion of the product recipes,
inputting of process data into control. The operator knows: Start-up and stop procedures, the check
of the process, safety minded behaviour when dealing with deviation and troubles. Servicing of the
machine.
Maintenance staff (specialist)

Tasks: Executing of allowed repair works.
2.5 Additional dangers

Dangers in using of special operating agents, external means and untested not authorized
accessory.
2.5.1 Transportation of the machine
For transportation of the machine and setting up, the directives mentioned in
chapter 10 have to be met.

Operating Manual
Safety Regulations
2.5.2 Danger zones operating / danger warnings and sign-boards
2.5.2.1 Lab
Warning! Warning! Warning!

The machine can tip over! Squeezing! Squeezing!
At lid/vessel rim.
Make sure the housing is closed before When the lid lifting device or the lid Between lid and vessel rim. Avoid danger
moving the machine. safety device are being defect. zone while closing the vessel.
Warning!
Splashing liquid!
Caution!
Hot parts!
When the safety relieve valve opens / or at

the heating circuit.
Do not overfill the vessel.
Warning!
Do not allow
to run dry!
The working area/homogeniser must be

covered with liquid.
Fig. 2-1 Lab
Danger! Before opening Warning!

Cutting! the homogenizer Splashing
Switch Mains „OFF“ Product splashes out from
the hopper or overflow pipe!
On the running homogenizer with the Secure switch with personal lock. Never activate manual valve, if vessel is
housing open. Do not start when the piping is pressurized ! Close valve immediately after
Never insert hand or tools. disconnected. feeding product.
General precautions
When working on open vessel, always bear personal protective means!

Operating Manual
Safety Regulations
2.5.2.2 From 200 - 3500 l
Warning! Warning! Warning!

Squeezing Fall! Squeezing!
At lid/vessel rim!
When the lid lifting device or the lid safety Use a platform when using the viewing Between lid and vessel rim.
device are being defect. glass or the vacuum control. Avoid danger zone while closing the vessel.
Warning!
Splashing liquid!
Caution!
Hot parts!
At the safety relieve valve / or at the heating

circuit.
Do not overfill the vessel.
Warning!
Do not allow
to run dry!
The working area/homogeniser must be

covered with liquid.
Fig. 2-2 700 l
Danger! Before opening Warning!

Cutting! the homogenizer Splashing
Switch Mains „OFF“ Product splashes out from
the hopper or overflow pipe!
On the running homogenizer with the Secure switch with personal lock. Never activate manual valve, if vessel is
housing open. Do not start when the piping is pressurized ! Close valve immediately after
Never insert hand or tools. disconnected. feeding product.
General precautions

Operating Manual
Safety Regulations
2.5.3 Danger zones service/maintenance / Danger warnings and sign boards
2.5.3.1 Lab
Warning! Danger! Warning!

The machine can tip over! Squeezing! Squeezing!
At lid/vessel!
Make sure the housing is closed before When the lid lifting device or the lid At lid/vessel rim.
moving the machine. safety device are being defect. Avoid danger zone while hoisting/lowering.
Danger!
Serious
injuries!
The lid lifting device or its attachment must

only be removed by expert persons.
Lid must be secured against fall if

removing the lifting device.
Warning!
Scalding!
Hot surfaces and equipment

Shut off valves for vapour and hot water.
Fig. 2-3 Lab
Danger! Danger!
Cutting! Transport!
Seriously injuries by cutting at the Do not fasten ropes a.s.o. to the vessel for
homogenizer. lifting the machine.
Switch mainpower „OFF“ and lock it.
General precautions

Operating Manual
Safety Regulations
2.5.3.2 From 200 - 3500 l
Danger! Danger of falling Warning!

Squeezing when working on top Squeezing!
At lid/vessel rim! of the lid!
When the lid lifting device or the lid safety Use a ladder or platform. At lid/vessel rim. Avoid danger zone while
device are being defect. Do not stand on the slippery housing. hoisting/lowering.
Danger!
Serious
injuries!
The lid lifting device or its attachment

must only be removed by expert persons.
Lid must be secured against fall if

removing the lifting device.
Warning!
Scalding!
Hot surfaces and
equipment!
Shut off valves for vapour and hot water.
Fig. 2-4 700 l
Danger! Danger!
Cutting! Transport!
Seriously injuries by cutting at the Do not fasten ropes a.s.o. to the vessel
homogenizer. Switch mainpower for lifting the machine.
„OFF“ and lock it.
General precautions

Operating Manual
3 Structure and Functions

Aim: To inform the user about the structure of the machine and it’s working principle.
TABLE OF CONTENTS
3 STRUCTURE AND FUNCTIONS �� 1

3.1 Introduction�� 2
3.1.1 Description of the process �� 2
3.2 Structure�� 3
3.2.1 Structure Lab �� 3
3.2.2 Structure 200-3500 l�� 4
3.2.3 Modules �� 5
3.3 Functional description�� 7
3.3.1 Product feed�� 8
3.3.2 Intermediate storage of a product �� 8
3.3.3 Mixing, dispersing, dissolving and moistening the product�� 8
3.3.4 Feeding and transporting product�� 9
3.3.5 Dispersing, homogenizing and emulsifying products�� 9
3.3.6 Heating, cooling �� 10
3.3.7 Influencing the quality of the product �� 10
3.3.8 Product discharge�� 11
3.3.9 Cleaning�� 11
3.3.10 Operation �� 11
3.4 Safety and monitoring systems�� 12
3.5 Module description�� 13
3.5.1 Vessel, lid and scraper agitator�� 13
3.5.1.1 Vessel�� 13
3.5.1.2 Vessel lid�� 13
3.5.1.3 Scraper agitator �� 14
3.5.2 Homogenizer�� 14
3.5.3 Units in the instrument cabinet/base frame�� 15
3.5.3.1 Vacuum system�� 16
3.5.3.2 Automatic temperature control/Tempering device (Optional)�� 17
3.5.3.3 Pneumatic system (Optional)�� 17
3.5.4 System control �� 17
3.5.5 Electrical switchgear, measuring instruments�� 18

Operating Manual
3.1 Introduction
3.1.1 Description of the process

The machine is a vacuum mixing system. Products with various viscosities can be dissolved,
mixed, dispersed and emulsified.
At the beginning of the process, the vacuum pump (10) is switched on and evacuates the process
vessel. Liquids and dry products are added to the mixing chamber of the homogenizer under
vacuum via the product inlets (1-3).
The homogenizer (7) is the core of the machine. The fast running homogenizer and stator system
will disperse and homogenize liquid and medium viscous products. The pumping effect of the
homogenizer feeds the product into the vessel via the circulation pipe.
This machine uses the so called „Disho grinding set“ (7b) or the „Delmix grinding set“ (7a) as
homogenizer. A description of the grinding set is found in chapter 3.2.1 „modules“.
10
A slow-moving scraper agitator (6) with flexible
scrapers rotates inside the vessel (5) with or without
4 a double jacket (for heating or cooling). The scraper
agitator is responsible for turning over and mixing
6 the product. The scraper blades move over the
9 6a inner surface of the vessel wall. In this way, they
prevent the product from adhering to the wall and
improve the heat exchange.
5
8 A fixed flow breaker (6a) increases the mixing
effect.
The product returns to the homogenizer from the
1-3 conical vessel outlet. During this process, the
7 vacuum pump evacuates the vessel and constantly
deaerates the product.
After the vessel has been aerated, the final product
is discharged into the circulation pipe (8) via the
3-way valve.
7a 7b
Fig.3-1 Processing aggregates
Caution !
Please note that homogenizers equipped with a single-acting mechanical seal
may not be switched on until the homogenizer has been filled with liquid !
Dry running of the homogenizer will lead to very rapid destruction of the
mechanical seal !

Operating Manual
3.2 Structure
The machine is a compact plant; all the components, vacuum or processing vessel, homogenizer,
vacuum pump, instrument cabinet, and the electrical switchgear are are located on the stainless
steel base frame.
The drive motor of the homogenizer and the vacuum system are mounted in the rust-proof
instrument cabinet.
3.2.1 Structure Lab
Scraper agitator 3.5.1.3

Viewing glass
Operator panel 3.5.3.4 Vessel lid
Lid lifting column Process vessel 3.5.1.1

8.4.1.3
Flap valve combined
Product outlet
Circulation pipe
Electrical switchgear 3.5.3.5
Product feed
Homogenizer 3.2.1 / 3.5.2
Instrument cabinet 3.5.3

Rest discharge
Fig. 3-2 Components of the machine
Drive Homogenizer
Pneumatic control 3.5.3.3
Media connections
(Water, steam, air and water
discharge)
Vacuum system 3.5.3.1

Heating control
(Valve manifold, option)
3.5.3.2
Fig. 3-3 Components in the instrument cabinet

Operating Manual
3.2.2 Structure 200-3500 l

Models 200/400 +700 are fitted with a lid-opening device (hinged lid). The lid can to be opened
completely by means of a hinge. In contrast to this, models 1300 - 3500 are delivered with a
securely bolted cover.
Vacuum tree 3.5.3.1
Scraper- agitator 3.5.1.3

Vessel lid, open 3.5.1.2
Viewing glass
Connection studs CIP-cleaning
Lid lifting column 8.4.1.3

Process vessel 3.5.1.1
Condensate trap (Option)
Flap valve combined
Operator panel 3.5.3.4 Product outlet
Electrical switchgear 3.5.3.5
Circulation pipe
Housing 3.5.3
Product feed
Homogenizer 3.2.1 / 3.5.2
Discharge for remaining

product/water
Fig. 3-4 Components of the machine
Pneumatic control 3.5.3.3
Drive Homogenizer
Vacuum system 3.5.3.1
Heating control (Valve manifold)

Media connections 3.5.3.2
(Water, steam, air and water
discharge)
Fig. 3-5 Components in the instrument cabinet

Operating Manual
3.2.3 Modules
Depending on the properties of the products, the homogenizer can be equipped with rotor / stator
elements (processing tools) specially designed for the particular products. This retrofitting or
modification can be performed by the customer‘s personnel.
Alternative: Disho grinding set ML

For production of e.g. emulsions the toothed rotor/stator dispersing tool is to be used as well as in
the case of products and/or suspensions with narrow and fine droplet distribution.
Mixing or conveyor elements (1) are below the vessels exhaust passage, in the mixing chamber.
They force the product from the vessel into the centre through the dispersing disc (2) to the suction
blade (3). Latter pushes the mixture through a rotor and the fixed stator (4), shearing it (crushing)
and smashing solid particles.
The utmost rotor (pump blade) which follows into direction of flow the stator works like a pump. Its
pump effect presses the product into the recirculation pipe. Through this the product gets to the
vessel in a circulation process and it will run again the process.
If the desired final quality is achieved, the product is discharged via the multipath valve in the
recirculation pipe.
(4) (3) (2)(1)
7 6
5 4
Fig 3-6 Homogenizer with Disho grinding set Rotierende Welle / Rotating shaf t
arbre tournante

Operating Manual
Alternative: Delmix-grinding set (colloid grinding tool)

The colloid grinding tool is extremely suitable for wet milling solid particles. The homogenising gap
of the colloid tool can be adjusted to the required shearing forces and the degree of dispersion,
using spacer discs.
Function: The components fed through the feed studs get straight into the mixing chamber and
enter the homogenising zone formed by the stationary stator (2) and the rotor (1). The product
passes the dispersion/emulsion gap. Here powder particles are cut and shattered and liquids are
decomposed in drops the size of a micron.
(1) (2)
Fig. 3-7 Homogenizer with Delmix-grinding set
The rotor works like a pump. Its pump effect presses the product into the recirculation pipe.
Through this the product gets to the vessel in a circulation process and it will run again the
process.
If the desired final quality is achieved, the product is discharged via the multi path valve in the
recirculation pipe. The characteristics of the teeth and the width of the dispersion/emulsion gap
have a great influence on the fineness; apart from the standard teeth, a fine teeth option is also
available to produce extreme fineness. The width of the dispersion/emulsion gap can be adjusted
with a distance ring.

Operating Manual
3.3 Functional description

The possibilities provided by the machine are made clear by the functions of the individual units
and components. For this purpose, we have outlined the production flow.
Functional chart
MaxxD
Standard Execution Options
Vacuum System Temperature Control Sealing Liquid Unit
1 Viewing glass with lighting 8 Valve 3 Temperature sensor 60 Sealing liquid vessel
4 Scraper-stirrer 13 Vacuum reg. valve 40 Steam inlet 61 Circulation pump
5 Homogenizer 30 Autom. aeration valve 41 Water outlet CIP-Cleaning
9 Safety relieve valve 31 Vacuum pump 42 Steam/Condensate out C1 Forced pump
14 Electrical switchgear 35 Exhaust air/waste water 43 Water inlet C2 Autom. Valve
18 Product discharge 36 Water inlet 45 Autom. temp. control C3 Spray nozzles
19 Double jacket
20 Feeding connection/ hopper
Vakuumsystem
Vacuum system
Système de vide
CIP Reinigung
CIP Cleaning
Lavage CIP PLC
Control
Heizen/Kühlen
Heating/Cooling
Chauffer/réfroidir
Sperrdruckanlage
Sealing liquid unit
Système de barrage
Fig.3-8 Functional scheme

Operating Manual
3.3.1 Product feed

Liquids and powders are drawn directly into the mixing chamber
with the aid of a vacuum. This vacuum feed makes it possible to
suck in the entire quantity of the product necessary for one batch
within just a few minutes. Products can be drawn in via feed pipes
(pre-containers), hoppers, meters, vacuum pipes.
The product feed studs are situated on the mixing chamber, right in
front of the homogenizer, so that liquid ingredients are immediately
mixed together and powders immediately moisturized.
Fig. 3-9 Product feed
3.3.2 Intermediate storage of a product

The drawn in products pass into the vacuum-proof processing
vessel.
This must not be overfilled and the minimum filling level must be
observed to prevent any damage to the machine.
Products can also be stored in hoppers.
Fig. 3-10 Intermediate storage of a product
3.3.3 Mixing, dispersing, dissolving and moistening the product

These operations are performed in the processing vessel with the
scraper agitator.
It is a slow-running mixing unit. It is responsible for circulating
and mixing the product, as well as for ensuring a good heat
exchange with the vessel wall. Its scraper blades strip the product
continuously from the vessel wall and bottom, preventing the
product from adhering to the heat exchange surfaces.
Fig 3-11 Mixing the product

Operating Manual
3.3.4 Feeding and transporting product

When the homogenizer is switched on, the product circulates
through the circulation pipe from the vessel through the
homogenizer and then returns to the vessel.
Fig 3-12 Feeding and transporting product
3.3.5 Dispersing, homogenizing and emulsifying products
The homogenizer enables:

• Powdered materials with a high share of liquid matter to be dispersed
• Oil/water mixtures to be emulsified intensively
The individual components reach the homogenizing zone of the homogenizer directly from the
different feed supplies.
The solid matter/liquid particles refine distributed dispersed between the fixed stator and the rotor.
The grinding set supplied with this machine is described under modules 3.2.3.

Operating Manual
3.3.6 Heating, cooling

The components water, oil, etc. are usually cold when drawn into the vacuum vessel.
The batch is heated from room temperature to 80°-90°C by:
• Circulation of the heating agent in the double jacket (steam, hot water,
thermo-oil), or
• by injecting steam directly into the batch (through the stud in the circulation
pipe) (optionally).
• Cooling is carried out by cold water, salt water, etc. flowing through the
double jacket.
Improving the heat transmission

When the scraper agitator is running, it improves the heat transmission between the product and
the vessel wall, both when heating and cooling.
It prevents:
• the product from adhering or forming crusts during the heating process
• the formation of an insulating layer of product during cooling
3.3.7 Influencing the quality of the product
Vacuum deaeration
The homogenizer and scraper agitator cause a turbulent flow and continuous
stirring of the product in the vessel. Any air bubbles trapped thus pass into the
vacuum area at the top of the vessel. There, they expand and burst. The air
released is continuously pumped out by the vacuum pump.
Attention !
Please note that when processing products which contain tensides, the maximum
possible useful volume during deaeration must be adjusted to suit the intensity of
foam formation. If the vessel is too full and the product foams too much, the foam
can reach up to the spray heads and be sucked in.

Operating Manual
3.3.8 Product discharge

The product is discharged via a disc valve combination
integrated in the circulation pipe.
When the final quality of the product has been attained,
the vessel is aerated and the 3-way valve switched over,
allowing the product to be discharged. The pump effect of the
homogenizer is used for this purpose.
As an alternative, it is also possible to install a discharge

pump. Discharge pipeline may have no shut-off valves (closed
valve). They can result in uncontrollable pressure rise.
Reminder of product will be discharged by means of a flap valve

at the bottom of the homogenizer.
Fig 3-13 Product discharge
3.3.9 Cleaning
Experience has shown that parts in contact with the product may be exposed to possible
biocontamination or even corrosion due to the long-term adhesion of the product.
This can be counteracted by regularly cleaning the machines and parts in the correct manner.
If cleaning is not carried out correctly, the guarantee expires in the event of a corrosive attack.
Particular importance is placed on fast and simple cleaning. The machine is constructed in
accordance with the GMP guidelines for minimum dead space operating conditions and is CIP-
capable. Any parts that come into contact with the product are easily accessible for control
purposes and can either be quickly removed or are freely accessible for cleaning. Grooves, dead
corners and indentations in which product remnants may collect have been avoided as far as
possible. This means that the machine can also be cleaned with the CIP process. For this purpose,
nozzles can be installed in the vessel as an option.
Furthermore as an option, the machine can be sterilised by steam flowing through. At the
lowermost point of the machine (homogenizer housing) there is a valve to fully discharge any
cleaning fluid or condensation. The cleaning fluid can also be returned to a CIP station via a pipe.
Note: The cleaning fluids can be supplied via the CIP inlet (connection at machine housing) to the vessel (spray heads).
If the CIP supply pressure during filling is too high, fluid can escape from the overpressure valve (on the vessel lid). In
this case, reduce the CIP pressure.
3.3.10 Operation
The machine is operated via a central operating panel. The individual units can be connected as
necessary.

Operating Manual
3.4 Safety and monitoring systems

The process takes place in a closed vessel. So the risk is small that operators are injured.
This can only be guaranteed if
• the instructions in the operating manual are observed and

• safety devices, covers, etc., are left in the original state.
EMERGENCY STOP
There is an emergency switch on the machine (switch cabinet). If the EMERGENCY STOP is
actuated, all the active processes in the machine are interrupted.
System main switch

The main switch is at the switch cabinet. In position „0“, the machine is not connected to the power.
The main switch is used to turn off the power to all the components in the machine, for repair work
and whenever this is prescribed in the operating manual.
Overload protection
The motors and electrically actuated elements are protected by over current triggers and miniature
circuit breakers and are located in the control cabinet.
Lid switch
A limit switch on the lid and vessel flange monitors whether the vessel is closed and prevents the
scraper and homogenizer from starting up when the vessel lid is open.
Safety switch homogenizer

This safety switch prevents starting of the dismantled homogenizer.
Sensor switch scraper agitator

A proximity sensor stops the scraper agitator if the scraper arm is at the back at the vessel. In this
way, it prevents that the scraper agitator while opening hits in front of the vessel.
Safety pressure valves

A safety pressure switch set to the permissible pressure is installed in every pressure system
(double jacket, internal area).
The safety valves are laid out for the specifications quoted in the order.
In the event that vessel filling is an on-site provision, the efficiency of the safety valves must be
adapted accordingly.

Operating Manual
3.5 Module description
3.5.1 Vessel, lid and scraper agitator
3.5.1.1 Vessel
Conical/cylindrical vessel with lid for vacuum-tight seal.
Double jacket: (as an option)

Vessel with double jacket for heating and cooling. The double jacket is designed for an
overpressure of 3 to 6 bar.
For machines using steam and hot water, a device discharges liquid from the double jacket before
the heating cycle with steam starts (by forcing liquid out with pressurized air).
3.5.1.2 Vessel lid

The following are mounted on the lid:
• Scraper agitator with flow breaker.
• Vacuum connection stud with pressure transmitter.
• Electrical operated aeration valve, non return valve and excess pressure valve.
• Illuminated sight glass with wiper.
• Connection studs for the CIP cleaning nozzles.
Lid lock
By means of segmental clamping screws (Lab up to 700 l).
Vessel lid securely bolted, equipped with jack rings (1300 up to 3500 l).
Opening and closing the lid

The machines have a device for opening and closing the lid (200 up to 700 l).

Operating Manual
3.5.1.3 Scraper agitator

This is located at the top centre of the vessel.
It is driven with a bevel gear motor (Option with frequency converter).
Scraper blades are attached to the arms of the scraper agitator and allow
movement, so that the product can be continuously scraped from the vessel
wall.
Fig 3-14 Scraper agitator with scraper blades
Shaft seal
The shaft feed through of the scraper agitator are fitted with two shaft sealing rings which do
not need any sealing liquid. Nevertheless also this sealing considers the GMP requirements.
3.5.2 Homogenizer
Shaft seals
The shaft duct of the homogenizer is sealed by a mechanical seal.
Take measures to prevent the homogenizer from running dry if single-acting mechanical seals are
used.

Operating Manual
3.5.3 Units in the instrument cabinet/base frame

The instrument cabinet stands on a rust-proof base frame and has a removable sheet metal case.
The frame is used to support the vessel and supports the auxiliary units.
Levelling screws in the base frame make horizontal installation possible.
The following items are located in the rust-proof cabinet:

• Vacuum pump with optional vacuum separator
• Homogenizer drive
• Pneumatic control and compressed air service unit
• Supply connections, supply/discharge of all operating mediums
• Piping
Depending on the order, the system contains further components:

• Sealing liquid station with pump

Operating Manual
3.5.3.1 Vacuum system

The vacuum system contains all the necessary fittings
• for deaerating products under vacuum
• for sucking in products under vacuum
• for evacuating the vessel
• optional with vacuum trap
A sturdy and generously dimensioned liquid ring vacuum pump serves as vacuum pump.
Automatic functions of the vacuum system
This facility includes:
- The vacuum automatic system:

The control signal of the pressure absorber switches the vacuum pump on or off in order to achieve
a vacuum with the minimum/maximum values.
- Aeration of the vacuum pump, Automatic ventilation system

An automatic stop valve in the suction pipe prevents the ring fluid from being drawn into the vessel
from the pump after the vacuum pump has been switched off. When the vacuum pump is switched
on or off, the stop valve is closed or opened respectively.
- Barring water supply to the vacuum pump, Automatic water system

To prevent the vacuum pump from flooding with water when not in operation, the water feed pipe
to the vacuum pump has a valve. When the vacuum pump is switched on or off, this automatically
ensures that the water supply is opened or shut off and avoids unnecessary waste of water.
Fig. 3-15 Water supply unit to vacuum pump

Operating Manual
3.5.3.2 Automatic temperature control/Tempering device (Optional)
Function
The nominal temperature selected on the temperature regulator is started up automatically. The
tempering block here acts as a switching point for incoming and outgoing heating and cooling
media. The heating or cooling commands for steam, hot water and cooling medium go from the
temperature controller to an electro-pneumatic valve that actuates the corresponding pneumatic
valve on the tempering block.
- Tempering block
The heating and cooling valves are coupled together in the tempering block.
3.5.3.3 Pneumatic system (Optional)

The pneumatic control includes:
• Pressure monitor (pneumatics)
• Air service unit
• Valve manifold
The product valves, CIP cleaning, aeration valve etc. are controlled from the valve block
(pneumatics).
3.5.4 System control

The machine has PLC control for the operation of the machine.
Manual operation of the machine via automatic control panel with display and centralised functions.
Controlled functions are shown on the display.
The PLC control is described in the appendix of chapter 6.

Operating Manual
3.5.5 Electrical switchgear, measuring instruments

The entire electrical system is designed in accordance with EN 60204-1.
The electrical switchgear is ready wired and comprises:
• Emergency stop button to stop all system functions

• Switchbox with main switch, fuses, contactors and thermal motor contactors for each motor,
and a transformer for the control voltage. The switchbox is splash-protected (IP 55) and
integrated in the cabinet, or installed separately.
• Motors:
Motors up to 7.5 kW are provided for direct starting, stronger motors for automatic star/delta
starting.All motors are splash-protected. Minimum IP 54 protection in accordance with DIN
40050. Other protection categories are available as an option.
• Controlling, measuring and regulation equipment

The scope of delivery comprises:
• an illuminated sight glass with wiper,
• an aeration valve to aerate the vessel,
• pressure transmitter for automatic regulation of a constant vacuum,
• a thermometer for measuring the product temperature at homogenizer inlet (temperature range
0-120°C),
• a pressure relief valve as safety precaution against unacceptable overpressure (only for
internal pressure vessels and double jacket),
• a pressure monitor and manometer for checking the water supply pressure of the vacuum
pump,
• a pressure relief valve to maintain vacuum when switching off the vacuum pump,
• an overpressure valve as precaution against pressure shock > 0.5 bar.

Operating Manual
4 Operating Modes and Controls

Aim: To familiarise the user with all elements necessary for expert handling and primary set-up of
the machine. This as a condition for Chapter 5 “Commissioning” and Chapter 6 “Operating”.
TABLE OF CONTENTS
4 OPERATING MODES AND CONTROLS �� 1

4.2 Alarm signals and safety elements�� 2
4.2.1 Alarm�� 2
4.2.2 Safety switch�� 2
4.3 Operating modes and controls�� 3
4.3.1 Controls at the control cabinet / operator panel �� 3
4.3.2 Controls in the control cabinet �� 4
4.3.3 Controls at the vessel�� 5
4.3.3.1 Lid lock and seal�� 5
4.3.3.2 Sight glass with lamp on the lid�� 7
4.3.3.3 Component of the vacuum system�� 8
4.3.3.4 Double jacket (Option) �� 8
4.3.3.5 Product feed / discharge, media�� 8
4.3.4 Controls inside the machine housing �� 9
4.3.4.1 Vacuum system�� 9
4.3.4.2 Pneumatic group�� 9
4.3.4.3 Components of the sealing liquid system�� 10
4.3.4.4 Optional tempering device (cooling / heating)�� 11
4.3.4.5 Supply connections �� 11
4.3.4.6 Purge appliance for the double jacket�� 11
4.3.4.7 Direct-steam injection (option) �� 12
4.3.5 Parts at the homogenizer�� 13
4.3.5.1 Single-acting mechanical seals�� 13
4.3.5.2 Double-acting mechanical seal (Option)�� 13
4.4 Operating modes �� 14

Operating Manual
4.1 Introduction
Even though the machine offers a number of possibilities to influence the process, it contains only
a few control elements. The scraper agitator and the homogenizer, as well as the vacuum unit are
operated from the operating console.
4.2 Alarm signals and safety elements
4.2.1 Alarm
The machine does not contain alarm controls in the system as standard.
Note: Optical (signal lamp) or acoustic alarm indicators (sounder) are not included in the system as standard.
Please refer to the instructions for the operating console (chapter 6) for more information
on the alarm indicators.
4.2.2 Safety switch
The homogenizer and the scraper agitator, can only be started if the vessel is closed.
The final position of the vessel is detected by the means of a proximity switch.
The latter will automatically stop the processing aggregates if the lid is not in its final (closed)
position.
The security switch at the homogenizer prevents starting of the dismantled homogenizer.

Operating Manual
4.3 Operating modes and controls
4.3.1 Controls at the control cabinet / operator panel
• Emergency stop push button
Pushing the emergency push button cuts OFF the electric power supply to all devices of the
machine.
In the OFF position following devices remain powered ON.
• Electrical Socket in the switch gear

• PLC-CPU/Inputs
• Sensors
Note: The emergency stop push button remains in its position until being unlocked (for unlocking turn button). Resume
the process by activating the recipe/program at the control panel.
Operating panel (PLC programmable logical controller)

Inputting of the process data will be done at the operator panel. Chapter 6 contains a detailed
description.

Operating Manual
4.3.2 Controls in the control cabinet
• Main power switch – Safety lock
Appears this signal in the operating manual, steps must be taken to prevent
others to inadvertently starting up the unit.
This is achieved by the following measures:

• Turn the main switch to ”OFF” position.
• Slide the lever on the main switch handle to allow access to the clearance notch
• Insert and lock personal safety lock (lockout/ tagout lock)
Up to 4 persons can protect themselves individually.
With exception of the fuses/automatic circuit breakers, no other operating elements are contained.
Depending on the order, the control cabinet’s house:

• Automatic circuit breakers, fuses and automates, terminal boards
• Frequency converters for homogenizer
• Heating control
• Main switch
Further specification about the content of the control cabinet are in the electrical wiring diagram in
chapter 5.

Operating Manual
4.3.3 Controls at the vessel
4.3.3.1 Lid lock and seal

These guarantee before evacuating starts, a sufficient contact pressure between vessel and lid.
Clamping screws
Clamping screws have to be always tightened after

closing the lid.
Fig. 4-1 Clamping screws
Opening/closing the vessel

First switch off the processing aggregates and aerate the vessel (no vacuum allowed). Afterwards
loosen the clamp screws.
• Lab
The lid is being opened/closed manually (push-type gas spring).
• 200 up to 700 l
The lid is being opened/closed with an electric lifting
spindle.
The machine is controlled /operated with a two-hand
control at the switchgear.
The operator opening the cover shall verify that there are
Fig. 4-2 Two-hand control
no unauthorized persons in the danger area.
Position of safety pin with lid opened
Fig. 4-3 Safety pin

Operating Manual
Option
A handle and counterbalanced hinge are used to open and close the lid.
Fig. 4-4 Lid handle
Position of the safety pin with lid opened
Fig. 4-5 Safety pin at the counterbalanced hinge
1300 up to 3500 l
Vessel lid securely bolted, equipped with jack rings.
Fig. 4-6 Vessel lid with jack rings

Operating Manual
4.3.3.2 Sight glass with lamp on the lid

A sight glass with light is fit at the lid. In this way, the processes in the vessel can be checked
visually.
The lamp is turned on with the push button (press).
A rotating handle is connected to a wiper inside of the vessel.

Activate the wiper by rotating the handle.
Fig. 4-7 Viewing glass / wiper

Operating Manual
4.3.3.3 Component of the vacuum system
Vacuum display
Pressure in the vessel will be displayed at the control panel.
Aeration valve
For aeration a valve opens by activating it at the control panel.
Condensate trap (Option)

Liquids sucked from the vessel or condensates are trapped in the
glass cylinder.
For discharge of the condensate, open the bottom valve only if the
machine is aerated completely.
Fig 4-8 Condensate trap/ Condensate collector
4.3.3.4 Double jacket (Option)
Safety valve for double jacket preventing overpressure (pressure =

set in factory)
Fig. 4-9 Safety valve of double jacket
4.3.3.5 Product feed / discharge, media

The connections are dimensioned according the machine dimensional drawing and correspond to
the scheme in chapter 5. Depending on order the valves may be controlled manually or electric-
pneumatically.

Operating Manual
4.3.4 Controls inside the machine housing

Access: Open the covers on the front, side and back with the special key.
Lab:
The control cabinet fitted to the rear of the machine is designed to be hinged
open. To this end, open the door of the control cabinet and release the nuts on
the opposite side of the cabinet.
Attention: Only for maintenance purposes and only by qualified personnel. Make sure the machine is not moved in the
process; it can otherwise tip over.
Please mind the drawing „Vacuum control“ in the

documentation 2-2.
F M P E
Fig. 4-10 Water supply
F) Water filter
M) Solenoid valve for the water supply
P) Pressure switch. Pressure signal to the control.
E) Regulating valve (manual). Serves for adjusting the amount of ring liquid flow of
the vacuum pump.
4.3.4.2 Pneumatic group

Serves for conditioning, monitoring and distribution of pressurized air
2 1 3
1 Pressure switch
2 Air service unit
3 Pneumatic valve manifold
Fig. 4-11 Pneumatic group

Operating Manual
4.3.4.3 Components of the sealing liquid system
(optional in case of double acting mechanical seal)

The vessel contains the sealing liquid, the level of which is monitored by a level switch. A
circulating pump forces the sealing liquid through the circuit. Compressed air regulated by means
of a pressure reduction valve is fed into the vessel containing the sealing liquid.The temperature
sensor is used to actuate the cooling fluid valve and to define a top limit temperature of 60°C.
A flow monitor checks the flow of sealing liquid through the mechanical seal.
Observe the information given in the manuals of suppliers.
Pressure reduction valve with manometer
Refilling sealing media
Sight glass
Level switch sealing media
Discharging sealing liquid
Circulation pump
Temperature sensor
Flow monitor
Fig. 4-12 Sealing liquid unit
Make sure that the sealing liquid system and the mechanical seal are completely
deaerated.
Ventilate sight glass/filler of the vessel before dismounting.

Operating Manual
4.3.4.4 Optional tempering device (cooling / heating)

The tempering unit encloses:
• Valves for heating and cooling
• Manifold
• Line out to consumers controlled by the processor
• Connections of water and air
The supply connections of the heating and cooling media lead directly onto the tempering
furnishings.
4.3.4.5 Supply connections

The connections correspond to the P+I diagram.
4.3.4.6 Purge appliance for the double jacket

Located in the rack of temperature controller. The double jacket
is emptied automatically before heating with vapour by blowing
compressed air.
Manometer (purge pression) < 1 bar
Fig. 4-13 Purge appliance

Operating Manual
4.3.4.7 Direct-steam injection (option)
Fig. 4-14 Direct-steam injection
Comprising:
• Injection socket
• Control valve
• Manometer incl. water siphon
• Dirt trap
• Condenser
• Steam connection

Operating Manual
4.3.5 Parts at the homogenizer
Recirculating pipe
Homogenizer / Feed chamber
Safety switch
Temperature sensor
Connections for hoppers
Studs with manually or pneumatic. activated flaps
Pneumatic actuator with adjusting screw and locknut for

user defined valve opening.
Remainder discharge at the mixing chamber and the

housing
Fig. 4-15 Homogenizer
*At pneumatic actuators, the knurled adjusting screw enables a variable valve aperture and
consequently product flow. Fix the adjusting screw by tightening the locknut.
Note: If product is sucked from atmosphere, the flow rate among others depends on the pressure (vacuum in the
working vessel.
4.3.5.1 Single-acting mechanical seals

The single-acting mechanical consists of a simple mechanical seals enclosed in a housing.
4.3.5.2 Double-acting mechanical seal (Option)

The double-acting mechanical seal consists of a combination of two simple mechanical seals
enclosed in a housing. Sealing liquid circulates inside this housing, that prevents the product
penetrating the seal and simultaneously serves to cool the seal.
Normal tap-water can be used as sealing and cooling liquid. When using tap-water, we advise you
to fit a pressure reduction valve to balance pressure fluctuations in the circuit, thus protecting the
seal.

Operating Manual
4.4 Operating modes
Fig. 4-16 Swivelling operating panel
Fig. 4-17 Operating panel / switchgear
Processing system control

The machine is furnished with a PLC control located in the switchgear.
Operating and the display of the process values occur via the operating panel at the control
console.
The standard version allows to run processes in the manual operating mode.
Also a module performing automatic task execution is available.

Operating Manual
Commissioning
5 Commissioning
Aim: To inform the user of the proper operating methods.
TABLE OF CONTENTS
5 COMMISSIONING�� 1
5.1 Safety�� 2
5.1.1 Safety Regulations�� 2
5.1.2 User Requirements�� 2
5.1.3 Technical Documentation�� 2
5.2 Assembly �� 3
5.2.1 Requirements�� 3
5.2.2 Transport�� 3
5.2.3 Site / Operation room�� 3
5.2.4 Handling, Unpacking and Cleaning�� 3
5.3 Commissioning�� 4
5.3.1 Interfaces of delivery and assembly�� 4
5.3.2 Assembly �� 5
5.3.3 Power supply, operating media�� 7
5.4 Primary Set-up �� 9
5.4.1 Measures before Initial Set-up �� 9
5.4.2 Primary Set-up �� 12
5.4.3 First cleaning�� 13
5.4.4 How to determine if cleaning has been successful�� 14
5.4.5 Test procedures �� 14
5.5 Acceptance�� 14
5.5.1 Acceptance criteria�� 14
5.5.2 Procedure�� 14
Annex: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram

Operating Manual
Commissioning
5.1 Safety
Experienced FrymaKoruma personnel are available to help with installation and initial operation of
the machine if this has been previously arranged. The customer should always take advantage of
this possibility if the requirements stated in chapter 5.1.2 are not fulfilled FrymaKoruma would not
be liable for damage caused by mistakes that were made when setting the machine into operation.
5.1.1 Safety Regulations

All of the safety regulations stipulated in chapter 2 must be adhered to.
Possible hazards caused by faulty assembly:

Electrical installations have to meet the federation, state and local government regulations.
Electrical equipment supplied by the client have to meet the requirements of the standards
EN60204-1 respectively IEC 204-1.
5.1.2 User Requirements

This part of the operating manual is addressed to all staff involved with the installation and initial
start-up of the machine. All steps of the installation have to be supervised by an expert person,
having knowledge about the assembly and the initial operational start of the machines and
equipment.
The execution of work must be done by qualified staff only.
5.1.3 Technical Documentation

The installation of the machine is based on the following documents:
• Layout plan
• P+I - diagram
• Wiring diagram

Operating Manual
Commissioning
5.2 Assembly
5.2.1 Requirements
Important: The machine requires for the operation:
• Power supply and equipment in accordance with chapter 1.2.2 of the operating manual.
5.2.2 Transport
Delivery check on arrival

We recommend that each delivery be checked for transport damages. The completeness of
the shipment is to be verified with the help of the shipping documents. Damages or incomplete
shipments are to be reported immediately.
Storage
Until such time as the assembly is to take place, the machine must be left in its original packaging
and stored protected from the weather. For the recommended storage conditions consult chapter
1.2.4 of the operating manual.
5.2.3 Site / Operation room
Space required and weight of the machine.

For the dimension please consult the layout plan.
For the weight of the machine see in „Technical data 1.2.1“
Room Requirements
Floor: The entire floor area must be level. Uneven floors or those with stumbling places and
differences in level pose a high accident risk. Keep work areas free.
Floors made of materials which are easy to clean are recommended. Ceilings, walls and floors
should be kept clean and free of dust. Clean these areas if required and keep them dry whenever
possible.
Lighting
The average flux density in the working area should be 600 Lux/m2.
5.2.4 Handling, Unpacking and Cleaning
Transport and handling of the individual parts.
Danger!
Mind the notes given in chapter 10 about the fixations made for the transport and
the proper use of the lifting devices delivered.

Operating Manual
Commissioning
5.3 Commissioning
5.3.1 Interfaces of delivery and assembly
Extent of delivery by FrymaKoruma

FrymaKoruma supplies and assembles the components according to the order confirmation. The
machine will be completely assembled and works tested. Usually the machine is delivered ready
for quick connection. Depending on the means of transport and destination it may be necessary
to demount individual components for dispatch. Such components have to be assembled before
setting-up again.
Customer Preparations*
The customer is responsible for:
• Setting up and grading the machine.
• Assembly of the components which have been removed for dispatch.
• Water supply of cooling- and fresh water, hot water or vapour.
• Connections for the product.
• Piping for compressed air.
• Waste water piping of the vacuum pump or used CIP-water.
• Power supply of the switchgear to the electric net.
• Electrical wiring between switch gear and components of the machine.
• Check of the fixation screws.
* provided that not other contract conditions were agreed upon.

Operating Manual
Commissioning
5.3.2 Assembly
Order of assembly:
- Putting on place
The machine has to be placed on a level ground. In most cases, no foundation is required, yet the
admissible floor loading imposed by the machine with filled vessel has to be considered.
- Levelling
The machine is to be aligned horizontally and vertically with the levelling screws in the base frame.
Reference horizon for the alignment is the surface of the vessel flange.
- Assembly of the components which have been removed for the dispatch
A list of the parts removed for the transport will be found in the shipment list. These components
have to be assembled according the drawings before start-up again.
• Water supply of cooling- and fresh water, hot water or vapour up to the base.
• Connections for the product.
• Optional piping for compressed air.
• If needed piping e.g. leak connection of the sliding ring seal.
• Sewage piping connection for the vacuum pump or for used CIP-water.

Operating Manual
Commissioning
- Connecting of media piping
• All connections for media are labelled at the machine.

• The DN of the piping has to be equal with the DN of the connection. For longer distances a
bigger nominal diameter of the piping has to be chosen.
• The piping has to be supported in order no inadmissible forces may damage the machine.
• Waste water piping has to be led with slope from the machine. No back pressure will be allowed.
• The piping is to be cleaned before installing to the machine and have to be free of dirt.
• Electrical work.
The electrical wiring between switchgear and the machine components are to be made according to the wiring diagram.
- Checking the fixing screws

All securing screws have been secured tightly before the machine left the manufacturer’s works.
According to experience, vibration might cause screws to become loose during transport. For
this reason, please tighten all visible screws before taking the unit into operation. This particularly
applies to
• the screws fixing the scraper agitator
• the clamping screws holding the homogenizer
• the screws fixing the motors, gear, vessel and lid, bearing shaft.
Information about the periodic check of the fastening screws are in chapter 7.4.4.2.

Operating Manual
Commissioning
5.3.3 Power supply, operating media
• Installation of the supply terminals

• Cooling water, hot water, vapour
• Compressed air supply
Requirements regarding the quality and quantity of operating media are to be found in the chapter 1.2.2 Power supply
and infrastructure.
- Electrical Connections
For the electrical power supply, overcurrent protection according to Chapter 1.2 of the operating
manual must be present. Details are found in the electrical documentation.
The electrical switchgear must be connected by an electrician to current supply.
With ex-protected designs:
• the control panel must be installed outside the potentially explosive area or room
• the wiring between the control cabinet and the control panel must be carried out
on site
• earthing cables must be installed
- Sense of rotation of three phase alternator motors
• The sense of rotation of all motors must correspond to the rotary arrow
• Since the machine is prewired, all motors will run correctly if the AC power is carried out with
„rotary field“ runs „clockwise“ (c.w.)
• Homogeniser: when looking from the motor side towards the unit, the rotational direction of the
motor shaft/fan is to the left or anticlockwise
• Scraper agitator: rotates c.c.w. (check through sight glass)
• Vacuum pump: check arrow
• Forced circulating- and CIP -pumps: check arrow
• Sealing liquid pump: check arrow

Operating Manual
Commissioning
- Operating, Lubricating and Auxiliary materials
• Heating- and cooling agents
- Filling of the vessel circuit (double jacket)

- Open discharge valve and vent valve at the double jacket
- Fill double jacket from the bottom with water
- Stop filling when water escapes out of the vent valve
- Close vent valve
- Close discharge valve at the double jacket
• Heating devices- and coolers/heat exchanger
• Pumps
• Gear
Gear to fill with oil
- Working area/homogeniser
The working area/homogeniser must be covered with liquid.
- Sealing liquid
Machines equipped with sealing liquid or forced sealing liquid systems:
The sealing liquid vessel has to be filled up to the marking of the level indicator (sight glass) with
sealing liquid. In the case of a “forced sealing liquid system” subsequently pressurize the sealing
liquid vessel with the force gas. Information about the sealing liquid is to be found in chapter 7.3.1.
The double acting mechanical seal has to be deaerated according to chapter 4.3.4.3
„Components of the sealing liquid system“
Observe the information given in the manuals of suppliers.

Operating Manual
Commissioning
5.4 Primary Set-up

During the initial set-up the machine is to be checked systematically for possible sources of errors
due of transportation or installation. The machine usually has been tested according to 5.4.1 by
FrymaKoruma. Therefore, not all the tests need to be repeated. However, tests 5.4.1.1 to 5.4.1.6
should always be carried out at the clients premise.
5.4.1 Measures before Initial Set-up

Setting the Basic Password*: Information about Password setting contains the operating manual
of the operator panel.(*only available with the option Operator panel).
Warning !
Inputting a password through a person not authorized to this (user, third person)
would cause damage to the machine. Furthermore, injuries could be the result of
faulty operation by an unauthorized person.
Check list for primary setting-up Yes No
5.4.1.1 Electrical connection
Check of the mains voltage with the information
Function of the main power switch
Connection and sense of rotation with rotary field clockwise at the input terminals. Tested successfully
5.4.1.2 Safety devices
The process aggregates can not be started with vessel open, or stop when opening the vessel?
Emergency button activated ’ immediate shut down of all electrical components?
Emergency button locked ’ automatic starting up of the machine not possible?
Safety valve for heating/cooling circuit mounted? Reading of set pressure bar
Safety valve on vessel? Reading of set pressure bar
Safety valve (others)? Reading of set pressure bar
5.4.1.3 Connection and flow direction of medias
Check all medias and release each separately, if functional
Check each medium for tightness in accordance with 5.4.1.6
Start pump and check/adjust flow of ring liquid. For data: Use the operating manual of the pump supplier

Operating Manual
Commissioning
Functional Tests and Checks according to Check List
Check List for Initial Set-up:
5.4.1.5 Displays/measuring instruments
Rotation speeds (rpm)

Reference Display
Designation
min. max. min. max.
High-speed (homogenizer)
± 5%
Slow-speed (scraper-stirrer)
± 10%
Temperature point of measurement (in ºC)
Temp. of medium in the vessel ± 2% (hot)
Temp. of medium in the vessel ± 2% (cold)
Reference
Vacuum and pressure (in mbar) Vacuum and pressure Display
device
Pressure transmitter -900
-250
500
2500
5.4.1.6 Check of tightness
Vessel interior
Max. vacuum mbar
Max. overpressure bar
Water temperature ºC
Loss of the vacuum with user volume (100 mbar abs) testing time min.
Acceptable vacuum loss: 10 mbar within 30 min. Pressure loss mbar
Tightness of shut off valves OK? Yes No
Tightness of the complete pipe layout (heating and coolant feed lines) successful tested
Tightness of the pneumatic system successful tested
Tightness of the mechanical seal (visual check of mechanical seal and sealing liquid vessel)

Operating Manual
Commissioning
5.4.1.7 Electric outfit
Measurement of the power consumption
Process aggregate with scraper-stirrer without vacuum
Rotation speed in rpm. at 50 Hz
Current consumption with water and minimal volume A
Current consumption with water and usable volume A
Homogenizer without vacuum
Current consumption (idle running) A
Mixed mode without vacuum
Test with vacuum
800 mbar, vessel filled with water and usable volume
Scraper-stirrer
Homogenizer
Vacuum pump
Current consumption (idle running)
Current consumption with vessel empty at -200 mbar und 0,5 – 1 bar ring liquid pressure A
CIP-pump
Current consumption A
Discharge pump

Operating Manual
Commissioning
5.4.1.8 Heating / Cooling
Heating/cooling time with 13 rpm. Scraper-stirrer and Homogenizer ON, water as a testing medium. min.
Heating from 20 ºC to 80 ºC (with vapour .....ºC) ºC min.
Heating from 20 ºC to 80 ºC (with water .....ºC) ºC min.
Cooling from 80 ºC to 30 ºC (with water .....ºC) ºC min.
Heating from 20 ºC to 80 ºC, electrical (heating power) kW min.
Type of device:
Temperature hold at 80 ºC for 20’ ºC
Temperature hold at 30 ºC for 20’ ºC

Test O.K.
5.4.1.9 Various functions
YES NO
Function test “burden value regulation” carried out successfully
Function test “recording” carried out successfully (view printout report)
Examination of “alarm functions” according enclosed alarm list successful
Function test “recipe administration” carried out successful
Weight pick-up (weighing cells)
Function test “cleaning” checked successfully
Procedure applied:
CIP process attached (test)
Function test “sterilization” checked successfully
Procedure applied:
SIP process attached (test)
Check of oil level of the fitted gear (scraper stirrer) O.K.
Visual check before Start-up of machine
5.4.2 Primary Set-up

Checks in accordance with chapter 5.4.1 must be performed as part of the initial operation.
Visual inspection: No damage, leakages, etc.

• Scraper agitator is running concentrically
• Drive shafts are running smoothly. No jamming or grazing when turned by hand. No overheating
of bearings and gear.

Operating Manual
Commissioning
5.4.3 First cleaning
IMPORTANT!
The system user is responsible for the first cleaning procedure (rinsing, chemical cleaning) as well
as for any further surface treatments (e.g. passivation, etc.).
The cleaning procedure described below is merely a recommendation and does not give the user
any guarantee that the customer-specific cleaning quality will be achieved.
This cleaning procedure removes residues in the vessel left over from commissioning. The inlet
and outlet pipes must also be included in this cleaning procedure.
• Recommended equipment:
• Heatable recipient vessel with approx. 50% of the volume of the vessel to be cleaned.
• CIP/pressure pump, conveying capacity 9 m3/h with 4 bars at the pressure joint.
• High-pressure cleaner
If these requirements are not met, the process must be adapted in such a way that heating, for
example, is performed inside the system. If necessary, cleaning must be repeated several times
until the desired level of cleanliness has been achieved.
1. Cleaning the vessel with a high-pressure cleaner, for example.
2. Fill the recipient vessel with 2/3 of the volume with tap water.
• Add cleaning agent (e.g. 1% P3-mipF, supplier: Henkel AG).
• Heat liquid to 63°C.
• Switch on the CIP pump. Let the cleaning liquid circulate over the spray nozzles for approx. 20
minutes. The spray water must be able to drain off freely; no damming up should occur in the
vessel if maximum spray effectiveness is to be achieved.
Raw materials generated at machine operation and service and particularly consumed detergents
are subject to CIP and proper recycling according to relevant valid state and in-house regulations.
Take care when handling with detergents
The material manufacturer should supply a corresponding safety data sheet. These safety data
sheets together with instructions for safe handling with dangerous materials must be available at
the workplace at any time.

Operating Manual
Commissioning
If a charge is changed (other receipt), the machine should be cleaned according to data specified
in the following table.
Contaminant Group Agent
Protein Alkali Sodium hydroxide
Soaps Soft soap

Fats/greases
Surface active substances Detergents
Mineral product residues Hydrochloric acid, acetic acid, tartaric

Acids
(e.g. milk deposits, lime) acid
3. Rinse the recipient vessel with tap water.

• Fill the recipient vessel with 30% of the volume with tap water and heat to 58°C.
• Rinse the spray nozzles in the vessel with tap water.
4. Check that cleaning has been successful (optional).

• Fill the vessel with 100% usable volume with cold tap water.
• Switch on the scraper, at approx. 24 rpm. Switch on the homogenizer, at approx. 1000 rpm.
• No vacuum
• Stop units after 1 hour operation.
• Visually inspect the scrapers, vessel wall and cover.

Operating Manual
Commissioning
5.4.4 How to determine if cleaning has been successful
• No discolouring is visible on the scraper blades

• There are no traces of grazing or scratching on the vessel
Activating the operating media:
• Cooling water Open the shutoff valve

• Hot water/steam Open the shutoff valve
• Compressed air Open the shutoff valve
Caution
Before starting, always fill the vessel with liquid!
Vessel must be filled to the minimum level in order to avoid it running dry.
Note: The scraper or homogenizer must never run dry. In the event of it running dry, the homogenizer might become
blocked or damaged. The scraper might damage the vessel (causing grooves, scratches, etc.).
5.4.5 Test procedures

Different test procedures can be obtained from the FrymaKoruma customer service and from the
suppliers of equipment on request.
5.5 Acceptance
5.5.1 Acceptance criteria

The acceptance criteria are listed as part of the order. Official acceptance can be made at
FrymaKoruma or on the customer’s premises.
5.5.2 Procedure
A report will be made of the acceptance procedure, which will be signed by the purchaser and
FrymaKoruma.

Operating Manual
Operation
6 Operation
Aim: To guide the user to operate the machine. This covers the safe and economical operation, as
well as the utilization of the various possibilities of the machine.
TABLE OF CONTENTS
6 OPERATION �� 1
6.1.1 Safety measures�� 2
6.1.2 Demands on the personnel�� 2
6.2 Production and organization�� 2
6.2.1 Processing control �� 2
6.2.2 Option „Automatic processing control“�� 2
6.2.3 Cleaning Process�� 3
6.2.3.1 Cleaning without CIP / Manual cleaning process�� 3
6.3 Operation �� 6
6.3.1 Installation/ Settings/ Equipment�� 6
6.3.1.1 Settings�� 6
6.3.1.2 Perform maintenance work according to plan of maintenance in chapter 7�� 6
6.3.2 Remarks on the operation�� 6
6.3.2.1 Product feeding�� 9
6.3.2.2 Heating and cooling down�� 11
6.3.2.3 Mixing, homogenizing, emulsifying and grinding �� 12
6.3.2.4 Deaeration and cooling down�� 13
6.3.2.5 Discharge of the product�� 13
6.3.2.6 Direct steam injection (Option)�� 13
6.4 Data entry / program run�� 14
6.5 Switching off / ending�� 14
6.5.1 Switching off�� 14
6.5.2 Long interruption�� 14
6.6 Starting / switching on�� 14
6.7 Monitoring, checking�� 15
6.8 Trouble shooting�� 15
6.8.1 Possible troubles�� 16
Appendix:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating instruction of the operating panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function-Specification (FS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NetBox Recipe Manager
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NetBox Administration Manual
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NetBox User and Operator Manual
Created: 06.06.2014 MaxxD_06_EN Chapter 6 Page 1 of 21

Operating Manual
Operation
6.1 Introduction
6.1.1 Safety measures

The safety instructions in chapter 2 are also valid for the operation.
The machine is only designed for use as explained in paragraph 1.1.
There are further safety instructions depending on the application.
6.1.2 Demands on the personnel

This section concerns the persons who are responsible for the operation or the safety of the
machine.
Note: FrymaKoruma would be willing to show users how to operate and maintain its systems. Experienced employees
explain all the steps necessary to process correctly and work safely with the machine.
6.2 Production and organization

Each firm structures its operating process depending on its production range, structure,
organization and employees. To do that, the product and processing quality are recorded and
documented in a suitable way in each company.
Note: Data logging, i.e. by continuously storing processing data to create a data logging will only be supported with
automatic process control systems.
6.2.1 Processing control

The machine is controlled from the operating panel. It runs in manual mode.
6.2.2 Option „Automatic processing control“

Depending on the execution this option is covered.

Operating Manual
Operation
6.2.3 Cleaning Process

As for cleaning, there is a difference between:
Open cleaning and closed cleaning / CIP cleaning (CIP = Cleaning In Place)
a) In many cases, the open cleaning is executed manually in spite of tools and is always
necessary for open surfaces, floors and vessels etc.
b) The closed or CIP cleaning includes the cleaning of vessels, pipelines and components
without having to take them apart and clean them manually.
Description of the CIP equipment (Option)
• Low-pressure spray nozzles

• Feed pipe between cleaning spray nozzles and valves.
• Connection pipes between each valve.
CIP cleaning incl. vacuum connection

An extra shutoff valve and a pipe to the vacuum connection are provided for this purpose.
WARNING!
The noise level during cleaning can exceed 74 dB.

The operator must wear ear defenders during the CIP process!
Tip:
To reduce the noise level, limit the speed of the homogenizer during the CIP process to max. 2500
rpm.
6.2.3.1 Cleaning without CIP / Manual cleaning process

Prerequisites: This cleaning process is used when there are no spray nozzles and the system must
be free from residues for the subsequent production.
Criteria for a successful cleaning are to be determined for each product and
cleaning process!
Discharge product
• Scraper agitator and homogenizer in operation.

Operating Manual
Operation
Mechanical cleaning
Purpose: Utilize as many products as possible. Keep load of waste water with product small.
• Open lid. Wear suitable protective clothing, gloves and goggles.
• Most of the product residue is to be found on the scraper blades.
• Remove product residues with rubber or synthetic scraper.
• Remove, clean and reinstall scrapers.
Wet cleaning
• Close vessel and apply vacuum. Fill 2/3 of vessel with tap water.
• Add detergent or mixture.
• Aerate vessel.
• Heat up fluid according to the product. When this has improved the cleaning effect, let the
scraper agitator and homogenizer run at maximum speed for about 15 to 20 minutes.
• Release fluid. Raw materials generated at machine operation and service and particularly
consumed detergents are subject to CIP and proper recycling according to relevant valid state
and in-house regulations.
Rinse the system with tap water
• Fill the vessel to the minimum volume with tap water.

• Let the scraper and homogenizer run at maximum speed for about 5 minutes. Do not heat
without detergent.
• Alternatively: open the vessel and rinse the vessel and the components with tap water using the
hand spray/spray gun.
Check the machine visually for cleaning results

The cleaning process is determined by the product to achieve the desired level of cleanliness. If
necessary, cleaning should be repeated several times until the desired level of cleanliness has
been achieved.
Cleaning of new machines or cleaning after maintenance

New machines or existing ones: when large maintenance has been carried out on them, proceed
with cleaning according to the procedure given in chapter 5.4.2 „First cleaning“.

Operating Manual
Operation
The cleaning process usually contains the

following sequences:
• Water rinsing (primary cleaning)

• Cleaning with detergent (fine cleaning)
• Hot/cold rinsing (final cleaning)
Primary cleaning
Open the valve with the spray nozzles for the
cleaning water.
Close vessel and evacuate vacuum.
Install circulation pipe
Start the CIP cycle!
Fill vessel to the minimum volume
Start the scraper and homogenizer at max. speed

When the vessel is half full, stop the pumps and the
water supply
Switch off the aggregates after about 15 to 20
minutes
Empty fluid out of the vessel.
Fine cleaning
Fill vessel to the minimum volume.
Start the processing aggregates.
Add detergent (acid, caustic, alkaline, for example).
Scraper and homogenizer at max. speed.
When the vessel is half full, heat up the cleaning
fluid following the instructions.
Switch off the processing aggregates/water supply
after about 30 minutes.
Empty the vessel (or neutralize it!)
Final cleaning
Similar procedure as for the fine cleaning but with
less fluid.
Fill vessel to the minimum volume and add de-
ionized water, a softener, for example, depending on
the requirements.
Start the processing aggregates, scraper and
homogenizer at max. speed.
Heat up to 58°C approx.
Switch off the processing aggregates after about
15 minutes, empty vessel.
Dismantle the circulation pipe, lock pipe stub.

Operating Manual
Operation
6.3 Operation
6.3.1 Installation/ Settings/ Equipment
6.3.1.1 Settings
It may be necessary to mount other processing tools in the homogenizer, depending on the
product. Changing the processing tools is described in chapter 7.4.4.
6.3.1.2 Perform maintenance work according to plan of maintenance in chapter 7
6.3.2 Remarks on the operation

The typical processing unit operating sequence of a product is as follows:
• Close the vessel
• Switch on the vacuum pump and evacuate the vessel
• Add the first liquid component and fill up to the minimum volume (apply vacuum)
• Switch on the processing aggregates (scraper agitator, homogenizer)
• Switch on the temperature control
• Add further components, fluid and powder (Suck in with vacuum)
• Mix, homogenize, emulsify or refine
• Deaerate and cool down
• Switch off the vacuum pump and ventilate the vessel
• Discharge the product, then switch off the processing aggregates
• Clean the system
Note: The machine has a drain or emptying function. Once the vessel has been filled by activating „Water on“ or „CIP on“
and subsequent to the CIP procedure, the vacuum line must be emptied (drained).

Operating Manual
Operation
Safety instructions
Wear safety goggles when working with the open machine to avoid injury from
splashing.
Caution!
Fill up the vessel up to the minimum volume before starting the processing
aggregates! Avoid dry running!
Danger!
The working area/homogenizer must be covered with liquid.

Operating Manual
Operation
Basic rules in the operation
1. Clean sealing surfaces on the 2. Close vessel 3. Start vacuum pump

lid and vessel
< Max.
> Min.
Observe filling quantity according to type plate, when filling the vessel
4. Never fall below minimal level! 5. Never overfill the vessel! 6. Start processing aggregates
Suck in powder components

only to liquid
Never add dry ingredients to an

empty vessel
I At first dissolve/melt solid-/block II Close lid III Start processing aggregates

materials
Notes: (Stirrer not running!!)

For 2) The segment clamping screws must always be tightened
For 3) This makes it possible to apply vacuum to liquids and solids
For 4) The scraper and the homogenizer must not run dry. In the event of them running dry the mechanical seal might
be damaged.
The scraper might damage the vessel (causing grooves, scratches, etc.).
For 5) The product could end up in the vacuum system in the event of the container being overfilled!

Operating Manual
Operation
6.3.2.1 Product feeding
Cleaning sealing surfaces
• The sealing surfaces on the lid and vessel flange must be clean before they are closed so that
the machine is tight.
• After cleaning, close the lid and tighten the clamping screws.
IMPORTANT!
The clamping screws on the vessel lid must always be tightened!
Switch on the vacuum pump

Under low pressure (vacuum), liquid, pasty or powdery products can be fed in the vessel without
the help of a conveying pump.
Product feeding
• Fill the vessel up to the minimum volume with a liquid phase in order to avoid a dry run.
(with single acting sliding ring seals).
IMPORTANT!
Dry running of the homogenizer will lead to very rapid destruction of the single
acting mechanical seal !
The vessel shall only be filled up to the maximum of its usable volume, otherwise the product
might get into the vacuum system.
• Put starting components in the vessel.
• Add the liquid component first of all.
• Set speed of homogenizer and scraper agitator according to the recipe and start .
• Add dry component according to the recipe.
IMPORTANT!
If melted or block materials are put in the vessel, the solid components have to
be dissolved before the scraper agitator is switched on.
If you do not observe these instructions, the scraper blades, the homogenizer or
the scraper agitator could be damaged.

Operating Manual
Operation
Manual operated valves on the hoppers and open pipe stub.
Warning:
Never open the valves when the vessel is under excess pressure!
The valves must be closed immediately after the product feed.
Opening the homogenizer, danger of product splashing out.
Warning:
never undo the fixing screws on the housing of the homogenizer:

• while the vessel is under pressure!
• while there is liquid in the vessel
Before working on the system, pressure must be released and it must be emptied.
Main switch “OFF“
Note: If the valve of a hopper or a stud is open while the vessel is under pressure, there is a risk of injury by flying
products (such as powders, content of the vessel, steam during cleaning, etc.).
If a valve is not closed properly, during the application of pressure for example, some of the product could be expulsed
during a subsequent pressure operation.

Operating Manual
Operation
6.3.2.2 Heating and cooling down
• Heating with steam or hot water
Warning!
Risk of scalding from boiling liquids. Take care to avoid contact with hot surfaces
during machine operation.
It is not permitted to heat up water or products containing water to more than
90°C in vessels not fitted with lid lock (only vacuum operation).
• Heating/Cooling down (option with tempering device).
Observe the information given in the manuals of suppliers (file 2, chapter 7).
For systems without a ventilating automatism, the heat cycle and the double jacket must be filled
and deaerated.
Let the scraper agitator and the homogenizer run at low speed during heating up. This results in an
even distribution of temperature and prevents the product from sticking to the vessel walls.
The temperature control system is suitable only for a maximum temperature of up

to 120°C; this must be monitored by the customer. The temperature regulator can
maintain the flow temperature up to 140° C (safety shutdown at 145° C). Machine
parts can be heated to this level.

Operating Manual
Operation
If the vacuum pump is making a loud noise while in operation, this means that it is cavitating
(crackling noise).
CAVITATION DESTROYS A PUMP VERY QUICKLY!
Note: If you notice cavitation, you must reduce the vacuum.
Please refer to the diagram in the appendix „Saturation line of steam“ to learn more about the
obtainable vacuum at a given temperature.
Note: The heating can be supported by mechanical energy (adjust high rpm for mixer). Shorter batch times may be
achieved.
6.3.2.3 Mixing, homogenizing, emulsifying and grinding
• Select the „Homogenizer device“ on the operating panel. This starts the homogenizer.
• Add the dry component. The homogenizer speed must be set in such a way that solid or
powdery materials are directly sucked into the liquid. Set the dosing valve, so that no lumps
or striae appear. Make sure that the fed component are processed directly by the processing
aggregates in the liquid phase. The product runs through the homogenizer which grinds rough
materials and homogenizes or emulsifies the product. Other component can be poured into the
product during this phase.
* In the case of pneumatic valves, please observe the use of the adjusting screw on the valve drives of the homogenizer
(Chapter 4.3.5).

Operating Manual
Operation
6.3.2.4 Deaeration and cooling down
• Set product temperature on the temperature controller (if any) or in the program!
• Apply final vacuum depending on the product temperature! (only possible with automatic process
control / not possible with standard systems). The product is deaerated while being mixed and
homogenized. The vacuum pump runs and continuously sucks the air contained in the product.
By observing the product surface from the sight glass, you can check the progress of the
deaeration. If the product tends to foam, you need to reduce the vacuum.
• Switch off the vacuum pump*
• Open the vacuum aeration valve manually. (Select the „Ventilating“ command on the operating
panel on machines with process control).
*Note: The water supply to the vacuum pumps stops automatically.
6.3.2.5 Discharge of the product
• Homogenizer and scraper agitator are running.

• Discharge the product by opening the product discharge valve. With vessels for pressure
operation, the product can also be discharged by superposing pressure with air or with an inert
gas, or, alternatively, with a conveying pump.
If there is no product left in the vessel, the Homogenizer and scraper agitator as well as the
discharge pump, if there is one, must be switched off.
Avoid material damage due to a dry run by switching off all the mechanical aggregates!
Note: The machine must then be cleaned or the next batch must start.
6.3.2.6 Direct steam injection (Option)

This function is described in the appendix of this chapter.

Operating Manual
Operation
6.4 Data entry / program run

Entering data, creation and process of a recipe sequence is only possible with an automatic
process control. Please see the manual for the console terminal and process control in the
appendix.
Entering the password
Warning!
The password must be kept secret to prevent unauthorized persons from

operating the system. If unauthorized persons were to operate the system, they
could cause severe damage.
6.5 Switching off / ending
6.5.1 Switching off
• Each aggregate is to be switched off on the control panel with the appropriate “OFF“-Function.
• Additionally, disconnect with the main switch to “OFF“. Always switch the system off when
carrying out repairs, during bank holidays, holidays etc.
6.5.2 Long interruption
• Disconnect with the main switch to “OFF“.
Additionally:
• Close the shut-off valve for water as well as cooling water and compressed air
• Set (release) the pressure reducing valve for the compressed air to 0
• Close the compressed air shut-off valve
6.6 Starting / switching on
To start the machine:
• Switch „ON“ the main switch at the switch gear

• Turn the emergency-switch to reset at the control panel
• Push the „starting button“ (green)

Operating Manual
Operation
6.7 Monitoring, checking
Checklist
Please use the checklist in chapter 7.
Whether an automatic process control/registration exists or not, we recommend that you check the
following operation parameters regularly and enter them on a check sheet. It is thus possible to
notice trends of incidental changes early and to carry out the necessary corrections in time.
Batch number / Charge number:

Date / Operator
Batch: recipe, quantity/weight, level

• Temperature in the vessel and of the operating mediums
• Operating pressure in the vessel and of the operating mediums
• Expulsion process: duration of time until the vacuum has been reached
• Mixer/scraper agitator: power consumption, speed
• Set up torque
Leakages of the mechanical seal, leakages in the pipelines and fittings, check additionnal devices
periodically such as the sealing liquid vessel and the pumps.
Refill of working stock (sealing liquid, gear oil, etc.).
Temperature and noises/loud noise/vibrations on the bearing of the aggregates and the pumps.
Specific events.
6.8 Trouble shooting

Information about the proceeding and the elimination of troubles finds themselves on the following
pages.
Notes on the alarms at automatized machines find themselves in the appendix of the operating
manual of the control panel.

Operating Manual
Operation
6.8.1 Possible troubles
Declarations to the table:

Column 1 „SOURCES OF ERRORS“ grouped in terms of kind of the failure,- or the causal
component.
Column 3 „MEASURES“ Procedure for elimination of the failure.
Column 4 „FIND IN“ specifies in which register of the file information to the problem
solution may be found. The digits refer to place of finding in the operating manual
(OM). e.g. 5.3.1) in chapter 5 of OM.
Column 5 „REPLACE-CODE“(1) = disassembly:
The part, may only be dismantled and/or installed from persons those
qualification isaccordingly to information.
O= Operator
S= specialist/occupational training. (e.g., electrician, mechanic, measurement and
control engineering) F/M= specialist from FrymaKoruma or from the manufacturer
of the part
Column 6 „REPAIR-CODE“(2) = repair
The part may only be repaired by persons, from whose qualification is accordingl
to above. The codes correspond to column 5.
Warning:
The performance of works through persons not authorized can lead to the loss
of assurance claims. The product liability of the manufacturer is not valid, if as a
result, danger of persons, of the environment or of the product occurs.

Operating Manual
Operation
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
Help: Electrical. docu-

Chap. 5
1. Electrical mentation and scheme
OM
in the switch cabinet.
a) One phase has no current/ 5.3.1
- check terminal S S
power 5.3.3
- Replace
b) Blown fuse, breakdown of - activate protective
the protective device due to device. 5.3.3 S S
overload or wrong setting. - check settings of protec-
tive device
1.1 Motor: does not start/or
hums. c)If equipped with frequency Check settings accord.
Manual F/M M
converter. supplier manual.
Repair/replace motor. Find

d) Defective motor S M
cause.
e) Defective bearing of motor

Replace S M
may block
Direction of rotation of
a) Mains connection or connec- motors (Perhaps reverse
1.2 Wrong sense of rotation. 5.3.3 S -
tion of motor reversed. two of the phases in the
switch cabinet).
a) If equipped with frequency Check settings accord.

Manual F/M M
converter. supplier manual.
b) Defective ball bearing of

1.3 Idle motor runs uneven. Replace all ball bearings. S S
motor.
c) Fan of motor may be dama-

Replace S -
ged

Operating Manual
Operation
REPLACE- REPAIR-
CODE (1) CODE (2)
2. Lifting mechanic Help: from supplier

a) Pressure or vacuum in the Ventilate vessel with the
4.3.3.1 O
vessel aeration valve
2.1 Lid does not move up
Check: Locking must be
b) Lid lock „closed“? O
open?
- Push id completely open,

2.2 Lid does not sink or lift
than pull down.
Or: extremely high strengh a) Lid holding (latch) is locked 8.4.1.3 S M
- Check the latch
needed for opening or closing.
mechanism
REPLACE- REPAIR-
CODE (1) CODE (2)
Take reading of vacuum 15

3. Vacuum too small Leakage of component 7.4.3.1 O
minutes after running idle
a) Shut-off valve in the

3.1 Increase of pressure in the
vacuum line contaminated or Clean, replace valve if need S
vessel if the pump is idle/off
defective
a) Lid seal contaminated or

Clean or replace the lid seal 7.4.4.4 O
defective
b) Aeration valve in the
vacuum line will not close Replace valve S
properly/leaks
3.2 Leakage on the vessel or in c) Check inspection window
piping to the pump? Replace leaky O rings S S
for tightness
d) All valves on the vessel Check for tightness / revise

S
and piping defective valves
Check for tightness / repla-

e) All screw joints S
ce defective seal
a) Mechanical seal or sliding

3.3 Leakage on the housing ring, O-rings defective or Replace defective parts 8.4.4 F/M M
or drive of the homogenizer or worn-out
scraper-stirrer
b) O-Rings defective or
Replace defective O-Rings
worn-out

Operating Manual
Operation
REPLACE- REPAIR-
CODE (1) CODE (2)
4. Vacuum pump Help: from supplier Manual
a) Defect on motor, Error location in accordance with 5.3.1

S M
protective device or control electro diagram 5.3.3
- Turn cautiously on the pump

4.1 Vacuum pump does b) Blocking due to standstill
clutch with a tongs O S
not start or deposits
- Clean vacuum pump
- Replace clutch, (backflow of the

c) Clutch defectively S M
ring liquid may cause defect)
a) Aeration valve in the
- Revise or replace aeration valve S S
vacuum line defective
b) Leak in the vacuum - Repair for leakage (due of frost
pump due of defective seal the liquid in the vacuum pump S F/M
or crack in the housing/lid may disrupt the pump housing/lid
c) Cavitation on the wheel,

- Blind off the pump, measure
housing, control disk, wrong
vacuum. If set points are not S/F F/M
gap or leaky
achieved, revise vacuum pump
4.2 Insufficient sucking mechanical seal
capacity of vacuum
d) too high product - Lower product temperature
temperature result in a lot (Mount additional steam O
of steam condenser)
e) warm ring liquid (in - Rise flow of ring liquid (if need,
S F
particular in the summer) install pre-cooler for ring liquid)
f) adjusted amount of ring-
- Adjust ring liquid settings
liquid too little/ or grating S
too largely
4.3 Pump is noisy strongly Rattling noise of cavitation - Change operational parameter S

Operating Manual
Operation
REPLACE- REPAIR-
CODE (1) CODE (2)
5. Scraper-stirrer / Homogenizer
- Close vessel
5.1 process will not start - Check final switch lifting
«vessel open» 4.2.2 O/F S
„error report“ device and adjust if ne-
cessary
- Close homogenizer
5.2 process will not start - Check safety switch,
«Homogenizer open» 4.2.2 O/F S
„error report“ homogenizer and adjust if
necessary
6. Scraper stirrer
Scraper blades worn out Adjust or replace scraper

7.4.4.1 O
or wrong position blades
6.1 Scraper unable to strip uniformly
Stirrer arm touches the vessel wall
Scraper arm or shaft bent
Revise scraper-stirrer 8.4.1.1 F F
due to overload
- replace ball bearing

6.2 Operating of the scraper-stirrer, a) Bearing collapsed
- check and replace if 8.4.1.1 F F
knocking sounds on the cross bracing b) Loose bolts
necessary
7. Homogenizer
a) Shaft of homogenizer
Aligning required 8.4.1.2 O/F F
bent
Dismantle homogeni-
b) Processing tool dama- zer and check tools for
7.1 Strong vibrations when running 8.4.1.2 O/F F
ged by foreign matter damage
Replace if need
c) worn out bearing replace bearing 8.4.1.2 S S

Operating Manual
Operation
REPLACE- REPAIR-
CODE (1) CODE (2)
Help: P+I diagram Chapt. 5

8. Heating/cooling system
Manual from supplier OM
a) Water filter plugged Clean filter S
b) Cooling water pressure
Check pressure relief valve S
too low
c) Solenoid valves contami-

Clean or replace S
nated
8.1 Deterioration of the cooling or d) Coil of solenoid valves

Replace S
heating time defect
e) Time relay defect Replace S
f) Machine calcifies, only with

Decalcify S
instantaneous water heater
g) Circulating pump is defect Replace S
9. Product quality
Air valves at homogeni-

zer and hoppers closed?
9.1 Air conclusions in the product a) Leaks on parts below ->close
O
in spite of correct vacuum product level Adjusting unit not tight
Eliminate leaks, replace
O-rings and seals
a) Homogenizing time too

Increase time O
short
9.2 Product not enough homoge-

b) Grinding gap to large O/S
neous
c) Rotation speed homogeni-

Increase rotation speed O
zer too small
a) valve in the vacuum line Clean or replace valve

S S
contaminated or defect
b) Aeration valve in the vacu-

9.3 When stopping the machine, um line in a contaminated or Clean or replace valve S S
water is dropping on the surface of defect state
the product
c) Solenoid valve for the water
Clean or replace solenoid
supply for the vacuum pump S S
valve
contaminated or defect.

Operating Manual
Maintenance
7 Maintenance
Aim: To preserve the nominal status and the operational integrity of the machine. Increasing
degree of use by avoiding unforeseen downtime. Efficient planning of the service work and of the
service material.
TABLE OF CONTENTS
7 MAINTENANCE�� 1
7.1.1 Safety regulations�� 2
7.1.2 Requirements on the personnel�� 2
7.2 Plan of maintenance�� 3
7.3 Supplies and accessories�� 5
7.3.1 Sealing liquid, lubricant, detergent�� 5
7.3.2 Measuring and checking aids�� 5
7.4 Service operations �� 6
7.4.1 Safety inspection�� 6
7.4.2 Care and cleaning work �� 6
7.4.2.1 Cleaning the area where the machine is located �� 6
7.4.2.2 Cleaning the vessel�� 7
7.4.2.3 Cleaning the outside of the machine�� 7
7.4.3 Pressure-limiting unit (valve) on the container‘s lid �� 7
7.4.3.1 The work of inspection, control and alignment �� 7
7.4.3.2 Parts of the pressure-relief valve �� 8
7.4.3.3 Dismantling for the cleaning�� 9
7.4.3.4 Assembly after the cleaning�� 10
7.4.4 Inspection, check up and adjustment works�� 11
7.4.4.1 Tightness of the machine�� 11
7.4.4.2 Tightness of the operating media�� 12
7.4.4.3 Vessel control�� 12
7.4.5 Checking and replacing submodules �� 13
7.4.5.1 Replacing the scraper blades�� 13
7.4.5.2 Rechecking the fixing screws�� 16
7.4.5.3 Tank cleaning head with split pin �� 16
7.4.5.4 Dismantling the homogenizer�� 17
7.4.6 Control/process �� 19
7.4.7 Mounting instructions for screw connection �� 20
Appendix:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating schedule

Operating Manual
Maintenance
7.1 Introduction
Service and maintenance works of the machine are to be carried out in accordance with the
maintenance plan.
7.1.1 Safety regulations

The general safety instructions in chapter 2 also apply to service and maintenance.
Further safety instructions can be found for specific applications.
Supporting equipment mentioned in this chapter must be used according to instruction.
7.1.2 Requirements on the personnel

This section is intended for the persons responsible for the service or the safety of the machine.
For the maintenance of the system, the service staff must be competent and sufficiently qualified.
Specialist staff, engineers or professional people must be engaged, where required.
FrymaKoruma service staff is to be engaged, where demanded.
Note: During the initial training, operators are also introduced to maintenance and servicing of the machine.

Operating Manual
Maintenance
7.2 Plan of maintenance
Structure and divisions of the maintenance plan:

Maintenance operations contain the periodic maintenance of the machine:
Column 1, contains the service work/components.
Column 2, indicates in key words, the work to be carried out. The number designates where to find
information to the topic in the operating manual.
Columns 3-9, Schedule for servicing- and maintenance.

„Job“ = work to be carried out after every batch.
„Day“ = work to be carried out daily.
„Week“ = work to be carried out weekly.
„Month“-“ = work to be carried out in intervals of x-months.
„x-Years/hours“ = work to be carried out in intervals of x- years/hours.
Columns 10 or 11, Competency for performing service works

Column10: Works to be carried out from client staff/operator.
Column11: Works to be carried out from Specialist-, or FrymaKoruma service staff.
Consequences of Omissions and Insufficient Service

Optimal results can only be obtained with a machine that receives good service maintenance.
Good service practice means; service is carried out in described manner and scheduled time.
Deficient service can also result in production breakdown of the Process. Insufficient service can
also lead to accidents for which the operator can be made liable.

Operating Manual
Maintenance
- 3000 to 5000 hours /
(Service Engineer)
Service specialist
Maintenance / Service MaxxD/DinexH
max. 2 Years
- 3 Months
- 6 Months
- Day/Job
Operator
- Month
- 1 Year
- Week
Cleaning
Machine outside 7.4.2.1 x x
Vessel 7.4.2.2 x x
Homogenizer x x
Filter water supply x x
Checks
Safety devices 7.4.1 Functions x x
Vessel / aggregates 7.4.4.2 Check of screws x x

x x
7.4.4.3 Wear of processing
Homogenizer
tools and motor bearings
x x
Scraper 7.4.4.1 Wear x x x
5.4.1.4 Adjusting of ring

Vacuum pump x x
liquid / pressure x x
7.4.4.1 Machine tightness x

x x
7.4.4.2 Operating media
Tightness of system x x
7.4.4.2 Mechanical seal
x x
7.4.3 Pressure-relief valve x
Bearing wear x
Product pump x x
Mechanical seal x
Water filter Pressure loss x x
Vacuum trap Drain of liquid x

x
(Option) Tightness / Gaskets x
Lid opening system Check function x x x
Tank cleaning head Replacing split pin x
Observe intervals in lubrication plan

and manuals for external parts
(Manual file 2)
Lid hing Lubrication x x
Motors Gear oil change x x

Operating Manual
Maintenance
7.3 Supplies and accessories
7.3.1 Sealing liquid, lubricant, detergent
• Lubricants used by FrymaKoruma are listed in the lubricating schedule (see appendix).
• Lubricants employed by suppliers find themselves in the supplier’s documentation.
Sealing liquid (double acting mechanical seal)

The sealing liquid must be compatible with the product and free from solid matters. It shall not be
likely to forming deposits, shall have a boiling point as high as possible and show a good thermal
conductivity as well as a low viscosity. Good results will be shown with a viscosity ranging from 0,8
to a maximum of 40 cSt (mm2/s). Set hydro-static backflow press. to 1,5-2 bar. The boiling point
should be as high as possible. A difference temperature of a minimum of 60 - 80°C to the boiling
point of the medium to be sealed is to be striven for.
The flow is to be adjusted such, a maximum outlet temperature of 80°C do not exceed (i.e. water
and similar products). With solvents or alcohol a maximal difference temperature of 60°C will
be allowed. When selecting a forced sealing liquid, make sure the liquid is compatible with the
materials of the mechanical seal.
It is not allowed to use inflammable sealing media!
7.3.2 Measuring and checking aids

In the case of specific problems, please apply to FrymaKoruma customer service.

Operating Manual
Maintenance
7.4 Service operations
7.4.1 Safety inspection
Check that the safety devices are working properly
• Emergency safety switch (4.3.1)

• Is the mechanical interlock that inhibits opening the cover in good working order?
• Switch cabinets must be closed
• Function of the signal lamp and the signal sounder if any (4.2.1)
• Are all covers fully functional (protective covers/hoods)? The machine may be operated in proper
functional conditions only.
• Safety valves and pressure relief devices
• Before carrying out any maintenance work, the pneumatic air pressure must be set to 0 bar. To
this end, adjust the pressure controller on the air service unit.
ATTENTION: The filter at the air service unit is still under pressure!
Don‘t forget: Make sure the air pressure is reset to 6 bar prior to operation.
Electrical connections
Visual inspection to check if the insulation has been damaged:
Warning!
Damaged electrical conductors, plugs and devices must be repaired by an

electrician.
7.4.2 Care and cleaning work
7.4.2.1 Cleaning the area where the machine is located
Warning!
Never use liquids when cleaning electrical components.

All electrical devices must be disconnected during cleaning!
Care must be taken when cleaning. Damaged parts must be replaced.

Operating Manual
Maintenance
7.4.2.2 Cleaning the vessel
General cleaning and sterilizing

If batches are made from the same recipe, only the working vessel needs to be scraped out
manually between batches. If a different batch (different recipe) is made, however, the vessel must
be cleaned using one of the procedures described in 6.2.3.
Sterilizing the unit with hot steam is only possible for machines that are pressure-proof. For this,
the lid and the vessel must be safely locked using the clamp screws.
”CIP” cleaning
Please refer to chapter 6.2.3.
7.4.2.3 Cleaning the outside of the machine

When cleaning the outside of the machine, make sure that the control panel does not come into
direct contact with the cleaning liquid; cover it up if possible.
The control panel can be cleaned separately afterwards with a cleaning cloth. The cleaning agent
used must have a neutral pH-value (6–8), must be free from aroma and above all must not contain
any solvents such as ethanol.
7.4.3 Pressure-limiting unit (valve) on the container‘s lid

The pressure-limiting unit on the processing plant‘s container ensures that the pressure in the
container‘s interior cannot rise above the intended pressure for which the container was designed
and constructed. Various types of pressure-limiting systems are utilized for this purpose, according
to the requirements.
Safety valves or bursting discs are used for containers in the overpressure range. Please take the
information for maintaining these components from the sub-supplier‘s documents.
The pressure-relief valve is used for pure vacuum processing plants and it permits a maximum
overpressure of 0.5 bars, which triggers the pressure-relief valve. This valve ensures that no
overpressure can build up in the container while the plant is operating.
7.4.3.1 The work of inspection, control and alignment

The pressure-relief valve is used for pure vacuum-processing plants in the underpressure range
and it permits a maximum overpressure of 0.5 bars, which triggers the pressure-relief valve. This
valve ensures that no overpressure can build up in the container while the plant is operating.
Fryma Koruma recommends checking the pressure relief valve during the weekly maintenance in
multi-shift operation, to ensure that it is in working order and clean.

Operating Manual
Maintenance
CAUTION !
The working order cannot be ensured any longer whenever there is bad
maintenance!
7.4.3.2 Parts of the pressure-relief valve

1. Up TC clamp
2. Seal
3. Blind lid
4. Guiding pin
5. Casing
6. Cone
7. O-rings
8. Seal
9. TC clamp on the side

of the container›s lid

Operating Manual
Maintenance
7.4.3.3 Dismantling for the cleaning

1) The pressure relief valve is removed first of all by loosening it and removing the TC clamp (9)
from the container's lid for the cleaning.
2) The TC clamp above (1) is loosened and turned. The

lid and casing must be held together while doing so in
such a way that they do not move or open in relation
to each other. Figure 7-1.
Figure 7-1. Holding the valve together
3) The valve is turned by 180° so that the TC blind lid (3)

with the seal faces downwards and the TC supports
face upwards. Figure 7-2.
Figure 7-2. Rotating the valve

Operating Manual
Maintenance
4) Now the casing (5) is slowly raised from the TC blind lid (3).
Care must be taken while doing so that the cone (6) sits on
the guiding pins (4) and that it is not tilted in the casing (5).
Figure 7-3.
5) The valve casing and all of the inner parts can now be
cleaned.
Figure 7-3. Extension of the internal parts from the valve housing
7.4.3.4 Assembly after the cleaning

The pressure-relief valve is assembled in the reverse order.
CAUTION !
It is important that the cone does not fall into the casing. The sealing surface can
be damaged otherwise. The working order is not ensured any longer as a result.
It must be checked that the cone (6) runs smoothly after assembling all of the inner parts and the
TC clamp (1).
The complete pressure-relief valve is now remounted on the container's lid and it is screwed tightly
to the TC clamp (9) and the seal (8).

Operating Manual
Maintenance
7.4.4 Inspection, check up and adjustment works

Purpose: To ensure that the unit is free of leaks and ready for operation
7.4.4.1 Tightness of the machine
• Evacuate the vessel to approx. 100 mbar absolute and switch off the vacuum pump.
• If the machine is tight, there should be no noticeable pressure increase after fifteen minutes.
Important: The vessel should only contain cold liquid during this test.
• Leakages can be located using foaming agents.
To guarantee the operational safety of the machine, it must be subjected to a

vacuum test every week.

Operating Manual
Maintenance
7.4.4.2 Tightness of the operating media

(Cold and warm water, steam, sealing liquid, hydraulics, pneumatics)
No leakage will be allowed, for each active circuit. Check by switching „On“ the aggregates (supply
valves, vacuum pump, etc.) and systematically supervise every media.
• Check all flanges and screw connections and tighten them.
• Replace defective seals and screws.
• Check the condition of the flexible hoses. Replace hoses that are defective or with damaged
surface (cracks, brittleness).
Measuring the amount leaked by the mechanical seals (only if equipped)

Every mechanical seal (MS) secretes a small amount of sealing liquid at the contact area of the
mechanical seal surface. The leakage by a MS depends on the type of operation, the product and
the actual manufacturing process.
As a double MS is made up of an internal MS (in contact with the product) and an external MS (in
contact with the atmosphere), leakages can occur in both MS. The quantity of liquid that leaks is in
the region of several millilitres per hour. If a leakage occurs, the quantity increases.
The amounts of liquid leaked by the MS that is in contact with the product can only be
assessed through the liquid level of the forced sealing liquid vessel. For this purpose, a clear
sticker has been attached to the sight glass. It features a scale which allows a noticeable relative
change of the level to be ascertained.
Replacing seals
General recommendation:
Seals that have been in use for any longer period of time must be replaced when the sealing
connection is opened.
7.4.4.3 Vessel control
It is the user‘s responsibility:
• to have the stipulated and requisite controls carried out on the pressure vessels by a notified
body in accordance with the national pressure vessel regulations (e.g. PED, ASME, etc.)!
• if the temperature regulator is equipped with a separate safety valve, this valve is subject to
testing, too.

Operating Manual
Maintenance
7.4.5 Checking and replacing submodules
7.4.5.1 Replacing the scraper blades

Consult the „scraper agitator“ drawing in the documentation.
- Scraper blades with wire bending tool
Removal
• Bend the locking wire (2) with the special tool (1)
• Bend the spring out off the guide
• Move the sidewards off its bearing
1 2
Fig. 7-1 Wire bending tool Fig. 7-2 Locking wire
Installation
CAUTION !
Fit the scraper blade into both bearings and let the spring snap in. Bend back the
locking wire (2) into locking position.

Operating Manual
Maintenance
- Scraper blades without wire bending tool
Removal
• Push the scraper blade upwards to the

mechanical stop.
Fig. 7-3 Scraper blade
• Now pull the scraper blade out sideways.
Fig. 7-4 Scraper blade Installation
Installation
• Insert the scraper blade from the side.
CAUTION!
Pay attention to the position of the spring when installing the scraper blade! See
Figure 7-1. When installed, the spring must push the scraper blade firmly against
the bin wall.

Operating Manual
Maintenance
- Scraper blades Lab
Removal
• Push the scraper blade out of the holders to the side.
Installation
• Pretension the spring. Allow the scraper blade to click into

place.
Fig. 7-5 Scraper blades Lab

Operating Manual
Maintenance
7.4.5.2 Rechecking the fixing screws

Fixing screws can become loose during transport and in the case of vibrations during operation.
All fixing screws must be checked and tightened for start-up and on a
monthly basis thereafter.
This concerns mainly the fixation screws of the

• working vessel
• homogenizer
• drives (motors, gears)
7.4.5.3 Tank cleaning head with split pin

Safety notice for machines from 200 l -
The split pin
When servicing, install a splint bracket according to mounting instructions and

check its tight fit constantly
Dismounted splint bracket must be replaced with a FrymaKoruma’s original part.
Otherwise, a tank washing head together with the splint bracket may fall into the
working area resulting in serious damage.
Note:
Bend clip end 30°!
Attention / Achtung !
for single use only / nur für einmal Gebrauch !
Installation instruction / Installationsvorschrift:
bend clip end 30° !
Splintende 30°umbiegen !

Operating Manual
Maintenance
7.4.5.4 Dismantling the homogenizer
Inspecting, replacing or exchanging processing tools
Competence: The processing tools may only be replaced by experienced persons

or by persons who have received instruction from FrymaKoruma.
Personnel shall be regularly trained in occupational safety.
The workers must acknowledge safe and prudent working procedures.
Please refer to the drawing supplied with the machine.
1) The vessel, hopper, all feed pipes and the homogenizer must be evacuated and cleaned!
Access to the rotor is available via corresponding orifices after dismounting pipelines at
material inlet/outlet. The discharge valve on the homogenizer is open.
2) All power and media lines to the homogenizer (steam, hot water, compressed air, etc.) must
be shut off at the main supply.
Main switch to “Off“ and

locked against being switched on.
3) Remove hopper, supply lines,

temperature probe.
4) Release and remove clip between

vessel and homogenizer.
5+6) Unscrew cap nuts and remove

mixing chamber
(safety switch disengages).
7) Remove shaft nut from rotor

(Attention! Left-hand thread).
Fig. 7-6 Dismantling homogenizer
8) All the parts of the homogenizer can then

be removed.
The mechanical seal may not be removed.
Fig. 7-7 Cut Disho grinding set

Operating Manual
Maintenance
Checks:
For wear and damage to the processing tools.
That rotor shaft runs true, without runout or bearing play.
Replace parts depending on wear.
Reassembly:
Replace O-rings and seals that have been removed with new ones.
Please refer to the table in the lubrication plan for lubricants that are to be used.
Activate safety switch!
Alternative: Delmix-grinding set
Installation of the ejector in order to obtain

the correct pumping effect.
Fig. 7-8 Ejector
Activate security switch!

If dismantling / partial disassembly is required for maintenance, the machine may not be put into
operation until proper condition has been restored and all pipelines have been installed.

Operating Manual
Maintenance
7.4.6 Control/process
The following means are available to solve hardware or software problems:
• The Operating instructions for the control in the appendix of chapter 6 features information on
how to proceed in the event of alarm signals and lists the system’s error messages.
• Additional descriptions of alarms can be found in the supplier’s documentation, e.g. for
frequency converters or other electronic equipment. These documentations are included with
these operating instructions.
• Please refer to 6.8 “Troubleshooting” for more information on how to clear faults.
• Both the switch cabinet of the unit and chapter 5 include the P+I diagram and the
electrotechnical documentation.
• If you cannot solve the problem with these means, please contact the FrymaKoruma customer
services.

Operating Manual
Maintenance
7.4.7 Mounting instructions for screw connection

1. AREA OF APPLICATION
Valid for screw connections of FrymaKoruma units.
2. SCREW FITTING CONDITIONS
2.1 Tightening procedure: tighten in accordance with the torque.

2.2 Screwing device, screwing class
Tighten the screw connection in accordance with tightening torque MA:
Screwing device of screwing class B in accordance with DIN 25202.
2.3 Lubricants for screw connections
The products listed are recommendations.
Lubricant Supplier Application
Klüber Lubrication AG (Schweiz)

Thurgauerstrasse 39
UH 84-201 H1 Product area or adjacent components
CH-8050 Zürich
Tel.: 01/302 79 79 / Fax: 01/302 57 45

Thurgauerstrasse 39 Components which are not in direct contact
NBU 8 EP H2
CH-8050 Zürich with products
Tel.: 01/302 79 79 / Fax: 01302 57 45

NBU 30 PTM Thurgauerstrasse 39 Components which are not in direct contact
Staburags CH-8050 Zürich with products
Tel.: 01/302 79 79 / Fax: 01302 57 45
AGIP (Suisse) AG
Verkaufsbüro Zürich
Components which are not in direct contact
AUTOL TOP 2000 Flüelastrasse 54
with products
CH-8047 Zürich
Tel.: 01/491 08 66 / Fax: 01/493 52 29
2.4 Surface treatment, surface condition

Surfaces A, B, C, D of screw connections under high stress (in acc. with the prescribed tightening torque) must be
plain or primed without body colour.
A C A
C
B
B
D
3. CONNECTIONS IN ACCORDANCE WITH PRESCRIBED THIGHTENING TORQUE

Always use a screwing device of screwing class B in acc. with DIN 25202 to tighten a screw connection with the
prescribed tightening torque. Tightening procedure in acc. with section 2.1.
3.1 Entry in the drawing Example: for M12 – A4-70 screw

MA = Nm MA = 50 Nm

Operating Manual
Maintenance
4. SECURING SCREW CONNECTIONS USING LIQUID GLUES

Guide values:
The tightening torque indicated in the drawing is generally based on a friction factor mtotal of 0.1
(variation range mtotal = 0.1 - 0.12).
If a lubricant other than those listed in the table in 2.3 is used, the variation range of the friction factor mtotal must be
calculated. Lubricants and friction factors beyond the variation range mtotal = 0.09 - 0.14 should not be used without
prior consideration.
5. GUIDE VALUES - TIGHTENING TORQUES: SCREWING CLASS B (TORQUE WRENCH)
6. EXCEPTIONS TO THE VALIDITY OF THE GUIDE VALUES MENTIONED ABOVE:
a) All screw connections with special boundary conditions and under high stress:
- Friction factors mtotal
- Special securing measures (e.g. liquid glues...)
- Different screwing classes and mounting tools
- High / low operating and mounting temperatures
b) Anti-fatigue bolts, flange bolts with ribs...
c) Materials with reduced admissible surface pressure
(e.g. plastics...)
d) Property class for screw and nut different from the one indicated
Tightening torques FM initial tension force for mounting

Screw 8.8 A2-70 A2-50 8.8 A2-70 A2-50
M = metric [Nm] [Nm] [Nm] [N] [N] [N]
Yield point 640 N/mm 2
450 N/mm 2
210 N/mm 2
640 N/mm 2
450 N/mm 2
210 N/mm2
M 4 2,5 1,8 0,85 4200 3080 1385
M 5 5 3.6 1,65 6900 5070 2250
M 6 8 6 2,8 9700 6930 3200
M 8 21 15 6,7 17900 13000 5800
M 10 40 28 13,2 28500 19800 9300
M 12 70 50 23 41500 29500 13600
M 16 170 120 56 78000 55000 25500
M 18 245 165 77 98000 66000 30900
M 20 340 235 108 126000 85680 39600
M 24 590 182000
M 30 1170 290000
Tightening torques FM initial tension force for mounting
Screw 8.8 A2-70 A2-50 8.8 A2-70 A2-50
F = fine tread [Nm] [Nm] [Nm] [N] [N] [N]
F 8x1 21,6 15 6,8 19600 13500 6200
F 10 x 1,25 42 29 13,8 30500 21200 10000
F 12 x 1,25 75 52 24 46500 32200 14900
F 16 x 1,5 180 123 57 85000 58000 27000
F 18 x 1,5 270 177 84 114000 75000 35700
F 20 x 1,5 380 250 117 144000 96000 45000
F 24 x 2 635 - - 203000 - -
F 30 x 2 1290 - - 332000 - -

Operating Manual
Repairs
8 Repairs
Aim: Re-establishing the initial status. Recognising and evaluation of the malfunction.
Troubleshooting sequence.
TABLE OF CONTENTS
8 REPAIRS�� 1
8.1.1 Safety regulations�� 2
8.1.2 Requirements on the personnel�� 3
8.1.3 Maintenance concept�� 3
8.2 General information �� 3
8.2.1 Special tools, measuring and inspection sets�� 3
8.2.2 Spares, accessories and repair sets�� 3
8.3 Troubleshooting and eliminating�� 3
8.3.1 Structure according to the functional sequences �� 3
8.4 Repairs�� 4
8.4.1 Dismantling and control of wear and tear of the various aggregates�� 6
8.4.1.1 Scraper agitator system �� 6
8.4.1.2 Homogenizer�� 7
8.4.1.3 Lifting device (Lab to 700 l)�� 8
8.4.1.4 Dismantling the vessel or the lid�� 11
8.4.2 Discharge and conveying pumps, sealing liquid system�� 11
8.4.3 Vacuum pump�� 11
8.4.4 Fittings, control equipment�� 11
8.4.5 FrymaKoruma customer service�� 11
8.5 Wiring diagrams / electric schematics�� 12

Operating Manual
Repairs
8.1 Introduction
8.1.1 Safety regulations

The general directions on safety in Chapter 2 also apply to maintenance works.
Further directions on safety are found in the Operating Manual.
The aids stated in this chapter must be used according to the instructions.
Warning!
When working inside the vessel, secure the lid additionally.
Note: This may be done i.e. by jamming a timber between the lid and vessel.
Before working in the vessel always carry out:
• Open the lid completely.

• Switch main power ”OFF” and lock it with your personal lock.
• Only enter the vessel, when it is free of materials injurious to health or dangerous.
WARNING!
Before executing works at the homogenizer always carry out:
• Discharge product of the vessel and homogenizer.
• If need clean and rinse the equipment.
• After machine modification (e.g., repairs or replacement of parts), check and
ensure that electrical bonding is fully provided.
The main switch is to be locked against unintentional switching on with your

personal lock.

Operating Manual
Repairs
8.1.2 Requirements on the personnel

This part applies to the persons responsible for the maintenance or the safety of the machine.
Maintenance and repair work is to be carried out only by skilled workers and qualified specialists.
Only qualified employees appropriately trained, sufficiently experienced in the relevant area and
working cautiously and prudently are authorized to maintain hazardous components (pressurized
sub-assemblies, electrical systems, acids and alkalis).
For maintenance’s designated to FrymaKoruma-Service staff or for tasks where the third-party
manufacturer demands special training, only authorised persons are to be engaged.
8.1.3 Maintenance concept

The service and maintenance schedule in chapter 7.2 applies to the planned maintenance works.
8.2 General information
8.2.1 Special tools, measuring and inspection sets

Tools and accessories delivered for this machine will be listed in Volume 2 of the operating manual.
8.2.2 Spares, accessories and repair sets

Repair parts ordered with the machine and accessories are listed in Volume 2.
8.3 Troubleshooting and eliminating
8.3.1 Structure according to the functional sequences

A table containing all alarms reported by the system and the measures to be taken is found in the
description of the process control.

Operating Manual
Repairs
8.4 Repairs
Overview of maintenance and repair works Lab
Control panel Fittings

8.4.5 8.4.4
Gear 8.4.1.1
Scraper agitator
Media piping 5.3.2
Lid 8.4.1.4
Shaft seals
Lid lifting device 8.4.1.3 Joints / Gaskets
Scraper agitator
8.4.1.1
Electrical switchgear Scraper blades

4.3.1 / 4.3.2 7.4.4.1
Vessel 8.4.1.4
Vacuum pump Homogeniser

5.4.1.4 / 8.4.3 8.4.1.2
Mechanical seal
Motor bearings
Valves, controller, Pneu-

matic 8.4.4
Fastening
of fixation
screws 7.4.4.2
Fig. 8-1 Lab

Operating Manual
Repairs
Overview of maintenance and repair works 200 - 3500 l
Fittings Gear
8.4.4 Scraper agitator 8.4.1.1
Lid 8.4.1.4
Lid lifting
device 8.4.1.3
Shaft seals
Joints / Gaskets
Scraper agitator 8.4.1.1
Scraper blades
7.4.4.1
Control panel Vessel 8.4.1.4

8.4.5
Media piping 5.3.2
Electrical
switchgear
4.3.1 / 4.3.2
Homogenizer
8.4.1.2
Mechanical seal
Motor bearings
Fastening
of fixation
Vacuum pump screws 7.4.4.2
5.4.1.4 / 8.4.3
Valves, controller, Conveying pump 8.4.2

Pneumatic 8.4.4
Fig. 8-2 700 l

Operating Manual
Repairs
8.4.1 Dismantling and control of wear and tear of the various aggregates
8.4.1.1 Scraper agitator system

The parts of the scraper/mixing system which could wear out are the scraper blades. Should a
readjustment prove impossible, new scrapers must be mounted. If the scraper blades are worn out,
replace as described in 7.4.4.1.
Shaft seal
The shaft bush is equipped with two shaft lip seals. Any serious leaks can be recognised by the
vacuum in the working vessel dropping rapidly with the vacuum pump switched off. In this case,
exchange the shaft lip seals.
Dismantling of scraper agitator
Danger!
Due to the risk of injury, it is not advisable for customers to perform repairs on
scraper agitator.
This warning applies to the dismantling / replacement of:
• Lifting device
• Scraper agitator and it’s gear
• Shaft seals in the lid
If performing these works, please ask for support at the FrymaKoruma Customer service.

Operating Manual
Repairs
8.4.1.2 Homogenizer
The main part subject to wear and tear is once again the mechanical seal, the deficiency of which
is shown by the rapid sinking of the vacuum in the vessel.
Please refer to the actual drawing of your machine.
Dismantling/replacing of the homogenizer

This is described under 7.4.4.4.
Checks on the homogenizer:
• For wear on processing tools.

• That the rotor shaft runs true and without runout, axial play or bearing play.
• Replace parts depending on wear.
Replacing the mechanical seal
The mechanical seal can be replaced by experienced or specially trained

personnel.
• A new mechanical seal is to be mounted according the manufacturer.
Replacing the homogenizer bearing
In some cases, it may only be done by authorized personnel (i.e. Ex motors).
• To do so, dismount the homogenizer and remove the electric motor.

• Press the shaft out of the bearings.
• Both bearings must subsequently be exchanged.
Reassembly
• Use new O-rings and gaskets for all parts being disassembled.
• Use appropriate grease according the lubricating plan.

Operating Manual
Repairs
8.4.1.3 Lifting device (Lab to 700 l)

Work on the lifting device
Danger !
Due to the risk of accidents, it is highly unadvisable to perform work within the
lifting device (Safety component) !
You must not change or repair any parts of the lifting system.
Only authorised persons shall perform such work.
Please call for support from the FrymaKoruma customer service.
- Alternative push type gas spring (Lab)
• Do not dismantle this device ! Also mind the information given by the manufacturer.
Danger !
The push type gas spring is loaded when the lid is closed.
Do not loosen the supporting brackets !
When the pull gas spring is dismantled with the vessel

being open, the latter is not supported any more.
Fig. 8-3 Push type gas spring

Operating Manual
Repairs
- Alternative pull gas spring
• Do not dismantle this device ! Also mind the information given by the manufacturer.
Danger !
The pull gas spring is loaded when the lid is closed.
Do not loosen the supporting brackets !
When the pull gas spring is dismantled with the vessel

being open, the latter is not supported any more.
Fig. 8-4 Pull gas spring
- Alternative lifting column
• Please mind the information given by the manufacturer.
Works in the vessel may only be carried out with the safety
pin locked.
Fig. 8-5 Lifting column

Operating Manual
Repairs
- Alternative lid handle and counterbalanced hinge
• Please mind the information given by the manufacturer.
A handle and counterbalanced hinge are used to open and close the lid.
Fig. 8-6 Lid handle
Works in the vessel may only be carried out with the safety pin locked.
Fig. 8-7 Counterbalanced hinge

Operating Manual
Repairs
8.4.1.4 Dismantling the vessel or the lid
Danger
Due to the risk of accidents, it is highly unadvisable to remove the vessel or the
lid.
Please call for support from the FrymaKoruma customer service.
8.4.2 Discharge and conveying pumps, sealing liquid system

The information on products delivered from suppliers for the machine is to be found in the
documentation of the supplier.
8.4.3 Vacuum pump

A mechanical seal is fitted in the liquid ring vacuum pump for sealing purposes. If an excessive
amount of leakage is found, the mechanical seal has to be replaced. Please refer to the supplier‘s
manuals for details in file 2 of the Operating Manual.
8.4.4 Fittings, control equipment
Valves, controllers, sensors, pneumatics

As a rule, only complete components or modules can be replaced. Please refer to the supplier‘s
manuals for details.
8.4.5 FrymaKoruma customer service
The following components must only be replaced by personnel of the

FrymaKoruma customer service.
• Parts of the operating console, PC/control system and software

• Shaft seals, gear, scraper-arm of the scraper agitator
• Lifting device
• Vessel, lid
• Homogenizer / mechanical seal. FrymaKoruma instruction will be required.

Operating Manual
Repairs
8.5 Wiring diagrams / electric schematics

The switch cabinets contain the electric circuit diagrams of the machine. A copy can be found in
chapter 5 of this volume.

Operating Manual
Recycling
9 Recycling
If you have any questions regarding the disposal of FrymaKoruma components, please contact
FrymaKoruma Customer Service.
Telephone number of customer service:

Tel. +41(0)61 8364 222
E-Mail: helpline@frymakoruma.com
Created: 01.06.2017 09_EN Chapter 9 / Page 1 of 1

Operating Manual
Transport
10 Transport
Aim: Information on how to correctly transport the machine.
TABLE OF CONTENTS
10 TRANSPORT�� 1
10.1 Center of gravity of the machine without control cabinet �� 2
10.2 Lifting of the machine�� 3
10.3 Transport of the machine �� 4
10.3.1 Lifting by means of a crane Lab�� 4
10.3.2 Lifting by means of a crane 200 - 1800 l�� 5
10.4 Moving the machine�� 6
10.4.1 Moving Lab�� 6

Operating Manual
Transport
10.1 Center of gravity of the machine without control cabinet

The approximate gravity center of the machine is in the middle of the red cross on the drawing.
Figure 10-1 MaxxD 700 without control cabinet
Consider the center of gravity when lifting the machine. The procedure is described in Chapter
10.3.2., item 3.

Operating Manual
Transport
10.2 Lifting of the machine

1. The machine must be lifted using a crane with a minimum
carrying capacity according to the table below.
2. Please refer to the following table for more information on

the accessories available for lifting the machine.
3. Any further procedure after loading the unit must be in

accordance with 5.2.2 of the operating instructions.
Transport and lifting devices table
1 2 3 4 5 6
Dimensions Weight Dimensional
Type LxWxH (mm)(approx.) (kg) (approx.) Lifting Bar Eye Bolts Drawing
1 This information is valid for the standard version

2 Without scope for packaging and without switch cabinet
3 Machine but without packaging and without switch cabinet
4 „yes“ = device which must be used for transportation by crane
5 Number of mountings for fastening ropes/cables to the machine
6 The dimensional drawing can be found in the annex of chapter 1

Operating Manual
Transport
10.3 Transport of the machine

The machine is delivered on a transport base with fixing hooks. This base stays on the machine
until it reaches its destination. Then the machine can be lifted by a crane (alternatively fork lift) and
the transport base removed. The gravity center of the machine is to be taken into consideration.
The machine shall be handled by experienced staff only using relevant tools.
10.3.1 Lifting by means of a crane Lab
Fig. 10-1 Lab
1. Block lid of vessel with bolts.
2. Entwine a hoisting strap around the point,

where the vessel is attached (see picture)
3. Entwine a hoisting strap around the machine.
4. Lift the machine for some centimetres and

check whether it is balanced in the centre of
gravity.
5. If need, adjust the straps until the machine is

balanced horizontally. Fig. 10-2 Lab

Operating Manual
Transport
10.3.2 Lifting by means of a crane 200 - 1800 l
Fig. 10-3 400 l Fig. 10-4 400 l
1. Block lid of vessel with bolts.
2. Attach hoisting straps according figure.

200 to -700 l figure 10-3 and 10-4.
1300 to -1800 l figure 10-5.
Do not fasten ropes a.s.o. to the vessel for
lifting the machine. Vessel is not screwed to
the base frame!
3. Lift the machine for some centimeters and check

whether it is balanced in the centre of gravity.
4. If need, adjust the straps until the machine is

balanced horizontally.
Fig. 10-5 1300 l

Operating Manual
Transport
10.4 Moving the machine
10.4.1 Moving Lab

Make sure the housing is closed before moving the machine.
Danger!
The machine can tip over!
The hinged control cabinet must be

swung open to permit access to the
housing.
Opening only by qualified personnel and

only for maintenance purposes.
Fig. 10-6 Lab

Parts Lists 1
Drawings 2
•
TABLE OF CONTENTS • PART 2
Vacuum System
Operating Instructions 3
Sealing Liquid Unit, Mechanical Seal

CIP-Cleaning, Conveying Pump

Instrumentation
Fittings 6
Pneumatic, Compressed Air
Heating-/Cooling Units
Vessel and Piping 7
Blending Vessel and Mixer
•
Drives and Gears

Components in the Switchgear

Certificates 10
Spare parts
□ Inquiry No.
□ Order No..
Customer Invoice
Address:
VAT no.
Delivery
Address:
Your reference
Phone no.
Machine
Typ of machine Serial No. Year of construction
Specification of spare parts

Part no. Quant. Drawing/Pos. No. Description
FrymaKoruma AG, CH-4310 Rheinfelden

Fax: +41 61 836 41 69

Manual Master MaxxD EN

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Customer Service and ProTec

Product transfer 1 2 3 Training

Optimisation of existing Calibration service

Our aim: to support your innovation efforts! Bespoke production

FrymaKoruma AG FrymaKoruma GmbH info@frymakoruma.com

Benefits for you:

Specification of spare parts

FrymaKoruma AG, CH-4310 Rheinfelden

Structure and Functions

Operating Modes and Controls

1 Description of the Machine

Annexe 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data sheets

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 1 of 9

1.1 Machine layout

Fig. 1-1 Cross-sectional view

Short description of the system

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 2 of 9

• Vessel with or without double jacket for heating or cooling.

1.1.1 Designated use

The contractual agreements are valid as designated use.

• It is designed for use in manufacturing emulsions, dispersions or suspensions. To do this, the

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 3 of 9

to use substances that are flammable or explosive, or that could create a

to use substances which could release harmful or toxic substances during

Warning against incorrect and misuse!

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 4 of 9

• Permissible level in vessel being exceeded.

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 5 of 9

1.1.3 Safety measures

• Safety data sheets are necessary for all used substances.

1.1.4 Conformity in relation to safety

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 6 of 9

1.2 Technical Data

1.2.1 Performance characteristics

1.2.2 Power supply and infrastructure requirements

Infrastructure / Operating media

Hot- and cooling water, steam

Quality of water: To maintain a good working of the machine we recommend the

Keep the pH-value of the water neutral, i.e., between 7.5-8.

Water must be free from contamination and solid matters.

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 7 of 9

Compressed air (Option)

Compressed air for control (optional)

Lubricating oil and grease

Information’s to components originating by suppliers (gears, motors a.s.o.) are

Created: 06.06.2014 MaxxD_01_EN Chapter 1 / Page 8 of 9

Materials being a danger to health

- Gases / danger of suffocation -

Protection against water and touching All equipment Motors IP 54

- Control and electric circuits

Ambient temperatures and humidity

1.3.2 Optional extra

• Optional extra according to the order specification.

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DANGER WARNING CAUTION NOTICE*

Immediate threats which Possible dangerous Possible dangerous Possible critical or

HAZARD FROM MACHINE

Jamming Squeezing Do not switch on Wear ear defenders

Explosive material Flammable material No source of ignition Wear gloves

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2.2 Basic Principles