Carbonated beverages

Carbonated Monobloc Filling Machine User Manual

I. OVERVIEW

1. Features of the product:

The DCGF18-18-6 washing, filling and capping machine produced by our company is a new product developed on the basis of introduction, digestion and absorption of similar products at home and abroad, combined with our company’s many years of production experience. The unit integrates washing, filling and sealing, and is driven by a transmission motor. It has the advantages of a high degree of automation, compact structure, beautiful appearance, convenient operation and maintenance, safety and reliability, continuously adjustable production capacity, etc. It is currently an ideal gas-filled liquid beverage filling production equipment at home and abroad.

2. Main uses and scope of application:

Mainly suitable for filling and sealing aerated drinks in the round, square or special-shaped polyester bottles. The main electrical components of this machine are brand-name products. The electrical control is controlled by the Mitsubishi PLC computer. The main motor is controlled by a Mitsubishi inverter. The touch operation display screen is Siemens.

This machine is manufactured in accordance with the appropriate safety regulations. Its structure guarantees safe operation in adjustment, maintenance, maintenance, repair and troubleshooting. During the above work, the machine must only be operated manually or with a jog switch.

When the safety device needs to be stopped during maintenance and repair, it should only be performed by trained and authorized personnel. Before turning on the power at any time, check whether there are tools, cleaning utensils, etc., in the aisle of the bottle and whether there are obstacles in each operating mechanism.

II, THE MAIN TECHNICAL PARAMETERS

Model: DCGF18-18-6

Number of stations: bottle washing 18, filling 18, capping 6

Production capacity: 3000 bottles / hour (500ml / bottle)

Filling temperature: 2 ~ 5 ℃

Filling pressure: 0.2-0.35MPa

Total power: 5kw

Rated voltage: 380V three-phase four-system

Dimensions: 2350 * 1700 * 2300 (mm)

Equipment weight: about 3800kg

III EQUIPMENT COMPOSITION AND STRUCTURE INTRODUCTION

1. Equipment composition:

Washing part, filling part and sealing part.

2. Structure introduction

⑴Washing part

The flushing port is mainly composed of the main part of the bottle washing machine, the fixed frame and the inlet and outlet liquid system, the dispenser part, and the bottle clamp part.

A. Spindle components

The big gear is driven by the main transmission gear, which makes the machine rotate synchronously with the filling machine to complete the tasks of flushing and conveying bottles.

B. The tail of the clip moves with the track, which drives the body of the bottle clamp to rotate around the rotation axis so that the bottle clamp is turned 180, and the washing work is completed in a vertical state.

C. Distributor components

The medium distributor is used to connect the medium used for flushing bottles to the equipment from the user’s pipeline and distribute it to each medium switching valve and nozzle. The materials of this part are stainless steel and special materials, which meet the food hygiene requirements.

(2) Filling section

The filling part is composed of a filling liquid cylinder, a filling valve, a bottle lifting part, an on-off valve and an exhaust port.

A. Filling valve consists of three parts: gas injection, exhaust and liquid valve.

B. Filling process and principle

The bottle is lifted by the bottle holder under the control of the lifting cam, and the bottle mouth is in contact with the rubber seal, which is tight and tightly sealed.

Under the action of the bottles and non-filling mechanism, the valve rod is opened by the blocking post, and the gas injection position is turned. The sterile air or CO2 gas in the cylinder also flows into the bottle through the inner hole.

When the pressure in the bottle is equal to the pressure in the filling cylinder, the liquid valve opens under the action of the spring, the liquid is evenly poured into the bottle along the bottle wall through the diverter umbrella, and the gas in the bottle flows back to the liquid cylinder through the air hole.

When the liquid level in the bottle reaches the gas pipe, the gas circuit is cut off, and the liquid stops flowing; that is, the length of the gas pipe can be changed to adjust the level of the liquid.

At the same time, when the valve is closed, the exhaust cam opens the exhaust rod, and the remaining gas in the bottle is discharged to the atmosphere to prevent foaming in the bottle after the bottle is removed.

(3) Sealing section

This single machine is configured for the production of polyester bottled beverages by most manufacturers at present. The machine has the characteristics of good sealing quality, compact structure, low noise, and easy maintenance. The single machine is mainly composed of two parts, the main shaft and the screw cap.

Capping head and its sliding sleeve

Working principle: The cap screwing head and the sliding sleeve are connected as a whole. When the cap screwing shaft rotates with the main shaft, the gear of the cap screwing shaft meshes with the internal ring gear through the intermediate gear to make it rotate and tighten the bottle cap. If it exceeds the specified torque, the sliding sleeve Rotate with the case, do not turn the cap sleeve to prevent damage to the bottle or bottle cap.

Adjusting the torque: loosen the fastening screw on the adjustment nut, turn the adjustment nut clockwise to turn the torque to a small torque, and tighten the fastening screw after adjusting to an appropriate torque.

When changing the caps of different bottles, the cap ring must be replaced.

IV, INSTALLATION AND COMMISSIONING

1. Equipment foundation, installation conditions and technical requirements for installation:

The ground is flat, the unit weight is more than 10kg per square centimetre, and the height of the plant is not less than 3.5 meters

2. Installation method and precautions

Because the equipment is heavy, there is no need to fix the machine on the ground with anchor bolts. The equipment should be installed on a load-bearing basis. The height of the adjustment table is the same as the height of the entire line. Check whether the connecting parts of the adjustment and connection parts are tight and whether the moving parts move freely.

3. Connect the equipment to the external pipeline

(1) Main liquid pipe (filling machine liquid)

(2) cleaning tube

(3) Compressed air pipe

(4) Water inlet pipe of bottle washing machine

(5) Return water pipe of bottle washing machine

V. OPERATION

1. Preparation and inspection before use

a. Cleaning:

Basic principles and purpose of cleaning

The purpose of the cleaning process on the food production line is to make the final product meet the required quality standards.

Water circulates through all parts that the filling liquid passes through at high speed, so the effect of mechanical cleaning is achieved. Each cleaning process can be divided into two categories: mechanical cleaning and sterilization cleaning by means of hot water or steam. The in-situ cleaning method enables the relevant cleaning agent to be used multiple times. During cleaning, the loss of concentration or temperature can be compensated by increasing the concentration again or by reheating. How often is the same solution used? Depending on the situation, one capsule can be used 2 to 3 times.

b. Precautions during maintenance

(1) It is not advisable to put water into the gears, bearings, seals and the inside of the table during cleaning. The residual liquid should be scrubbed clean.

(2) When repairing the parts, try not to damage the outer surface of the parts, seals and non-metal parts.

(3) Where grease needs to be filled in advance, the grease should be replenished during maintenance.

(4) The maintenance of supporting parts should be maintained according to the manufacturer’s instructions. If necessary, professional manufacturers can be assisted in the maintenance.

2. Equipment and operation

(1) Before starting the machine, the operator should be familiar with the machine’s manual. They should have a basic understanding of the main structure of the machine, the features and functions of each structure, and the automatic control functions introduced in the previous sections.

(2) Connect the power supply, run idly at idle (pay attention to forward and reverse), check whether the transmission part is normal and whether the safety devices are reliable.

(3) When idling, fill the oil injection place described above, and check whether the lubricating oil in the worm gear reducer is in the scale position in the oil mark.

VI, FAULT ANALYSIS AND TROUBLESHOOTING

VII, MAINTENANCE, REPAIR

(1) Lubrication

(2) Maintenance

1. Daily maintenance, maintenance, calibration

Maintenance after daily operation:

(1) Drain the residual liquid in the medium pipe.

(2) Clean the bottles or sundries on the workbench and conveyor belt.

(3) Check whether the medium conversion device and medium conversion valve of the bottle washer are normal.

(4) Check whether the clamp of the bottle washer is damaged.

(5) Check whether the filling valve is damaged.

(6) Check the hopper slide for damage.

(7) Check whether the filling valve is damaged.

(8) Check whether the hopper slide is damaged.

(9) After the production is completed, the equipment is cleaned internally and externally. It is best to refuel the exposed lubrication points after cleaning.

2. Weekly maintenance

(1) Check if the height adjustment is flexible.

(2) Check the plastic parts of the flushing pliers for wear.

(3) Check the elasticity of the filling valve spring of the filling machine and whether the gasket is damaged.

(4) Inspection and cleaning of the filling machine pipeline.

(5) Check the media dispenser of the rinser and the dispenser of the filler.

(6) If necessary, check the oil level or refuel the gearbox.

(7) Check the transmission gear and perform maintenance.

(8) Check and clean the hopper.

3. Monthly maintenance

(1) Check the calliper opening cam of the bottle washer, the lifting roller of the filling machine, and the wear of the sliding sleeve of the capping machine and adjust it.

(2) Check the moving parts of maintenance equipment, adjust and repair.

4. Maintenance every six months

In addition to the above-mentioned routine maintenance, it is recommended that the equipment be minor repaired and the whole machine adjusted, cleaned and refuelled every six months or after each peak season.

5. Precautions during maintenance

(1) It is not advisable to put water into the gears, bearings, seals and the inside of the table during cleaning. The remaining liquid should be wiped clean.

(2) When repairing the parts, try not to damage the outer surface of the parts, seals and non-metal parts.

(3) Where the grease is first filled, the grease should be replenished during the maintenance process.

The primary classification of beverages in the general rules of beverages

According to the classification of GB10789 “General Rules for Beverages”, beverages in China can be divided into:

• Carbonated drinks (soda) category,
• Fruit and vegetable juices,
• Protein drinks,
• Drinking water,
• Tea beverages,
• Coffee beverages,
• Plant beverages,
• Flavoured beverages,
• Special purpose beverages,
• Solid beverages
• And other beverages

Carbonated beverages refer to beverages filled with carbon dioxide gas under certain conditions, including cola-type, juice type, fruity type, soda, ginger ale, etc.

Fruit and vegetable juices refer to beverages made from fruits and (or) vegetables, etc., which are processed or fermented, including 100% fruit juice (vegetable juice), fruit and vegetable juice beverages, compound fruit and vegetable juices (pulp) and other beverages. Beverages, pulp drinks, fermented fruit and vegetable juice drinks, etc. Among them, the fruit juice or vegetable juice content of fruit juice and vegetable juice beverages must be more than 10%; fruit beverage juice content must be more than 5%.

Protein beverages are beverages made by processing milk or dairy products or plant fruits, seeds or kernels with a certain protein content as raw materials, including milk-containing beverages, vegetable protein beverages, and composite protein beverages. Among them, milk-containing beverages include formulated milk-containing beverages and fermented milk-containing beverages. The milk protein content of these two types of milk-containing beverages must be more than 1%; milk-containing beverages also include lactic acid bacteria beverages. The milk protein content of lactic acid bacteria beverages must be within 0.7% or more. Vegetable protein beverages include soy milk (pulp), soy milk beverages, coconut milk, almond milk, walnut milk, peanut milk, etc. The protein content must be above 0.5%.

Drinking water refers to directly drinkable water sealed in containers, including drinking natural mineral water, natural spring water, other natural drinking water, pure water, mineral water, and additional drinking water (such as flavoured water).

Tea beverages are beverages made by processing the water extract of tea leaves or its concentrated liquid, tea powder, etc., as raw materials, including tea beverages (tea soup), flavoured tea beverages, compound (mixed) tea beverages, etc. Among them, flavoured tea is further divided into fruit juice (flavour) tea beverage, milk (flavour) tea beverage, and carbonated tea beverage.

Coffee beverages are processed from coffee water extracts or concentrates and instant coffee powder as raw materials, including espresso beverages, coffee beverages, and decaffeinated coffee beverages.

Plant beverages refer to beverages made from plants or plant extracts (except fruits, vegetables, tea, and coffee) through processing, including edible fungus beverages, algae beverages, cocoa beverages, cereal beverages, herbal tea beverages, etc.

Flavoured beverages refer to beverages that are processed by using edible flavours (materials), sugar and/or sweeteners, sour agents, etc., as the primary means to adjust the flavour, including fruit-flavored beverages, milk-flavoured beverages, tea-flavoured beverages, Coffee-flavored beverages, etc.

Special-purpose beverages are beverages that adapt to the needs of certain special people by adjusting the composition and content of nutrients in the beverage or adding specific functional ingredients to meet the needs of certain special people, including sports drinks, nutrient drinks, energy drinks, etc.

Solid beverages refer to products that are processed into solid materials such as powder, granular or lump from food raw materials, food additives, etc., for brewing and drinking, such as juice powder, bean powder, tea powder, coffee powder (instant coffee), fruit Flavored solid beverages, solid soft drinks (effervescent tablets), ginger powder, solid protein beverages, etc.