Manual For Strip Packing Machine SE - 140 [PDF]

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STRIP PACKING MACHINE Model: SE – 140 Customer: M/S. AIRELA INDUSTRIA FARMACEUTICA LTDA, BRAZIL Machine Sr. No.: 1388 Document No: VTPL/DOC/0313

MARKETED AND EXPORTED BY Vibrer Technology Pvt. Ltd. Mumbai-68, India

INSTRUCTION MANUAL STRIP PACKING MACHINE

From M.D’s Desk Dear Customer, We take pleasure in presenting this Instruction: Operation: Maintenance and Parts Manual for Strip Packing Machine. The Machine which you are about to use is a state of the art. It has been conceptualized, designed, developed and produced with a great amount of effort and research. This machine is a culmination of many years of experience and technical expertise. This Manual covers important topics like safety, installation, alignment and settings, operation, service and maintenance, trouble shooting, spare parts and electrical circuits. We are sure this Manual will be of great help to your operational staff while handling the Machine at different stages of operation, installation, repairs and maintenance, troubleshooting and spare parts ordering. This will also help in reducing the down-time and increasing the productivity. We request you as well as your operating staff to go through this Manual thoroughly and give us feedback and suggestions on the usefulness. We value the suggestions and opinions from our customers like you and I am sure you will help us in introducing improvisations in our Machine and Manuals. With Best Regards

Managing Director Vibrer Technology Pvt. Ltd. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

TABLE OF CONTENT: Sr. No 1.

Contents Company Profile i. Global Presence

Page Number 5 7

2.

Introduction

8

3.

Objective Of The Manual

9 10 10

4.

5.

i. Management Responsibility ii. Manual Updating In Case Of Machine Modification iii. Safe Keeping Of The Instruction Manual Safety Instructions I. Identify Safety Spots II. Statutory Accident Prevention Health & Safety Requirements i. Health ii. Safety iii. First Aid iv. Employment Of Young Persons v. High Noise Level vi. Statutory Accident Prevention Regulations III. Personal Qualifications And Training i. Working With Process Material a) Health and Skin Protection b) Cleaning Agents ii. Safety Devices Check Statutory Information i. Copyright ii. Warranty iii. Liability Restrictions

MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

10 11 12 14 14 15 17 17 17 17 18 19 19 20 20 21 21 21 22

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6.

Transport And Handling i. The Package ii. Transporting The Packed Machine iii. Storing The Packed Machine iv. Unpacking The Machine v. Care To Be Taken During Unpacking vi. Instructions For Packing And Verifying vii. Disposal Of The Packing Material

23 23 23 23 24 24 25 25

7.

Packing List

26

8.

27 27 27

9.

Installation i. Foundation Preparation ii. Prerequisites & Conditions to be Prepared For Installation iii. Leveling The Machine iv. Pre Start Check Up a) Electrical Check Up b) Mechanical Check Up Technical Specification

28 28 28 29 30

10.

Machine Description

32

11.

Safety Instructions

33

12.

Operation And Adjustments i. Dismantling of rollers from the machine ii. Assembling rollers back on the machine iii. Sealing roller adjustment iv. Roller temperature adjustment v. Vertical slitter vi. Cam operated horizontal cutter vii. Changing the cutting length

34 34 35 36 37 37 38 38

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INSTRUCTION MANUAL STRIP PACKING MACHINE

13.

Table for change of cutting gears as per requirement

39

14.

Adjustment of feeding device

40

15.

41

17.

Adjustment of chute with sealing roller and S.S. Feed bowl Adjustment of dropping of product in center of strip pocket. Vibrator

43

18.

Daily routine check ups

44

19.

Disc plate feeding device

45

20.

22.

Maintenance of reduction gear box i. Description ii. Lubrication iii. Oil Lubrication iv. Routine Maintenance v. Changing of Oil Batch Printing Unit i. Introduction and working principle ii. Installation iii. Precautions iv. Operation and observations Preventive maintenance check list

46 46 46 46 47 47 48 48 48 49 49 50

23.

Sub assembly drawings

52

24.

HMI Manual (Login Credentials)

64

25.

GA drawing

79

26.

Electrical drawings

81

27.

Change part details along with layout of strips

98

16.

21.

MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

42

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INSTRUCTION MANUAL STRIP PACKING MACHINE

1.0 COMPANY PROFILE: VIBRER TECHNOLOGY PVT. LTD. Is one of India's leading solution providers in the field of Formulation Processing. Vibrer Technology Pvt. Ltd. has got a good Channel partners in many countries who are assisting to have a large customer base spread across 5 continents of the Globe. We have strong customer base in many countries that range from European countries like U.K, France, Sweden, Poland, Romania to Latin American countries like Brazil, Chile, Venezuela, Nicaragua, Peru and entire Asia and Africa where again we are extremely strong. We have very good installation base in USA also. Vibrer Technology is involved in the Marketing / Exporting of the entire formulation processing equipments starting from  Granulation Line  Rapid Mixer Granulator  Fluid Bed Dryer and Processors  Blender (V-Blender/Double Cone Blender/Octagonal Blender/Conta Blender/ Drum Blender)  IPC Bins  Planetary Mixer For Powders  Shifter  Conventional Coaters  Mills  Multi Mill  Co Mill  Colloid Mill  Oscillating Granulator  Ointment Preparation Plant and Tube Filling Machine  Encapsulation  Manual Capsule Filling  Semi-Automatic Capsule Filling  Automatic Capsule Filling  All Line Machines MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

 Tablets  Tablet Compression  On Line Deduster and Metal Detector  Packaging  Strip Packing Machine  Cartooning Machine  Blister Packing Machine  Packaging Material (Aluminum Foils and PVC Foils)  Also we deal with the consumables and spare parts of the above machines. The Vibrer Technology Pvt. Ltd offers ‘Unique Value Proposition’ to its customers which include    

High Level of product quality World class cGMP Standards Excellent aesthetics Commitment towards providing best of customer support in terms of ‘After Sales Service'

 Customized solution  Product Quality Vibrer provides products which comply with cGMP standard. Our products are used by many customers which having US FDA/ UK MHRA approved plants in overseas markets. – Which includes companies in developed markets Europe. Biggest Value Proposition of Vibrer Technology is to meet the customers need by making its products and services exactly as per customer’s requirement. Vibrer Technology has the Capability / Flexibility and inherent strength to provide that extra bit in terms of satisfying each customer’s special requirement suiting their products.

MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

Global Presence:

MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

2.0 INTRODUCTION: This Instruction, Operation, Maintenance and Parts Manual is meant for the Strip Packing Machine Marketed & Exported by Vibrer Technology Pvt. Ltd. In all the subsequent pages henceforth in this manual: i. ii. iii.

This Instruction, Operation, Maintenance and Parts Manual will be referred to as the ‘Manual’. The Strip Packing Machine for which this ‘Manual’ is meant for will be referred to as the ‘Machine’. The Machine is Marketed and exported by Vibrer technology Private limited will be referred as “Vibrer”

This Machine is a top-quality product from vibrer. It demands utmost care and caution for its operation and maintenance. Correct operation and maintenance of the Machine is indispensible to retain the quality of the Machine. To help you to ensure this, every Strip Packing Machine comes to you with a Complimentary copy of this Manual. The Manual contains very important information enabling the user a safe, correct and trouble-free operation of the Machine. It explains in details with vivid illustrations, various machine functions, pertaining to transport, unpacking, installation, commissioning, operation, cleaning, repairs and maintenance trouble shooting and spare parts requirements. If you strictly follow the guidelines and instructions given in this Manual, you will avoid accidents, failures and costly downtimes and repairs, thus ensuring economic operation and prolonged machine life. All the personnel connected with the handling of the Machine including the Manager and the shop floor Supervisor should first study this Manual thoroughly and get familiar with the Machine.

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3.0 OBJECTIVES OF THE MANUAL: The objectives of the Manual are following: I. To make the management aware of the necessity to: i. ii. iii.

iv.

v. vi.

Study the Manual carefully in detail. Make the operating and maintenance staff read and understand the portions of the Manual which relate to them. Impart hands-on training to the operating and maintenance staff for transportation, installation, commission, operation and maintenance of the Machine. Provide and make available at all the time safety provisions and implement and ensure that all the safety requirements are observed by everybody involved in transportation, unpacking, installation, commission, operation and maintenance of the Machine. Ensure that this Manual is easily available for reference at all times to everybody connected with the Machine in any way. Update this Manual with latest modification notes issued by Satellite Engineers or Vibrer from time to time.

II. To make the operating and maintenance staff aware of the necessity to: i. ii. iii. iv. v. vi. vii.

Study this Manual carefully and strictly follow the instructions. Strictly observe the safety instructions and handle the Machine under safe conditions. Keep this Manual at a safe place and to handle it carefully with clean and dry hands and not fold or remove any pages from the Manual. Ensure correct installation and commission. Ensure correct operation and regular maintenance. Carry out production change - over correctly. Take all precautions so as to avoid any damage to the Machine and injury to the persons.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

i. Management’s Responsibility It should be the responsibility of the Manager or the shop Supervisor after having studied the Manual himself to impart necessary training to the operator of the Machine and ensure that the Manual is easily accessible and available to the operator whenever he needs it. The time spent in studying this Manual will be largely compensated by the time and money saved by operating and maintaining the Machine correctly as per the instructions given in the Manual. However, the Manual should not be seen as a substitute for intensive hands-on training of the operating and maintenance personnel. The Manual presupposes that the prevailing health and safety norms as per the laws of the land are observed in the establishments where the machine is installed and operated. ii. Manual Updating in case of Machine Modification Manufacturer of the machine reserves the right to make any technical changes or modifications for improvements in the Machine. Such modifications will be communicated to the customers as and when necessary and the clients will be responsible to ensure that only the updated version of the Manual is kept in the place where the machine is being operated. iii. Safe Keeping of the Instructions Manual The Instruction Manual must be kept with care and must be kept in proximity to the Machine. It must accompany the Machine wherever and whenever the Machine is shifted to a new place. The Manual must be handled with care with clean and dry hands and must not be placed on wet and dirty surfaces. It must be stored in a place free from humidity and heat. Pages must not be folded, torn or arbitrarily modified. No pages or a part thereof must be removed from the whole volume.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

4.0 SAFETY INSTRUCTIONS: Basic Safety Instructions and Warnings  The Machine should always be maintained in perfect working order. It should always be handled by authorized and trained personnel and should be used only for its intended purpose strictly in accordance with the instructions contained in this Manual.  It is necessary that this Manual should always be kept with the Machine for easy reference whenever required.  It is the responsibility of the Management and the Supervisor to study the Manual thoroughly and then impart proper training to the operating and maintenance staff in respect of all the vital functions of the Machine emphasizing the necessity of strictly observing the safety precautions and follow the instructions laid down in the Manual.  This has to be done well before installation, commission and starting the operation. Besides the Manager and Supervisor.  It is imperative for all the operational and maintenance personnel to have read and understood the Manual thoroughly.  Only competent, trained and reliable persons who have reached the legal adult age should be allowed to handle the Machine.  The operator should be authorized to take instructions only from an accredited Supervisor or Manager and not from anybody or everybody so as to ensure that the Machine remains always in good and safe condition.  While working on the Machine, the operational and maintenance staff should not keep their hair open, wear loose clothing, tie, jewellery or ornaments including necklace, bracelet, ring and chain. There is a risk of injury as any of these may get caught or pulled into the Machine and cause an accident or injury.  All safety and warning signs on or about the Machine should be clearly visible and legible at all times.  The operator should be familiar with the location and operation of fire extinguishers in the vicinity of the Machine.  Do not carry out any additions, deletions, conversions or modifications to the Machine without written consent from Satellite Engineers is can adversely affect its safety and cause accidents, injuries or damage to the Machine.  The main switch of the Machine must be switched off during the process of installation, assembly, disassembly, maintenance and cleaning and the Machine must be protected against unintended operation by disconnecting it from the main source of power, vacuum.  Never deactivate the safety devices installed on the Machine. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

 Never run the Machine in automatic mode with the safety guards removed.  The operations carried out under reduced safety conditions must be strictly carried out as per indications provided in the relevant instructions.  After carrying out operations under reduced safety conditions, the state of the Machine with active safety devices must be re-established as soon as possible.  The cleaning operations must be carried out only after disengaging the Machine from its electric and pneumatic power supply.  Clean the surface, panels and controls of the Machine with soft, dry cloth or slightly dampened with a mild detergent solution. Do not use any type of solvent such as alcohol or petrol as it could damage the surfaces and cause fire or explosion. I.

Identifying Danger Spots

The following symbols have been used at different places in this manual relating to work safety where there is a risk to the life, limb and health of persons, danger to the Machine and to the environment.

1] CAUTION

Warning of a danger spot

Instructions against this symbol should be read very carefully. They relate to a dangerous spot on the Machine and/or to a procedure, if not followed strictly may result in danger to life, limb, the Machine and the environment.

2] NOTE

: Note carefully

Text against this symbol should be read very careful and to be given special attention to ensure that directives, regulations, instructions and the correct sequence of work are observed. Failure to do so may result in damage and destruction of the Machine or parts thereof. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

3] Electric current: Danger Live hazardous voltage and dangerous electric current. Can cause severe injury or death. Always switch off electric current & disconnect or unplug power supply cable before performing any repairs or maintenance work. Always connect power supply cord to a grounded electrical circuit with the specified voltage and fuse protection. Never use any equipment which is powered by electricity in rain, wet area or near an explosive environment.

4] Environment pollution: Danger of environmental pollution Failure to follow the instructions against this symbol may Pollution cause environmental pollution.

5] Fire Hazard: Danger from Fire Inflammable vapours can cause a fire or an explosion and result in severe injury or death and destruction.

6] Hazardous fumes: hazardous vapours Can cause severe nausea, fainting or death. Use a respirator or mask whenever there is a risk or chance of inhaling hazardous mists or vapours emanating out of formulations, solvents or lubricants.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

7] Danger to limb: Moving parts can cause severe injury. Before commencing any maintenance or repair work, ensure the following. Switch off the electric power supply and disconnect the power supply cord. Wherever you find any of these symbols in the Manual, read the instructions against these symbols very carefully and follow them strictly. Also communicate such safety instructions to all concerned with the Machine. II.

Statutory Accident Prevention, Health and Safety Requirements a) Health

i. Cleanliness The place where the Machine is installed and is in operation must always be kept clean. Accumulation of dirt and refuse must be removed daily by sweeping or by any other effective method. The floor must also be cleaned at least once in every week by washing, using disinfectant.

ii. Disposal of Wastes and Effluents Effective arrangements should be made for the disposal of wastes and effluents generated during the process, so as to render them innocuous and their ultimate disposal.

iii. Dust and Fume If dust, fumes, formulations or any other offensive substance is given off during the operation of the Machine to such an extent as likely to be injurious or offensive to the workers, effective measures should be taken to prevent its inhalation and accumulation around the Machine. If any exhaust system is felt necessary for this purpose, it should be installed as near as possible to the point of origin of such offensive substance and such point should be enclosed to the extent possible. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

iv. Lighting The workplace should be provided with sufficient and suitable lighting either natural or artificial or both. All glazed windows and skylights used for lighting the workplace should be kept clean on both the inner and outer surfaces and should be such as to prevent any glare, either directly from a source of light or by reflection from a smooth or polished surface and also as to prevent the formation of shadows to such an extent as to cause eye-strain or the risk of accident to the workers. b) Safety i. Fencing of the Machine The Machine should be securely fenced by safeguards which should be kept in position while the parts of the Machine which they are fencing are in motion or in use. ii. Work on the Machine while Operation No person shall be allowed to clean, lubricate, repair or adjust any part of the Machine while it is in motion / operation. iii. Employment of Persons on the Machine No person shall be allowed to work on the Machine unless the person has been fully explained and instructed on the dangers involved, precautions to be observed, has received adequate training in operation and handling the Machine and is under adequate supervision by a person who has a thorough knowledge and experience of the Machine. iv. Cutting Off of Power in Emergency. Suitable devices for cutting off power from the running machinery should be provided and Maintained in case of emergencies. v. Lifting Devices, Chains, Straps, Ropes and Tackles All parts including working gear, whether fixed or moveable of every lifting device and every chain, strap, rope or tackle should be of good construction, sound material and adequate strength and free from defects, properly maintained and thoroughly examined periodically by a competent person. It should be ensured that a crane does not approach close to the place where a person is working on the Machine.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

vi. Manual Lifting Of Excessive Weight No person should be allowed to carry or move any load so heavy as to be likely to cause him injury. vii. Protection of Eyes Effective screens or suitable goggles shall be provided for the protection of the operators working on processes involving risk of injury to the eyes from the particles, fragments or process material thrown off during the process or which involve risk of injury to the eyes due to exposure to excessive light. viii. Use of Portable Electric Light No portable electric light or any other electric appliance of voltage exceeding 24 volts should be permitted for use inside any chamber, tank, pit, pipe or any other confined space unless adequate safety devices are provided. If any inflammable gas, fume or dust is likely to be present in such chamber, tank, pit, pipe, flue or other confined space, no lamp or light other than that of flameproof construction should be permitted to be used therein.

ix. Explosive or Inflammable Dust and Gas Where the process produces dust, gas, fumes or vapours which are likely to explode on ignition, all practical measures should be taken to prevent such explosion by:  Effective enclosure of the plant or machinery used in the process.  Removal or prevention of accumulation of such dust, gas, fume or vapors.  Exclusion or effective enclosure of all possible sources of ignition. x. Precautions against Fire All practicable measures shall be taken to prevent outbreak of fire and its spread, both internally and externally and to provide and maintain.  Necessary firefighting equipment and facilities for extinguishing fire.  Safe route and means of escape for all, in the event of fire. Effective measures should also be taken to ensure that all the workers are familiar with the route and means of escape in case of fire and have been adequately trained in the routine to be followed.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

c) First – Aid First-aid boxes or cabinets should be made available and accessible to all workers during all working hours. These first-aid boxes or cabinets should be equipped with prescribed contents. These should be kept in charge of a responsible person who is trained in first-aid treatment and who shall always be available during all working hours. d) Employment of Young Persons No child who is not an adult shall be required or allowed to work on the Machine. e) High Noise Levels Suitable engineering control or administrative measures should be taken to ensure that no worker is exposed to sound levels exceeding the maximum permissible noise exposure levels. Sound level equal to or greater than 85 dB (A) can cause hearing damage. Even a short exposure to a very high noise level can cause hearing damage. In other case where the exposure is not to a very high noise level but to a noise level exceeding 85 dB (A) for a protracted period, it can trigger a gradual process of hearing loss. The intensity of noise from and around the Machine can be significantly controlled by reducing vibrations and improving sound insulation. The noise level measurement carried out near the Machine in our works was found to be of a sound level of 78 to 82 dB (A).Where it is not possible to reduce the noise levels by reasonable engineering or administrative measures, the exposure to noise should be reduced by providing each worker with suitable ear protectors. f) Statutory Accident Prevention Regulations Apart from the Safety Instructions and Warnings indicated at different places in this Manual as well as the Safety symbols given on the Machine and the Manual, the prevailing Statutory Accident Prevention Regulations of the country in which the Machine is installed and is in operation will have to be observed by the client.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

III.

Personnel Qualifications And Training

The persons entrusted with the job of installation, commissioning, operation, maintenance and servicing of the Machine must be adequately qualified and competent to handle the Machine in their respective fields. It is imperative that the following requirements are met with before a person is allowed to handle the Machine. ! The Manager or the Supervisor himself should first study and understand the Instruction Manual and the Machine.  The management has to ensure that everybody who is entrusted with handling of the Machine at any stage should have read and understood the contents of the Manual.  They should be educated enough to read and understand the text, signs, symbols, diagrams, drawings and illustrations in the Manual and on the Machine.  They should have adequate knowledge, experience and training in handling products like foods and drugs.  They should have adequate knowledge and experience in Statutory Safety and Accident Prevention Regulations in their country.  They should be able to understand generally accepted guidelines and technical codes so that they can judge the safe condition of the machine  They should be familiar and knowledgeable with the protective equipments, relevant tools, first aid measures, fire fighting and other emergency equipment and services.  If the personnel do not have adequate competence, knowledge or experience, they should be first provided necessary training in their respective field of responsibility, before allowing them to handle the Machine in any way, whatsoever.  Even if they have in general previous experience and knowledge of all the above mentioned aspects the specific training of this equipment is a must before allowing anybody to handle the Machine.  If necessary the clients can request Satellite Engineers or Vibrer to organize necessary training of their personnel.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

i. Working with Process Materials The mineral oils, lubricants and coolants used on the Machine may contain additives which even in howsoever small quantities could have detrimental effects on health. Skin damage may occur following contact with such oils, lubricants and coolants. Pulmonary illness may be caused by inhaling oil mists and vapors from these substances.

a) Health and Skin Protection Please take following precautions to avoid adverse effect to your health. i. ii. iii. iv. v. vi. vii. viii. ix. x. xi.

Avoid prolonged, extensive and repetitive skin contact with either fresh or used oils, lubricants and coolants. Use suitable skin protection and gloves while working with oils, lubricants and coolants. Change your clothing before it becomes saturated with these materials. Do not keep any wet cleaning rags in the pockets of your clothes, coats or aprons. Wash your skin immediately with soap and water if it has been soiled with oils and lubricants. Never wash your hands with coolants or solvents. If skin damage takes place while working with these substances, consult a doctor as soon as possible. If any of these materials get into your eyes, rinse your eyes immediately with clean water and consult a doctor as soon as possible. Ensure that no oil is spilled on the floor. If this happens, scatter sawdust or an oil absorbent over the spilled oil and clean the spot. Never pour oils or liquids containing oils into a drain or open waters. Waste oil should be collected and disposed off at the collection points specified for such wastes.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

b) Cleaning Agents Cleaning agents and solvents contain substances which are a health hazard. Quite a number of them are also combustible and explosive. Please take following precautions while handling such cleaning agents. i. Carefully read and follow safety instructions on the container or the package. ii. Ensure adequate ventilation while working with solvents. iii. Smoking and naked flames should be strictly prohibited while working with combustible cleaning agents and solvents. iv. Use available skin protection and skin care products before and after using the cleansing agents. v. Do not pour any solvents in the drains or open waters. vi. Ensure that all cleaning agents and solvents are removed from the machine before starting the Machine. ii. Safety Devices Check Check the proper working condition of the emergency and safety Systems once a week. The electrical maintenance personnel should check that electrical control switches on the panel, emergency switch and the safety limit switches to ensure are in perfect working condition & that once activated, Machine would not start.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

5.0 STATUTORY INFORMATION: i. Copyright The instructions, drawings, illustrations, photographs and documents contained in this Manual are strictly the property of Manufacturer so no part of this Manual may be copied, reproduced, sold or transmitted in any form or by any means, electronic or mechanical including photocopying, recording by any information storage and retrieval system without written Permission from the Machine Manufacturer or supplier. The Manual may only be used for its approved purpose by the customer who has purchased and installed our Machine directly from us. Legal proceedings will be initiated against anyone who violates this copyright. ii. Warranty The Machine is under warranty for a period of 12 months from the date of receipt by the client for any premature failure of a component / assembly. This Manual contains all the instructions necessary for observance of the warranty conditions. The Manual should be carefully studied by all concerned before installing and commissioning the Machine for regular use. Consumable and Expendable components are not covered by the warranty after their useful life. The warranty will lapse in the event of damages arising out of usage of non-genuine spare parts and / or accessories as well as unauthorized alterations or modifications to the Machine or any of the accessories. The warranty will also lapse in the event of: Wrong or negligent handling Improper or inappropriate use of the Machine Operating by an untrained or unauthorized person Incorrect installation Incorrect or negligent connection of cables, electrical or mechanical controls between the Machine and the accessories.  Non-compliance of the instructions contained in this Manual by the clients or any of their personnel handling the Machine at any stage.  Damage resulting as a consequence of error in operation, maintenance and repairs.  Protective devices removed or modified without permission from Manufacturer or Supplier (Vibrer Technology Pvt. Ltd).     

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INSTRUCTION MANUAL STRIP PACKING MACHINE

iii. Liability Restrictions We assume no liability for damages, breakdowns or stoppages consequent to noncompliance of instructions contained in this Manual. All technical data, information and instructions for the operation and maintenance of the Machine, contained in this Manual are provided to the best of our knowledge and experience at the time of printing of this Manual. We reserve the right to make any technical changes in the Manual and / or the Machine with a view to improve the Machine performance from time to time and will not entertain any claims arising out of the contents and illustrations in this Manual. The illustrations provided in this Manual project just a general profile of the given component or assembly to facilitate easy identification and understanding of the function of the given component / assembly and do not necessarily give exact specifications, size or shape as they are not drawn to scale in relation to the whole Machine or to other assemblies or components The original text of this Manual is drafted in English language and this original English Language Manual will remain decisive for the handling, operation and maintenance of the Machine. In case of translations in any other language, we assume no liability consequent to any errors, additions, deletions, omissions and misunderstandings in such translations carried out by the client or any other agency then Manufacturer or Supplier (Vibrer Technology Pvt. Ltd) also does not accept any liability arising out of :  Damage to Machine, injuries to persons or total accidents if safety instructions are ignored.  Damage to Machine due to faulty transportation, installation, operation, maintenance or repairs  Contact with or inhalation of harmful fluids, gases, mists, fumes and dusts by the operating personnel.  Exposure of operating personnel to any biological or microbiological hazards.  Fire or explosion arising out of materials substances used during the operation. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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6.0 TRANSPORT AND HANDLING: i. The Package The package containing Strip Packing Machine consists of a reinforced wooden case with removable top and sides and a base platform capable of supporting the Machine and allowing it to be transported. The Machine is covered all around with polythene sheets. The case also contains sachets of hygroscopic salts to absorb any moisture during transportation and storage. ii. Transporting the Packed machine The case can either be moved by a forklift or a crane. For moving by a forklift, the forks must be placed properly considering the weight of the machine. If the case is moved by a crane, The Slings should be placed properly If the dimensions of the case are such that, it obstructs the view of the forklift operator, he must be guided by another person walking alongside the forklift. Immediately on delivery of the consignment by the carriers, it should be checked that the case containing the Machine does not show any outward signs of damage. Any sign of damage to the case points to the possibility of damage to the Machine. iii.

Storing the Packed Machine The cases containing the Machine and the additional optional units must not be stacked one on top of the other. The case containing the packed Machine must be stored in a cool, dry and covered place protected from sun, rain and snow. After taking delivery of the consignment room the carriers, the cases should be unpacked and the Machine installed as early as possible within a reasonable time.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

Vibrer shall not be responsible for any deterioration or damage to the Machine resulting from prolonged or faulty storage of the Machine in packed or unpacked condition. iv.

Unpacking of the Machine The packed Machine after unloading, should be placed on the floor with ‘Top Side Up’ as marked on the case with symbols. The unpacking of the Machine should then be done in the following sequence as shown First remove the top plank of the case. Then remove the all Side Planks Carefully remove all the accessories & other components and place them on the floor. The Machine with the base platform should then be transported with the help of a forklift or/and a crane as near to the location as possible where it is to be installed again taking care of.

v. During Unpacking following aspects to be taken care:  Always ensure that while transporting the machine on a forklift or a crane, the mounting pads are fitted on the bottom of the machine.  Use Hemp/Manila ropes to lift the machine. Do not use chain or steel cable  Remove the polythene shrink pack and the polythene cover from the Machine.  Similarly unpack other packages received in the same consignment containing accessories and other components.  Check the total contents of the consignment actually received with the ‘Packing Slip’ and other documents retrieved from the ‘Packing Slip’ pocket and check for any shortage, damage or breakage.  Any shortage, damage or breakage should be immediately reported to the Insurance Company and A copy of such letter to the Insurance Company should also be forwarded to Vibrer Technology.  While moving the Machine at all stages, take proper care to ensure that the Control Pendant and the Acrylic Safety Doors are not damaged. Note: Satellite Engineers /VIBRER shall not be responsible for any damage to the Machine or its components or injury to the persons lifting or transporting or unpacking the Machine, if the instructions are not strictly observed and the Machine is lifted or transported or unpacked in any way other than that indicated. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

vi.

Instruction For Unpacking And Verifying a) Unpack the case and the crates carefully under the supervision of responsible person and remove the contents without trying to force open any package. b) Check contents with the packing note. c) Should any shortage be observed in the first check, the cases or individual packages, also the packing materials should be thoroughly searched for a Second time in the presence of responsible person who will certify the shortage. Similarly, for any wrong supply of parts and components the material should be immediately brought to the notice of Satellite Engineers MACHINES, their agents or the Supplier giving full reference of supply. d) In case of breakage or damage, the nature and extent of each article, component or equipment should be documented in clear and precise terms and report sent to the supplier within a week of the receipt of the consignment. e) All the parts and components should be thoroughly cleaned of packing material before assembly with particular reference to moving parts. f) All contact parts should be washed thoroughly with warm water and soap before the equipment is put in production.

vii.

Disposal of the Packing Material:

Disposal of the wooden planks, polythene waste and all other material used for packing should be disposed off in conformity with the prevailing statutory environmental regulations of the country where the Machine is installed.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

7. 0 PACKING LIST  Main body with drive, cutter assembly.  Vibrator with Vibrator Mounting Plates.  Disc plate drive with base plate.  Hopper with telescopic mounting stand.  Conveyor.  Batch Printing Attachment.  Foil Holder Assembly.  S.S. Bowl and S.S. Chute Channel in case of Vibrator Feeding.  Disc plate and S.S. / Hylam Chute in case of Disc plate Feeding.  Sealing Roller Set along with Back Gear & Cam Disc.  Denotes Optional Accessories.

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8.0 INSTALLATION: Pre-Installation Check List This is the check list which needs to be filled by customer once the machine is received at location. This is to ensure everything is intact before service engineer reached to the site to help to reduce the installation time to smooth installation and commissioning. This check list also help customer to install the utilities of correct specification. i. Foundation preparation The machine is provided with jacking mounts, which has to be mounted on machine at bottom side. The mounting of jack should be uniform. Select the location for the machine to be installed by taking care the space required for maintenance from all sides of the machine preferably about 600 mm minimum space. ii. Prerequisites and Conditions to be prepared for Installation 1. Minimum space required to house the basic Machine Strip Packing Machine: 3000 mm (length) x 3000 mm (width) x 3000 mm. (height) 2. Maintain temperature at the Machine site between 20 Degree and 25 Degree depending upon formulation requirement if any 3. Maintain humidity at the Machine site between 40% RH and 75% RH and / or lower depending upon formulation requirement if any 4. Sufficient lighting at the Machine site. 5. Ensure electrical supply connections for the Machine and the accessories as per their technical specifications. 6. Availability of isolator of triple pole 63 Amps. For 2 phase 380 V + Earth / ground, 60 Hz. 7. Provide proper earthing for the Machine and accessories. 8. Keep sufficient quantity of tablets ready for conducting machine trials minimum for 1 / 2 batches of production. 9. Operating and maintenance personnel to be designated so that they can be trained by our engineer. The above activities carried out prior to arrival of our engineer will help him devote more time towards setting formulations and training your personnel

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iii. Leveling the Machine Notes: These equipment required firm leveling, the jacking of the equipment should be uniform.

CAUTIONS: Do not operate the machine until the machine is mounted with the jacking pads. The Top portion of the machine should be checked with spirit level. To check if the machine is jacked uniformly. iv. Pre Start Check Up a) Electrical Check‐up * DO NOT USE EARTH LINE AS A NEUTRAL LINE. d) All the electrical connections should be connected as per illustration no. e) Over load relay of the starter should be set at 2.5 to 4 Amps. f) Check M.C.B. g) Check single phase protector. h) Check Starter Cutouts. i) Check Cutouts of Heater. j) Check Cutout of Vibrator. k) Vibrator feeding controls. 1) Thermostat or Thermocouple of Roller. m) Heater switch supply. n) Amp meter reading for heater

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 Amp meter is connected through both or individual heaters. Therefore when Both heater is connected through a single Amp meter then the Amp meter will show the reading as mentioned in the following table in the column Both whereas when a Single heater is connected through a Single Amp meter then the Amp meter will show the reading as mentioned in the following table in the column Single as shown below:1) 2) 3) 4) 5)

No. of Tracks 2 track 4 track 6 track 8 track 10 track

Watts 500 W 750 W 1000 W 1500 W 1600 W

Single 2 amps 3 amps 4 amps 6 amps 8 amps

Both 4 amps 6 amps 8 amps 12 amps 16 amps

If any one of the heater does not work then in Single the Amp meter will not show any reading and in Both the Amp meter will show half of the above reading. b) Mechanical Check‐Up  Place the machine on firm level surface for Trouble free working. For permanent installation at the site, machine can be grouted with appropriate foundation bolts ensuring proper leveling.  Adequate space is a must all around the machine for the maintenance inspection and change over adjustments.  Ensure all bolts and nuts are properly tightened.  Cleaning  Clean all parts thoroughly after identifying them with the packing list.  Remove all rust preventing grease with solvents. Sealing Rollers are to be handled carefully to prevent the damage to the Knurling of the roller. Firstly clean sealing roller surface with cloth soaked in kerosene oil and then with Liquid Paraffin and then brush gently with soft brass wire brush.

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9.0 TECHNICAL SPECIFICATIONS Sr. No. 1.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

BOUGHT OUT ITEMS Make: Hindustan Motors Specification: 1 HP /0.75 Kw /1415 RPM /380 V/ 60 Hz/ 3 phase. + Earth Gear box Make: Bonfiglioli, Gear Box - Ratio: 14 : 1 Type: VF 49 A 14 HS B3 FENNER/NIRLON Make V-Belt. VFD Make: Mitsubishi Electric/ D700 Model: FR-D740-022-E16 PLC – Allen Bradley Make (Model: Micrologix 1400). HMI – Allen Bradley make (model: Panel view Plus7) Fail Phase Relay: OMRON (K8AK) Line Filter Make: SAKURA, Model: SAK-DRV – 40/04 SMPS - OMRON make Model: S8VK-C12024 (24VDC/ 5 Amps) SELEC Make Temperature Controller (PID 500). – 2Nos. Ethernet Port - Make: Allen Bradley (Stratix – 2000) SALZER Make 63 Amp, 3 Pole, Rotary ON/OFF Switch Electrical Heater - Cartridge type - 240 Watts each. TECKNIC make Start Push Button. TECKNIC make Red Stop Push Button. TECKNIC make Yellow Inch Push Button. TECKNIC make Mushroom Head Red Emergency Stop Push Button. TECKNIC make Alarm ACK Push button TECKNIC make Phase Lamps (220V). Contactor for Vibrator – Make: Siemens (SIRIUS) Contactor for Heater 1 - Make: Siemens (SIRIUS) Contactor for Heater 2 - Make: Siemens (SIRIUS) Allen Bradley make Ethernet Hub (stratix 2000) Siemens make MCB (C -10, 2 pole 4 nos.) Siemens make MCB (C -6, 3 pole 1 nos.) SSR for Heater Make: Laptron, Model: ESSR-LA40 – 2No.

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 Machine with Sr. No. – 1388 is of SE – 140 Model

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10.0 MACHINE DESCRIPTION  This machine is totally self-contained. If required it can be mounted on a solid foundation or a raised platform to suite Strip packing conveyor to Packing table conveyor. This machine is a universal type machine to pack.  Pharmaceutical products like Tablets, Pills, Granules, Hard gelatin capsules and Soft gelatin capsules.  Food products like Hard boiled sugar candy Scented Supari, Black pepper, Seeds, Roasted peanuts etc.  Engineering products such as Steel Balls, Ball Bearing, Rubber Seals, Pencil or Button Batteries etc.  Strip size can be designed to suite your requirement„ taking care of pocket size and sealing area.  Note: Change parts like Sealing Rollers, feeding S.S. Bowl and S.S. Chute Channel are specially designed for packing of a particular product. The orders for extra set of change parts for different products are to be placed separately.  Packing Material: Two rolls of heat sealing packing material comes from both the right side packing material holder and the left side packing material holder to the sealing rollers, at this stage one of the rolls of packing material passes through the Batch printing unit to print the required batch code, manufacturing date etc. of the product to be packed. The product which has to be packed is loaded into the hopper which then flows through, the feed disc through the chute channel and then to the sealing rollers. The packed and sealed strip from the sealing rollers then passes through the brush shaft which is fitted with the draw brushes and slitters to give the desired vertical cutting which then passes through the cutter to cut the strip horizontally as per the required length.

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11.0 SAFETY INSTRUCTIONS  Do not open Electrical panel box when Mains are ON.  Do not attend on any terminals when supply is ON.  Do not try to collect strips directly from cutter, to avoid serious injury to your hands. Let the strips fall by itself.  Do not make any adjustments when the machine is in operation.  Do not touch the following parts when the machine is in operation.       

Sealing rollers. Thermostat adjustments and Slip Rings. Brush Shaft assembly and Slitters. Cutter Assembly. Chute Channel and Release pin. Cutting Gears adjustment. Back Gear Pin Ring/Cam Disc adjustment.

 Do not keep inspection window covers open.  Do not keep Cutting Gear cover open.

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12.0 OPERATION AND ADJUSTMENTS i.

Dismantling of Rollers from the machine  Switch off electrical Mains. Allow the rollers to cool down completely.  Remove or Disengage the Thermocouples from the Sealing Rollers

 Loosen the locking collar of the heater conduit pipe (Illustration No. l ) by loosening the Grub screws and then Pull out heater assembly along with heater from roller shaft and hand it inversely on the same supporting pipe

Grub Screws

 Release the pressure of sealing roller by rotating pressure knob till both the rollers are separated from each other. By rotating it in clockwise direction

 Loosen the Grub screw of sealing rollers and pull the rollers off from the shaft one by one. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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 Loosen Back Gear Colar and pull back gears from the shaft (Illustration No.5)

ii.

Assembling Roller back on the machine: While mounting the rollers back on the machine, this above procedure should be reversed. Ensure that knurling on respective rollers match properly. The Center of both the rollers matched should be exactly with the center of Draw brushes & cutter.

Should any adjustment be called for your left hand side roller shaft can be adjust-it by means of stud and nuts of Rigid Hanging Bracket (Illustration No.9) on left side of the machine.

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And Parallel position of your right hand sealing roller can be effected by regulating Pressure adjustment knob on right side of the machine (Illustration No.7)

iii.

Sealing Roller Adjustment.  Loosen Back Gear Locks’s  Release Roller Pressure  Match both Roller Cavity  Apply Pressure for sealing roller  Tighten back gear Locks  Pass Packing material (foil) through the roller by means of rotating Fly Wheel (hand wheel) or by INCH  Check the impression on the foil for proper Matched Cavity and equal Knurling Impression  To get equal Knurling Pressure need to adjust rear Flexible Hanging Bracket Bolt  Excess of equal impression pressure will develop Pin Holes in packing web.  Equal pressure can be adjusted by pressure Knob (Illustration No. 7 )

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iv.

Roller Temperature Adjustment

Electronic Digital Temperature Controller cum Indicator will give direct temperature reading and it can be easily adjusted while the machine is ON. If Cartridge Thermostat is fitted in the roller and one wire is grounded to roller and second wire is connected to Slip Ring which is connected to heater circuit. For adjusting the sealing roller temperature. You need to hold the Square key with your heft hand and use the Arrow key Screw to increase or decrease the temperature Thermometer has to be used to measure the temperature of roller when the MACHINE IS IN STOP POSITION.

CAUTION : Thermometer has to be Removed before switching ON the machine. v.

Vertical Slitters

Vertical Slitters are fitted on the shaft above the Brush Shaft Assembly (Illustration No. 11). When packed strip comes out from the Sealing Rollers it passes through the Vertical slitter assembly which slits the sealed strip as per the required adjusted width. Each set of Slitters consists of 2 slitters,

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INSTRUCTION MANUAL STRIP PACKING MACHINE

vi.

Cam Operated Horizontal Cutter  Cutter Assembly has 2 Blades one Fix Blade and the other Moving Blade. This assembly is operated by Cams, one pushing the cutter assembly downwards and upwards and the other imparting Scissors action to the moving blade of cutter to cut strips. Ensure that both the cams are adjusted properly. (Illustration No. 12)  To avoid clogging of strips in the cutter, Moving Blade Operating Cam has to be adjusted by means of the two Allen bolts provided on the cam disc.  Adjustment of cutting of strips is by means of main cutting gear Lock Collar.  Loosen Lock Collar and rotate Hand Wheel Clockwise or Anti-clockwise to achieve the desired result of cutting of strips. If hand wheel is rotated clockwise the cutting, achieved will be upwards and if hand wheel is rotated anticlockwise cutting achieved will be downwards.  To change Cam gear loosen the screw on Hand Wheel and remove Hand Wheel then loosen the screw of cam gear and pull the gear from the shaft.  To remove Main cutting gear, loosen locking collar and pull.

vii.

Changing the Cutting Length.  The cutting length can be altered by changing the Main Cutting Gear and/or the Cam Gear depending on the number of cavity in the Sealing roller.  The Cam gear is fitted on the Cam Shaft which can be identified as the shaft on which the hand wheel is fitted. (Illustration No. 12)  The Main cutting gear is fitted on Main Cutting Shaft.  The Idler gear is fitted in between the Cam gear and the Main cutting gear to match the drive.  See cutting gear chart to achieve the proper cutting length.

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13.0 TABLE FOR CHANGE OF CUTTING GEARS AS PER REQUIRMENT

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14.0 ADJUSTMENT OF FEEDING DEVICE.  S.S. Bowl has to be fitted on Vibrator by means of 3 Nos. Allen bolts along with S.S. Washer.  Out-let of S.S. Bowl (i.e. track mouth) should match the in-let of the channel (i.e. channel mouth) of Chute channel release pin.  Ensure that hopper does not touch S.S. Bowl. This can be achieved by means of the telescopic Hopper stand assembly which also controls the product feed rate to the Bowl.  Product feed rate from the S.S. Bowl to the S.S. Chute Channel is controlled by Vibrator controller. Over feeding of product will choke the tracks on the S.S. Bowl and consequently feeding of product to chute channel will not be uniform, at the same time product will be damaged. To achieve proper rational feeding regulate vibrator control knob.  Clearance of the channel mouth and S.S. Bowl bottom (i.e. bowl mouth) can be adjusted by 3 Nos. of vibrator mounting cups.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

15.0 ADJUSTMENT OF CHUTE WITH SEALING ROLLER AND S.S. FEED BOWL Remove Chute front cover. Fit Chute in the Chute holder slot. Match Chute slot with the center of sealing roller cavity. Adjust distance between Chute and Sealing roller. Clearance between the Chute & Sealing roller should be between 4to 6mm depending on product size and shape and type of packing material.  Adjust and lock Chute location guide stopper which is fitted on Chute holder.  Match release pin slot with upper slot of the Chute, so that product passes freely to release pin when release pin is in back position, this adjustment can be made by means of spring loaded Allen bolt which is fitted in front of Chute and then lock Allen bolt nut so that setting is not disturbed.     

 To drop the product down from release pin to roller cavity, release pin has to travel forward by means of release pin rod assembly which operates with the help of Cam disc. To control correct distance to drop product from release pin to lower slot (i.e. lower forward slot) of chute, adjust release pin rod stopper which is at the rear end of machine.  If length is increased the travel of release pin rod is less.  If length is decreased the travel of release pin rod is more. Therefore adjust the length so that the release pin slot matches lower slot of chute, to take care of dropping of product to Sealing roller without any obstruction.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

16.0 ADJUSTMENT OF DROPPING OF PRODUCTS IN CENTER OF STRIP

POCKET This is achieved by adjusting Cam disc which is fitted with back gear of roller shaft. Cam disc has 2 Allen cap bolt which has to be loosened after which the following adjustments can be made so that the product drops in the center of the pocket.  If cam disc is rotated clockwise (Refer Picture A) or Anticlockwise ( Refer Picture B) the dropping will be late.  If cam disc is rotated anti clockwise (Refer Picture A) or clockwise ( Refer Picture B) the dropping will be early

B A

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17.0 VIBRATOR Electro Magnetic vibrator consist of M.S. Base, 3 sets of Electromagnetic coils, spring reeds, Aluminum top plate, 2 amps Voltage Variac controller coupled with diode and condenser. (Illustration No. 13) To get satisfactory and desired vibration, set as following: 2 Track to 4 Track Bowls :- 4 rows of Spring reeds to be fitted in each Pole and air gap between coil and spring reed should be 1.5mm to 2mm.  6 Track to 10 Track Bowls :- 5 rows of Spring reeds to be fitted in each Pole and air gap between coil and spring reed should be 2mm to 2.5mm. Inspite of setting these gaps, if vibrations results are not satisfactory check the following: Diode and Condenser burnt. To replace.  One of the Coil burnt. To replace.  Spring reeds broken or cracked or have lost its tension. To replace. Note : To identify cracked or tension lost spring reeds, drop them one by one onto a hard surface ground. If it sound like a bell neatly then spring reeds are good. If blunt sound occurs then the spring reed is bad.  Check allen bolt of coil holder. If loose then tighten them.  S.S. Feed Bowl bottom surface should match properly with vibrator Top plate. If there is any air gap between Vibrator top plate and S.S. Bowl, products in the Bowl will start jumping instead of flowing smoothly. It is advisable to set vibrator control as following :  2 Track to 4 Track 120v to 160v  6 Track to 12 Track. 160v to 200v  Vibrator spring reeds and its setting : 2 Track to 4 Track :- 4 rows of spring reeds to be fitted in each pole and air gap between coil and spring reed should be 1.Smm to 2mm.  6 Track to 10 Track :- 5 rows of spring reeds to be fitted in each pole and air gap between coil and spring reed should be 2mm to 2.Smm. MARKETED & EXPORTED BY: VIBRER TECHNOLOGY PVT. LTD.

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18.0 DAILY ROUTINE CHECK UPS  Before starting the machine, see that all the inspection doors of the machine are closed. This prevents any dust or powder from reaching the bearing surfaces. The product should be free from dust and broken pieces before using it for strip packing.  The rollers should be cleansed by means of a soft brass wire brush.  The feeding assembly viz. Bowl, Chute channels should be dust free for efficient operation.  Check the following :     

Roller presser and lock bolts. Chute center and release pin setting. Cutting length. Batch coding. Conveyor belt should be tight.

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19.0 DISC PLATE FEEDING DEVICE This is generally supplied for packing soft gelatin capsule, odd shape tablets which will not feed through Vibrator feeding system e.g., sugar candy etc. The machine is equipped with a worm and worm wheel assembly driven by main shaft. This drives the disc plate for feeding. The worm shaft can be disengaged from main drive by disc plate clutch lever. 2 nos. of feeding brush are provided to feed the Disc hole and scrap excess material. In special cases we may have to provide geared motor with round brush to control feeding to disc plate. The adjustment of the product dropping into the sealing roller cavity can be done by loosening the screws on the disc plate holder and by advancing or retarding the disc plate feeding depending on the dropping of the product in pockets being late or early respectively. Feeding Device in case of Disc plate attachment (Illustration 14) Product is fed into the hopper from where it is guided onto the Linear Vibrator (Optional) from where it is further guided onto the Disc plate which has cavities into which the product settles when the disc plate rotates. A slot is provided at a particular place on the base plate just above the mouth of the Chute. When the Disc plate rotates the product from the Cavities of the Disc plate is then transferred into the Chute through this slot. The Chute guides the Product onto the Sealing Roller where the product is sealed. Cutting System in case of Pneumatic Cutter: (Illustration 15) The Packed and sealed Strip from the Sealing Roller first passes through the air outlet station, at this stage cool air from the blower is blown on the warm strip through the minute holes provided on the pipe on either sides of the strip which cools the strip (so that the strips can be cut easily) form here the strip passes through the Puller and Slitter Shaft which cuts the Strips vertically. These vertically cut strips then passes through the pneumatically operated Cutter Assembly which Cuts the Strips Horizontally into the desired Strip Length as per the pre defined Calculations.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

20.0 MAINTENANCE OF REDUCTION GEAR BOX i.

Description

Universal Type Reduction Gear box Fitted with Worm and Worm Wheel Reduction Gear Box Size 0.4 x Ratio I4: 1 The worm gears in all units are correctly adjusted before dispatch and no further adjustment is necessary to ensure satisfactory operation. ii. Lubrication An oil filler and breather plug and oil level and drain plugs are provided in the gear box for brush motor and it has to be topped up with oil (SURVO 68). iii. Oil Lubrication Only good quality straight mineral oils should be used, as inferior or unsuitable oils may cause rapid wear and possible damage to the unit. Oils in three viscosity ranges - light. medium and heavy, are listed below with a number of manufacturer names and reference numbers. The medium grades of oil are recommended for all units which operate under normal conditions of speed and load and where the surrounding atmospheric temperature is never likely to be less than 32°F (0°C). If the load is known to be light duty or if the surrounding temperature is less than 32°F (0°C), the lighter grades of oil may be used according to the conditions. For very heavy duty, the heavy grades of oil may be used providing the pour point is low enough to allow for starting under the coldest conditions in which the unit will operate. Lubrications with strong EP additives, such as those used for hyped gears, are not recommended for worm gearing

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INSTRUCTION MANUAL STRIP PACKING MACHINE

In application where gears are subjected to higher than normal temperature conditions due to higher ambient temperatures and or continuous heavy loads, the cylinder oils as follows are recommended by Hindustan Petroleum:  For Continuous Medium duty : CYNDOL - TC -140  For Continuous Heavy duty : CYNDOL - TC -190 iv.

Routine Maintenance

The Oil level in the unit should be regularly maintained and should be checked at least once a month. To avoid false readings, examination of the oil level should be made with the gear stationary , and to maintain free ventilation of the unit under all conditions, the breather hole in the filler plugs should be kept clear at all times. v.

Changing Of Oil

After 200 hours running, the worm gear unit should be drained, flushed and refilled with clean oil. Subsequently, the oil should be changed completely at intervals dependent upon working conditions. The intervals should not exceed 2000 hours for heavy duty and 2500 hours for light duty. In any case, a complete oil-change is a must once every 12 months.

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21.0 BATCH PRINTING UNIT i.

Introduction & Working Principle

This unit is basically overprinting assembly wherein ink soaked felt roller gives the required ink to stereos to get it printed on packaging material. This system. Eliminates the use of ink-pot and also avoids spillage of ink on the foil and printing area, it also avoids number of settings. This unit has the following: Stereo drum fitted with stereo rings and rubber roller tyres to fit grove type rubber stereos. OR  Stereo drum without stereo rings but with rubber tyres on both ends of roller for fitting of sticker type rubber stereos.  Felt roller to soak ink.  Foil running drum roller.  The assembly is both side supported type with pressure adjustment tumble screws for easy setting of stereo to packaging material and felt roller to stereo.  It is designed to suit any packing material like Aluminum Foil, Glassine Poly, Paper Poly and Poly Polystyrene & Cellophane.  This unit is very simple and easy to mount on any type of strip packing machine ii.

Installation

Mount Batch printing mounting bracket by means of fixing 4 nos. bolts on strip Packing machine body either on left hand of right hand side as required and mount the B.P. unit.

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INSTRUCTION MANUAL STRIP PACKING MACHINE

iii.

Precautions  While mounting the unit on strip packing machine, the stationary roller should be parallel to the sealing roller of SPM.  Stationary roller should be in right angle to the body of the strip packing machine.

iv.

Operation & Observation  Observe the printing impression.  If printing impression is weak, then add few drops of "Felt type Ink", to the felt roller.    

If printing is very dark then : It means too much ink is added. Wait and allow sufficient time for the pad to absorb the ink. If still smudging continues, then add few drops (5 to 6) of printing aid (Ink) on the felt rollers.

 Repeat the printing operation and if need be adjust pressure.  If the felt roller is properly soaked with enough ink then the printing may last for at least one to two hours.  As and when printing becomes lighter then add few drops of ink while unit is in operation.  Recommended ink - Felt type ink to be used.

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22.0 PREVENTIVE MAINTENANCE CHECK LIST

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23.0 SUB ASSEMBLY DRAWINGS

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24.0 HMI MANUAL: WELCOME SCREEN:

Welcome screen will be displayed once the HMI is ON. Following options are accessible on welcome screen: LOGIN: User can login at different access levels with respective user id and password. Usually three levels are provided i.e., Operator, Supervisor and Manager. With desired accessibilities.

LOGIN CREDENTIALS LEVELS Level 1 Level 2 Level 3 Level 4

USER ID OP1 SUP1 MAN1 ENGG1

PASSWORD 111 222 555 777

LOGOUT: User can logout by pressing this button. ABOUT US: This screen will give details of the equipment supplier.

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MAIN SCREEN:

Once the user is logged in with correct id and password, he can access the main menu for various functional selections. Following are the screens accessible through Main Menu screen:  CONTROL OPTIONS: PROCESS MODE: This button will guide the user into the process mode, wherein he can operate the machine. All setting and display of parameters are accessed from this screen. SETTING MODE: This button will guide into the setting screen, where the operator can set the machine or do mechanical adjustments or change overs. This mode can be used during maintenance period.

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 MONITORING OPTIONS: INTERLOCKS: Safety parameters for stating the machine is displayed in this screen. All the parameters should be green for healthy condition. Any parameters in red has to be attainted before starting of the process. TRENDS: Trends are the graphical representation of the temperature controlling and variation. Two different trends are displayed one is for temperature and other one is for the heater current. ALARM HISTORY: Alarm history is the screen which displays the safety alarms of the equipment. This screen displays current as well as previous alarm history. I/O STATUS: This is the diagnostic screen used for displaying of input and output status of the machine. All the input and output components connected to the PLC are displayed in this screen.  SYSTEM SETTING: USER MANAGEMENT: User management is provided for creating and deleting of users. Manger has the accessibility of this screen. ENGINEERING SETTING: Engineering setting screen is provided setting some critical parameters of the machine. This screen is only accessible for manager level.

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PROCESS MODE SCREEN:

This screen is used for full functioning of the machine. All the set parameters for operation has to set through this screen. Displaying of actual values are also visible through this screen. START and STOP buttons for Drive, Heaters, Vibrator and machine is accessible from this screen. User can also enter into other necessary screens like trends, interlocks, Alarm set points through this screen. Reset Count: this button is provided for resetting the production count. This can be done only by supervisor and higher level.

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SETTING MODE SCREEN:

Through this screen the operator can set the machine or do mechanical adjustments or change overs. This mode can be used during maintenance period. Operator can check the outputs independently in case of troubleshooting if any issue.

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INTERLOCKS SCREEN:

Safety parameters for stating the machine is displayed in this screen. All the parameters should be green for healthy condition. Any parameters in red has to be attainted before starting of the process.

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TRENDS SCREEN: Trends are the graphical representation of the temperature controlling and variation. Two different trends are displayed one is for temperature and other one is for the heater current.

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ALARM HISTORY SCREEN:

Alarm history is the screen which displays the safety alarms of the equipment. This screen displays current as well as previous alarm history. The pop up if any alarm occurs in between the process will be displayed as bellow:

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I/O STATUS SCREEN: This is the diagnostic screen used for displaying of input and output status of the machine. All the input and output components connected to the PLC are displayed in this screen.

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USER MANAGEMENT SCREEN: This Screen is used for Adding, editing and deleting of user from the operation panel. This screen is accessible only to manager.

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ENGINEERING SETTING SCREEN:

Engineering setting screen is provided setting some critical parameters of the machine. This screen is only accessible for manager level.

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ALARM SETPOINTS SCREEN:

This are the critical parameters necessary for tuning of respective components. Only accessible at higher level.

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POP UP SCREENS: Below are the pop ups which will occur during the process or after any specific action.

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ABOUT US SCREENS:

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BATCH PRINTING UNIT: (Optional Attachement) Introduction & Working Principle Ink Jet printer is used for printing of batch code and necessary data. 3 head printing system is mounted on the machine which uses cartridge type printer head for printing. Encoder is provided for detecting the speed of foil pulling and thus printing at desired position on the foil. The printing is done before the foil passes into the sealing zone. A laptop is provided along with the system for configuring the printer heads through Ethernet communication.

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25.0 GA DRAWING:

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FRAME DRAWING:

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26.0 ELECTRICAL DRAWING

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AFTER SALES – SERVICE: The machines designed marketed & exported by vibrer technology are guaranteed to give trouble free performance as per the general conditions of sale. If during the period of guarantee there are any functional defects or failure of any component covered under the guarantee, so Manufacturer will repair or replace the defective component after checking the Machine. The guarantee of the Machine will lapse in case of any modifications carried out on Machine without specific written authorization of supplier or use of non-genuine spare parts or not strictly following the safety instructions contained in this Manual or not adhering to the preventive and regular maintenance, lubrication and cleaning schedules. For any service assistance required, you may get in touch with any of the below details. Vibrer Technology Pvt. Ltd. 418, Diamond Industrial Estate, Ketkipada Road, Off W.E. Highway Dahisar East Mumbai 400068 India Tel / Fax: 0091-22-28964927/28 Mobile: 0091-9821513204 Email: [email protected]

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27.0 LAYOUT OF STRIPS:

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