Manuals. Syncom rehanger (killing - evisceration) Original instructions

Transcription

1 Manuals Syncom rehanger (killing - evisceration) Original instructions

2 Copyright Copyright by Meyn Food Processing Technology B.V. All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electrical, photo copying, recording, or otherwise, without the prior written permission of Meyn Food Processing Technology B.V. Improper use This manual has been carefully prepared. However, it does not contain all the conceivable hazards and involved risks that could happen during installation, operation and maintenance of the machine. The machine is not to be used for any purpose other than specified when it was built. Improper use can lead to injuries and, or, material damage.

3 Table of contents Table of contents Dear customer... 5 CE... 6 Disclaimer... 6 Address... 6 Meyn Field Service Support Introduction Technical specifications General assembly drawing General description Inlet shaft Outlet shaft Workstation(s) Product output The machine technical Introduction Single Board Computer Functioning Single Board Computer Performance of the machine Safety General Hazards Hazard zones Protective measures Machine safety Transportation General Hazards Personal Protective Means General Installation General Hazards Personal Protective Means Installation Required floor area Protective earth points Electrical connection Air connection Meyn Food Processing Technology B.V. 1

4 Table of contents 5 Operation General Hazards Personal Protective Means Hazards protective measures Preparing for safe operation Safety measures during operation Controls Functions of the manual controls Start-up procedure In production Emergency stop Stop procedure Cleaning information for this machine Standard Operating Procedure Safety requirements Training Instructions made from the supplier of the cleaning chemicals Cleaning aids Hazard pictograms on containers of cleaning chemicals Personal Protective Means Cleaning and disinfection equipment, materials and implements Required utensils for manual removal of dirt High pressure cleaning equipment Foam-cleaning equipment (alkaline- and acid foam) Rinsing after foaming process Disinfection equipment Rinsing after disinfection process Quality of water: potable quality and of limited hardness Recommended cleaning and disinfection chemical agents Meyn recommended Alkaline foaming products Meyn recommended Acid foaming products Meyn recommended Disinfection products Cleaning-, foaming-, rinsing- and disinfection-procedure Check the effectiveness of the cleaning and disinfection procedure General Hazards Preparations Lockout -Tagout After cleaning Special cleaning areas for this machine Cleaning mode; partial disassembly before cleaning (equipment-specific) Meyn Food Processing Technology B.V.

5 Table of contents 7 Maintenance and troubleshooting table General Hazards Personal Protective Means Preparations Lubricants Lubrication-point list Drive motor(s) Checklist - Weekly Assembly and adjustments General Hazards Personal Protective Means Preparations Inlet shaft Shackle guide Leg guide Timing of the killing shaft Height of the shackle Angle of the cutting unit Height of the cutting unit Timing of the transfer wheel Nylon ejector disc Position of the evisceration shackle Timing between master and slave Dismantling instructions General Hazards Personal Protective Means Dismantling Disposal Environment Recycling Meyn Food Processing Technology B.V. 3

6 Table of contents 4 Meyn Food Processing Technology B.V.

7 Dear customer Thank you for purchasing this Meyn product. To ensure your safety, please read this instruction manual before use, and have it in place for future reference. Manufacturer Meyn Food Processing Technology B.V. is the reliable and committed partner of renowned poultry processing companies in over 90 countries worldwide. Meyn is widely recognized for its ability to support its customers in their ambition for higher capacity and increased yield and efficiency. Meyn equipment has proven to maintain its highlevel performance under a wide variety of line speeds and bird sizes, allowing its customers to achieve a top-level productivity with an absolute minimum of effort. Manual This manual will enable you to use the machine in a safe and correct manner. Everyone working with the machine must be familiar with this manual. Insufficient knowledge can have serious consequences. 1. This manual is written for the personnel installing, operating, adjusting, maintaining, repairing or moving machinery. 2. Only competent personnel are allowed to operate the machine. 3. All personnel mentioned in point 1 must know where the manual is kept. Meyn Food Processing Technology B.V. 5

8 CE The CE mark indicates that this product complies with the European requirements for safety, health, environment and customer protection. CE-mark products are for sale in Europe. NOTE: The illustrations shown in this manual were produced during the development stages and may differ from the actual product. Unless otherwise specified, the explanation about these illustrations is provided for this specific MEYN product. Disclaimer This MEYN equipment is designed to process raw food products only. Raw poultry products may contain pathogenic bacteria like Salmonella, Campylobacter, Listeria and are therefore Not Ready To Eat (NRTE), see 9 Code of Federal Regulations NRTE products need to be sufficiently cooked to make them Ready To Eat (RTE), see 9 Code of Federal Regulations After touching MEYN equipment, poultry products are still NRTE, so these products require labelling, handling and cooking before consumption. MEYN is not responsible for labelling, handling and cooking. Subsequently, MEYN declines any responsibility for the bacteriological safety of products in the RTE stage. Address Head office: Meyn Food Processing Technology B.V. Westeinde 6, 1511 MA Oostzaan The Netherlands Chamber of Commerce Zaandam nr Meyn Food Processing Technology B.V.

9 Meyn Field Service Support Meyn America Meyn worldwide - Monday to Friday: :00 - Monday to Friday: 08:30 16:30 (GMT +1) - T: T: +31 (0) Ask for Help Desk Assistance - Ask for Help Desk Assistance - Saturday and Sunday & out of hours - Saturday and Sunday & out of hours - T: / T: +31 (0) Follow instructions & leave a message - Follow instructions & leave a message - E: help.america@meyn.net - E: help@meyn.com - F: F: +31 (0) Meyn Food Processing Technology B.V. 7

10 Meyn Field Service Support (Emergency service) 24/7 emergency support +31 (0) Teleservice: Cost and time savings due to reduced machine downtime Quick response to emergencies Full customer history kept on file Remedial repairs suggested to maintain production and yield General check up and advice First 20 minutes per issue free of charge Warranty issues will stay free of charge when customer claim is assigned Annual Help Desk Agreements can be quoted upon request When you contact Meyn Field Service Support please have the machine number at hand. This number can be found on the machine plate (image below) mounted on the machine, and on the frontpage of the associated Partmanual. Machine No. Serial No. Type Year Meyn Food Processing Technology B.V. Oostzaan The Netherlands. 8 Meyn Food Processing Technology B.V.

11 Introduction 1 Introduction A functional description of the machine. 1.1 Technical specifications L W H Specifications: Length (L) 2,655 mm Cutting in rehanger Yes Width (W) 1,630 Height (H) 3,545 mm Noise level < 70 db(a) Meyn Food Processing Technology B.V. 9

12 Introduction 1.2 General assembly drawing The syncom rehanger consists of the following main parts: 1. Killing shaft 2. Frame 3. Transfer shaft 4. Transfer wheel 5. Emergency stop button (If applied) 6. Evisceration shaft 7. Cutting unit (incl. motor) 8. Tacho meter 9. Inlet guide 10.Shackle guide 11.Pull-cord safety 10 Meyn Food Processing Technology B.V.

13 Introduction 1.3 General description The MEYN Syncom Rehanger has been developed to rehang products from the killing line (A) to the evisceration line (B). During the rehanging the hocks of the product will be cut off by a knife unit (C). B C A Meyn Food Processing Technology B.V. 11

14 Introduction Inlet shaft The products are delivered by the killing line, hanging in shackles with the breast towards the machine. Guided by a inlet guide, shackle guide and leg guide the shackle with product will be positioned correctly in the wheel of the inlet shaft (A). The legs of the product will be bended during transportation of the product in the wheel of the inlet shaft (B). This is needed for a correct cut of the cutting unit. Before cutting the hocks the transfer wheel will take over the product from the inlet shaft (C). The shackle with the hocks will be transported to the hock unloader where the hocks will be removed from the shackle. The product will be transported by the transfer wheel to the outlet shaft. A B C 12 Meyn Food Processing Technology B.V.

15 Introduction Outlet shaft After transporting the product a half cycle the product will be rehanged to the outlet shaft. The product will at the centre of the machine be rehanged in the shackle of the the outlet shaft. Just above the transfer wheel is a plastic disc mounted, which takes care that the product really will be rehanged in the shackle of the outlet shaft. The disc gives the legs a little push to realize the rehanging (A). A Meyn Food Processing Technology B.V. 13

16 Introduction 1.4 Workstation(s) Note Keep work area clean and tidy. Ensure properly adjusted work surfaces (if applicable). Make sure there is proper lighting at workstations ( lux). Provide non-slip flooring in areas that become wet or soiled with animal fat. Wear all relevant personal protective means suited for the task and environment. Make sure employees are aware of hazards in the environment in which they work. Implement programs to identify and correct ergonomics-related problems in work. 1.5 Product output The output from the machine must satisfy the following requirements: To rehang the products from the killing line to the evisceration line. All hocks must be cut off. 14 Meyn Food Processing Technology B.V.

17 Introduction 1.6 The machine technical Introduction Single Board Computer The MEYN SYNCOM Single Board Computer has been designed to control the speed of a secondary (or slave) overhead conveyor track (or line) as opposed to the speed and shackle pitch of a primary (or master) overhead conveyor track. When using the MEYN SYNCOM with a MEYN Rehanger, chickens can be rehung from shackles of the master line into shackles of the slave line, in a continuous synchronised process. Meyn Food Processing Technology B.V. 15

18 Introduction Functioning Single Board Computer The master line (field I) has a certain shackle pitch and runs at a certain speed, driven by an electric motor (Mm). The electric motor is controlled by a frequency converter (FCm). The speed of the line as well as the passing shackles are detected by a tachometer (Tm). The output signal of the tachometer is led into the syncom board. II Ms Ts FCs The syncom board now generates a signal for the slave frequency converter (FCs) in the slave line (field II). The slave frequency converter makes sure the slave motor (Ms) is running at about the required speed. A second tachometer (Ts) is mounted in the slave line, detecting the speed and passing shackles. The output signal of the slave tachometer is also led into the SYNCOM. I Mm Tm SYNCOM Here the two tachometer signals are compared; both the speed as well as the position of the shackles are taken into account. The difference in information between the master and the slave signals will make the SYNCOM adjust the speed of the slave motor (through the slave frequency converter) until synchronization is reached. FCm In this situation the number of shackles passing the master tachometer (per hour) is equal to the number of shackles passing the slave tachometer (per hour). 16 Meyn Food Processing Technology B.V.

19 Introduction 1.7 Performance of the machine The rehanger is driven by a overhead conveyor, as most of the Meyn line machines. This overhead conveyor consists of a round bar chain, to which synthetic trolleys are mounted. The trolleys roll over a T-profile. The shackles which transport the birds are mounted to the trolleys. The overhead conveyor is driven by so-called drive units. Meyn Food Processing Technology B.V. 17

20 Introduction 18 Meyn Food Processing Technology B.V.

21 Safety 2 Safety A description of safety aspects related to the machine. It is particularly important that you study this paragraph carefully. The Meyn Food Processing Technology B.V. provides you with all the necessary information concerning risks that may exist when the machine is in use. The customer is responsible for understanding and applying this safety information. Meyn Food Processing Technology B.V. 19

22 Safety 2.1 General Hazards During the life cycle of the machine, the following potential hazards may occur: MOVING PARTS Crushing hazards due to drive mechanisms. Cutting hazards due to cutting parts. Entanglement hazards due to rotating parts or conveyor systems. SHARP EDGES Cutting hazards because of cutting parts. STORED ENERGY This is electric-, hydraulic-, or pneumatic energy, depending on which connections are present. Situations are likely to occur if components containing energy fail or if the energy is released in an uncontrolled way. ELECTRICAL The electrical equipment on the machine can cause electric shock and burns. Electricity has the potential to cause a fatal injury. Risk of electric shock can be increased due to the following: Parts wear because of frequent operator intervention. Water entering the electric enclosures. Corrosion due to detergents and disinfectants. SLIPPERINESS The wet nature of the process and products make surfaces slippery. Wet materials which spill out or overflow make surfaces slippery. Runoff water and detergents from cleaning cause slipperiness. 20 Meyn Food Processing Technology B.V.

23 Safety 2.2 Hazard zones Do not come near the rehanging point between the inlet shaft and the transfer shaft. You might get stuck. 2. Do not come near the knife. Knife is very sharp. 3. Do not come near the rehanging point between the transfer shaft and the outlet shaft. You might get stuck. 2.3 Protective measures In order to make the use of this machine as safe as possible the following safety devices have been fitted: An emergency stop button is mounted on the frame. Meyn Food Processing Technology B.V. 21

24 Safety 2.4 Machine safety SAFETY SIGNS The machine safety signs are used to highlight safety information related to installation, operation, use and maintenance of the machine. For this machine the following machine safety signs are used: Warning; Sharp element Warning; Counterrotating rollers Due to diversity in safety stickers, graphics may differ from templates shown. CHECK SIGNS During the machine life-cycle attached signs can get damaged and or wear-off. Check these signs regularly and replace when necessary. See illustrations in this section for the proper safety signs and their right locations. Ensure that safety stickers are in stock. Please contact Meyn to order new stickers. 22 Meyn Food Processing Technology B.V.

25 Safety Meyn Food Processing Technology B.V. 23

26 Transportation 3 Transportation A description of actions to transport the machine. 3.1 General Hazards During the transportation of the machine, the specific following potential hazards can occur: Loss of machine stability Prevent loss of machine stability by: Installing the machine on a flat surface. Using the adjustable legs to stabilize the machine. Following up the lifting and moving instructions. Read chapter Safety for more general hazards. 3.2 Personal Protective Means Wear protective shoes. Wear head protection. Wear protective gloves. Wear protective clothing. Meyn Food Processing Technology B.V. 23

27 Transportation 3.3 General Precautions Cleanliness and order on the site will increase the safety considerable. Use only approved lifting equipment during transport. Make use of all necessary transport tools. Ensure that only qualified personnel execute transportation of machinery. While working with Meyn equipment, always follow local rules and regulations. Wear relevant personal protection means (especially when working on high level). Make sure all cables and hoses are correctly secured. Do not walk or work under suspended loads. Make sure you cannot get trapped between the load and the wall or a fixed object. If possible, position yourself such way that you are visible to the leading foreman. If this is not continuously possible make sure a second man (flag-man) is available to signal the leading foreman. Considerations Consider the weight and dimensions of the load. See chapter Introduction. Ensure the floor strength is sufficient to support the machine weight. Checking The transport floor should be flat and preferably smooth. Ensure there is sufficient space to install the machine. Basic steps Read all safety, lifting and moving instructions. Carefully plan the route to the final destination. Carefully transport the machine to its destination. 24 Meyn Food Processing Technology B.V.

28 Installation 4 Installation A description of the actions that must be performed before the machine can be used. 4.1 General Hazards During the life cycle of the machine, the following potential hazards may occur: Loss of machine stability Loss of machine stability can occur during the following circumstances: Prevent the machine is installed on a slope or uneven surface. Prevent the machine is not stabilized by means of the adjustable legs. When moving the machine: always follow up the lifting and moving instructions. ELECTRICAL Electrocution. For example when connecting an electrical motor(s) or changing the phases. Read chapter Safety for more general hazards. 4.2 Personal Protective Means Wear protective shoes. Wear head protection. Wear protective gloves. Wear a safety harness. Wear protective clothing. Meyn Food Processing Technology B.V. 25

29 Installation 4.3 Installation The Meyn Syncom rehanger from the killing line to the evisceration line must be placed between the killing line and the evisceration line. The rehanger is driven by a overhead conveyor and also the shackles with products will be provided by a overhead conveyor. The Syncom rehanger is delivered as a completely assembled unit. The machine must therefor be installed and connected electrically only. High pressure air is required. When position the rehanger make sure that the entire rehanger is placed on a flat surface and that the rehanger is level. An area of at least one meter around the machine has to be cleared to provide operators and maintenance personnel with necessary space for check-up and maintenance activities. When moving the rehanger by fork lift, make sure not to damage the underside of the machine. At delivery the machine is set according default settings. See Chapter Assembly and adjustments for optimal machine settings Required floor area See Technical Specifications (LxW). Meyn advises to maintain an open space of 1 meter around the machine to execute cleaning and maintenance safely. 26 Meyn Food Processing Technology B.V.

30 Installation 4.4 Protective earth points The customer is responsible to earth the machine in accordance with the international standard IEC : Electrical connection Precautions Only qualified personnel should connect the machine/device. All power supplies should be properly polarized and grounded. All power supplies should be protected with fuses or circuit breakers. Replace grounding wires when damaged. Use lockout procedure before service or maintenance. Replace any wiring when it shows signs of wear and tear or other damage. Keep safety guards in place. All electrical connections must be dry and free of moisture before applying power. Ensure that voltage and frequency are consistent with motor specifications. Any power supply not coinciding to the recommended electrical requirements of the machine could cause the machine to malfunction. Connect the motor or device according to local regulations and the electrical diagram. Make sure the motor (if applied) is thermal protected. The electrical diagram is inside the main panel. Check if the direction of rotation of the motor is correct. If the rotation is wrong switch off the power to the control panel and swap two of the three phases after the frequency converter. 4.6 Air connection The meyn rehanger is provided with a high pressure system. The air pressure is minimal 6 bar. Use a PU4 hose. Meyn Food Processing Technology B.V. 27

31 Installation 28 Meyn Food Processing Technology B.V.

32 Operation 5 Operation This chapter gives a description of the actions that must be taken before operation. 5.1 General Hazards During the life cycle of the machine, the following potential hazards may occur: MOVING PARTS Crushing hazards due to drive mechanisms. Cutting hazards due to cutting parts. Entanglement hazards due to rotating parts or conveyor systems. SLIPPERINESS The wet nature of the process and products make surfaces slippery Read chapter Safety for more general hazards. 5.2 Personal Protective Means Wear protective gloves. Wear protective clothing. Wear protective shoes. Wear eye protection. Wear ear protection. Meyn Food Processing Technology B.V. 29

33 Operation 5.3 Hazards protective measures Preparing for safe operation Before operating the machine, Ensure that the machine is placed in a correct and stable position. Ensure that the machine is not modified in any way that might affect proper and safe operation of the machine. Ensure that the area around the machine is free from materials and tools. Ensure the power supply complies with local regulations. Ensure only qualified personnel operates machinery. Operators must have a relevant training before operating the machine. The operator must be aware of the possible hazards when working with this machine. Read the instructions in this manual. Ensure you understand the machine safety systems and act accordingly. Take all recommended precautions. Use all personal protective means available. Follow all procedures and instructions. Ensure the use of correct tools for the job. When applicable use lifting equipment Safety measures during operation While operating the machine it is essential that a number of safety instructions are taken: Ensure that no persons are on top, inside or under the machine while in use. Keep the area around the machine free from materials and obstructions. Keep hands and other body parts away from moving parts of the machine. Keep all safety guards and doors closed. Before starting maintenance use proper lockout procedures. Check yourself that no jewelry, hair or clothing is hanging loosely, tuck it away. 30 Meyn Food Processing Technology B.V.

34 Operation 5.4 Controls The central control box of the evisceration line is provided with the manual controls: 1. ON/OFF switch 2. Emergency stop button. This is located on the frame. 3. Safety switches for the motors. This will not be delivered and/or installed by Meyn Food Processing Technology B.V. 4. Cleaning switch. This is for the whole line. 5. Operating switch for the knife motor Functions of the manual controls The list below gives a short description about the functions of the manual controls. The sequence corresponds to the numbering used in the previous paragraph. 1. If you put the switch ON, a green lamp goes on. The machine is working now. 2. Press on the emergency button, in case of an emergency, and the whole line stops. The machine will stay in the last position. A central red lamp goes on. 3. Switch OFF the safety switch before starting maintenance and serviice works on the machine. 4. Switch ON the cleaning switch before starting cleaning the machine. 5. Switch ON the operating switch for starting the knife motor Start-up procedure Start the knife motor. The machine is part of the overhead conveyor system. This is controlled from the central control box. The start/stop button of this machine is located on this central control box. The switch is a selection switch; Start 1 and stop 0. To start the machine put the switch in the 1 position and the machine is also ready for production. Meyn Food Processing Technology B.V. 31

35 Operation In production When the machine is correctly adjusted it will continue to function independently. However, it is important to follow the cleaning procedures and make any adjustments necessary for different size and weight of the broilers Emergency stop For use in emergency situations, emergency stop push buttons are mounted on the overhead conveyor and on the frame of this machine. When these red push buttons are pressed, the machine will stop immediately. They may only be used in cases of emergency. For re-starting the machine after using an emergency stop switch you must first reset the switch. The procedure is as follows: Cancel the emergency situation. Reset the emergency stop switch. Reset the emergency stop switch circuit by means of the blue button on the panel. Accept the fault on the touch screen. After this you can restart the machine Stop procedure The start/stop button of this machine is located on this central control box. Stop the supply of the broilers to the machine and wait till the last processed broiler is transported out of the machine before stopping the machine. To stop the machine put the switch in the 0 position and the machine wil stop. Stop the knife motor. 32 Meyn Food Processing Technology B.V.

36 Cleaning information for this machine 6 Cleaning information for this machine The explanation and advice for the entire machine cleaning process is divided in two stages: General cleaning information for this machine is described in chapters 6.1 till 6.9 Specific cleaning information for this machine starts at chapters Standard Operating Procedure These cleaning instructions meet the cleaning and disinfection requirements of the following international standards: 1. EN :2005+A1:2009 (E). 2. NSF/ANSI/3-A NEN EN ISO Hygiene requirements for the design of machinery. Meyn Food Processing Technology B.V. 33

37 Cleaning information for this machine 6.2 Safety requirements Training All cleaning personnel need to be properly trained for the job, and be made aware of: The general and specific cleaning instructions for this machine. The instructions from the supplier of the cleaning chemicals. The meaning of pictograms. Particular risks during cleaning and especially the use of chemicals. The risks of moving equipment, cleaning aids like platforms, slippery floors and such. The importance of thorough cleaning and disinfection. The importance of wearing protective clothing. Cleaning personnel must have access to cleaning instruction made for the machine being cleaned Instructions made from the supplier of the cleaning chemicals The recommended suppliers, Diversey and Ecolab, provide information of their products as follows: By means of digital (website) and hardcopy documentation. On the stickers of the actual product. This information includes the characteristics of the chemical, the prescribed concentration, and contact time. Meyn FPT recommends that these instructions are strictly followed because they describe how to use the products in a safe and effective way. Any deviation from these instructions easily leads to dangerous situations or equipment damage, by e.g.: Too high a concentration. Too long contact time that may affect the equipment. Too low a dose, or a short contact which may lead to poor cleaning. The chemicals and methods recommended by Meyn are listed in chapter "Recommended cleaning and disinfection chemical agents. 34 Meyn Food Processing Technology B.V.

38 Cleaning information for this machine Cleaning aids The topside of a machine or equipment is generally much higher than the eye of a person that is standing on the floor. To enable cleaning personnel to reach inaccessible areas of the machine/equipment it may be required to provide a platform, preferable a moving-platform. This platform is not part of the delivered equipment. The customer is advised to provide a safe and sturdy platform, including at least a proper railing and anti-slip floor. In case of a movable platform, a brake is required. In all cases, such a platform should meet all local requirements Hazard pictograms on containers of cleaning chemicals GHS (Global Harmonized System) pictograms indicate the severity and the character of the risk. Below some examples. Skin corrosion; corrosive to metals Acute toxicity Skin irritation Hazardous to the aquatic environment May cause allergy or asthmatic symptoms or breathing difficulties if inhaled. Meyn Food Processing Technology B.V. 35

39 Cleaning information for this machine Personal Protective Means Personal Protective Means includes: Gloves that are waterproof and resistant to the applied chemicals Coat and trousers, resistant to the applied chemicals Anti-slip boots that are waterproof and resistant to the applied chemicals Safety goggles that are waterproof and resistant to the applied chemicals Hairnet and safety helmet 36 Meyn Food Processing Technology B.V.

40 Cleaning information for this machine 6.3 Cleaning and disinfection equipment, materials and implements Required utensils for manual removal of dirt High pressure cleaning equipment Above a stationary high pressure-system, ring pipe with several satellites. Meyn Food Processing Technology B.V. 37

41 Cleaning information for this machine On the right a mobile high pressure system of Kärcher, with high pressure gun with bent head. Water pressure: The recommended water-pressure is in between 20 and 40 bar. Flow: - A pressure lower than 20 bar has an insufficient cleaning impact. - A pressure higher than 40 bar is not recommended because of aerosol formation. At 30 bar, the flow per spray gun should be around 800 liters per hour. Nozzle Type: Flat spray, with an angle that is in between 20º and 25º. - An angle smaller than 20º will reduce the reach of the water spray. - An angle larger than 25º will reduce impact of the water droplets. Temperature: - To avoid denaturation and sticking of proteins a water temperature of 50ºC to 55ºC is recommended. 38 Meyn Food Processing Technology B.V.

42 Cleaning information for this machine Foam-cleaning equipment (alkaline- and acid foam) Enduro Power satellite unit (courtesy Diversey). Meyn recommends the Enduro Power system of Diversey, for rinsing, foaming and disinfection. Such systems can have a central or de-central set up. 1. Rinsing 2. Foaming 3. Disinfection Above: central system (Courtesy Diversey). Meyn equipment must be foamed bottom-up, from feet to top of equipment. Periodically, the alkaline foaming process is replaced by an acid foaming process, to remove calcium- magnesium- and iron residues. Acid foaming should be done: Once per week, if water hardness is higher than 8 GH. Once per 2 weeks if the water hardness is lower than 8 GH. Meyn Food Processing Technology B.V. 39

43 Cleaning information for this machine Rinsing after foaming process After (alkaline or acid) foaming, the equipment needs to be rinsed after a prescribed time. Recommended equipment see chapter Foam-cleaning equipment (alkaline- and acid foam). Maintain a low pressure. Water temperature is in between 10ºC and 55ºC. Rinse directly after the recommended contact time of the foam, to avoid chemicals and dirt from sticking to the equipment again. Result: the entire removal of chemicals and dirt from the equipment. The equipment should be clean and ready for disinfection Disinfection equipment After rinsing, the equipment needs to be disinfected. Temperature of the disinfection fluid can be cold or warm. Recommended equipment see chapter Foam-cleaning equipment (alkaline- and acid foam). The cleaner needs to work in a systematic way, because it is difficult to see which surfaces have been disinfected and which have not. Disinfection chemicals do their job in 5 minutes. Contact time should be 5 to 10 minutes. A shorter time than 5 minutes is insufficient for proper disinfection. A longer time than 10 minutes has no added value, and increases the risk of corrosion. 40 Meyn Food Processing Technology B.V.

44 Cleaning information for this machine Rinsing after disinfection process After disinfection, the equipment needs to be rinsed after a prescribed time. Recommended equipment see chapter Foam-cleaning equipment (alkaline- and acid foam). Maintain a low pressure. Water temperature must not be higher than 55ºC. Water should be of potable quality. Rinsing should take place directly after the recommended contact time of the disinfectant, see chapter Meyn recommended Disinfection products, during e.g. 5 to 10 minutes, until all surfaces are thoroughly rinsed Quality of water: potable quality and of limited hardness Water contains Calcium- and Magnesium salts which may cause a deposit on equipment surfaces. Especially when the concentration of these salts is high, the exposure time is long and the water is heated in the equipment a deposit will be formed. The deposit is generally a porous film, which provides an opportunity for bacteria to hide and survive. This layer is difficult to remove. In case of "hard" water expressed in Degrees German Hardness, acid foaming is needed more often. It is recommended to ask the supplier of the water for the hardness of the water, and/or measure the hardness by a simple laboratory method, Meyn Food Processing Technology can give advice in this. In case of "hard water" (higher than 8 GH) it is recommended to soften the water, especially if water is to be heated in the equipment. Meyn Food Processing Technology B.V. 41

45 Cleaning information for this machine 6.4 Recommended cleaning and disinfection chemical agents The listed chemicals are selected to the best of our knowledge and based on our information concerning: Proven effectiveness in the poultry processing industry. Availability from the 2 major suppliers worldwide, Diversey and Ecolab. compatibility with the used materials, that is: If the chemicals are used in the prescribed way, they are not expected to be aggressive on the materials applied in the equipment. Note: Chemical products and recommendations can be changed by their suppliers. Recommendations can be obtained from these suppliers. Material Safety Data Sheets can be obtained from these suppliers. The recommendations of the supplier always prevail above the recommendations in this manual. After alkaline foaming, acid-foaming or disinfection the equipment always needs to be rinsed directly after the prescribed contact time Meyn recommended Alkaline foaming products Product Concentration Temperature Contact time (minutes) Diversey EnduroChlor VE to 3.0 % Cold or warm Diversey EnduroForce VE to 3.0 % Ecolab Topax to 5.0 % Ecolab Topax to 5.0 % 42 Meyn Food Processing Technology B.V.

46 6.4.2 Meyn recommended Acid foaming products Cleaning information for this machine Product Concentration Temperature Contact time (minutes) Diversey EnduroEco VE to 3.0 % Cold or warm Diversey Aciplusfoam VF to 4.0 % Ecolab Topax to 5.0 % Ecolab Topax to 5.0 % Meyn recommended Disinfection products Product Concentration Temperature Contact time (minutes) Diversey Cleardes T4b (based on chlorine) 1.0 % when wet (*1) Cold or warm 5 to 10 0,5 % when dry (*2) Diversey Divosan Extra (Quat) 1.0 % when wet (*1) 0,5 % when dry (*2) Ecolab P3 Hypochloran SM 2.5 % Cold or warm 5 to 60 Ecolab P3 Topactive des 2.0 % when lower than 40ºC 3.0 % when higher than 40ºC *1. when equipment is wet before disinfection. *2. when equipment is dry before disinfection. Lower than 40ºC 5 Higher than 40ºC Meyn Food Processing Technology B.V. 43

47 Cleaning information for this machine 6.5 Cleaning-, foaming-, rinsing- and disinfection-procedure Study and understand the instructions made by the supplier of the chemicals that are being used. Execute the cleaning and disinfection procedure according the steps listed in the table below. 1 Remove all products 2 Cleaning mode 3 Remove of coarse dirt After production and before cleaning, all poultry products, containers, packing materials, pallets, etc. should be removed from the department. When required dismantle parts of the equipment. Turn the machine into cleaning mode. Removal of coarse dirt (product, parts of packs, pieces of fat etc) should be removed by hand, using tools as suggested in chapter Manual removal of crude product waste/parts. 4 Settings Use a mobile high pressure unit, or a stationary system. 5 High pressure cleaning Water pressure must be in between 20 and 40 bar. Temperature must be in between 50ºC. and 55ºC. Cleaning must be executed top-down. The cleaner must be in such a position such that he/she is spraying downward High pressure cleaning is finished once all visible dirt is removed. Cleaning personnel must inspect whether all visible dirt is removed this, with special attention for the parts indicated in chapter Special cleaning areas for this machine. 44 Meyn Food Processing Technology B.V.

48 Cleaning information for this machine 6 Foaming When available use the Enduro Power system. Alkaline foaming is done with the chemicals listed in chapter Recommended cleaning and disinfection chemical agents. Depending on the hardness of the water, the alkaline foaming can periodically be replaced by an acid foaming. Foaming chemicals are listed chapter Recommended cleaning and disinfection chemical agents. Start foaming bottom-up and apply a layer of foam all over the machine. Cleaning personnel must inspect whether all target surfaces are fully covered with foam. 7 Rinsing After the prescribed contact time, all foam must be removed. Rinsing can be done with for instance the Enduro Power system. Rinse the machine in the same order as the foaming has been done, this way the contact time is about equal on all surfaces. Temperature of the water must be in between 10ºC and 55ºC. Rinsing must be done top-down. Check after rinsing, that all foam residues is thoroughly removed. Do not delay rinsing. A longer than prescribed contact-time does not contribute to cleaning, but may increase the risk of for instance corrosion. 8 Disinfection If the equipment is wet after rinsing it is advised to increase the concentration of the disinfectant fluid to compensate for dilution, see chapter Recommended cleaning and disinfection chemical agents. To avoid any risk of dangerous chlorous vapors it is advised not to apply a chlorine-containing disinfectant after acid-foaming. Disinfection must be done in a systematic way because the cleaning personnel cannot see what has been done, and what has not been done. Disinfection chemicals are designed to do their work in only 5 minutes, leading to 5-log reduction(i.e. 99, 999% reduction of bacterial count). A longer time has no additional effect, and increases the risk of corrosion. It is especially advised not to postpone rinsing, or to forget rinsing. After rinsing, the equipment is ready for disinfection, using e.g. the Enduro Power system. Meyn Food Processing Technology B.V. 45

49 Cleaning information for this machine 9 Rinsing Rinsing can be done with e.g. the Enduro Power system. Rinse the equipment in the same sequence the disinfection has been done, this way contact time of the disinfectant on all surfaces is about equal. Rinse with cold water at low pressure: this way aerosols are avoided. Rinse must be executed top-down. Rinsing must be done in a very systematic way because cleaning personnel cannot see what has been done, and what has not been done. After the prescribed contact time all disinfection residues must be removed. 10 Reassembly After the entire cleaning procedure has been executed the parts that have been dismantled, see chapter Cleaning mode; partial disassembly before cleaning (equipment-specific), must be assembled again in their "production" position. 46 Meyn Food Processing Technology B.V.

50 Cleaning information for this machine 6.6 Check the effectiveness of the cleaning and disinfection procedure The cleaning personnel must check the effectiveness of their work after high pressure cleaning, foaming, and rinsing after foaming. Afterwards the final result needs to be checked; this check is a part of the local Hazard Analysis Critical Control Plan. Various methods (like swab methods or agar contact methods) are available to detect surviving micro-organisms. Adenosine-Tri-Phosphate methods (see provide an instant (but not specific) indication of the amount of residual pollution/contamination. Such a method may be a useful tool. The methods and the applied tolerance standards will depend on local regulations, and customer standards. It is advised to pay special attention to parts described in Special cleaning areas for this machine. When test results show that dirt still remained in specific machine areas, the high pressure cleaning-process must be executed more carefully. When a superficial layer remains after foaming, the foaming-process must be executed more carefully. When the surface is clean, but still bacteria are detected, the disinfection-process should be evaluated. Registration by the Quality Assurance department of the contaminated areas, and feedback to the cleaning crew are crucial. Meyn Food Processing Technology B.V. 47

51 Cleaning information for this machine 6.7 General Hazards During the life cycle of the machine, the following potential hazards may occur: ELECTRICAL Electrical equipment on machinery can potentially be a cause to electric shock and burn hazard. Electricity has the potential to cause fatal injuries. The risk of electrical shock can be increased due to the following: Water entering the electric enclosures. Corrosion due to detergents and disinfectants. SLIPPERINESS Water and detergents may make the operating environment slippery. CORROSIVE FLUID Industrial cleaning products are often aggressive to skin and eyes. Beware of the risks. HAZARD ZONES Machine hazard-zones are defined in the Safety chapter. Do not remove any safety guards or components except when absolutely necessary. Put all safety guards and components back to their original position after cleaning. HAZARDOUS SITUATION Beware: in cleaning mode the machine runs at a low speed. Keep your distance from moving parts. Read chapter Safety for more general hazards. 48 Meyn Food Processing Technology B.V.

52 Cleaning information for this machine 6.8 Preparations Power OFF: Adjustments, maintenance, repair, cleaning and servicing must be carried out while the main switch is turned OFF except where otherwise specified in this manual. Use proper Lockout -Tagout procedure(s). Beware of possible mechanical hazards and hazards from live components. Preparation: Read and understand the instructions belonging to the cleaning products. Wear all personal protective means. Prepare the machine for cleaning. Remove all big product parts from the machine by hand. Work from top down. Note: Only qualified and trained personnel should clean machinery. Always keep your distance from electrical circuits and moving parts. Do not remove any safety components except when indicated in this manual. Put all safety components back to their original position after cleaning. Ensure that all electrical components are suitably protected from cleaning products. Ensure that the control panel is suitably protected from cleaning products. Meyn Food Processing Technology B.V. 49

53 Cleaning information for this machine Lockout -Tagout Directives require employers to establish procedures for isolating machines or equipment from their source of energy to prevent any unexpected startup or release of stored energy that could injure workers. Before servicing: 1. Identify type of energy used and its potential hazards. 2. Inform everyone who may be affected by isolating the machinery. 3. Turn off the equipment or machine. 4. Use the proper lockout devices to disconnect the energy source or containing residual or stored energy. 5. Apply lock so no one can turn the switch or valve. 6. Warn against accidental use by attaching lockout warning tags. 7. Ensure that all machine controls and electrical circuits are completely isolated. 8. Perform maintenance and or servicing. After servicing: Ensure that machine or equipment components are operationally intact. Ensure that all employees are safely positioned or are outside the hazard zones. Ensure that lockout devices are removed from each energy-isolating device. Ensure that tagout devices are removed from each energy-isolating device. Restore the energy to the machine or equipment. 6.9 After cleaning Take all necessary precautions to do the next steps safely. Apply a lubricant on all moving parts. See also chapter Maintenance and troubleshooting table. Put back all parts, safety guards and safety measures to their original position. 50 Meyn Food Processing Technology B.V.

54 6.10 Special cleaning areas for this machine Cleaning information for this machine For some machines/equipment, special requirements may apply which have been specified during the initial design stage, or during the Meyn Hygiene procedure. When this is in order it will be explained and illustrated in this paragraph. If special requirements are not in order, the text "not applicable" will be shown. Machine areas which require special attention The shafts and wheels inside the cabinet. The knife unit. All product contact surfaces. Discharge gutters Cleaning mode; partial disassembly before cleaning (equipment-specific) Some equipment may need to be set in a "cleaning mode" to enable a thorough cleaning. Some equipment may need to be partly disassembled to enable a thorough cleaning. If this is in order it will be explained and illustrated in this chapter. If special requirements are not in order, the text "not applicable" will be shown. Not applicable Meyn Food Processing Technology B.V. 51

55 Cleaning information for this machine 52 Meyn Food Processing Technology B.V.

56 Maintenance and troubleshooting table 7 Maintenance and troubleshooting table This chapter describes the maintenance activities that are necessary to keep the machine in good condition and to facilitate safe operation. We advise to maintain the machine regularly, because it increases the working life of the machine and reduces the chance of failures. 7.1 General Hazards A general hazard exists when electrical or mechanical equipment is accidentally activated when the machine is undergoing maintenance. Therefore use a proper lockout/ tagout procedure: All energy sources that could activate the machine shall be locked out (blocked). Warn against accidental use by attaching lockout tags/warning tags. Read chapter Safety for more general hazards. 7.2 Personal Protective Means Wear protective gloves. Wear protective clothing. Wear protective shoes. Wear eye protection. Wear ear protection. Meyn Food Processing Technology B.V. 53

57 Maintenance and troubleshooting table 7.3 Preparations Power OFF: All adjustments, maintenance, repair, cleaning and servicing must be carried out while the main switch is turned OFF unless otherwise specified in this manual. Use proper lockout procedure. The personnel must be aware of possible mechanical hazards and hazards from live components. Warning: Maintaining and servicing the machine with power ON is not allowed. Note: Only qualified and trained personnel should service machinery. Put on all relevant personal protective means. Always maintain maximum clearance from both live circuits and moving parts. Do not remove any safety components except when absolutely necessary. Ensure that all safety components are properly reinstalled to their original position. 54 Meyn Food Processing Technology B.V.

58 Maintenance and troubleshooting table 7.4 Lubricants Lubricants used in food processing plants are categorized and registered by the NSF in two groups: H1 lubricants, are used when incidental contact with food products cannot be excluded. H2 lubricants are used for all other applications in a food plant. For all bearings and moving parts Meyn advises to use multipurpose NLGI 2 H1 grease with the following characteristics: Excellent water resistance. Chemical resistant. Food grade H1. High pressure (EP) properties. Compatible with other greases. Note: it is advised not to mix greases. Meyn uses Jax Halo Guard FG2 as general purpose grease for most applications. Other greases are used for: For high speed rotations (> 5000 rpm). For low temperatures (< - 5 C or 23 F). For gearboxes. For hydraulics. Meyn Food Processing Technology B.V. 55

59 Maintenance and troubleshooting table 7.5 Lubrication-point list Part Check Daily, slide units. Vegetable oil (after cleaning). * Every two weeks, bearing killing shaft. Grease. * Every two weeks, bearing transfer shaft. Grease. * Every two weeks, bearing evisceration Grease. * shaft. Every two weeks, bearing house cutting Grease. * unit. * See paragraph Lubricants 7.6 Drive motor(s) See supplier documentation. Carry out all recommended maintenance work. 7.7 Checklist - Weekly Part Shackle belt. Knife. Check Check for wear and tear. Replace if necessary Check if the knife is sharp. Sharpen the knife if necessary. 56 Meyn Food Processing Technology B.V.

60 Assembly and adjustments 8 Assembly and adjustments The following adjustments can only be made when the machine is not running. 8.1 General Hazards A general hazard exists when electrical or mechanical equipment is accidentally activated when the machine is undergoing maintenance. Therefore use a proper lockout/ tagout procedure: All energy sources that could activate the machine shall be locked out (blocked). Warn against accidental use by attaching lockout tags/warning tags. Read chapter Safety for more general hazards. 8.2 Personal Protective Means Wear protective gloves. Wear protective clothing. Wear protective shoes. Wear eye protection. Wear ear protection. Meyn Food Processing Technology B.V. 57

61 Assembly and adjustments 8.3 Preparations Power OFF: All adjustments, maintenance, repair, cleaning and servicing must be carried out while the main switch is turned OFF unless otherwise specified in this manual. Use proper lockout procedure. The personnel must be aware of possible mechanical hazards and hazards from live components. Warning: Adjusting the machine with power ON is NOT RECOMMENDED. However, there are situations that this cannot be excluded. Please notice: Exposure to live circuits and moving parts is potentially hazardous. Note: Only qualified and trained personnel should service machinery. Put on all relevant personal protective means. Always maintain maximum clearance from both live circuits and moving parts. Do not remove any safety components except when absolutely necessary. Ensure that all safety components are properly reinstalled to their original position. TIP Mark the settings you have made before changing the basic settings. This will save you a lot of time and annoyance. 58 Meyn Food Processing Technology B.V.

62 Assembly and adjustments 8.4 Inlet shaft Correct adjustments for the inlet guide depends on size and weight of the birds being processed. The function of the inlet guide in combination with the lower leg guide and the shackle guide is to guide the shackle so that the legs of the bird are firmly positioned in the wheel of the killing shaft. How to adjust the inlet guide: Loosen the bolts (A). Move the inlet guide so the shackle (B) hangs straight. Tighten the bolts firmly after finding the correct position. A A B Meyn Food Processing Technology B.V. 59

63 Assembly and adjustments 8.5 Shackle guide Correct adjustments for the shackle guide depends on size and weight of the birds being processed. The first function of the shackle guide in combination with the lower leg guide and the inlet guide is to guide the shackle so that the legs of the bird are firmly positioned in the wheel of the killing shaft. The second function of the shackle guide is to guide the shackle away from the cutting unit so that the legs of the product get in the bended position (A), so you can determine where the leg is cut off. How to adjust the inlet guide: Loosen the nut (B) and knob (C). Move the shackle guide (D) horizontally (X) and/or vertically (Y). Tighten the nut (B) and knob (C) firmly after finding the correct position. Loosen nut (D). Screw-in nut (E). Clockwise for direction (F) and counter clockwise for direction (G). Tighten the nut (E) firmly after finding the correct position. A B C E D Y X G F 60 Meyn Food Processing Technology B.V.

64 Assembly and adjustments 8.6 Leg guide Correct adjustments for the leg guide depends on size and weight of the birds being processed. The function of the leg guide in combination with the inlet guide and the shackle guide is to guide the shackle so that the legs of the bird are firmly positioned in the wheel of the killing shaft. The second function of the leg guide (A) is to keep the tighs (B) in the wheel (C) till rehanging to the transfer wheel. How to adjust the leg guide: Loosen the nut (D). Screw-in nut (E). Clockwise for direction (F) and counter clockwise for direction (G). Tighten nut (C) firmly after finding the correct position. C B B A D E F G Meyn Food Processing Technology B.V. 61

65 Assembly and adjustments 8.7 Timing of the killing shaft The angle of the wheel is already done in the factory. The angle of the wheel should be ± 12. A correct timing of the killing shaft is necessary to get a correct rehang of the product into the transfer wheel. The correct adjustment is that the screw (A) between the two legs is inline with the middle of the shackle (B). How to adjust the timing of the killing shaft: Loosen the six bolts (C). Rotate the wheel (D) so that the screw (A) is inlen with the middle of the shackle. Retighten the six bolts firmly after finding the correct timing of the killing shaft. B A D C 62 Meyn Food Processing Technology B.V.

66 Assembly and adjustments 8.8 Height of the shackle It is possible to adjust the height of the shackle by adjusting the drive wheel a little. How to adjust the height of the shackle: Loosen the screw (A). Adjust the drive wheel (B) a little up or down. Retighten the screw firmly after finding the correct height of the shackle. B A Meyn Food Processing Technology B.V. 63

67 Assembly and adjustments 8.9 Angle of the cutting unit The knife unit is built on a tilting beam. The angle of the tilting unit can be adjusted. How to adjust the angle of the knife unit: Angle Loosen nut (A; at both sides of the tilting unit). You can determine the angle of the knife by rotating the knife in direction (B). The correct position of the knife unit is: The knife (C) may not damage the wheel (D) of the inlet shaft. The knife has to cut the shank off (E). The space between the knife and the wheel should be ± 3 mm. Tighten the nut (A) after finding the correct angle of the knife unit. A B E C D 64 Meyn Food Processing Technology B.V.

68 Assembly and adjustments 8.10 Height of the cutting unit The knife unit is built on a tilting beam. The height of the tilting unit can be adjusted. How to adjust the height of the knife unit: Height Loosen nut (A; at both sides of the tilting unit). Screw the nut (B) clockwise to put the knife unit higher and counter clockwise to put the knife unit lower. The correct position of the knife unit is: The knife (C) may not damage the wheel (D) of the inlet shaft. The knife has to cut the shank off (E). The space between the knife and the wheel should be ± 3 mm. Tighten the nut (A and B) after finding the correct position of the knife unit. E C D B A Meyn Food Processing Technology B.V. 65

69 Assembly and adjustments 8.11 Timing of the transfer wheel The recesses in the transfer wheel must be on time at the rehanging point. The timing can be done by rotating the transfer wheel How to adjust the timing of the transfer wheel: Loosen the six bolts (A). Rotate the transfer wheel (B) till the recess and the wheel are inline (C). Tighten the six bolts (A) firmly after finding the correct timing of the transfer wheel. Check the adjustment with one bird. Check if the timing is correct. If the timing is not correct to this adjustment again till it is correct. A C B 66 Meyn Food Processing Technology B.V.

70 Assembly and adjustments 8.12 Nylon ejector disc The nylon ejector disc just above the transfer wheel pushes the legs of the product into the shackle. How to adjust the nylon ejector disc: Loosen the nut (A). Move the disc (B) in direction (X). The product must be pushed at the correct moment into the shackle (C). Retighten the nut (A) firmly. Check the adjustment with one bird. Check if the moment of opening and closing is correct. If the moment is not correct repeat this adjustment till it is correct. A X B C Meyn Food Processing Technology B.V. 67

71 Assembly and adjustments 8.13 Position of the evisceration shackle The position of the shackle in the evisceration shaft can be done by rotating the catch plate in the evisceration shaft. How to determine the position of the shackle: Loosen the six bolts (A). Rotate the catch plate (B) in direction (X). Move the catch plate till the space between the shackle (C; 1st leg) and the catch part (D) is ± 10 mm. The plucking finger (E) will push the shackle against the catch part. Retighten the six bolts firmly. Check the adjustment with one bird. Check if the timing is correct. A B D C E X 68 Meyn Food Processing Technology B.V.

72 Assembly and adjustments 8.14 Timing between master and slave To get a correct rehanging process you need to achieve a correct timing between the master and slave. Here below you see how to get from a wrong timing to a correct timing. Wrong timing: ; 0 % % $ $ 6 $ & < $ & 7P 7V % & & 0 6 % B; Zero point of the master tachometer. C; Zero point of the slave tachometer. A; Rehang point of the master line. A ; Rehang point of the slave line. X; Shackle distance between two shackles of the master line (1024 pulse/revolution) Y; Shackle distance between two shackles of the slave line (1024 pulse/revolution) Meyn Food Processing Technology B.V. 69

73 Assembly and adjustments How to get the correct timing: By rotating the tachometer of the master line you will get the zero point of the master line exact the same as the zero point of the slave line. Loosen the three bolts (A) of the master tachometer (do not remove the bolts). Rotate the tachometer in the slotted holes to the desired direction (X). X A If you reached the end of the slotted holes then replace the bolts at the end of the slotted holes (B), one by one, one hole back (C). B C 70 Meyn Food Processing Technology B.V.