BALL MILLING MACHINE MODEL MQM–1000
OPERATION MANUAL
TABLE OF CONTENTS
1
INTRODUCTION
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MACHINE MODELD & TECHNICAL SPECIFICATIONS
2
3
MQM 1000 CAPACITY
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4
MAIN STRUCTURE AND WORKING PRINCIPLE
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5
OPERATION AND WORKING PRINCIPLE
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6
CHOCOLATE SYRUP PUMP OPERATION
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7
MAINTENANCE AND TROUBLE SHOOTING
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8
BALL MILLING MACHINE ELECTRIC SCHEMATIC
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INTRODUCTION Chocolate confectionaries possess color, aroma and taste that are irresistible by both adults and children. Chocolate confectionary has of 575 kcal/100g .
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MACHINE MODEL AND TECHNICAL SPECIFICATIONS MACHINE MODEL
MQM 1000
MAIN TECHNICAL SPECIFICATIONS Maximum Capacity
1,000 Liters
Ball Milling Time
14-20 Hours
Total Electrical Rating
17.5 KW
Heating Rating Machine Dimension
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4.0 KW 2740 x 1560 x 2200 mm
MQM 1000 CAPACITY 3.1 The Ball Milling Machine is used for fine grinding of chocolate syrup to meet the fineness of 20–25 microns grain size within 14– 20 hours. 3.2 Ball Milling Machine Model MQM 1000 has compact structure, with easy to operate and quick access to services. It contains Automatic temperature control system chocolate syrup recirculation filtration system, and mixing paddles rotated in clockwise and counter-clockwise direction. It possesses functionalities for gas evacuation, deodorization, water expelling, and air bubble removal. The machine is designed for lower electrical and water consumption in grinding chocolate without metal debris to yield the finest grinding result. 4 4.1
MAIN STRUCTURE AND WORKING PRINCIPLE The fine grinding machine is made up of main machine, mixing tank and syrup pump, and connecting pipes with insulation. The tank jacketed wall can run with cold water, hot water, and steam. Located at the mixing top cover are product inlet pipe, high
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pressure blower outlet, and at the tank barrel there is cold water inlet and overflow outlet at the top. The machine is equipped with jacketed medium temperature control and syrup temperature controller. 4.2 The machine is equipped with automatic machine fault alarm. 4.3 Main machine temperature control principle Within the system control, the automatic temperature control on main machine is activated only when the main machine is on STOP mode. It switches to OFF mode when the main machine starts, while the cooling system (when main machine is at ON mode) is at automatic control state. When the syrup temperature is above set temperature, the cold water valve opens to start the cooling process. To stop the entire machine, first to stop is the main machine and syrup pump, then the motors and temperature control system. 4.4
Transmission Assembly: Electric motor 11 KW with planetary gear and main spindle rotator
OPERATION AND WORKING PRINCIPLE 5.1 The Ball Milling Machine is able to mix evenly the chocolate syrup raw material, can detect the presence of ________ , and can effectively dilute and emulsify the chocolate syrup. 5.2
The pre-set temperature can be altered; the temperature of main machine, and product tank and cooling water should not be set below zero. It is necessary to preset related temperature during the production, to adjust individual temperature setting according to process requirement. If the main machine temperature is not set, the machine cannot run.
5.3
If the main machine temperature is set at 50 o C, and when the process temperature exceeds 50 o C, the cold water valve opens to release water, the main machine cannot start, the product tank cannot trigger automatic heating, cooling temperature control cannot start, the automatic cooling cannot operate. It is advisable to set all parameters after the main machine is turned ON.
5.4 The agitator tank product outlet spout and exhaust valve are in adjacent position. During the ball milling machine process, shut OFF product blower. Gas exhaustion has positive impact to water
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removal and odor removal, thus maintaining natural chocolate flavor. 5.5 Before starting, make sure the main machine and product tank jackets fill up with water. Should the machine stop operation for a longer period of time, discard the water in the jacket. The ball milling machine has insulation for double jacket. Temperature is best control adjustable, good insulation, grinding process is totally closed, and conforms with sanitary requirements. 5.6 Observe that the ball milling machine rotate as indicated by the arrow sign. When the machine is run without load, the product tank must be pre-heated to the pre-set temperature. 5.7 The sequence of ball milling machine input: First, fatty product, then
powder, then place these two products alternately afterwards. Cocoa cubes must be pre-cut to smaller pieces. Heat the product to become fluid to 250 oC before feeding. Strictly no solids/granule feeding, or no one-time feeding. 5.8 Feeding should be done in gradual portions until completion. Product feeding should be stopped should the product become viscous. Add lecithin until the product tank syrup is found fluid before resumption of product feeding. 5.9 When adding ingredient, wait until the main machine is fully agitated before turning on the syrup pump. 5.10 During ball milling process the chocolate syrup becomes more viscous
as the temperature increases. To increase the syrup fluidity, it is recommended to add proper amount of lecithin and vanilla. When adding aroma essence, turn off the blower before the addition.
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CHOCOLATE SYRUP PUMP OPERATION 6.1 MQM 1000 Ball Milling Machine has two (2) sets of syrup pump. Under normal working conditions, only one is required and the second unit is used as standby. On the control panel, the syrup inlet and outlet of Pump #1 and Pump #2 are at the opposite. 6.2 Only the working pump is completely stopped before starting the standby pump. Starting the standby pump when the working pump is in operation will cause machine damage and lead to defective product.
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MAINTENANCE AND TROUBLE SHOOTING 7.1
After the day’s production, the ball milling machine should be cleaned only with edible oil. It is strictly prohibited to flush and clean with water and steam to avoid the balls to develop rust. The syrup pump and mechanical parts, inlet and outlet of filtration cylinder are installed with magnetic parts require regular cleaning.
7.2 Main spindle seal gasket should be replaced periodically to avoid aging of the spindle that cause leaks. 7.3
Before stopping the ball milling machine, turn the syrup pump to ON to continue to suck up all syrup until the main machine cylinder is empty, to pre-heat the chocolate residue syrup in the melting tank before running the machine. If the machine stops for a short period of time, and the ball milling machine is still holding syrup at full tank or half tank, the machine tank temperature must be maintained at the 40–50 o C level, and the agitator allowed to rotate for 3–5 minutes each hour, to avoid the syrup to solidify and damage machine parts when restarted.
7.4
When preparing products for production, initially add fats, allow it to re-circulate before adding powder ingredient.
7.5
Speed reducer O-ring should be checked periodically and replaced. Planetary gear oil must be inspected periodically and replaced; select #40 or #50 lubricating oil.
7.6
When strange noise is heard during dry run without load, stop the machine for inspection.
7.7
Check if there is foreign part dropped into the tank.
7.8
Check if mesh plate is blocked.
7.9
Check if syrup contains solid metals.
7.10
Check if any bolts and machine are loosened.
7.11
Before turning ON the syrup pump, open the 3–way valve are in line with the pump; check if pipeline is free of blockage.
7.12
Strictly prohibited to turn on the syrup pump on cold machine. The chocolate syrup along the pipe route and syrup pump must be heated up to obtain allowable viscosity. 6
7.13
Strictly prohibited to turn on the syrup pump when flow of chocolate syrup is blocked.
7.14
After extended period of machine stop operation, pre-heating of the pipe route for 5 hours is necessary. It is necessary to warm up or increase the temperature of the tank.
7.15
Syrup pump oil seal and gear oil must be replaced periodically.
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