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Serial Number: 095-096 / Year: 2017 / Rev. 00 Edition: 10/2017 Rev.

00

USE AND MAINTENANCE HANDBOOK

SPARE PARTS CATALOGUE & DIAGRAMS

CURD CUTTER-STRETCHING MACHINE

T28-FT60

Via Emilia Est, 2009 - 41018 S.Cesario s/P (Modena)


Tel. +39 059 93.80.10 - Fax: +39 059 93.86.00
E-Mail: info@almacsrl.com - Web: www.almacsrl.com
ALMAC srl Use and maintenance handbook 095-096/2017

INTRODUCTION

 Original instructions in English language for the use, safety and maintenance, spare parts catalogue and
diagrams of the following machines:

POS. MACHINE DESCRIPTION MODEL SERIAL N°. CONSTRUCTION YEAR


A Curd-Cutter T28 095
2017
B Stretcher FT60 096

B
A

VERSION TRANSLATED INTO ENGLISH LANGUAGE

 ALMAC SRL is responsible for the information mentioned only in the Italian version of this use and
maintenance handbook.

 All rights reserved. Copy forbidden. ALMAC SRL protects itself on drawings, sketches and catalogues as
by law enabled.

Edition: 26th September 2017 (Rev. 00)

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ALMAC srl Use and maintenance handbook 095-096/2017

CE CONFORMITY DECLARATION

 A Type : Original CE Conformity Declaration in Italian language for a machine not included in the IV
enclosure (Directive 2006/42/CE - Enclosure II - Par. A), exclusively pertaining the machine in the
conditions of its introduction in the market, excluding the added components and/or the operations
afterwards made by the user.

REV. DATE DESCRIPTION PREPARED APPROVED


00 13/10/2017 First issue Gabriele Cortelloni Marcello Toma
01
02
03
04
05

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ALMAC srl Use and maintenance handbook 095-096/2017

CE CONFORMITY DECLARATION

(Encl. II A - Directive 2006/42/CE)

THE MANUFACTURER
ALMAC s.r.l.
Company

Via Emilia Est, 2009 41018 MO


Address CAP Prov.

San Cesario sul Panaro ITALY


Town Country

DECLARES THAT THE MACHINE


Curd-Cutter T28
Machine description Model

095 2017 00
Series / Register number Construction year Revision

Curd-Cutter mod. T28


Commercial description

Curd mincing in small pieces (crumbs or flakes)


Foreseen use

IS CONFORM TO THE DIRECTIVE AND RULES

Directive 2006/42/CE of the European Parliament and of the Council of 17 May 2006 pertinent to the machines and that
modifies the Directive 95/16/CE (rewriting).

Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the harmonization of the laws of
the Member States relating to electromagnetic compatibility (recast).
Directive 2014/35/EU of the European Parliament and of the Council of 26 February 2014 on the harmonization of the laws of
the Member States relating to the making available on the market of electrical equipment designed for use within certain
voltage limits (recast).
CE n. 1935/2004 Regulations of the European Parliament and Council dated 27th October 2004 pertinent to the materials and
objects destined to come in contact with foods and that cancels the 80/590/CEE and 89/109/CEE Directives.

AND AUTHORIZES
Marcello Toma
Name

Via Emilia Est, 2009 41018 MO


Address CAP Prov.

San Cesario sul Panaro ITALY


Town Country

TO FORM THE TECHNICAL BROCHURE

San Cesario sul Panaro (MO), 13/10/2017 Marcello Toma


Place and date President

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ALMAC srl Use and maintenance handbook 095-096/2017

CE CONFORMITY DECLARATION

(Encl. II A - Directive 2006/42/CE)

THE MANUFACTURER
ALMAC s.r.l.
Company

Via Emilia Est, 2009 41018 MO


Address CAP Prov.

San Cesario sul Panaro ITALY


Town Country

DECLARES THAT THE MACHINE


Stretcher FT60
Machine description Model

096 2017 00
Series / Register number Construction year Revision

Discontinuous stretching machine mod. FT60


Commercial description

Foodstuffs and curd cooking, stretching and mixing for the production of stretched doughs (pasta filata) for the dairy industry
Foreseen use

IS CONFORM TO THE DIRECTIVE AND RULES

Directive 2006/42/CE of the European Parliament and of the Council of 17 May 2006 pertinent to the machines and that
modifies the Directive 95/16/CE (rewriting).

Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the harmonization of the laws of
the Member States relating to electromagnetic compatibility (recast).
Directive 2014/35/EU of the European Parliament and of the Council of 26 February 2014 on the harmonization of the laws of
the Member States relating to the making available on the market of electrical equipment designed for use within certain
voltage limits (recast).
CE n. 1935/2004 Regulations of the European Parliament and Council dated 27th October 2004 pertinent to the materials and
objects destined to come in contact with foods and that cancels the 80/590/CEE and 89/109/CEE Directives.

AND AUTHORIZES
Marcello Toma
Name

Via Emilia Est, 2009 41018 MO


Address CAP Prov.

San Cesario sul Panaro ITALY


Town Country

TO FORM THE TECHNICAL BROCHURE

San Cesario sul Panaro (MO), 13/10/2017 Marcello Toma


Place and date President

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ALMAC srl Use and maintenance handbook 095-096/2017

INDEX

 CE CONFORMITY DECLARATION

1 GENERAL INFORMATION
1.1 General information Page 7
1.2 Handbook aim Page 7
1.3 Handbook conservation Page 7
1.4 Handbook updating Page 7
1.5 Collaboration with the user Page 8
1.6 Manufacturer guarantee Page 8
1.7 Manufacturer responsibility Page 8
1.8 Handbook composition Page 9
1.9 Abbreviations Page 9
1.10 Symbology Page 10
1.11 Glossary Page 11
1.12 Pictograms pertinent to the operator qualification Page 12
1.13 Machine identification label Page 13
1.14 Intervention and technical assistance request Page 15

2 SAFETY
2.1 Safety general instructions Page 16
2.2 Safety instructions for the maintainers Page 17
2.3 Safety instructions for the electricians Page 17
2.4 Environmental conditions Page 17
2.5 Potentially explosive environment Page 17
2.6 Electromagnetic environment Page 17
2.7 Lighting Page 18
2.8 Vibrations Page 18
2.9 Sound emissions Page 18
2.10 Safety signals on the machine Page 19
2.11 Safety devices Page 20
2.12 Hazards and residual risks Page 23

3 TEST, DELIVERY AND FIRST INSTALLATION


3.1 Test Page 25
3.2 Packing and transport Page 25
3.3 Storing Page 25
3.4 Unpacking and positioning Page 25
3.5 Packing material disposal Page 25
3.6 Machine lifting and handling Page 26
3.7 Levelling Page 27

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INDEX

4 TECHNICAL DATA
4.1 General description Page 28
4.2 Technical data Page 28
4.3 Electrical data Page 29
4.4 Conditions of use Page 29
4.5 Electrical connection Page 30
4.6 Hydraulic and steam connections Page 31

5 CONTROLS
5.1 Controls list and description Pag. 32

6 COMMISSIONING
6.1 Operator’s position Page 35
6.2 Preliminary checks Page 36

7 START-UP
7.1 Operation cycle Page 39
7.2 Starting the production cycle Page 39

8 MAINTENANCE
8.1 Manual cleaning Page 41
8.2 Recommended products Page 46
8.3 Manual washing by foaming technology Page 49
8.4 Daily maintenance Page 49
8.5 Periodic maintenance Page 49
8.6 Lubrication Page 50
8.7 Scrapping and disposing of harmful substances Page 50

9 SPARE PARTS CATALOGUE


9.1 Spare parts inquiry rules Page 51
9.2 Spare parts tables Page 52

10 LAYOUT AND DIAGRAMS


10.1 Electrical diagram Page 64

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Chapter
1 GENERAL INFORMATION

1.1 GENERAL INFORMATION


 This handbook contains all the information for the machine installation, use and maintenance and it’s
destined to its users, that is to say all persons that need or are obliged to supply instructions or to
operate on the machine.
 This handbook has to be considered as an integral part of the machine and it has to be kept for any
eventual future reference until the machine final demolition and scraping.
 The ORIGINAL TEXT OF THIS DOCUMENTATION, ISSUED IN ITALIAN, represents a unique reference for any
eventual interpretational disputes resolution connected to the translation into the EEC language. ALMAC
SRL is responsible just for the information written in the handbook original version.

1.2 HANDBOOK AIM


 Handbook aim is to allow persons attached to the machine to understand the unit operation through
clarifying texts and pictures and to use the machine in a safe way according to the safety, use and
maintenances basic instructions and criteria.
 It’s forbidden to use the machine in disagreement with the instructions supplied in this handbook.

1.3 HANDBOOK CONSERVATION


 The handbook must be preserved in a protected place and always kept available on the machine (or near
it at least) for the consultancy.
 It is recommended to make a copy of the handbook and to keep it on record for good measure. In case
of information exchange with the manufacturer or with service personnel authorized by him, please refer
to the label data or to the machine register number (Chap. 1 - Par. 1.13).
 The handbook must be preserved for all machine life and, in case of need (i.e. damaging, loss, etc.) the
user must ask a new copy exclusively to the manufacturer.

1.4 HANDBOOK UPDATING


 Indications contained in the handbook are conforming to the machine directive in force and have to be
considered updated to the machine status at the supply moment. It cannot be considered unsuitable just
in case it has been afterwards updated according to the new technical directives or to new experiences.
 Any eventual modification, adjustment, improvement, etc. to the afterwards commercialized machine
does not oblige the manufacture neither to intervene on the previously supplied machine, nor to consider
it and its handbook as lacking and inadequate.
 Any eventual integration of the handbook that the manufacturer consider convenient to be sent to the
users must be preserved together with the handbook of which it will be an integral part.

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Chapter
1 GENERAL INFORMATION

1.5 COLLABORATION WITH THE USER


 The manufacturer is at his Clients’ disposal to supply further information and to consider improvement
proposals in order to issue a handbook as much correspondent to its purpose needs as possible.
 In case of machine conveyance, that must always be accompanied by the use and maintenance
handbook, the primary user is invited to advise the manufacturer of the new user’s address, so that to
reach him with any strictly necessary information and/or updating.

1.6 MANUFACTURER GUARANTEE


Guarantee provisions are specified in the sale contract.

1.7 MANUFACTURER RESPONSIBILITY


The manufacturer denies every direct and indirect liability for:

 No observance of the machine use instructions different from those provided by the handbook.
 Use by personnel that have not red and understood the handbook content.
 Use by unskilled personnel.
 Non-complying use to the specific rules in force in the machine installation Country.
 Wrong installation.
 Feeding faults.
 Unauthorized modifications or interventions on the machine.
 Unauthorized repairings made by the personnel.
 Maintenance deficiency.
 Use of non-original spare parts and accessories.

NOTE: The machine conveyance to a second user implies also the handbook delivery; the handbook lack
of delivery makes the manufacturer responsibility lapse relatively to its correct use.

NOTE: If the machine is ceded to a second user in a different language country, it will be primary user’s
responsibility to supply a true translation of this handbook in the language of the country where the
machine will operate.

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Chapter
1 GENERAL INFORMATION

1.8 HANDBOOK COMPOSITION


 The handbook has been subdivided into independent chapters, each one addressed to a specific operator
(labourer, mechanical maintainer, electric engineer, technician, and driver), for which the necessary
competences have been defined to operate on the machine in the highest safety conditions.
 Chapters sequence corresponds to time logic of the machine life.
 To facilitate the text comprehension quickness, here are used abbreviations and pictograms whose
meaning is indicated in their pertinent paragraphs.
 The handbook is composed by a cover, an index and a sequence of chapters, each one composed by
paragraphs pertinent to the chapter argument.
 On the opening page are mentioned the machine identification data, model, register number, handbook
revision index and a machine picture.
 Pictures are numbered according to their belonging chapter.
 Components mentioned in the pictures are numbered according to the picture number.
 Units of measurement herein after mentioned are those provided in the International System (SI).
 Components mentioned in the « Spare parts catalogue » are numbered according to the belonging table.

1.9 ABBREVIATIONS

Sect. : Section Ex. : Example


Chap. : Chapter Mod. : Model
Par. : Paragraph On : Switched on and/or under movement
Page : Page Off : Switched off and/or under stop
Fig. : Picture Min : Minimum
Tab. : Table Max : Maximum
Tab. : Illustrated table PLC : Programmable Logic Controller

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Chapter
1 GENERAL INFORMATION

1.10 SYMBOLOGY
In the handbook are mentioned some symbols having the aim to catch reader’s attention on the different
risk levels in the machine use and maintenance operations.

SYMBOL DESCRIPTION
DANGER: Information or procedure that, if not strictly followed, may cause personal
death or serious injuries.

WARNING: Information or procedure that, if not strictly followed, may cause personal
injuries or damages to the machine.

NOTE: Important information or procedure

Some normalized symbols and/or texts mentioned in the handbook and applied even on some machine
parts (see Chap. 2 - Par. 2.10) have the aim to inform the reader about the obligation to use the personal
protection devices (DPI) during the performing of some operations with non-evident potential risks for
the operator.

PROTECTIVE PROTECTIVE PROTECTIVE GRAVITY CENTRE


GLOVES SHOES CLOTHS BARYCENTRE

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Chapter
1 GENERAL INFORMATION

1.11 GLOSSARY
In the handbook are mentioned some words having a meaning exclusively pertinent to the machines
(Directive 2006/42/CE - Enclosure I - Par. 1.1.1).

 DANGER: Injury or health damage potential source.


 DANGEROUS AREA: are into and/or near a machine where the presence of a person represents a damage
for his safety and health.
 EXPOSED PERSON: any person which completely or partially stands in a dangerous area.
 OPERATOR: person/s responsible for installation, operation, adjusting, cleaning, repairing, moving or
maintenance of a machine.
 RISK: combination of probabilities and graveness of an injury or a damage for the health that may arise
in a dangerous situation.
 SHELTER: machine element specifically used to assure the protection by a material barrier.
 PROTECTION DEVICE: device (different from a shelter) that reduces the risk, alone or together with a
shelter.
 FORESEEN USE: Use of the machine conform to the information supplied in the use instructions.
 REASONABLY FORESEEABLE INCORRECT USE: use of the machine in a different way from the one mentioned
in the use instructions, but that may come from an easily foreseeable human behaviour.

 OTHER WORDS

 MACHINE: Unit that is equipped, or destined to be equipped with, an activation system different from the
direct human or animal force, composed by parts or components of which one is mobile, at least, solidly
connected one to the other for a well determined application (Directive 2006/42/CE - art. 1 - par. 1 -
letter A).
 MACHINE STATUS: machine actual operation mode.
 OPERATOR QUALIFICATION: competence minimum level that the operator must have to perform the
described operation.
 OPERATOR NUMBER: operator adequate number to perform the described operation in an optimal and
complete safety.
 SAFETY COMPONENT: component having the aim to assure, by its use, a safety function and whose fault
or bad operation jeopardizes the exposed persons safety or health.
 RESIDUAL RISK: non-totally reducible danger by the protection design and techniques, this means a non-
evident potential danger.

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Chapter
1 GENERAL INFORMATION

1.12 PICTOGRAMS PERTINENT TO THE OPERATOR QUALIFICATION

A) GENERIC LABOURER: operator without any specific competence, able to perform simple
tasks only upon skilled technicians’ instructions.

B
1
B) 1ST LEVEL MACHINE OPERATOR: operator without any specific competence, able to perform
simple tasks only , this means the machine running by the use of buttons placed on the
electrical control panel, charging and discharging operations of the row material used during
the production cycle, with the installed and active safety guards.
C
2
C) 2ND LEVEL MACHINE OPERATOR: operator able to perform the tasks of the 1st level machine
operator, the production and/or CIP washing cycles start-up and stop phases and
reestablishments following to stops and adjustings.
D

D) MECHANICAL MAINTENANCE MAN: qualified technician able to run the machine in normal
conditions, able to intervene on the mechanical organs to carry out adjustings, as well as
necessary maintenance and repairing operations. He is not typically able to intervene on the
electrical plant in presence of tension.
E

E) ELECTRICAL MAINTENANCE MAN: qualified technician able to run the machine in normal
conditions, able to perform all electrical interventions on the machine as well as to carry out
the adjusting, maintenance and repairing operations. He is able to operate in presence of
tension inside cabinets, electrical control panels and junction boxes.
F

F) MANUFACTURER TECHNICIAN: skilled technician put at user’s disposal by the manufacturer


to perform complex operations in particular situations or, anyway, what agreed with the user.
His competences are, according to the different situations, of mechanical and/or electrical
and/or electrical and/or software type.
G

G) LIFTING AND HANDLING MEANS DRIVER: operator able to use the materials and machines
lifting and handling means (strictly following the manufacturer instructions), according to the
laws in force in the machine user Country.

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Chapter
1 GENERAL INFORMATION

1.13 MACHINE IDENTIFICATION LABEL


Every ALMAC SRL machine is equipped with a label (Fig. 1.1) which is fixed in an unmovable way on its
frame, mentioning the following information:

D
E

F
G H I
L M

Fig. 1.1

POS. DESCRIPTION
A Manufacturer data
CE mark (mark that certifies the machine conformity to the Directive 2006/42/CE of the
B
European Parliament and Council dated 17th May 2006.
C Machine description
D Machine model
E Register number
F Construction year
G Voltage (V)
H Frequency (Hz)
I Installed power (kW)
L Total F.L.A (A)
M Phase (Ph)

NOTE: For any reason, data mentioned on the identification label can be modified or removed. In case of
tampering or removal the guarantee immediately lapses and the manufacturing company gets out of any
eventually caused damage, both material and economic.

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Chapter
1 GENERAL INFORMATION

 LABELS POSITION
The identification label is fixed on machine body or frame (Fig. 1.2) in an unmovable way. In case of its
damaging or poor readability of the mentioned data, the user must inform the manufacturer asking for
the replacing.

 CURD-CUTTER MOD. T28 - STRETCHER MOD. FT60

Fig. 1.2

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Chapter
1 GENERAL INFORMATION

1.14 INTERVENTION AND TECHNICAL ASSISTANCE REQUEST


In case of operation faults or anomalies for which it is necessary the intervention of skilled technicians,
please directly contact the manufacturer.

ALMAC srl
Company

Via Emilia Est, 2009 - Loc. Gaggio


Address

41018 S. Cesario sul Panaro Modena


ZIP Code Town Prov.

+39 059 938010 +39 059 938600 info@almacsrl.com


Telephone Fax Mail (Sales Dept.)

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Chapter
2 SAFETY

2
2.1 SAFETY GENERAL INSTRUCTIONS
 The machine must be used for the use foreseen by the manufacturer.
 Before proceeding with the transport, use, ordinary and extraordinary maintenance operations, carefully
read the information contained in the handbook. In case of doubt directly contact the manufacturer (see
Chap. 1 - Par. 1.14).
 It’s the user employer and safety manager task to supply the individual protection means, such as gloves,
masks, suitable shoes, boots, smock, caps, according to the laws and rules pertinent to the working
environment safety and hygiene.
 Avoid the use of metallic clothing accessories (watches, rings, necklaces, bracelets, etc.).
 If necessary, in the handbook it will be specified further recommendations that the user must observe
about prevention measures, protection personal means and about the information aimed to prevent
human errors and reasonably foreseeable, not-allowed behaving bans.
 The machine must be used by personnel considered suitable to perform the task in a reliable way and to
have physical, skilfulness and aptitude capacities necessary to carry out the job.
 Do not allow any non-authorized or unskilled personnel to intervene on the machine.
 Do not use the faulty machine.
 The driving and moving organs are protected by fixed guards blocked by screws. Their removal is strictly
forbidden.
 The machine is equipped with mobile shelters (lids, grids, etc.) coupled to interblocking devices (sensors,
safety switches, etc.) that impede any dangerous operation performing until the shelter complete closing.
It’s absolutely forbidden to remove the mobile shelter and the applied safety devices.

NOTE: For any dispensation to what above mentioned, it’s necessary a specific written declaration by
company ALMAC SRL.

NOTE: Any modification non-authorized by the manufacturer that distorts the foreseen machine
functionality by modifying the risks and/or creating new risks will be a complete responsibility of the
person that makes this modification.

NOTE: These modifications, if performed without any manufacturer authorization, will make any released
guarantee lapse and the conformity declaration foreseen by the Machine Directive 2006/42/CE null and
invalid.

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Chapter
2 SAFETY

2.2 SAFETY INSTRUCTIONS FOR THE MAINTAINERS

WARNING! Maintenance and repairing operations must be made by skilled personnel only, after having
isolated the machine from any power feeding (electrical, pneumatic, steam, etc.).

 Before any maintenance and/or repairing intervention put the label « MACHINE UNDER MAINTENANCE » in
a well visible position.
 Do not use thinners and inflammable materials.
 Do not use free flames as a lighting mean.
 To operate on the machine highest parts, use the means suitable for the operations to be performed.
 Do not go up on the machine organs as they have not been designed to support persons.

2.3 SAFETY INSTRUCTIONS FOR THE ELECTRICIANS

WARNING! Any eventual intervention must be made by skilled personnel only, after having isolated the
machine from any power feeding (electrical, pneumatic, steam, etc.).

WARNING! All operations on the control panel must be always made with the cut-out machine feeding
device.

2.4 ENVIRONMENTAL CONDITIONS


ALMAC SRL machines are designed and built to be used in a dairy environment. They must not be used
in open spaces, exposed to atmospheric agents and to environments where corrosive and contaminant
particles are present.

2.5 POTENTIALLY EXPLOSIVE ENVIRONMENT


The machine is not destined to operate in environments having explosion danger or with a potentially
explosive atmosphere.

2.6 ELECTROMAGNETIC ENVIRONMENT


The machine is suitable to operate in an electromagnetic environment of the industrial type, by being
included in the emission and immunity limits foreseen by the Directive 2014/30/EU.

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Chapter
2 SAFETY

2.7 LIGHTING
The machine must be equipped in a lighted-enough area, with values included between 300 and 500 lux.
The lighting source must be such to assure a total and uniform lighting of the machine structure and to
avoid any eventual reflection and reverberation to the operator.

2.8 VIBRATIONS

In use conditions conform to the correct installation and employ instructions, vibrations are not such to
create danger situations.

2.9 SOUND EMISSIONS


 The ecologic test is made on ALMAC SRL machine samples in order to determine the emitted noisiness
level. Test is made in order to check that the noisiness level is conforming to the current rules or to the
specific supply instructions.
 Test supplies quantitative data that allow the sound level in the machine surrounding are to be evaluated
with certain accuracy.
 The noticed levels of weighted sound pressure A are:

MACHINE DESCRIPTION MODEL SERIAL N°. CONSTRUCTION YEAR LEQ PA


Curd-Cutter T28 095
2017 < 70 dB (A)
Stretcher FT60 096

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Chapter
2 SAFETY

2.10 SAFETY SIGNALS ON THE MACHINE


On some machine parts are applied labels with ban, danger and obligation normalized symbols, having
the aim to catch the operator’s attention on non-evident potential risks. Be sure that they are always
present and readable. On the contrary apply new labels or replace them by directly contacting the
manufacturer (see Chap. 1 - Par. 1.14).

 BAN LABELS

 WARNING AND DANGER LABELS

208 Volt

DANGER DANGER
HOT SURFACE HIGH TEMPERATURE

DANGER DANGER DANGER


HANDS SQUEEZING HANDS PULLING HIGH TEMPERATURE

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Chapter
2 SAFETY

2.11 SAFETY DEVICES


DEFINITION OF SAFETY DEVICE: « DEVICE (OTHER THAN A SHELTER) WHICH REDUCES THE RISK, ALONE OR ASSOCIATED
WITH A SHELTER ».

 Every machine built by ALMAC SRL is equipped with movable shelters (panels, lids and grids), individual
or coupled to safety devices (magnetic sensors, proximity inductive sensors, safety switches) that
reduces potential risks for the operator.

SAFETY SENSOR BLOCK SAFETY SWITCH SAFETY MAGNETIC


WITH ACTUATOR WITH ACTUATOR SENSOR WITH LED

WARNING! IT’S ABSOLUTELY FORBIDDEN TO REMOVE OR TAMPERING WITH THE SAFETY DEVICES.

WARNING! BEFORE EVERY MACHINE START-UP IT’S NECESSARY TO CHECK THE SAFETY DEVICES CORRECT
OPERATION.

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Chapter
2 SAFETY

 SAFETY DEVICES POSITION


The machines are equipped with safety devices aimed to guarantee the below mentioned safety
functions.

 CURD-CUTTER MOD. T28 - STRETCHER MOD. FT60

16
PX1

15
PX1

Fig. 2.1

ALMAC ID DIAGRAM ID DESCRIPTION


Safety sensor with always active actuator used to exclude and/or stop
15PX1 15PX1
the machine operation owing to the diving arms safety grid opening.
Safety sensor with always active actuator used to exclude and/or stop
16PX1 16PX1
the machine operation owing to the curd-cutter feeding grid opening.

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Chapter
2 SAFETY

15
PX4

15
PX2

15
PX3

Fig. 2.2

ALMAC ID DIAGRAM ID DESCRIPTION


Safety sensor with always active actuator used to exclude and/or stop
15PX2 15PX2 the machine operation owing to the lifting of the discharging mouth
safety grid.
Safety sensor with always active actuator used to exclude and/or stop
15PX3 15PX3 the machine operation owing to the Curd-Cutter rotation from the
operation position.
Safety sensor with always active actuator used to exclude and/or stop
15PX4 15PX4 the machine operation when the Curd-Cutter body is opened from the
motor support plate.

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Chapter
2 SAFETY

2.12 HAZARDS AND RESIDUAL RISKS


RESIDUAL RISK DEFINITION: « NOT COMPLETELY ELIMINABLE DANGER BY MEANS OF THE DESIGNING AND THE
PROTECTION TECHNIQUES, OR RATHER, NOT EVIDENT POTENTIAL DANGER ».

 The machine has been designed and built in compliance with the Directive 2006/42/CE and with regards
to the fundamentals security requirements provided by the EC regulations in force and applicable to the
machine. Even if all the possible causes of risk have been duly estimated, it reasonable to think that
besides the risks due to the illegitimate use, the following residual risks can be happen:
 The employer has the duty to inform the staff on the risks of accidents, security devices and on the
accident prevention regulations provided by the European directives and by the place where the machine
will be installed. It is thus necessary that the use, maintenance and cleaning done by the user are given
to trained and competent staff.
 It is duty of the employer to make sure that the given instructions have been duly understood.

RESIDUAL RISK DUE TO IMPACT, ABRASION, CRUSHING, CUTTING AND SHEARING OF THE LIMBS

It is forbidden to remove and / or tamper with the fix guards and safety devices (Chap. 2 - Par. 2.11).
The use of the machine without fixed guards (Chap. 2 - Par. 2.10) is forbidden.
During the phases of tooling, maintenance, cleaning and all manual operations it remains a residual risk
due also to the need of disassembling and/or positioning the machine tools and mechanical components.
The lifting and handling operations of the machine or its parts, are manual operations that involve a
residual risk, so they should be performed by qualified personnel according to the manufacturer's
instructions (Chap. 3 - Par. 3.6).

RESIDUAL RISK DUE TO ELECTROCUTION DANGER


A residual risk for the maintenance man of the electrical system is also present in the medians circuits DC
of the activations when the fix protections which guarantee the protection are opened, due to the
presence of a voltage higher than 60V for a period superior to 5 seconds after the power supply
interruption, by opening the general sectioning device of the power supply.
Therefore the maintenance men have to operate with caution, and follow the instructions on the labels
fixed nearby those components and waiting at least 5 minutes after the power supply interruption, by
opening the general sectioning device of the power supply, before operate on the medians circuits DC of
the activations. Those operators have to follow as well the security regulations typical for the
maintenance men.

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Chapter
2 SAFETY

RISK DUE TO THE NATURE OF THE USED PRODUCTS


The Curd-Cutter mod. T28 and the Stretcher mod. FT60 are machines designed to cut the curd in crumbs
or flakes and perform the cooking, stretching and mixing of curd and foodstuffs for the production of
pasta filata (stretched dough) for the dairy industry.

NOTE: ANY OTHER KIND OF USE OF THE MACHINES ARE ALLOWED ONLY PREVIOUS EXPRESS AND SPECIFIC
WRITTEN AUTHORIZATION OF ALMAC SRL.

RISK DUE TO A POSSIBLE SLIPPING AND/OR FALL

To avoid the dangers of slipping and/or fall on the working surface (foot-surface) during the normal use
of the machine and during the cleaning and maintenance interventions, the operator and the
maintenance man, has to be duly informed and trained and use apposite feet protection equipment as for
example non-slippery shoes and/or boots, resistant and suitable to the particular nature of the risk. In
any way the user has to keep clean the foot-surface where operator and the maintenance man operate
and free from substances which can easily provoke the slipping, as for example the working liquid (milky
water) produced by the machine and the liquids produced by the environmental conditions of the dairy
milk sector (water, steam, humidity).

RISK DUE TO POSSIBLE BURNING


For the operator in the working area remains the residual risk due to possible burning during the working
phase, furnishing, maintenance and cleaning and during all the further manual operations due to the
presence of parts which have a temperature higher than the burning level (45°C).

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Chapter
3 TEST, DELIVERY AND FIRST INSTALLATION

3.1 TEST
The machines are strictly controlled and tested in such a way to assure a reliable and operating product
in all their components. During the test the machine is subject to a series of test and checkings in order
to attest the correct operation before the delivery.

 TESTS
 Aesthetic conformity verification.
 Conformity verification of all components correct assembling.
 Conformity verification of the machine connections to the energy feeding sources (electrical, pneumatic,
steam, compressed air).
 Safety devices operation tests.
 Each motorization current absorption tests (3 phases).
 Hydraulic circuit watertight tests.
 Operation tests under processing conditions.

3.2 PACKING AND TRANSPORT


The type of packing is defined at the delivery moment, according to the distance and transport mean.
Normally the machine is equipped with a thermo-retractable nylon coiling or, for specific cases, into a
wooden case.

3.3 STORING
In case it’s necessary to store the machine for an inactivity period, it is recommended to locate it in a
closed environment that allows protecting it from bad weather, collisions, shocks, humidity and corrosive
substances.

3.4 UNPACKING AND POSITIONING


Even if it’s packed, the machine must be transported with the highest care, by using suitable means and
located in an area having suitable spaces for the material handling. The machine must be positioned on a
flat and well-levelled indoor surface, keeping a minimum distance of 1 m from the walls or from other
machines to allow the operator accessibility during the use and the ordinary and extraordinary
maintenance.

3.5 PACKING MATERIAL DISPOSAL


Packing and transport materials (pallets, wooden cases, nails, nylon, pluribol, tape, expanded
polystyrene, etc.) must be disposed according to the Directive 2008/98/CE of the European Parliament
and the Council dated 19th November 2008 pertinent to wastes or according to the rules in force in the
machine installation Country.

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Chapter
3 TEST, DELIVERY AND FIRST INSTALLATION

3.6 MACHINE LIFTING AND HANDLING

WARNING! MACHINE LIFTING, HANDLING AND POSITIONING OPERATIONS MUST BE MADE BY AN OPERATOR
ENABLED IN THE USE OF LIFTING MEANS (LIFTING TROLLEY). IF THE LIFTING MEAN DRIVER DOES NOT HAVE
VISIBILITY ENOUGH, IT’S APPROPRIATE TO FORESEE THE ASSISTANCE ON THE GROUND OF A SECOND OPERATOR
CHARGED OF THE SIGNALING.

IMPORTANT! THE CURD-CUTTER (T28) AND THE STRETCHER (FT60) MUST BE HANDLED TOGETHER,
PREVIOUSLY CHECKING THE CLAMPING OF THE KNOB THAT FIX THE CURD-CUTTER IN THE WORKING POSITION.

WARNING! LOAD MUST BE HANDLED THE LOWEST AS POSSIBLE, SLOWLY AND CHECKING TO HAVE OBTAINED A
GOOD LOAD BALANCING BEFORE THE DISPLACEMENT.

ATTENTION! THE MACHINE MUST BE INSTALLED WITH EXTREME CAUTION SO AS NOT TO DAMAGE THE
ADJUSTABLE SUPPORTING FEET.

IMPORTANT! TO PROCEED WITH THE MACHINE LIFTING, TRANSPORT AND POSITIONING OPERATIONS, IT’S
NECESSARY TO USE A HOIST WITH A SUITABLE CAPACITY TO SUPPORT THE LOADING TOTAL WEIGHT (~ 415
KG) AND FORKS ≥ OF 1,2 METERS LENGTH. FOLLOW THE BELOW LOADING DIAGRAM (FIG. 3.1), CHECKING
THAT THE FORKS CENTRE CORRESPONDS TO THE INDICATED ( ) HALF POINT AND THAT THE FORKS TIPS
PROTRUDE FROM THE MACHINE SUPPORTING FRAME (FIG. 3.1 - DET. A).

NOTE: « CENTER OF GRAVITY » (ISO 7000 - No. 0627).

Fig. 3.1

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3 TEST, DELIVERY AND FIRST INSTALLATION

3.7 LEVELLING

WARNING! Machine levelling operations must be made only by skilled personnel and only after having
isolated the machine from the power feeding sources.

The machine is equipped with four casters with brake (Fig. 3.2), which have to be levelled on the ground
of the installation site. At the end of the operations check the machine levelling using a spirit level.

 SERVICING CATWALK
Using a hexagonal key (24) loosen the M16 nuts (Fig. 3.2 - Det. 3.2.1) and using a second hexagonal key
(13) level the adjustable feet (Fig. 3.2 - Det. 3.2.2). At the end of the operations tighten the M16 nuts
again.

 STRETCHER MOD. FT60


Using a hexagonal key (30) loosen the M20 nuts (Fig. 3.2 - Det. 3.2.1) and using a second hexagonal key
(17) level the adjustable feet (Fig. 3.2 - Det. 3.2.2). At the end of the operations tighten the M20 nuts
again.

3.2.1

3.2.2

Fig. 3.2

NOTE: No floor anchoring needed for the machine and its components.

NOTE: The adjusting hexagonal keys and the spirit level are not included in the supply.

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Chapter
4 TECHNICAL DATA

4.1 GENERAL DESCRIPTION


The Curd-Cutter mod. T28 and the Stretcher mod. FT60 are a suitable machine for cut the curd in small
pieces (crumbs or flakes) and perform the cooking, stretching and mixing of curd and foodstuffs for the
production of pasta filata (stretched dough) for the dairy industry. The machines structure is completely
built in AISI 304 stainless steel and plastic materials suitable for the food contact. As per the supply
technical specifications, some parts in direct contact with the cheese are coated by a fine micro shot
peening suitable for the food use.

4.2 TECHNICAL DATA

DIMENSIONS
A B C * WEIGHT
1180 mm 1190 mm 2440 mm ~ 415 Kg

* The « WEIGHT » refers to the empty machines without servicing catwalk.

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4 TECHNICAL DATA

4.3 ELECTRICAL DATA

POWER VOLTAGE FREQUENCY PHASES AUXILIARY VOLTAGE * RATED POWER RATED CURRENT

400 V 50 HZ 3 24 VDC 3,5 KW 9A

* The « RATED POWER » refers to the electrical consumption by the Curd-Cutter (T28) and Stretcher (FT60).

4.4 CONDITIONS OF USE


The machine is exclusively destined to the use foreseen by company ALMAC SRL for which it has been
designed and built. Any other use has to be considered « INCORRECT » and implies the lapsing of all
conformity and safety inquiries adopted by the manufacturer.

 FORESEEN USE
DEFINITION: « MACHINE USE ACCORDING TO THE INFORMATION SUPPLIED IN THE USE INSTRUCTIONS ».

 The Curd-cutter mod. T28 is used to cut the curd in small pieces (crumbs or flakes).
 The Stretching mod. FT60 is used to cook, stretch and knead foodstuffs and fresh and/or industrial curds
for the production of pasta filata (stretched dough) for the dairy industry.

NOTE: OTHER USES OF THE MACHINES ARE ALLOWED ONLY IF EXPRESSLY AUTHORIZED BY COMPANY ALMAC
SRL BY A SPECIFIC WRITTEN DECLARATION.

 REASONABLY PREDICTABLE INCORRECT USE


DEFINITION: « MACHINE USE IN A DIFFERENT WAY FROM THAT MENTIONED IN THE USE INSTRUCTIONS, BUT WHICH CAN
COME FROM THE EASILY FORESEEABLE HUMAN BEHAVIOUR ».

WARNING! IT’S ABSOLUTELY FORBIDDEN TO FEED THE CURD-CUTTER MOD. T28 WITH FROZEN CURD.

WARNING! IT’S FORBIDDEN TO FEED THE STRETCHER MOD. FT60 DIVING ARMS CHAMBER WITH A QUANTITY
OF ROW MATERIAL TOTAL QUANTITY (CURD AND WATER) > THAN 60 KG FOR EVERY PROCESSING CYCLE.

WARNING! DURING THE MACHINES OPERATION IT’S ABSOLUTELY FORBIDDEN TO INTRODUCE ANY TOOL
THROUGH THE DIVING ARMS CHAMBER SAFETY GRID.

 The machines use without the necessary use precautions in safety conditions and in unsuitable places
and environmental conditions is strictly forbidden (Chap. 2).
 The machines use with products and/or foodstuffs that, owing to their nature or features, do not allow
the processing for which they have been designed and built is strictly forbidden.

NOTE: ALMAC SRL COMPANY DISCLAIMS ANY RESPONSIBILITY FOR DAMAGES AND INJURIES CAUSED BY THE
FAILURE TO COMPLY WITH THESE INSTRUCTIONS, THE SAFETY AND PREVENTION RULES DESCRIBED IN THE
HANDBOOK, BY AN INCORRECT USE OF THE MACHINES, TAMPERING AND/OR MODIFICATIONS OF THE
COMPONENTS.

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Chapter
4 TECHNICAL DATA

4.5 ELECTRICAL CONNECTION


 Before proceeding with any operation, be sure that the line tension corresponds to the one mentioned on
the machine identification label (Chap. 1 - Fig. 1.1) and on the attached electrical diagram (Chap. 10 -
Par. 10.1). Normally the machine is arranged for a line tension of 400V - 50 Hz, but the machine can be
supplied with other tensions too according to the rules in force in the installation Country and/or the
supply specific instructions.
 It’s user responsibility to verify that the electrical connection to the feeding net is conforming to the rules
in force in the machine installation Country.
 Before connecting the machine to the feeding net, it’s a user task to install, upstream the electrical
equipment, a switch and/or a magnetothermal differential switch for the operators protection during the
cleaning, maintenance, repairing or processing steps. FOR THE MACHINES EQUIPPED WITH INVERTER, IT’S
NECESSARY TO INSTALL A DIFFERENTIAL MAGNETOTHERMAL SWITCH WITH MINIMUM SENSITIVITY OF 300 MA.

 Company ALMAC SRL denies liability for any tension fluctuation higher than the ± 2% (CEI EN 60204-1
rule) that may damage or compromise the correct operation of the machine and its instruments.
 Connect the feeding cable to the net.

L1 L1
L2 L2 Id
Id
L3 L3
N PE
PE

ELECTRICAL FEEDING ELECTRICAL FEEDING


3PH + N + PE 3PH + PE

NOTE: ALMAC SRL COMPANY DISCLAIMS ANY RESPONSIBILITY FOR THE LACK OF THE DIFFERENTIAL
MAGNETOTHERMAL SWITCH, LACK OR NON-SUITABILITY OF THE ELECTRICAL PLANT EARTHLING AND PERTINENT
CONNECTION TO THE MACHINE TERMINAL BOARD.

NOTE: THE ELECTRIC DIAGRAM IS ENCLOSED IN THE PRESENT DOCUMENTATION (CHAP. 10 - PAR. 10.1).

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Chapter
4 TECHNICAL DATA

4.6 HYDRAULIC AND STEAM CONNECTIONS


The machines are equipped with fittings used for the below mentioned hydraulic utilities connections.

D
A

C
Fig. 4.1

POS. UTILITY AND CONNECTION DESCRIPTION


STEAM INLET Ball valve with fitting used to connect the steam inlet pipe.
A
Ø ¾” GAS (ISO 228) Pressure: Max. 3 bar
Pipe with ball valve with fitting used for the milky water
MILKY WATER OUTLET
B outlet during the production cycle.
DN25 (DIN 11851)
NOTE: Avoid the discharge of the liquids on the ground.
Plug with Clamp fitting used to totally discharge the residual
TOTAL DISCHARGE
C liquids contained into the stretching vat.
2” CLAMP
NOTE: Avoid the discharge of the liquids on the ground.
COMPRESSED AIR INLET Fitting used to connect the compressed air inlet pipe.
D
Ø 6/4 MM Pressure: Min. 6 bar

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Chapter
5 CONTROLS

5.1 LIST AND DESCRIPTION OF THE CONTROLS


The processing controls are located on the electrical power panel (Fig. 5.1) and electrical control panel
(Fig. 5.2). All controls are equipped with a label on which their function is displayed.

NOTA: THE ALPHA- NUMERIC CODES INDICATED IN THE « DIAGRAM ID » COLUMN REFER TO THE SAME
REFERENCES MENTIONED IN THE « ELECTRICAL DIAGRAM » ATTACHED TO THIS DOCUMENTATION (SEE CHAP.
10 - PAR. 10.1).

 ELECTRICAL POWER PANEL

5.1.1

Fig. 5.1

ALMAC ID DIAGRAM ID DESCRIPTION


MAIN : 2-position cut-out switch (O-1) to enable the insertion of the power
5.1.1 5IG1
supply voltage (400V) to the power circuit (O:OFF - 1:ON).

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Chapter
5 CONTROLS

 ELECTRICAL CONTROL PANEL

5.2.1

5.2.2
5.2.13
5.2.3
5.2.4

5.2.5

5.2.6
5.2.7
5.2.10
5.2.11
5.2.8

5.2.9

5.2.12

Fig. 5.2

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Chapter
5 CONTROLS

 ELECTRICAL CONTROL PANEL

ALMAC ID DIAGRAM ID DESCRIPTION


LINE 24V O-1 : 2-positions (O-1) key selector used to control the 24V
5.2.1 5SA1
tension connection to the auxiliary circuits (O:OFF - 1:ON).
LINE 24V : white light indicator which indicates the voltage supply to the
5.2.2 5HL1
auxiliary circuits (24VDC).
THERMAL RELEASE : yellow light indicator which indicates that a drive is
5.2.3 40HL1
malfunctioning or overheating.
DIVING ARMS START : white light button which activates the start-up of the
5.2.4 20PM1
diving arms functions.
STRETCHER PUMP START : white light button which activates the start-up of
5.2.5 20PM2
the stretching pump functions.
CURD-CUTTER START : white light button which activates the start-up of the
5.2.6 20PM3
curd-cutter functions.
DIVING ARMS STOP : black button which activates the stop of the diving
5.2.7 20PA1
arms functions.
STRETCHER PUMP STOP : black button which activates the stop of the
5.2.8 20PA2
stretching pump functions.
CURD-CUTTER STOP : black button which activates the stop of the curd-
5.2.9 20PA3
cutter functions.
HEATING O-1 : 2-positions (O-1) green light selector aimed to activate the
5.2.10 18SA1
processing water heating functions.
15PM1 START : 2-position green-red button (O-I) which starts and stops the
5.2.11
15PA1 functions of the processing cycle (O:OFF - I:ON).
THERMOREGULATION : ELIWELL device used to set and display the heating
5.2.12 18TG1
water temperature.
STOP EMERGENCY : emergency stop push-button to disable all the machine
5.2.13 15PE1
functions.

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Chapter
6 COMMISSIONING

6.1 OPERATOR’S POSITION


The machine can only be controlled by appropriately trained and specifically appointed personnel.
The normal working zone is on a service catwalk (not included in the ALMAC srl supply) in the frontal
position with respect to the controls placed on the electrical control panel (Fig. 6.1 - Det. A) in normal
operating conditions with fixed and movable guards locked and closed.

Fig. 6.1

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Chapter
6 COMMISSIONING

6.2 PRELIMINARY CHECKS

ATTENTION! Skilled personnel must perform the inspection operations after having isolated the
machine from the power sources.

 Make sure the connections to the utilities are correct (Chap. 4 - Par. 4.5 and 4.6).
 Check the tightness of all the components.
 Open the safety grids and check that there isn’t any foreign body into the curd-cutter body, diving arms
chamber and stretching vat.
 Check the clamping of the knob (Fig. 6.2 - Det. 6.2.1) that fix the Curd-Cutter in the working position
(see Fig. 6.2).

6.2.1

Fig. 6.2

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Chapter
6 COMMISSIONING

 Check the clamping of the 3 knobs (Fig. 6.3 - Det. 6.3.1) that fix the Curd-Cutter body (Fig. 6.3 - Det.
6.3.2) against the motor support plate.

6.3.2

6.3.1
6.3.1

6.3.1

Fig. 6.3

 Loosen the tightening of the knob (Fig. 6.4 - Det. 6.4.1) and lower the dough outlet wall (Fig. 6.4 - Det.
6.4.2) till the mouth closing position (see Fig. 6.4). During the production cycle, when stretching is
finished, loosen the tightening of the knob, adjust the wall height and clamp the knob again.

6.4.2

6.4.1

Fig. 6.4

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6 COMMISSIONING

 Remove the vat lid (Fig. 6.5a - Det. 6.5.1) and fill the vat with tap water until reaching the maximum
level. At the end of the operation replace the lid in the operating position.
 Check the presence of the milky water filter vat (Fig. 6.5a - Det. 6.5.2).
 Close the DN40 butterfly valve (Fig. 6.5a - Det. 6.5.3) for the milky water outlet.
 Adjust the DN25 butterfly valve opening (Fig. 6.5a - Det. 6.5.4) that determines the processing water
output into the stretching chamber.
 Close the DN25 butterfly valve (Fig. 6.5b - Det. 6.5.5) for the processing water discharge.

6.5.4

6.5.5
6.5.3

6.5.1

6.5.2

Fig. 6.5a Fig. 6.5b

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Chapter
7 START-UP

7.1 OPERATION CYCLE


The curd parts (not frozen) are loaded into the Curd-Cutter (T28) cylindrical body and harvested by the
motorized auger that continuously powers the rotary disk cutter with 3 knives, where it is shredded into
small pieces (crumbs and flakes) and discharged in the Stretcher (FT60) mixing chamber. Curd crumbs
are mixed with the processing water, which is heated by the steam direct injection into the preparation
vat. The processing water is sucked by the service pump and conveyed through the pipe into the
stretching chamber. The temperature probe equipped into the vat causes the proportional opening or
closing of the steam inlet pneumatic valve according to the temperature (set-point) set on the
thermoregulator. The diving arms section allows performing the curd stretching process until its
transformation into pasta filata (stretched dough). When the dough reaches the desired stretching
degree, it is discharged through the outlet mouth into the downstream molding machine.

7.2 STARTING THE PRODUCTION CYCLE

IMPORTANT! BEFORE EVERY START-UP CHECK THE UTILITIES CONNECTIONS (CHAP. 4 - PAR. 4.5 AND 4.6) AND MAKE
SURE ALL THE INSTRUCTIONS PROVIDED IN THE « PRELIMINARY CHECKS » PARAGRAPH HAVE BEEN IMPLEMENTED (CHAP. 6
- PAR. 6.2).

IMPORTANT! BEFORE EVERY MACHINE START-UP ALWAYS CHECK THE WATER PRESENCE AND LEVEL INTO THE
HEATING VAT.

WARNING! IT’S FORBIDDEN TO FEED THE STRETCHER MOD. FT60 DIVING ARMS CHAMBER WITH A QUANTITY
OF ROW MATERIAL TOTAL QUANTITY (CURD AND WATER) > THAN 60 KG FOR EVERY PROCESSING CYCLE.

WARNING! IT’S ABSOLUTELY FORBIDDEN TO FEED THE CURD-CUTTER MOD. T28 WITH FROZEN CURD.

BURNING DANGER! DURING THE PROCESSING CYCLE IT’S FORBIDDEN TO COME IN CONTACT WITH THE
PROCESSING LIQUIDS CONTAINED INTO THE HEATING VAT.

 Open the Curd-Cutter safety grid and put the curd pieces (unfrozen) into the feeding mouth. At the end
close the safety grid.
 Enter the electrical power panel (Fig. 5.1 - Page 32) and turn the « MAIN » (Fig. 5.1 - Det. 5.1.1 - Page
32) power cut-out switch to position 1 (ON).
 Enter the electrical control panel (Fig. 5.2 - Page 33) and check that « STOP EMERGENCY » (Fig. 5.2 - Det.
5.2.13 - Page 33) button is in the release position. On the contrary proceed with the unblock manoeuvre
by anticlockwise turning the button head.
 Turn the « LINE 24V O-1 » (Fig. 5.2 - Det. 5.2.1 - Page 33) key selector to position 1 (ON).
 Push the « I » green button of the « START » button (Fig. 5.2 - Det. 5.2.11 - Page 33).
 Turn the « HEATING O-1 » selector (Fig. 5.2 - Det. 5.2.10 - Page 33) to position 1 (ON) and set on the
« THERMOREGULATION » (Fig. 5.2 - Det. 5.2.12 - Page 33) device the stretching water heating
temperature value. Before proceeding, wait for the set value reaching.

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7 START-UP

 Push the « CURD-CUTTER START » (Fig. 5.2 - Det. 5.2.6 - Page 33) button.
 Push the « DIVING ARMS START » (Fig. 5.2 - Det. 5.2.4 - Page 33) button.
 After the first kneading step, push « DIVING ARMS STOP » (Fig. 5.2 - Det. 5.2.7 - Page 33) button, adjust
the DN25 butterfly valve opening to allow the heated water introduction into the stretching chamber and
push « STRETCHER PUMP START » (Fig. 5.2 - Det. 5.2.5 - Page 33) button.

NOTE: FOR A CORRECT PROCESSING CYCLE, IT IS RECOMMENDED TO FIRSTLY PUT A WARM WATER QUANTITY
EQUAL TO  THE 30% OF THE CURD QUANTITY.

EXAMPLE: 60 KG. OF CURD  20 LT. OF WATER.

NOTE: MENTIONED WATER AND CURD QUANTITIES MUST BE CONSIDERED AS INDICATIVE. DIFFERENT VALUES
CAN BE SUGGESTED BY USER’S EXPERIENCE AND BASED ON THE WORK LOAD THE USED ROW MATERIAL
FEATURES.

 At the end of this processing step, push « STRETCHER PUMP STOP » (Fig. 5.2 - Det. 5.2.8 - Page 33)
button.
 Discharge the exceeding processing liquid (milky water) contained in the stretching chamber by operating
on the special DN40 butterfly valve. At the end of the operation, close the valve.
 Push « DIVING ARMS START » (Fig. 5.2 - Det. 5.2.4 - Page 32) button.
 At the end of the second processing step, push « DIVING ARMS STOP » (Fig. 5.2 - Det. 5.2.7 - Page 33)
button and push « STRETCHING PUMP START » (Fig. 5.2 - Det. 5.2.5 - Page 33) to allow introducing a
new processing water quantity (30% of the curd quantity).
 Push « STRETCHING PUMP STOP » (Fig. 5.2 - Det. 5.2.8 - Page 33) button.
 Push « DIVING ARMS START » (Fig. 5.2 - Det. 5.2.4 - Page 32) button.
 At the end of the stretching step, lift the guillotine wall to allow downloading the dough from the
discharging mouth.

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Chapter
8 MAINTENANCE

8.1 MANUAL CLEANING

WARNING! The manual and maintenance operations must be made by specialized personnel, after
having isolated the machine from the electrical power feeding source.

At the end of production cycle:

 Switch the machine off.


 Empty the processing water contained into the heating vat.
 Enter the Curd-Cutter (T28) and loosen the tightening of the knob (Fig. 8.1 - Det. 8.1.1) until releasing
the tie-rods from the fixing plate.

8.1.1

Fig. 8.1

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Chapter
8 MAINTENANCE

 Slowly outwards turn the Curd-Cutter until reaching the maximum opening position (see Fig. 8.2b).

Fig. 8.2a Fig. 8.2b

 Loosen the tightening of the 3 knobs (Fig. 8.3 - Det. 8.3.1) until releasing the tie-rods from the fixing
plates on the Curd-Cutter body. At the end of the operation remove the Curd-Cutter body.

8.3.2

8.3.1
8.3.1

8.3.1

Fig. 8.3

 Remove the curd solid residuals contained in the Curd-cutter.

WARNING RISK OF CUT: THE CURD-CUTTER CLEANING OPERATIONS MUST BE MADE BY SKILLED
PERSONNEL ALWAYS USING THE SAFETY GLOVES.

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 Lift the diving arms protection grid (Fig. 8.4 – Det. 8.4.1) from the operating position until it is locked by
sliding the pin between the support plate guide (Fig. 8.4 – Det. 8.4.2).

DANGER HANDS SQUEEZING: DURING TIGHTENING PROTECTION GRID OPERATIONS ALWAYS USING THE
SAFETY GLOVES.

8.4.1

8.4.2

Fig. 8.4

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 Remove the vat lid (Fig. 8.5 - Det. 8.5.1) and the milky water filter vat (Fig. 8.5 - Det. 8.5.2).
 Release the knob clamping (Fig. 8.5 - Det. 8.5.3) and outwards pull out the mouth closing wall (Fig. 8.5 -
Det. 8.5.4) until allowing the component removal.

8.5.4

8.5.3

8.5.1

8.5.2

Fig. 8.5

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 Manually remove all processing residuals.


 BY USING A PRESSURE WASHER PROCEED WITH THE MACHINE INTERNAL AND
EXTERNAL WASHING BY WARM WATER (55÷70°C) AND/OR BY DETERGENTS
HAVING A NEUTRAL PH. (~ 1,5%). DO NOT USE SOLUTIONS CONTAINING
CHLORINE (E.G. CHLORIC ACID).DO NOT LEAVE THE DETERGENT SOLUTION
DRYING ON THE SURFACES AND AT THE END OF THE WASHING PHASE, PLENTIFUL
RINSE BY TAP WATER UNTIL COMPLETELY REMOVING THE DETERGENT. AS AN
ALTERNATIVE, PROCEED WITH THE « MANUAL WASHING BY FOAMING
TECHNOLOGY » STRICTLY FOLLOWING THE PROCEDURES DESCRIBED IN THE
DEDICATED PARAGRAPH (SEE CHAP. 8 - PAR. 8.3).

WARNING! KEEP THE WATER CLEANER NOZZLE AT A MINIMUM DISTANCE OF ± 70÷80 CM FROM THE
SURFACE TO BE TREATED. DO NOT POINT THE WATER CLEANER NOZZLE TO THE ELECTRICAL CONTROL PANEL,
SAFETY DEVICES, ELECTRONIC DEVICES, ETC.

WARNING! NEVER USE ABRASIVE MATERIALS AND/OR TOOLS ON THE EVENTUAL NON-STICKING MATERIAL
COATED SURFACES AND/OR COATED BY A FINE MICRO SHOT PEENING SUITABLE FOR THE FOOD USE.

IMPORTANT! Before using any washing detergent it is recommended to carefully read the use
instructions and precautions mentioned on the product data sheet. In the “Recommended Products”
(Chap. 8 - Par. 8.2) paragraph are mentioned some of the detergents (use and compatibility with the
surfaces and/or materials to be treated) distributed by ECOLAB. These products must be considered as
examples of industrial detergents used to carry out the manual washing operations and/or circulation
(CIP washing) in the different application fields. As alternative, it’s possible to use equivalent products
distributed by JOHNSON DIVERSEY.

WARNING! DISCHARGE THE WASHING SOLUTIONS ACCORDING TO THE RULES IN FORCE IN THE ANTI-
POLLUTION AND WATER DISCHARGE FIELD.

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8.2 RECOMMENDED PRODUCTS


ECOLAB SRL PRODUCTS ARE INDUSTRIAL DETERGENTS USED FOR THE MANUAL WASHING OPERATIONS
AND/OR CIRCULATION (CIP WASHING) IN DIFFERENT APPLICATIONS FIELDS.

ATTENTION! BEFORE USING ANY CLEANING SOLUTION, IT’S RECOMMENDED TO GET AND/OR CONSULT THE
TECHNICAL SHEETS OF EVERY PRODUCT AND CAREFULLY READ THE USE, WARNINGS AND PRECAUTION MODES.

Via Trento, 26 - 20871 Vimercate (MB) - Italy


Tel. +39 039 60501 - Fax +39 039 6050300
www.it.ecolab.eu - www.ecolab.com

PRODUCT DESCRIPTION AND FEATURES


POWDER ALKALINE ACTIVE CHLORINE DETERGENT WITH SILICATES FOR FOOD INDUSTRY
CLEANING USE.

 SUITABLE FOR ALUMINIUM SURFACES;


 HIGH DETERGENT POWER;
P3-Z
 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:
METALS: STAINLESS STEEL (QUALITY DIN 1.4301 = AISI 304), IRON, GLASS,
ENAMELLED SURFACES, ALUMINIUM AND ITS ALLOYS.

PLASTIC: ALL ALKALINITY RESISTANT PLASTICS (PTFE, PVDF, PVC);


GASKETS: ALL ALKALINITY RESISTANT GASKETS (EPDM, NBR, PTFE).
ACTIVE CHLORINE LIQUID DETERGENT WITH ADDITIONAL ANTICORROSIVE ACTION.

 EFFECTIVE IN THE REMOVAL OF TOUGH DIRT RESIDUALS;

 EXCELLENT DEGREASING AND SANITIZING PROPERTIES;

P3-ZINNFEST FL  APPLICABLE EVEN ON DELICATE MATERIALS;


 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:
METALS: STEEL, IRON, ALUMINIUM, TINNED IRON, ENAMELLED SURFACES;
PLASTIC: ALL OXIDATION RESISTANT PLASTICS (PE);
GASKETS: ALL OXIDATION RESISTANT GASKETS (VITON, EPDM).
ACTIVE CHLORINE ALKALINE LIQUID DETERGENT AND DISINFECTANT FOR THE FOAMING
CLEANING IN THE FOOD INDUSTRY.

 EXCELLENT REMOVAL OF GREASE AND PROTEIN DIRT;


P3-TOPAX 66
 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:
METALS: STAINLESS STEEL (QUALITY DIN 1.4301 = AISI 304);
PLASTIC: HD-PE, PP, PVC RIGID.

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PRODUCT DESCRIPTION AND FEATURES


MEDIUM-ALKALINE LIQUID DETERGENT FOR THE FOAMING CLEANING IN THE FOOD
INDUSTRY.

 EXCELLENT REMOVAL OF GREASE AND PROTEIN DIRT;


TOPAZ MD3  ALLOWS REDUCING THE FREQUENCY OF ACID PASSAGES, EVEN IN PRESENCE OF HARD
WATER.

 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:


METALS: STAINLESS STEEL (QUALITY DIN 1.4301 = AISI 304);
PLASTIC: HD-PE, PP, PVC RIGID.
DISINFECTANT FOR PLANTS IN THE FOOD INDUSTRY
 HIGH DISINFECTANT EFFICACY EVEN AT LAW TEMPERATURES;
 ENERGY AND WORKING TIME SAVING;
 EFFECTIVE EVEN ON SPORE-FORMING AND VIRUSES;
 NO CORROSION FOUND ON ALUMINIUM, ON CHROME/NICKEL STEEL AND ON TINNED
IRON. GALVANIZED IRON, COPPER, ITS ALLOYS AND IRON (ST 37/2) UNDERGO
REMOVALS WITHIN ACCEPTABLE LIMITS, BASED ON THE USED SOLUTION
CONCENTRATION. SHORT-TIME ACTIONS ARE ALLOWED. STATIC SANITATIONS ARE NOT
P3-OXONIA ACTIVE RECOMMENDED IN THIS CASE.

 SALTS CONTENT IN THE WATER (HARDNESS) DOES NOT INCREASE THE PRODUCT
AGGRESSIVENESS ON THE MATERIALS. ON THE CONTRARY, CHLORIDES CONTENT IN THE
WATER MAKES P3-OXONIA ACTIVE SOLUTIONS CORROSIVE, CONSEQUENTLY IT’S
RECOMMENDED THE USE OF THE PRODUCT MIXED WITH WATER WHERE THE CHLORIDES
CONTENT SHOULD NOT EXCEED 50 PPM.
 THE USE OF P3-OXONIA ACTIVE MIXTURES WITH DETERGENT SOLUTIONS MUST BE
ADJUSTED BASED ON THE ACID DETERGENT SOLUTIONS BEHAVIOUR TOWARDS
CORROSION. PLASTIC MATERIALS, SUCH AS TEFLON, POLYSTYRENE AND POLYETHYLENE
DO NOT SUFFER ANY CORROSION. FOR COATING MATERIALS (E.G. IN TANKS) AND IN
CASE OF VARNISHING, MAKE PRELIMINARY TESTS.

ACID LIQUID SANITIZER WITH FOAMING PROPERTIES, BASED ON HYDROGEN PEROXIDE /


PERACÉTICO ACID, FOR THE FOOD COMPANIES.

 EXCELLENT MICROBICIDAL CAPACITY EVEN AT LOW TEMPERATURE;


 APPLICABLE ON THE SURFACES IN THE FORM OF FOAM;
P3-TOPACTIVE DES  GOOD DE-CRUSTING POWER;
 CHLORINE-FREE;

 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:


METALS: STAINLESS STEEL (QUALITY DIN 1.4301 = AISI 304), ALUMINIUM;
PLASTIC: PP, PE, PVC RIGID.
NEUTRAL DISINFECTANT FOR THE FOOD INDUSTRIES.

P3-TOPAX 91  IT DOES NOT CORRODE MATERIALS SUCH AS CARBON STEEL, STAINLESS STEEL, LIGHT
METALS (ALUMINIUM, ZINC), PLASTICS, CERAMICS, GLASS AND GASKETS NORMALLY USED
IN THE FOOD INDUSTRY.

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PRODUCT DESCRIPTION AND FEATURES


STRONG ALKALINE LIQUID DETERGENT FOR THE DAIRY INDUSTRY, SPECIFIC FOR THE
CONTEMPORARY WASHING AND DE-CRUSTING TREATMENT.

 SUITABLE FOR THE WASHING OF STEEL, NICKEL-CHROME, PLASTIC AND ENAMELLED


P3-MIP SP 180 SURFACES.

 SUITABLE IN THE AUTOMATIC WASHING SYSTEMS AND IN ALL CIP PROCESSES, EVEN
WITH HARD WATER.

 NOT SUITABLE FOR THE TREATMENT OF ALUMINIUM AND ITS ALLOYS, ZINC PLATED AND
TINNED SURFACES. WITH HARD WATER.

ALKALINE LIQUID DETERGENT FOR THE FOOD INDUSTRY.


 EXCELLENT WASHING AND SUSPENDING PROPERTIES FOR THE ORGANIC DIRT;
 SUITABLE FOR ALUMINIUM AND LIGHT METALS;
P3-AQUANTA SI  ANTI-FOAMING ACTION AT TEMPERATURE > 35°C;
 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:
METALS: STAINLESS STEEL (QUALITY DIN 1.4301 = AISI 304), IRON, ALUMINIUM,
LIGHT METALS;

PLASTIC: PP, PE, PVC;


GASKETS: ALKALINITY-RESISTANT GASKETS (EPDM, FPM, PTFE).
SURFACTANTS-FREE LIQUID DETERGENT AND DE-CRUSTER BASED ON PHOSPHORIC ACID FOR
THE FOOD INDUSTRY SURFACES TREATMENT.

 REMOVAL OF INORGANIC AND ORGANIC DIRT;


 EASY TO BE RINSED;
P3-PE 4 SPEZIAL A
 AT THE CORRECT USE CONDITIONS, IT’S SUITABLE FOR:
METALS: STAINLESS STEEL (QUALITY DIN 1.4301 = AISI 304), ALUMINIUM, COPPER
AND ALLOYS;

PLASTIC: PP, PE, PVC RIGID, PTFE, PVDF.

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8.3 MANUAL WASHING BY FOAMING TECHNOLOGY

NOTE: PRODUCTS USE DATA (°C AND TIMES) REFER TO STANDARD PROCEDURES; IT IS RECOMMENDED TO
ADAPT THESE FEATURES ACCORDING TO THE SPECIFIC NEEDS.

 STANDARD MANUAL WASHING

STEP DESCRIPTION PRODUCT CONTACT TIME TEMPERATURE


1 Rinse Tap water – Max. Press. 25 bar - 20°C
2 Washing P3-TOPAX 66 (2÷5%) 10÷20 min. -
3 Rinse Tap water – Max. Press. 25 bar - 40÷60°C

NOTE: To perform the machines cleaning operations, it’s recommended using product P3-TOPAX 66.

 OR

STEP DESCRIPTION PRODUCT CONTACT TIME TEMPERATURE


1 Rinse Tap water – Max. Press. 25 bar - 20°C
2 Washing TOPAZ MD3 (2÷5%) 10÷20 min. -
3 Rinse Tap water – Max. Press. 25 bar - 40÷60°C
4 Disinfection P3-TOPACTIVE DES (1÷3%) 10÷30 min. -
5 Rinse Tap water – Max. Press. 25 bar - 20°C

8.4 DAILY MAINTENANCE


 Proceed with the machine cleaning and sanitizing operations (Chap. 8 - Par. 8.1).
 Check the safety devices efficacy and correct operation (Chap. 2 - Par. 2.12).
 Check the status of the surfaces coated with non-sticking material (Teflon lining).

8.5 PERIODIC MAINTENANCE


 Check the tightening of all machines components.
 Check that the slots for the ventilation of carters are free from any dust or soil that could obstruct
motorizations cooling.
 Check the lubricant level inside the motorizations.
 Check the presence and the readability of the warning and danger labels mounted on the machine (Chap.
2 - Par. 2.10).

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8.6 LUBRICATION
A suitable lubrication and the use of correct lubricants are essential factors for the correct operation and
the machine duration. It’s recommended to respect the lubrication rules using suitable lubricants or
equivalent ones from the quality and features points of view.

WARNING! Lubrication operations must be performed by skilled personnel, after having disconnected
the machine from the electrical source.

WARNING! It’s absolutely forbidden to adjust, lubricate, repair and clean any moving organ.

IMPORTANT: Before the machine start-up, be sure that the oil appears from the motorization level
warning light.

IMPORTANT: THE MACHINE’S MOTORIZATIONS ARE LUBRICATED WITH FOOD-SUITABLE NON-TOXIC OIL
APPROVED NSF-H1.

MOTORIZATION LUBRICANT TYPE NOTE


REDUCERS FOOD-SUITABLE OIL ANDEROL PQAA 320 NSF H1
SPEED VARIATORS FOOD-SUITABLE OIL ANDEROL SYNCER HE32 NSF H1
GEARBOXES FOOD-SUITABLE GREASE MOL FOOD GREASE 00 NSF H1

IMPORTANT: It IS RECOMMENDED TO CHANGE OIL IN THE REDUCERS EVERY 24 MONTHS.

8.7 SCRAPPING AND DISPOSING OF HARMFUL SUBSTANCES


 The machine is mainly composed by AISI 304 stainless steel and plastic materials.
 The user will have to provide the machine components dismantling and disposal, separating the parts
according to the construction materials and components (electrical, electronic, etc.)
 Detergents used for the machine washing must be discharged and disposed according to the current
rules in force in the water discharge matter (Directive 2008/98/CE of the European Parliament and
Council dated 19th November 2008 pertinent to wastes).
 Before their disposal, speed reducers must be emptied from the contained exhausted oil and assigned to
skilled companies in the toxic substances disposal.

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9 SPARE PARTS CATALOGUE

9.1 SPARE PARTS INQUIRY RULES


The following tables have the aim to help the user in the finding of the main spare parts that compose
the machine, with their pertinent codes for the order.

NOTE: Mark « C » in the « NOTE » column indicates a spare part recommended by company ALMAC
SRL.

 HOW TO ORDER:

ALMAC s.r.l.
Azienda

Via Emilia Est, 2009 - Loc. Gaggio


Indirizzo

41018 S. Cesario sul Panaro Modena


CAP Città Provincia

+39 059 938010 +39 059 938600 info@almacsrl.com


Telefono Fax Mail (Uff. Commerciale)

 DATA TO BE ENCLOSED IN THE SPARE PART INQUIRY


 Machine name and type.
 Machine register number.
 Component position.
 Component name and code.
 Quantity.
 Shipping method.

NOTE: Spare parts supply is guaranteed for 10 years at least after the machine registration year. After
this term company ALMAC SRL does not guarantee some commercial components availability.

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9.2 SPARE PARTS TABLES

PAR. DESCRIPTION TAB.


9.2.1 General view 1.0
9.2.2 Curd-Cutter group 2.0
9.2.3 Curd-Cutter motorization group 2.1
9.2.4 Diving arms motorization group 3.0
9.2.5 Diving arms group 3.1
9.2.6 Completion group 4.0

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9.2.1 GENERAL VIEW Tab. 1.0


2440 mm 

1180 mm 
1190 mm 

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9.2.2 CURD-CUTTER GROUP Tab. 2.0

2.05

M.1

2.02
2.03
2.04

2.01
2.04

2.03
2.02

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9.2.2 CURD-CUTTER GROUP

POS. DESCRIPTION CODE Q.TY NOTE


Motor ABB M2VA 80CB - 1,1 KW 320020224 01 -
M.1
Reducer STM RMI 50FL - R=1:15 320100354 01 -
2.01 Curd-cutter rotation arm 560610011 01 -
2.02 VTE M8 screw Comm. 02 -
2.03 Washer 567020060 02 -
2.04 Bushing 560510165 02 C
2.05 Curd-Cutter body 561060135 01 -

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9.2.3 CURD-CUTTER MOTORIZATION GROUP Tab. 2.1

2.09

2.08

2.06
2.07

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9.2.3 CURD-CUTTER MOTORIZATION GROUP

POS. DESCRIPTION CODE Q.TY NOTE


2.06 VTSEI M8 screw Comm. 01 -
2.07 Washer 567021001 01 -
2.08 Bushing for shaft 560510175 01 C
2.09 Shaft 560010206 01 -

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9.2.4 DIVING ARMS MOTORIZATION GROUP Tab. 3.0

3.02

3.01

3.03

3.04

M.2

3.06

3.05

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9.2.4 DIVING ARMS MOTORIZATION GROUP

POS. DESCRIPTION CODE Q.TY NOTE


Motovariator SPAGGIARI SF/020/M - 1,5 KW 320060056 01 -
M.2
Reducer TRAMEC 2096546011- Int. 230 - R 1:40 320100201 01 -
3.01 VTE M12 screw Comm. 02 -
3.02 Washer 567020023 02 -
3.03 Short diving arms handle 564510002 01 -
3.04 Long diving arms handle 564510001 01 -
3.05 Diving arm on the operator opposite side 568161002 01 -
3.06 Diving arm on the operator side 568161000 01 -

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9.2.5 DIVING ARMS GROUP Tab. 3.1

3.14
3.13

3.11
3.11
3.14 3.12

3.11

3.11

3.13 3.14 3.09

3.13 3.08

3.04
3.11 3.10

3.10

3.03
3.11
3.09

3.08

3.09
3.08
3.07

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9.2.5 DIVING ARMS GROUP

POS. DESCRIPTION CODE Q.TY NOTE


3.07 Washer 567020040 01 -
3.08 VTSEI M12 screw Comm. 03 -
3.09 Washer 567020022 03 -
3.10 Handle pin 566030007 02 -
3.11 Bushing 560510017 06 C
3.12 Diving arms union pin 566030006 01 -
3.13 Washer with pin 567020004 03 -
3.14 VTE M12 screw Comm. 03 -

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9.2.6 COMPLETION GROUP Tab. 4.0

4.04

4.05

4.03

4.02 4.01

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9.2.6 COMPLETION GROUP

POS. DESCRIPTION CODE Q.TY NOTE


4.01 Pump FLUXINOS LT200 - 9mc/h - H10- HP1 320080082 01 -
4.02 Thermal probe ELIWELL PTC 6x100 310040004 01 -
4.03 Level probe ENDRESS+HAUSER FTL31 310040080 01 -
4.04 Safety sensor ALLEN BRADLEY RIFID M18 INOX 310020294 05 -
4.05 Pneumatic valve – BSG206SXX00 ¾” 330020647 01 -

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10 LAYOUT AND DIAGRAMS

10.1 ELECTRICAL DIAGRAM

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Serial Number: 095-096 / Year: 2017 / Revision: 00 Edition: 10/2017 Rev. 00

ELECTRICAL DIAGRAM

CURD CUTTER-STRETCHING MACHINE

T28-FT60

TECHNICAL DATA
COMPANY MACHINE DESCRIPTION TYPE SERIAL N°. REVISION CONSTRUCTION YEAR

ALMAC SRL CUTTER-STRETCHER T28-FT60 095-096 00 2017

ELECTRICAL DATA
POWER VOLTAGE FREQUENCY PHASES AUXILIARY VOLTAGE RATED POWER RATED CURRENT

400 V 50 HZ 3 24 VDC 3,5 KW 9A

Via Emilia Est, 2009 - 41018 S.Cesario s/P (Modena)


Tel. +39 059 93.80.10 - Fax: +39 059 93.86.00
E-Mail: info@almacsrl.com - Internet: www.almacsrl.com

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