Manual de Uso y Mantenimiento Pasteurizador - Teknoice

USE AND
MAINTENANCE MANUAL
Machine : HTST Pasteurization System

Type : Teknomix 2000 / 3000
Year : 2011
Rev. : 01 Edition 03/2011
EC
STANDARDS
TRANSPORT AND
INSTALLATION
GENERAL INFORMATION,
DESCRIPTION AND SAFETY DEVICES
USE
MANUAL
VIDEO PAGES OF
THE OPERATOR PANEL
MAINTENANCE OF
THE MACHINE
VOLUME
OF DIAGRAMS
VOLUME
OF SPARES
MACHINE
DISMANTLING
ANNEXES TO
THE MANUAL
Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Tel. 0039.02.4886761 - Fax 0039.02.4882153 - Web www.teknoice.com
General introduction
Teknoice S.r.l. has designed and built this machine in compliance with the regulations provided by
European Community Directive 2006/42/EEC.
The machine is not hazardous for the operator if used according to the instructions provided by
Teknoice S.r.l. in observance of the conditions of use.
Moreover, the safety devices must be kept constantly efficient, and the prescribed maintenance
operations must be carried out according to the frequencies indicated.
This manual must be kept for the entire lifetime of the machine, and must always be within reach of
the operator and maintenance engineer.
The information contained in this manual is the property of Teknoice S.r.l.
Teknoice S.r.l. reserves the right to make changes to the product specifications described in this
manual without any prior notice.
The disclosure and reproduction, even partial, of this manual without the written authorization of
Teknoice S.r.l. is prohibited.
Technical Service
Teknoice S.r.l.
Via Lazio, 37
20090 Buccinasco (MI)
Italy
Tel. 0039.02.4886761
Fax 0039.02.4882153
Web www.teknoice.com

Manufacturer Liability
The manufacturer Teknoice S.r.l., delivers to the buyer goods compliant with the laws in effect in
Italy.
It is understood that any liability that may derive from the goods due to events occurring after the
risks have been transferred to the buyer, therein including any injuries to people or damage to
things (even when they are parts or accessories of the Teknoice S.r.l. machining centre), shall be
borne by the buyer only, which shall hold the seller harmless and which also undertakes to
adequately insure all relative risks, without right of recourse against the Manufacturer.
Limitation of Manufacturer Liability

Malice or gross negligence of the manufacturer excepted any compensation for any damage to the
buyer may not in any case exceed the value of the Teknoice S.r.l. apparatus regarding the
defective part.
Note for the user

Total attention has been given to the writing and checking of this manual so that the information
provided in this documentation is complete, precise and up to date.
However, Teknoice S.r.l. cannot give any guarantee on the performance and results achieved with
the use of this documentation, and neither can it be held responsible for damages or benefits
deriving from the improper use of this documentation and the devices to which it refers.
The same holds true for all people or companies involved in the creation, production and
distribution of this documentation.
Neither can Teknoice S.r.l. guarantee that modifications or updates of devices or software
supplied by third parties to which this documentation refers will be compatible with the information
contained in the documentation and will not alter its instructions and data.
General notes on safety

Teknoice S.r.l. can not be held responsible for injuries and damages of any type sustained by
people, things or other objects that are caused by improper use or misuse of the machine.
Modification and/or elimination of the equipment inside the machine or modification and/or
elimination of the guards and safety devices provided inside the machine, built by Teknoice S.r.l.,
involves immediate forfeiture of the warranty.
All control devices are active only if all guards and safety devices are working properly.

Warranty
Teknoice S.r.l. guarantees the machine for a period of 12 months from the date of dispatch,
based on a 8 hour/day work shift.
Teknoice S.r.l. shall replace or repair any defective parts during the above period. The warranty is
limited to the replacement and/or repair of the defective part and does not include delivery or
labour costs.
The warranty for electrical components is limited to 6 months, from the date of dispatch of the
machine.
The warranty does not cover any parts subject to wear such as brasses, bearings, seals etc.
Warranty forfeiture arises from machine fault or damage caused by improper use or tampering of
the same, repairs made by unauthorised technicians or use of non-original spares.
Teknoice S.r.l. shall have no further obligations in relation to the above.
For any technical communications with Teknoice S.r.l., please use the form below.

Notice form
ATTENTION
Fill in the top of the form and use it to make additional copies to attach to your communications
with Teknoice S.r.l.
Machine Date of
model: installation:
Serial Order
number: number:
Description of the fault:
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
Reported
Date:
on:
Working Signed and
hours: stamped:

EC DECLARATION OF CONFORMITY
(according to the machines directives 2006/42/CE and subsequent amendments, Enclosure II A –
almost machine - point A)
We Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Tel. 0039.02.4886761 - Fax 0039.02.4882153,
declare under our sole responsibility that the machine or system :
Job nr XXX.XXX
Constituted by the following groups :
Type Q.ty Matricule Code Year

2011
2011
2011
2011
IS CONFORM :
the Directive 2006/42/CE (and successive modifications);

the Directive 2004/108/CE (and successive modifications);
the Directive 2006/95/CE (and successive modifications).
The signer of the Declaration of Conformity and of whom constitutes the Technical Issue:
Surname: Maganza Teknoice S.r.l
Name : GianCarlo
Place : Buccinasco
Data : ___________ ___________________
Firma :

EC Standards
EC Standards
TEKNOMIX 2000 / 3000 Page 1 Volume 01_ECS_Language _Rev.01

EC Standards
CONTENTS IN THIS CHAPTER
......................................................................................................
EC STANDARDS .............................................................................................................................................. 1
EC STANDARDS: ACCORDING TO DIRECTIVES 2006/42/EC AND SUBSEQUENT AMENDMENTS .................... 3
1.1.1 DEFINITIONS ................................................................................................................................................. 3
1.1.2 PRINCIPLES OF INTEGRATION OF SAFETY .............................................................................................. 3
1.1.3 MATERIAL AND PRODUCT........................................................................................................................... 4
1.1.4 LIGHTING ....................................................................................................................................................... 4
1.1.5 DESIGN OF THE MACHINE FOR TRANSPORTATION PURPOSES ........................................................... 4
1.2.1 SAFETY AND RELIABILITY OF THE CONTROL SYSTEMS......................................................................... 4
1.2.2 CONTROL DEVICES...................................................................................................................................... 4
1.2.3 START-UP ...................................................................................................................................................... 5
1.2.4 STOP DEVICES ............................................................................................................................................. 5
REGULAR STOP ............................................................................................................................................... 5
EMERGENCY STOP ......................................................................................................................................... 5
1.2.5 OPERATING MODE SELECTOR SWITCH.................................................................................................... 5
1.2.6 CONTROL DEVICES...................................................................................................................................... 5
1.2.7 MALFUNCTION OF THE CONTROL CIRCUIT .............................................................................................. 6
1.2.8 SOFTWARE.................................................................................................................................................... 6
1.3.1 STABILITY ...................................................................................................................................................... 6
1.3.2 RISKS OF BREAKAGE DURING OPERATION ............................................................................................. 6
1.3.3 RISKS DUE TO OBJECTS FALLING OR BEING THROWN.......................................................................... 6
1.3.4 RISKS DUE TO SHARP EDGES AND SURFACES....................................................................................... 6
1.3.5 PREVENTION OF RISKS DUE TO MOVING PARTS .................................................................................... 6
1.3.6 SELECTIONS FOR A PROTECTION AGAINST RISKS DUE TO MOVING PARTS...................................... 7
1.4.1 GENERAL REQUIREMENTS ......................................................................................................................... 7
1.4.2 PARTICULAR REQUIREMENTS FOR SAFETY ............................................................................................ 7
1.4.2.1 FIXED GUARDS .................................................................................................................................... 7
1.4.2.2 MOVING GUARDS ................................................................................................................................ 7
1.4.2.3 ADJUSTABLE GUARDS THAT LIMIT ACCESS.................................................................................... 7
1.5.1 RISKS DUE TO ELECTRICITY ...................................................................................................................... 7
1.5.3 RISKS DUE TO DIFFERENT ENERGY.......................................................................................................... 7
1.5.4 RISKS DUE TO ERRORS OF ASSEMBLY .................................................................................................... 8
1.5.5 RISKS DUE TO EXTREME TEMPERATURES .............................................................................................. 8
1.5.6 RISKS OF FIRE .............................................................................................................................................. 8
1.5.7 RISKS OF EXPLOSION.................................................................................................................................. 8
1.5.8 RISKS DUE TO NOISE................................................................................................................................... 8
1.5.9 RISKS DUE TO VIBRATIONS ........................................................................................................................ 8
1.5.10 RISKS DUE TO RADIATION ........................................................................................................................ 8
1.5.11 RISKS DUE TO OUTSIDE RADIATION ....................................................................................................... 8
1.5.12 RISKS DUE TO LASER DEVICES ............................................................................................................... 9
1.5.13 RISKS DUE TO GAS AND DUST EMISSIONS ............................................................................................ 9
1.5.14 RISK OF BEING TRAPPED IN THE MACHINE ........................................................................................... 9
1.5.15 RISKS OF FALLING ..................................................................................................................................... 9
1.6.1 MACHINE MAINTENANCE ............................................................................................................................ 9
1.6.2 MEANS OF ACCESS AT THE WORK PLACE AND INTERVENTION ........................................................... 9
1.6.3 INSULATION OF THE SOURCES OF ENERGY AND SUPPLY .................................................................... 9
1.6.4 INTERVENTION OF THE OPERATOR .......................................................................................................... 9
1.6.5 CLEANING OF THE INTERNAL PARTS ........................................................................................................ 9
1.7.1 INFORMATION DEVICES ............................................................................................................................ 10
1.7.2 WARNING DEVICES.................................................................................................................................... 10
1.7.3 WARNINGS AS TO RESIDUAL RISKS ........................................................................................................ 10
Volume 01_ECS_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

EC Standards
EC Standards: according to Directives 2006/42/EC and

subsequent amendments
1.1.1 Definitions
1. By “dangerous zone” we mean an area of the machine which puts the individual’s safety and
health at risk (see layout).
2. By “exposed person” we mean a person located in a dangerous zone of the machine.
3. By “operator” we mean the person or persons who are in charge of installing, making the
machine run and perform maintenance on it.
1.1.2 Principles of integration of safety

a) Construction of the machine provides for it to operate, be adjusted and undergo maintenance
without these operations exposing risks to people, if performed in the conditions envisaged by
the Manufacturer. The purpose of the measures adopted is to eliminate the risk of injuries
during the machine’s foreseeable lifetime, including the assembly and disassembly states, even
if said risk should be the consequence of a foreseeable abnormal situation. Proof of what is
stated above will be illustrated in the following paragraphs of this report.
b) The machine is designed so as to almost completely eliminate risks due to moving parts. For
those cases in which these risks are not completely eliminated, appropriate guards that will be
described further on have been adopted.
c) The machine has been designed for the production of mixture for industrial/artisan ice cream
and can only operate for this purpose. Other uses must not be performed without written
approval by the Manufacturer as indicated in the use manual.
d) Particular effort on the part of the operator is not required because the control systems are
made up of push-buttons and not levers, flywheels, etc. During operation in cycle, the operator
controls the machine through an operator panel.
e) Carefully read the paragraph “Protection devices” in this manual for helpful references to
personal protection.
f) Special equipment: For the elements forming the machine, common equipment normally found
in all maintenance departments suffices.

EC Standards
1.1.3 Material and product

Materials which could represent risks to the operator such as: asbestos, alloys containing
beryllium, etc. were not used.
The products used during processing which could be noxious are given in the manual, with the
relative instructions on how to manage said products, moreover following the instructions given by
the supplier with the relative safety sheets.
It is the responsibility of the operator to obtain the safety sheets of the products.
1.1.4 Lighting
The machine must be provided with adequate lighting both in the work zones, and in the in areas
where the operator must perform maintenance.
1.1.5 Design of the machine for transportation purposes

The machine has been designed and built taking into account the requirements of transportation
and it is possible to dismantle it in several parts, depending on the type and with systems suitable
for handling.
1.2.1 Safety and reliability of the control systems

The control systems are safe and can stand normal service stresses and are wired with logic for
the machine cycle, while emergencies and safety functions are redundant and not subject to the
PLC logic.
The emergency push buttons all work in series on relays that, disconnecting, interrupt the supply of
the auxiliary equipment. All the outtakes of the PLC, not having an intake signal, disconnect all the
control relays.
1.2.2 Control devices

The control devices can be easily distinguished by the label placed on the electrical panel, with
description of the operation, and the practical uses and by the abbreviations given in the wiring
diagram for a clear and unequivocal identification.
Starting the machine occurs from a highly visible and safe position so that the safety of the
individuals is not compromised at the moment of start-up.
Use personal protection gear such as: masks, goggles and shoes.

EC Standards
1.2.3 Start-up
Restarting the machine after a stop only occurs with a voluntary action.
With the connection of the general switch and/or because of lack of voltage and/or due to
emergency, the machine must be reset with the specific push button and all the operations
restarted.
1.2.4 Stop devices
Regular stop
There is a button for general stop. Regular stop is performed by operating the various stop buttons
which are available in every work zone.
Emergency stop
The emergency stop is done with the same push button (mushroom) placed in every work zone.
For the new start command, the push button must be unblocked and all the motors and the
operations restarted after having been reset.
1.2.5 Operating mode selector switch

Through the operator interface panel, one has the choice of selecting the method of the cycle with
which one wants to work the machine.
In the passage between the various modes there is no possibility of wrong movements of functions
but only those selected.
1.2.6 Control devices

Electrical circulation is performed in such a way that there is no early start-up, drop or discharge of
a mobile element of the machine or of a part of the machine, etc....
Lack of voltage blocks the machine in all its operations and, when voltage returns, the devices
must be restored and restarted.
The same applies to compressed air and oil pressure. In case of short circuit, the thermal magnets
trip; the same applies for an eventual discharge to ground or unexpected overload.

EC Standards
1.2.7 Malfunction of the control circuit

The control circuit has been designed to avoid dangerous situations, and in particular:
• Early restart;
• Impediment in stopping machine;
• Ineffectiveness of safety devices.
1.2.8 Software
The software is designed so that no dangerous situations are created, is easy to manage and has
self-diagnosis system.
1.3.1 Stability
Stability is guaranteed by following the instructions given in this manual.
1.3.2 Risks of breakage during operation

All the elements used have sufficient resistance characteristics and are suitable for the
environment and their utilization; in particular, the elements subject to pressure and stress
(especially flexible and rigid pipes).
1.3.3 Risks due to objects falling or being thrown

None.
1.3.4 Risks due to sharp edges and surfaces

All the angles have been bevelled to avoid risks.
1.3.5 Prevention of risks due to moving parts

All the moving parts (rotating shafts, pistons, racks, etc.) are protected and/or separated by casing,
and the fixed safeguards are suitable for avoiding contact with the operator and therefore an
accident in accordance with UNI EN 12100 points 4.2.2.1 and 4.2.2.2.

EC Standards
1.3.6 Selections for a protection against risks due to moving parts

The protections of moving parts are the fixed type with possibility of removal wit special tools and
are sturdily built. They comply with point 1.4.2.1 of the Machinery Directive 2006/42 and
EN12100 points 4.2.2.1 and 4.2.2.2.
1.4.1 General requirements

All the guards have been drawn and designed to resist mechanical stresses.
1.4.2 Particular requirements for safety

None.
1.4.2.1 Fixed guards
See point 1.3.6.
1.4.2.2 Moving guards
See point 1.3.6.
1.4.2.3 Adjustable guards that limit access
See point 1.3.6.
1.5.1 Risks due to electricity

The electrical system is designed and built in accordance with EN 60204-1 standards.
1.5.3 Risks due to different energy

The machine has been designed and built in order to prevent all risks due to the various systems
installed with signs and instructions. The sources of energy are:
Air For the operation of the pneumatic parts (6 bar).

Water For the operation of the hydraulic parts.
Process elements The flexible pipes for the elements of process are tested at 2 times the
operating pressure (see paragraph 1.3.2).

EC Standards
1.5.4 Risks due to errors of assembly

The direction of rotation of the motors is indicated on the casing of the motors with a “directional
arrow”.
The flexible pipes are marked with coloured heat-shrinking that indicate where they must be
mounted. Inversion therefore becomes impossible during assembly which could damage the
machine and create risks for the operator.
1.5.5 Risks due to extreme temperatures

The system when operating normally does not handle materials at high temperatures (max. 90 °C).
The parts relative to the heating station have been protected and insulated with insulating
materials. The temperatures on the uncovered parts of the machine are tolerable to human touch.
There are no components with temperatures under 0°C.
1.5.6 Risks of fire

The machine has been designed to avoid this risk. Adhere scrupulously to this volume.
1.5.7 Risks of explosion

None.
1.5.8 Risks due to noise

None.
1.5.9 Risks due to vibrations

None.
1.5.10 Risks due to radiation

None.
1.5.11 Risks due to outside radiation

None.

EC Standards
1.5.12 Risks due to laser devices

None.
1.5.13 Risks due to gas and dust emissions

The machine does not exhibit risks from emissions of dust.
1.5.14 Risk of being trapped in the machine

None.
1.5.15 Risks of falling

None.
1.6.1 Machine maintenance

Maintenance work must always be done with the machine stopped and by qualified personnel.
Adhere scrupulously to the instructions in the chapter “Machine Maintenance”.
1.6.2 Means of access at the work place and intervention

They are provided where necessary.
1.6.3 Insulation of the sources of energy and supply

See the wiring diagrams.
1.6.4 Intervention of the operator

It is limited to the regular production functions: “Start-Up”, “Stop” and “Control of the work
parameters”.
1.6.5 Cleaning of the internal parts

See the chapter “Maintenance”.

EC Standards
1.7.1 Information devices

They are given on the electrical panel and on the operator command panel; see the chapter “Use
Manual” where they are clearly explained.
Moreover, an instruction manual is provided edited in conformity with the instructions given in EN
12100.
1.7.2 Warning devices

The machine is equipped with process warning signals identifiable by warning lights and acoustic
alarms.
1.7.3 Warnings as to residual risks

All the warnings relative to the operations of loading/unloading such as for example of the tanks,
are given in this instruction manual with specific references to the use of the personal safety
devices.

Transport and installation
TEKNOMIX 2000 / 3000 Page 1 Volume 02_TI_Language _Rev.01

......................................................................................................
TRANSPORT AND INSTALLATION ................................................................................................................ 1
TRANSPORT AND HANDLING.................................................................................................................................... 3
TRANSPORT........................................................................................................................................................... 3
REMOVAL FROM THE MEANS OF TRANSPORT ................................................................................................. 3
PRECAUTIONS ....................................................................................................................................................... 4
REFERENCE SYMBOLS FOR TRANSPORT ......................................................................................................... 4
TRANSPORT AND POSITIONING ............................................................................................................................... 5
DESCRIPTION OF THE CASES ............................................................................................................................. 6
OPENING THE CASES ........................................................................................................................................... 7
CHECKING PACKING WHEN THE MACHINE IS DELIVERED.............................................................................. 8
IN THE EVENT OF DAMAGE.................................................................................................................................. 8
STORING THE MACHINE ....................................................................................................................................... 8
PHYSICAL CHARACTERISTICS OF THE STORAGE AREAS............................................................................... 8
POSITIONING THE MACHINE ..................................................................................................................................... 9
PROTECTION FROM ATMOSPHERIC AGENTS ................................................................................................... 9
SPACE REQUIREMENTS..................................................................................................................................... 10
ENVIRONMENTAL CHARACTERISTICS OF THE POSITIONING AREA ............................................................ 10
FIXING AND LEVELLING........................................................................................................................................... 11
FLOORING AND FOUNDATIONS......................................................................................................................... 11
TOOLS, EQUIPMENT AND CONSUMABLE MATERIAL ...................................................................................... 11
TESTING ............................................................................................................................................................... 11
MACHINE CONNECTIONS ........................................................................................................................................ 12
ELECTRICAL CONNECTION................................................................................................................................ 12
HYDRAULIC CONNECTION ................................................................................................................................. 13
MAINS WATER ................................................................................................................................................ 13
FROZEN WATER............................................................................................................................................. 13
PNEUMATIC CONNECTION................................................................................................................................. 13
BOILER CONNECTION......................................................................................................................................... 14
Volume 02_TI_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Transport and handling

This chapter describes the procedures to follow for the machine transport, installation and start-up
operations.
Properly trained and instructed personnel must install, assemble and start up the machine on the
Customer’s premises, under the supervision of the technical service of the company Teknoice
S.r.l. (if agreed in writing).
NOTE
If these instructions are not followed, Teknoice S.r.l. does not answer for any machine damage or
subsequent services not complying with the technical specifications provided.
Transport
The machines and the assemblies that form it are designed and built so they can be transported
damage-free with vehicles (fork lift trucks) and suitable lifting means (bridge cranes, cranes, double
chain hoists).
The means of transport and lifting must be proportionate to the weight of the material to be
transported. To this regard, the lifting force or capacity must be at least 20% higher than that
required for lifting the machine and packing.
ATTENTION
During transport, pay close attention to never lift the machine parts with unsuitable means, such as
directly by the fork lift truck, but always use the slings shown in the drawing and figure in the next
paragraph. Otherwise, you risk damaging the machine more or less seriously.
Removal from the means of transport

When loading and unloading from the means of transport, and every time lifting the machine
proves necessary, you must use a fork lift truck for carrying out these operations.
The machine and assemblies that form it must be firmly anchored so they do not slip, overturn or
fall from the lift truck’s loading bed.

Precautions
Abide by the precautions and warnings given in the foregoing paragraphs in order to ensure
stability and to prevent uncoupling as well as damages and risks correlated with handling the
machine. Appoint trained personnel (slingers, lift truck operators, crane operators, etc.) to the
handling and transport operations.
ATTENTION
Carefully check the condition of the lifting devices and their capacity.
Reference symbols for transport

Some materials require special identification for handling, so their packing has been marked or
labelled with the international symbols shown in the table. Any danger symbols are placed on the
same sides on which the marking is found. Indication of the centre of gravity must also be shown
on the lid and bottom of the case.
PRESCRIPTION SYMBOL/MARK EXAMPLE OF APPLICATION
Up
Fragile
Protect from damp
Anchor points for slinging
Centre of gravity
Centre of gravity (loadable)
Store indoors
Store in rooms with a temperature

higher than 0°C

Transport and positioning

Check the state of the cases, and that there is no damage, upon receipt. Place the cases in a dry
place.
The cases should be handled by a lift truck: pay attention to the position of the forks that must
match the position shown in the figure.
The machine is identified and marked, and the identification code is given on the transport
document or delivery note.
The parcels are marked with highly visible writings that are resistant to sea water and sunlight, or
with pre-printed plates.
The list of the various units that make up the machine (packing list) shows the marking, weight,
dimensions and position of the centre of gravity, to be regularly transported separately.

Description of the cases

1. Metal covering (only if the Customer so requests);
2. Address of the recipient and the sequential number of the parcels;
3. Centre of gravity of the case (indicated only if the material inside the case is positioned in
such a way as to require special attention during transport and handling).

Opening the cases
The package contains 3 cases:
• One for the heating unit,

• One for the tank unit,
• One for homogenizer, exchanger and constant level tank.
The case with the heating unit contains a package with standard spares, wiring diagram and
instruction manual. Put it to a safe place before continuing with the unpacking.

Checking packing when the machine is delivered

The packing must be inspected upon delivery according to the criteria provided below
• the cases must be intact and without any signs of crushing;

• there must be no damage to the mechanical parts, such as guides, planes, etc.
If there is any damage, the transported material is to be accepted conditionally since its integrity
must be checked. Before removing any packing from the parts making up the machine,
immediately contact Teknoice S.r.l. if it has sustained damage.
Check the state of the machine visually, inside and outside the packing. Any deformations may
indicate impacts sustained by the machine during transport that could jeopardise its normal
operation.
Specifically, check that the following are in good condition:
• Safety devices and guards (if present);

• Elements and pneumatic pipes;
• Metal and painted surfaces;
• Tightness of the screws, nuts and bolts, and fittings.
In the event of damage

It is necessary to ascertain the conditions of the machine before positioning it. Damages caused by
transport must be immediately reported to Teknoice S.r.l.
Any damage undergone by the machine during transport, for any number of reasons, could cause
injuries to people or damage to things, in addition to not ensuring perfect machine operation. The
Customer, or the Customer’s representative, is asked to thoroughly examine the machine before
positioning it and starting it up.
Storing the machine

The instructions given in this section must be observed during periods of temporary machine
storage, in view of the fact that the following situations may occur:
• The machine is installed not immediately after it has been supplied;

• The machine is uninstalled and is stored awaiting a relocation.
Physical characteristics of the storage areas

If stored, the machine must be provided with the proper space for movement and manoeuvring in
order to allow personnel to easily and safely perform the machine slinging and lifting operations.

Positioning the machine

• Place the units to the desired place, put them close and secure them.
• Level the machine using a "spirit level" turning the adjustable feet accordingly.
• Leave at least 800 mm free around the machine for maintenance operations.
• Prepare the mixture piping between the pasteurization system and the ripening vats.
• The frozen water tank must be positioned close to the machine, on the homogenizer end.
HTST PASTEURIZATION SYSTEM
Teknomix 2000 Teknomix 3000
Dimensions
7200 x 3600 x 2200 7600 x 3600 x 2800
mm.
Weight 2400 4550

Kg. (approx.) (approx.)
Protection from atmospheric agents

The machine must be positioned in a room covered and protected from direct contact with
atmospheric agents.

Space requirements
The layout drawing of the machine shows the minimum and maximum distances to be observed for
proper placing and positioning of the various component units.
In addition to the overall dimensions of the machine, it is necessary to provide additional space (at
least 800 mm) to permit:
• Handling, raising and assembly;

• Maintenance;
• Positioning electrical board, any push-button panels and/or control stations;
• Installation of accessories such as robots and manipulating automatisms, control units, etc.
Consult the relevant manuals for their overall dimensions.
Environmental characteristics of the positioning area

The environmental values allowed in the area where the machine is positioned are:
• Ambient temperature -15°C to 40°C

• Relative humidity 20% to 90%

Fixing and levelling

The machine must be properly levelled and suitably fixed to the ground. Follow these directions:
• Lift the machine and position it on the floor;

• Level it through special adjustments.
Flooring and foundations

The particular type of construction does not require heavy-duty types of foundation from the aspect
of the flooring building works. Refer to the layout included with this manual. Check that the flooring
has undergone skid-proof treatment.
Tools, equipment and consumable material

Handling: lifting equipment cited in this chapter
Levelling check: level / centesimal grading spirit level
Assembly of mechanical / electrical parts: commonly used equipment
Testing
Testing has been performed at the Teknoice S.r.l. Plant, where all mechanical calibrations and
dimensional checks envisaged have been carried out.
In order to ensure correct installation, pay attention that the geometric characteristics established
during the design stage and defined in the mechanical drawings are maintained.
The engineers in charge of reassembly will pay close attention to these characteristics.

Machine connections
Electrical connection
ATTENTION
The electrical connection must be made only by specialised personnel.
After having moved the bases close to each other and fixed them, proceed to the relevant electrical
connections.
Follow these directions:
• Each base has a pull box similar to that installed on the next base.
• Connect the boxes to each other, using the cables set up with the numbered wires.
• Check the values shown on the identification plate to ensure that machine voltage and
frequency are compatible with local voltage and frequency.
• Based on the same data and regulations on the installation region, obtain the section of the
power supply cable, which in any case should not be less than 1 mm every 5 Ampere.
• A safety switch should be installed close to the machine according to the local regulations.
• From this switch, lead the electrical cable to the machine, through the electrical power board
and through the special cable gland.
• Then, connect the 3 phases to terminals "R-S-T" and the Earth to the special terminal.

Hydraulic connection
Mains water
The mains water is used to pre-cool the mixture, to make the mixture itself, to lubricate and cool
down the homogenizer and to supply the heating circuit. Follow these directions:
• Connect the mains water to the check valve located at the exchanger inlet.
• The water coming from the exchanger is sent to the selected tank and is used to prepare the
mixture as primary ingredient.
• A second connection must be made to supply the heating unit and the homogenizer. This
connection is essential:
- For lubricating and cooling the pumping pistons of the homogenizer (disposable)
- For keeping the pressure in the heating circuit constant.
Frozen water
The frozen water is used to cool the mixture to the temperature of 4/5 °C. Follow these directions:
• Connect the frozen water delivery pipe to the three-way valve located at the exchanger inlet
and the return pipe to the exchanger outlet union.
ATTENTION
Refer to the technical characteristics given in this manual for the required capacity and the pipe
sizing. In any case, the pipe dimensions should not be smaller than the dimensions of the inlet
unions or have choking in their path.
Pneumatic connection
• Connect the compressed air piping to the union located behind the machine.
• The required pressure is 6 bar.
• A manual check valve should be installed on the compressed air line close to the machine.
ATTENTION
Refer to the technical characteristics given in this manual for the compressed air consumption and
the pipe sizing. In any case, the pipe dimensions should not be smaller than the dimensions of the
compressed air inlet union or have choking in its path.

Boiler connection
• Connect the hot water pipes of the boiler to those of the exchanger and tank unit by the special
unions in 3 parts already mounted on the machine.
• Connect the gas piping to the special union mounted on the boiler.
• If LPG is used, a set with multiple cylinders is recommended, connected to a single header that
feeds the boiler, so as to have a more constant gas pressure and longer endurance.
The boiler is set up and tested at the factory with LPG; if methane gas is used, remove the
pressure reducer on the gas supply and replace the burner nozzles.
For additional explanations, please refer to the technical documentation of the boiler attached to
this manual.

General information, description and safety devices
TEKNOMIX 2000 / 3000 Page 1 Volume 03_IDS_Language _Rev.01

DEVICES........................................................... 1
GENERAL INFORMATION, DESCRIPTION AND SAFETY DEVICES....................................................
GENERAL INFORMATION AND PURPOSE................................................................................................................ 3
DESCRIPTION OF THE MACHINE .............................................................................................................................. 4
TECHNICAL CHARACTERISTICS.......................................................................................................................... 6
ELECTRICAL DATA........................................................................................................................................... 6
COMPRESSED AIR........................................................................................................................................... 6
MAINS WATER (HOMOGENIZER BOILER FEEDING)..................................................................................... 6
MAINS WATER (MIXTURE PRE-COOLING) .................................................................................................... 7
FROZEN WATER (MIXTURE COOLING).......................................................................................................... 7
HEATING (METHANE GAS BOILER)................................................................................................................ 7
HEATING (STEAM)............................................................................................................................................ 7
MARKING ..................................................................................................................................................................... 8
IDENTIFICATION PLATE ........................................................................................................................................ 8
RESIDUAL RISKS ........................................................................................................................................................ 9
MACHINE SAFETY DEVICES............................................................................................................................... 10
EMERGENCY BUTTON LOCATION..................................................................................................................... 10
GENERAL WARNINGS .............................................................................................................................................. 11
NOTES OF WARNING .......................................................................................................................................... 11
NOTES OF WARNING .......................................................................................................................................... 12
PERSONNEL QUALIFICATION ................................................................................................................................. 13
GENERAL COMPETENCES ................................................................................................................................. 13
COMPETENCES RELATIVE TO QUALIFIED PERSONNEL ................................................................................ 13
PERSONAL PROTECTION EQUIPMENT .................................................................................................................. 14
TABLE OF OPERATOR PROTECTION DEVICES ............................................................................................... 16
Volume 03_IDS_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

General information and purpose

The purpose of this manual is to provide the instructions and use conditions to the personnel who
must work on the machine, in compliance with the technical and project characteristics for which it
was built.
Its reading is essential, but cannot replace the expertise of the personnel in charge that have
completed appropriate training.
The manual must be kept at the disposal of all personnel appointed to work on the machine, or in
any case involved in its operation. It is recommended that professional operators sufficiently
trained and who are familiar with all control functions use the machine.
More specifically:
• the operator using it;

• the manager and person in charge of maintenance;
• the manager and person in charge of the prevention and protection service.
The Customer must make sure that all appointed personnel have read and understood the content
of this manual with regard to the parts of their province.
This manual must be kept intact and in good condition for the entire lifetime of the machine. Keep
the original of the manual in a safe, protected place.
The EC conformity declaration is the document that certifies conformity of the machine to the EC
Machinery Directive. It must therefore be carefully stored and produced, if necessary, upon the
request of the competent authorities.
If the documentation should be lost or damaged, it is possible to get a copy of it from the
Manufacturer by quoting the reference number, the serial number of the machine and the year of
manufacture in the order.
The machine is built in compliance with the directives in force in the European Community and with
the technical regulations that assimilate their requirements, as is certified by the EC Declaration of
Conformity issued by the manufacturer and attached to this use manual.

Description of the machine

The machine TEKNOMIX HTST is a system for making ice cream mixtures, supplied complete with
all the components mounted on the frame, connected and tested at the factory.
The most important machine components are:
• Self-bearing frame of stainless steel with adjustable feet. The frame includes 3 different bases:
- for the heating unit
- for the tank unit (resting on the base or on the ground)
- for the exchanger, plenum chamber and electrical board (the homogenizer is normally
without base)
• Heating system with electrical, gas or steam boiler (consisting of a water/steam heat
exchanger), with hot water circulation pump (Ref. 15). The system also includes a filling unit
with pressure reducer for the inlet water, pressure gauge/thermometer for hot water, safety
valve (calibrated at 3 bar) and air bubble separator.
• 2 tanks (Ref. 01) for preparing and heating the mixture, with air space and solenoid valve for
hot water circulation and stop. Stirrer motors, washing balls, ingredient loading pipes and
mixture output valves are mounted on the tanks (Ref. 02). The two tanks are insulated to
prevent heat dispersion.
• Powder mixing unit consisting of: hopper, centrifugal pump, work table and sanitary piping.
• 2 centrifugal pumps, a transfer pump (Ref. 03) to transfer the mixture from the tanks to the
plenum chamber, with mixture filtering system (Ref. 06) and a second one (Ref. 03) to feed the
homogenizer and the exchanger.
• Constant level tank (Ref. 05).
• Homogenizer (Ref. 08) with pneumatic control of the homogenization pressure, safety valve
and pressure gauge.
• Plate heat exchanger with 4 sections:

- Mixture pasteurization section, by hot water circulation (Ref. 07-B)
- Recovery section, with mixture circulation in both directions (Ref. 07-A)
- Mixture pre-cooling section, by mains water (Ref. 07-C)
- Mixture cooling section, by frozen water (Ref. 07-D)
The pre-cooling water check valve and the frozen water 3-way valve are mounted on the
exchanger.
• Litre counter unit to set the amount of water required to prepare the mixture.
• Stand-by piping (Ref. 10).
• Set of sanitary pipes.
• Electrical board with control panel and temperature recorder for pasteurization.

Specifically:
01) Tank
02) Three-way valve
03) Pump
A. Powder mixer pump
B. Feeding pump
C. Circulation pump
04) Powder mixer
05) Constant level tank
06) Mixture filters
07) Main heat exchanger
A. Pasteurization section
B. Recovery section
C. Pre-cooling section
D. Cooling section
08) Homogenizer
09) Mixture by-pass valve
10) Stand-by piping
11) Flow deviation equipment
12) Litre counter
13) Heating temperature controller – Pasteurization
14) Heating temperature controller – Mixture preparation water/tanks
15) Hot water circulation pump
11
08 09
10
04
02 05 07
06
A B C D
03
C
A
B
15
01
12
13
14

Technical characteristics
TEKNOMIX HTST Unit 2000 3000 Notes

Hourly production L/h 2000 3000
Electrical data

Standard voltage Volt 400 400 Other voltages on request
Standard frequency Hz 50 50
If an electrical boiler is
used, the boiler power
Total installed power Kw 25 29
should be added to the total
installed power
Powder mixture Kw 2.2 2.2
Mixer motors Kw 1.7 1.7
Mixture pump Kw 2.2 2.2
Homogenizer Kw 11 15
Mixture circulation pump Kw 3 3
Hot water circulation pump Kw 1.5 1.5
Electrical boiler Kw - -
Compressed air

Inlet union ½ ½
Consumption Nl/min 150 200
Minimum/maximum pressure bar 4/6 4/6
Mains water (homogenizer boiler feeding)

Inlet union 1” 1”
Flow rate L/h 300 400
Minimum pressure bar 1.5 1.5

Mains water (mixture pre-cooling)

Inlet union 1 ½” 1 ½”
Inlet temperature °C 20 20
Outlet temperature °C 65 65
Frozen water (mixture cooling)

Inlet/outlet union 1 ½” 1 ½”
Inlet temperature °C 1 1
Outlet temperature °C 4 4
Recommended frozen water tank HP 20 30
Heating (methane gas boiler)

Power Kcal/h 130000 150000
Water inlet/outlet union 1 ½” 1 ½”
Gas inlet union 1” 1”
Stack coupling union mm 240 240
Heating (steam)

Water inlet/outlet union 1” 1”
Min pressure Bar 1 1
Consumption KG/h 200 300
Steam inlet union ¾“ ¾“
Condensate outlet union ¾“ ¾“

Marking
Safety signals with self-adhesive danger labels are placed in the following positions:
• High voltage inside the electrical board

• Electric current inside the electrical board
• Danger inside the electrical board
• Voltage danger inside the electrical board
• Earth inside the electrical board
Put up a “MAINTENANCE IN PROGRESS” sign in highly visible areas before starting machine
maintenance procedures.
Identification plate
The machine is fitted with an identification plate showing the essential technical data, such as:
• Model
• Serial number
• Voltage
• Total installed power
• Frequency
• Number of phases
• Refrigerant type and charge
Example of plate:
MODEL
SERIAL
ELECTRICL DATA
Volt ph Hz Kw
REFRIGERANT
REFRIGERANT CHARGE Kg.

Residual risks
Although the Teknoice S.r.l. machine is built based on the current technological level and its
operation can be called safe, it may generate hazards if used inappropriately by non-specialised
personnel or for purposes not envisaged by its specific intended use.
There are residual risks for the operator when working on the machine, which are pointed out each
time.
The residual risks can be eliminated by carefully following the procedures indicated in this manual
and by adopting the personal protection equipment prescribed.
Use of and maintenance and any necessary repairs made on the machine must be entrusted to
AUTHORISED PERSONNEL that are duly trained and informed of the dangers that can derive
from it.
The user undertakes to operate the machine only if it is in perfect condition.
The operator must in turn keep watch that unauthorised people do not work on the machine.
The machine’s protection devices must not be altered or tampered with without the written
authorisation of Teknoice S.r.l.
In the case of damage or breakdown, the machine must remain out of service until the protection
devices are once again in operation.
There is a HIGH DEGREE OF DANGER during machine maintenance operations, so they must be
performed with the machine STOPPED and OFF.
Electrical breakdowns can be repaired only by AUTHORISED TECHNICAL PERSONNEL.
The machine covers should be removed only for repair or maintenance purposes. Before start-up,
they must be replaced and fixed to their original position.
The accident prevention rules in the most recent edition are to be followed during the machine
transport, installation and start-up operations.
Residual risks during machine operation and after it is stopped:
• Any objects (except for the machining pieces) accidentally left in the work area could cause risk
for the operator;
• Nobody except for the operator can stay in the safety zone or, in any case, in the hazardous
zoned while the machine is in operation.

Machine safety devices

The system machines are fully closed.
Any parts that may pose a hazard (such as: gears, belts, etc…) are protected by fixed guards.
Emergency button location

Emergency button =
ATTENTION
If maintenance works are to be carried out on the machine, the machine must be stopped with the
master switch set to OFF.
The user should not enter inside the machine zones when the devices are running. These zones
are dangerous and can pose serious risks of accidents. Only one operator can operate the
systems in this zone.
The Manufacturer declines all responsibility for damages to third party or property resulting
therefrom; in this case, the operator works under his sole responsibility. The subject zones are
therefore fitted with safety structures compliant with (safety distance to prevent reaching
dangerous zones for the upper limbs).

General warnings
Notes of warning
Always cut out all main and auxiliary machine power
supplies before performing maintenance operations on
it.
Affix special warning signs – EQUIPMENT

UNDERGOING MAINTENANCE – DO NOT SWITCH
ON POWER SUPPLY – next to the master switches.
ATTENTION
MAINTENANCE
IN PROGRESS
• Moving parts that can cause serious injuries to people are present in the equipment in
operation. Avoid contact with these parts.
• Never cut out the safety and protection devices installed on the equipment. If this should
prove necessary, indicate the condition with special warning signs and work taking every
precaution. Reinstate all safety and protection devices as soon as possible. The work
positions the operator must assume are shown in the layout attached to this manual.
• Failure to earth the equipment may cause serious injuries to people. Always make sure the
earth connections are in place and that they meet the Standards.
• Do not use flammable or toxic solvents such as petrol, benzene, ether and alcohol. The use of
trichloroethylene or another compatible detergent is recommended, using the necessary
precautions.
• Toxic waste, such as machining residue, lubricants, etc., must be collected in special labelled
containers and disposed of according to current local regulations.
• Always make sure that the maintenance personnel are located at a safety distance and that
tools or materials are not left close to the equipment before putting the machine into operation.
• Always use protective goggles and gloves during equipment maintenance operations.

• Never use jets of water in the case the equipment catches fire; section all power supplies and
use ABC class powder extinguishers.
• It is severely prohibited to store combustible materials in the proximity of the electrical

board.
• The electrical control board should always be locked and access is permitted to authorised
and specialised personnel only.
• Working inside the electrical board must be done only after the main electric power
supply switch has been disconnected and the machine’s power supply line has been
electrically sectioned.
• Ensure that the tools to be used are in perfect condition and have insulating handgrips where
required. Check that the isolation of the cables and conductors of the equipment shows not
even the least sign of breakage or damage.
ATTENTION
Before starting the machine installation operations, the Customer must adapt the work environment
to the regulations locally in force pertaining to “Safety at the work place” and get ready adequate
accident prevention clothing for qualified personnel and operators in defence of “Health safety
during work”.
Notes of warning
• Before putting the equipment back into operation following a failure, it must be thoroughly
inspected and checked to reveal any possible damage.
• Always use dry air while cleaning and a pressure not higher than 2 bar.
• Always use tools in perfect condition and appropriate for the operation to be performed; the
use of unsuitable non efficient equipment may cause serious damage.
• Always ensure the presence and proper distribution of lubrication. A lack of lubricant can
damage the machine.
• Never touch the adjustments and positioning of the limit switch micro-switches. Tampering
with them can cause the machine serious damage and expose the operator to risk.
ATTENTION
All preventive, routine and extraordinary maintenance operations must be recorded in a special log
by entering the date, time, type of intervention, operator’s name and all useful information.

Personnel qualification
The maintenance operations can be performed in user safety conditions after the
recommendations and instructions furnished by this manual have been carefully read and
understood.
Terminology provisions for the operator:
User: personnel qualified to use the machine.
Maintenance engineer: personnel qualified for the use, preparation and maintenance.
General competences
• Be familiar with the construction and functions of the systems for manufacturing special pieces.
• Know how to use and consult the machine’s documentation.
• Assume responsibility for taking autonomous decisions relative to interventions on entirely
automatic systems.
• Verify irregularities in the production process and, when necessary, take the necessary
measures.
Competences relative to qualified personnel

The make-up and qualification of the personnel crews indicated in the maintenance plan are those
recommended by Teknoice S.r.l.
If necessary, the various operations may also be performed by personnel having the same or high
qualification and that have taken specialised training courses.

Personal protection equipment

If the environmental analysis detects a higher presence of fumes than
local regulations, or in any case the safety data sheets of the products
used, allow, an appropriate protective mask must be worn.
In the event of contact with the components, wash immediately with

water, or follow the instructions of the safety sheet.
Keep at hand a special eye wash or water fountains suitable for the
purpose.
The operator/maintenance engineer allowed to operate and/or pass

close to the machine must not wear clothing with loose sleeves, laces or
belts that might produce danger.
Long hair must be gathered inside a hat so it does not constitute

danger.
The area where the operator works must not only remain free of foreign
objects, but its flooring must also have undergone skid-proof treatment
(responsibility of the Customer). An alternative would be to use
adhesive mats.
The operator must always wear safety shoes that have a rubber sole
with reinforced toe.
ATTENTION
Protective goggles, gloves, helmet, gas masks and clothing that totally covers the skin must be
used during use and maintenance operations.

PROTECTIVE GOGGLES
Used: always
PROTECTIVE HELMET
Used: always
WATERPROOF RUBBER GLOVES

Used: always
SHOES WITH RUBBER SOLE

Used: always
PROTECTIVE MASK
Used: if the environmental analysis detects a higher
presence of fumes than local regulations, or in any
case if the safety data sheets of the products used
require it.

Table of operator protection devices
temporary pipes and fittings

Wiring and electrical board
under pressure for liquids

Operations performed on
Operations performed on
System maintenance
Cleaning the system
Pipe assembly and
Using the system

live components
connection
and gases
mounting
Testing
Protective helmet X X X X X X
Appropriate gloves X X
Manual labour gloves X X X X
Insulating gloves for the

X X
max. rated voltage
Gloves for naphtha-based

X X
detergents
Gloves for high

X X X
temperatures
Goggles or faceplates when

X X
flashes might be expected
Eyewear with transparent

X X X
lenses
Eyewear with transparent
lenses for grinding and X X X
drilling work
Safety shoes with puncture-
X X X X X X X
resistant sole
Safety shoes with insulating

X X
sole
Faceplate X X
Accident-prevention
coveralls covering the entire X X X X X X X X
body (skin)

Use manual
Use manual
TEKNOMIX 2000 / 3000 Page 1 Volume 04_UM_Language _Rev.01

Use manual
MANUAL......................................................................................................
USE MANUAL................................................................................................................................................... 1
INTRODUCTION ........................................................................................................................................................... 3
OPERATOR STATUS.............................................................................................................................................. 3
GENERAL RULES................................................................................................................................................... 3
OPERATION MODES ................................................................................................................................................... 4
MANUAL CYCLE ..................................................................................................................................................... 4
FUNCTIONAL CONTROL............................................................................................................................................. 5
TEKNOMIX: DESCRIPTION OF OPERATION........................................................................................................ 8
PRELIMINARY OPERATIONS ................................................................................................................................... 10
START-UP OF THE MACHINE ............................................................................................................................. 11
PERSONNEL ASSIGNED TO START THE MACHINE ................................................................................... 13
OPERATOR ............................................................................................................................................................................................. 13
QUALIFIED PERSONNEL........................................................................................................................................................................ 13
TURNING OFF THE MACHINE............................................................................................................................. 14
EMERGENCY STOP ............................................................................................................................................. 15
FUNCTION OF THE CONTROL PANELS AND OTHER COMPONENTS ................................................................. 16
CODE/COLOURS FOR THE PUSH BUTTONS AND THEIR MEANING .............................................................. 16
COLOURS OF THE LIGHT INDICATORS AND THEIR MEANING WITH REGARD TO THE CONDITIONS OF
THE MACHINE ...................................................................................................................................................... 17
ELECTRICAL PANEL AND CONTROL PANEL ........................................................................................................ 18
Volume 04_UM_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Use manual
Introduction
This chapter describes the operations required for the realization of the final product.
Operator status
Personnel enabled to carry out the machine preparation and maintenance procedures must be
informed and have been properly trained in advance as the various operations must be performed
in manual mode, except for the safety devices.
Specifically, the personnel must have been informed about the safe execution of the procedures
contained in this manual and wear the personal protection equipment described.
The preparation phase of the machine must be performed only by authorized personnel that have
the keys and any access codes that enable the preparation procedures of the machine.
General rules
The selection of the operation status, the activation of the run/stop, the alarm and emergency
signals are located on the control panel.
It is a good rule of thumb to supervise operation and the signals furnished by the machines
sensors and anomaly indicators located on the control panel.

Use manual
Operation modes
The machine can operate in the following modes:
Manual cycle
Every operation can be controlled with push buttons or with the screen pages of the operator
panel.
Pressing a push button or a function key causes the controlled area to move, a subsequent
pressing of the same key or the relative stop button causes the immediate stop.

Use manual
Functional control
ATTENTION
Before starting the machine, a test with water must be performed to verify that all operations are
occurring without problems.
1) Release the emergency button located on the control panel, turning it clockwise.
2) Turn the main switch of the power board to ON.
3) Verify that the rotation direction of all the motors corresponds to the one indicated on the
motors by the specific arrows. The machine is tested in the factory, therefore if a motor is
turning correctly, all the others will also have the correct rotation direction. Should the rotation
direction not correspond to what is indicated, reverse the two phases of the general supply.
4) Supply the machine with compressed air by opening the relative shut-off valve. Verify that there
are no leaks of compressed air.
5) Open the mains water for the supply of the boiler and the homogenizer; remove the cap on the
automatic discharger of air bubbles and adjust the pressure of the water in the heating circuit to
0.8/1 bar using the specific pressure reduction unit.
To eliminate all the air in the pipes, select the first tank with the specific function key (tank
selection), enable the tank heating with the specific function key (tank heating), also enable the
pasteurization heating with the specific function key (pasteurization heating).
Given that the switch of the boiler is in idle position, only the hot water pump will function,
making water circulate in the tank selected and in the exchanger, section of pasteurization;
leave in operation until no more air comes out of the discharger, then select the second tank,
still with the specific function key (tank selection) and wait again until no more air bubbles come
our of the discharger.
Stop the heating using the specific function key (heating) and disable the pasteurization using
the specific function key (pasteurization heating).
6) Set on the litre counter (Ref. 12) a quantity of water equal to the capacity of your system
(Example: 2000 litres for the TEKNOMIX HTST 2000).
7) Open the mains water using the shut-off valve located on the input exchanger of the pre-
cooling section.
8) Start the frozen water tank so that it can become fully operational.

Use manual
9) Select the first tank using the specific function key (tank selection) and start the litre meter
using the specific function key (start litre counter). Adjust the pressure reduction unit of the
mains water located right after the litre counter in order to have a flow of water entering the
tank at 70% of the capacity of the machine (Example: 1400 l/h for the TEKNOMIX HTST
2000).
10) Turn the boiler switch to the on position, then turn on the gas if it is a gas boiler, or open the
steam intake valve if it has steam heating. Always refer to the attached boiler manual before
the first start-up of the boiler.
11) Set a temperature of 55 oC on the specific temperature window relative to the first tank and a
temperature of 95 oC on the temperature window of the hot water.
12) Press the key to start the heating of the tanks: the hot water pump, boiler and solenoid valve of
the first tank will start automatically; also start the agitator of the first tank to promote the
thermal exchange between hot water in the air space and test liquid within the tank. The
temperature set at 55 oC for the liquid in the tank must be reached in about one hour.
13) When the temperature of the liquid reaches the value set, the boiler shuts off, leaving however
the circulation pump of hot water running for another 3 minutes so as to avoid over-
temperature in the boiler which could cause the safety thermostat to kick in.
Select the second tank in order to open of the outtake valve of the mixture of the first tank, wait
a few seconds so that the water fills all the outtake pipe, then start the pump for transferring the
mixture using the relative key.
The test liquid at 55 oC is withdrawn from the first tank and sent to the tank at a constant level,
where a specific valve controls its level.
14) Set the control mixture flow valve on “AUTO”: in this way the temperature of mixture
pasteurization will be automatically controlled and if it falls below the value set, the mixture will
repeat the heating cycle until it reaches the temperature set.
If, instead, the manual operation “MAN” is selected, the mixture continues in the cycle
regardless of the temperature of pasteurization.
Instead, if set on “BY-PASS”, the mixture will always return to the constant level tank. This last
option is useful during production to change for example the vat into which the mixture is sent
without stopping production.
15) Enable the pasteurization with the specific pasteurization heating key, set on the specific
window the desired temperature of pasteurization (normally 85 oC) and the temperature of the
hot water 5/6 oC higher than that of the mixture (pasteurization) therefore at 90/91 oC.
Also start the heating of the tanks. The hot water coming from the heating unit is sent to the air
space of the second tank and to the pasteurization section of the exchanger.

Use manual
16) Make sure that the by-pass valve of the homogenizer is in the on position, then start the feed
pump of the mixture using the relative key and the homogenizer using the specific start push-
button.
Wait another few seconds to allow the homogenizer to eliminate all the air still inside it, then
press the homogenizer pressure key and operate on the pressure regulator located on the
homogenizer until reaching the desired homogenizer pressure.
With the pump for circulation of the mixture, the test liquid at 55 °C is withdrawn from the
constant level tank and sent to the recovery section of the exchanger where it is heated to 76
°C thanks to the heat supplied by the same liquid during cooling. (Since initially there is no
liquid at high temperature, in the other circuit of the recovery section, initially in this phase there
is no increase in temperature of the test liquid).
17) The test liquid, from the recovery section, passes into the homogenizer and then to the
exchanger (pasteurization section) where, thanks to the hot water coming from the heating unit,
it reaches the temperature of pasteurization of 85 °C.
(During the first pasteurization, since in the recovery section there has not been an increase in
temperature, the set temperature of pasteurization is not reached straight away but the test
liquid must recirculate several times between the constant level tank, homogenizer and
pasteurization section before reaching the set temperature).
After the pasteurization section, the test liquid passes into the stand-by pipe, at the end of
which a probe determines the temperature. If it is lower than the temperature desired, the test
liquid returns to the constant level tank to repeat the heating cycle until it reaches the
temperature of pasteurization.
If, instead, the temperature is equal to or greater than the one set (85 °C), the machine enters
into AUTOMATIC cycle. The control valve of the mixture flow changes position, making the
liquid proceed towards the recovery section, to start its cooling and simultaneously reheat the
liquid in heating phase. Having started at this point the litre counter so that the mains water can
pass into the exchanger, cool the test liquid and flow into the second tank at a temperature of
approximately 58 °C.
In the recovery section, the test liquid passes from 85 °C to 64 °C (while in the heating phase it
passes from 55 °C to 76 °C). It then enters the pre-cooling section where from 64 °C it drops to
34 °C to then pass into the final cooling section where it will be chilled to 4 °C.
Then check that the water, used as test liquid, coming out of the exchanger, has a temperature
of approximately 4 °C and that the flow corresponds to the flow of the machine. (Example:
TEKNOMIX HTST 2000 = 2000 l/h).

Use manual
TEKNOMIX: Description of operation

Its principal function consists in the preparation of mixtures at continuous cycle, normally
composed of fresh or powdered milk, sugar, vegetable or animal fats, stabilizers, emulsifiers and
water.
The water necessary for the preparation of the mixture is sent to the tank selected, in the quantity
set on the litre counter. Simultaneously all the solid ingredients will be poured into the same tank
through the powder mixer.
The agitator of the tank together with the powder mixer (Ref. 04), takes care of mixing the
ingredients. The heating system, which could be a steam one, with gas or electric boiler, supplies
the water at high temperature, which through the hot water pump (Ref. 15), is sent into the air
space of the tank selected, to heat the mixture contained in it up to 55 °C.
At this point the mixture is sent by the feed pump (Ref. 03-B), to the constant level tank (Ref. 05),
from this tank the circulation pump (Ref. 03-C) withdraws the mixture and sends it to the
exchanger, recovery section (Ref. 07-B).
In this section the mixture is heated to 76 °C thanks to the energy supplied by the mixture that is
cooling. The mixture then enters the homogenizer (Ref. 08), where the molecules of fat are
crushed and reduced in volume thanks to the high homogenization pressure.
From the homogenizer the mixture passes to the exchanger, pasteurization section (Ref. 07-A),
where it reaches a temperature of 85 °C, thanks to the action of the hot water coming from the
heating unit.
The mixture then passes into the stand-by pipe (Ref. 10) where it remains for 40 seconds without
variations in temperature. At the end of the pause, a probe determines the temperature of the
mixture: if it is lower than the preset temperature of pasteurization, the specific flow control valve of
mixture makes it return to the constant level tank to repeat the heating cycle and the
homogenization.
If instead it is equal or greater than the preset temperature of pasteurization, the mixture continues,
by starting the cooling phase and entering into the recovery section where it is cooled to 64 °C
thanks to the transfer of energy (therefore heat) to the mixture in heating phase.
From here the mixture passes directly to the pre-cooling section (Ref. 07-C) of the heat exchanger
where it is pre-cooled to 34 °C thanks to the action of the mains water; then passes into the cooling
section (Ref. 07-D) of the exchanger where it is further chilled to 4 °C, by means of frozen water.
The frozen water comes from a specific tub, normally located beside the machine.
The mixture thus obtained is sent automatically to the ripening vats, where it will rest for
approximately 8 hours before it can be used for the production of ice cream.
Then the preparation of the next mixture can be started by selecting the tank not used in the first
mixture and sending the necessary water with all the ingredients.

Use manual
The time necessary for all the mixture contained in the first tank to be homogenized, pasteurized
and sent to the ripening vats, which is about 1 hour, corresponds to the time necessary to pour
and mix all the ingredients in the second tank.
In this way there is a continuous cycle of pasteurization, without wait times.
The mains water, used for the pre-cooling of the mixtures, exits the exchanger with a temperature
of approximately 58 °C and is sent to the empty tank for the preparation of the next mixture.
This process, together with interchange of heat in the recovery section of the exchanger (mixture
during heating cools the mixture being cooled and the mixture in the cooling phase heats the
mixture being warmed) lowers considerably the energy consumption of the TEKNOMIX-HTST
machine.
11
08 09
10
04
02 05 07
06
A B C D
03
C
A
B
15
01
12
13
14

Use manual
Preliminary operations
Before starting production make sure that:
• The general switch is in the ON position (Ref. 01).

• The emergency button (Ref. 04) is released and the lamp of voltage activity (Ref. 02) is lit.
• The machine has been carefully washed and disinfected.
• Discharge, if necessary, all the water and the disinfecting solution from the machine.
• The sanitary pipes are correctly mounted with the CLAMP connections well tightened.
• Shut-off valves of the mains water, the frozen water, the gas or steam, and the compressed air
are in operating position.
• The BY-PASS valve (Ref. 09) of the homogenizer is shut.
• The frozen water tank is in operation.
02 04
01

Use manual
Start-up of the machine

To start production, operate as follows:
1) Set on the litre counter the quantity of water necessary for the preparation of the mixture.
2) Select the first tank using the select tank key and start the litre counter using the start litre
counter key.
3) Take the boiler switch to operating position.
4) Press the key to start the heating of the tanks:
5) When the water in the tank has reached about one third of the set quantity, start the agitator
and powder mixer and begin to pour in the solid ingredients: powdered milk, sugar, fats (these
last can be added if the temperature of the mixture being prepared has reached at least 40 °C)
and stabilizers/emulsifiers in sequence.
6) When all the water and the ingredients have been added and mixed and the temperature of the
mixture has reached the set value of 55 °C, select the second tank in order to open the mixture
outtake valve of the first tank and prepare for heating and loading water into the second tank.
Wait a few seconds so that the mixture fills the whole outtake pipe then start the mixture feed
pump: the mixture is sent in a continuous manner to the tank at constant level.
7) Enable the pasteurization warm-up, set in the specific window the desired temperature of
mixture pasteurization (85 °C) and the relative hot water temperature (90 °C) which must heat
the mixture: the hot water coming from the heating unit will start to circulate even in the
pasteurization section of the exchanger.
8) Connect the mixture outtake pipe to the ripening vat.
9) Start the mixture circulation pump with the specific key; the mixture is sent to the exchanger
from the constant level tank (recovery section) where the preheating occurs and then to the
homogenizer.
10) Start the homogenizer; wait another few seconds to allow the homogenizer to eliminate all the
air still inside it, then press the homogenizer pressure key and operate the pressure regulator
located on the homogenizer until the desired homogenizer pressure is reached. The mixture in
outtake from the homogenizer continues towards the exchanger (pasteurization section) where
it reaches the temperature set at 85 °C; then enters the stand-by pipe where it remains without
variations in temperature for 40 seconds.
ATTENTION
Initially, the desired temperature will not be reached instantly since the heating action of the liquid
to high temperature during the cooling phase is missing. Therefore, the mixture after the pause will
return to the constant level tank to be recirculated a few times until it reaches the correct
temperature.

Use manual
ATTENTION
Some water could have remained in the pipes: to avoid having it return to the constant level tank,
blending with the mixture, the pipe of return mixture in discharge should be moved, allow all the
water to discharge and then reposition this pipe on top of the constant level tank.
11) Set the litre counter for the quantity of water necessary for the preparation of the second
mixture, then start the litre counter until the mains water passes into the exchanger, cool the
mixture and let it flow into the second tank at a temperature of approximately 58 °C. If the
quantity of water necessary for the preparation of the second mixture is identical to the first
mixture, it is not necessary to set this quantity since it has remained in memory.
12) At the end of the stand-by pipe a specific probe checks the temperature of the mixture. If below
the set temperature, the control mixture flow valve returns the mixture to the constant level tank
to be recirculated until it reaches the correct temperature. If instead the temperature of the
mixture is equal to or greater than the set temperature of pasteurization, then the mixture
continues its cycle entering the recovery section where a first cooling occurs then into the pre-
cooling section and finally into the cooling section. From this section, the mixtures exits at
approximately 5 °C and is sent to the ripening vats.
ATTENTION
The water that remained in the pipes or in the exchanger could come out instead of the mixture.
Discharge all the water before sending the mixture to the ripening vat. When one stops the
homogenizer, it is not necessary to unscrew the pressure regulator but only to disable the
homogenizer pressure. In this way, the next time the homogenizer is restarted there will be no
problems for its components.
13) Now it is possible to start the preparation of another mixture in the second tank by repeating
the same operations performed for the preparation of the first mixture. When, during the
homogenization phase, the level of the mixture in the tank drops to about one third, it is
recommended to stop the agitator to avoid incorporating air into the mixture. The production of
mixtures can continue without stop, by always alternating the pasteurization in one tank and
the homogenization in the other until end of production.
ATTENTION
The TEKNOMIX HTST machine in based on the recovery of heat from the mixture in the cooling
phase to the one in preparation/heating phase. Therefore, to function correctly, the mixtures being
prepared must be of the same capacity. If mixtures of smaller quantity than the standard must be
prepared, it is recommended to prepare them at the end of the day.

Use manual
Personnel assigned to start the machine
When starting the machine, for safety reasons, only those engineers directly assigned must be
present, in order to avoid eventual risks to the operators not typically assigned to the start-up of the
machine.
Following are the most important definitions which appear in this manual.
Operator
The term operator is applied to personnel capable of ordinary use and cleaning of the machine.
Qualified personnel
By qualified personnel, we mean personnel knowledgeable of the methods of installation,

assembly, repair and servicing of the machine and who have specific technical qualifications such
as for example:
• A technical training that authorizes them to operate in accordance with the safety standards in
relation to the dangers that the presence of electricity, circuits under pressure, etc….can
represent.
• A technical training or in any case specific instruction relative to the procedures of use and
maintenance of the machine under safe conditions.
• Training in basic first aid.

Use manual
Turning off the machine

To stop production operate as follows:
1) When the last mixture of the day starts to homogenize, set on the litre counter a quantity of
water equal to the capacity of the tank in order to fill completely the empty tank.
2) When the mixture being homogenized is about to finish, disable the homogenizer pressure and
allow the homogenizer to run without pressure until finishing the mixture. This manoeuvre
serves to avoid breaks in the homogenizing head (Please refer to the homogenizer manual)
3) When the mixture is finished, select the other thank, so that the mixture outtake valve of this
tank is closed and open the mixture outtake valve of the tank containing water.
4) Leave the mixture feed pump, circulation mixture pump and homogenizer running until water
does not comes out of the mixture outtake pipe, then stop the circulation mixture pump and the
homogenizer. Disconnect the mixture outtake pipe from the ripening vat and put it into
discharge.
5) Close the mains water and frozen water shut-off valves located on the exchanger. Open the
BY-PASS valve of the homogenizer, then restart the circulation mixture pump and the
homogenizer without pressure.
6) Let it run for approximately 10 minutes after which stop both the pumps and the homogenizer
and proceed with the washing of the machine.

Use manual
Emergency stop
If, during production, it became necessary to immediately deactivate all the functions of the
machine, press the emergency button (Red mushroom type).
All the functions will be deactivated and it will not be possible to restart them until the button is
released by turning it clockwise.
To resume production, release therefore the emergency button and repeat the sequences of start-
up described in the paragraph START-UP OF THE MACHINE.
ATTENTION
The emergency stop eliminates the risks associated with the moving parts of the whole machine.
Should it be necessary to work on the inside of the machine, use the necessary personal safety
devices.
To restart the machine, following the procedure of START-UP OF THE MACHINE

Use manual
Function of the control panels and other components

All the push buttons, selectors, signalling devices and other controls that are on the panels of the
system are listed and described in this paragraph. On the system there are:
• Electric panel;
• Light;
• Auxiliary button panel.
Code/Colours for the push buttons and their meaning
COLOUR MEANING EXPLANATION EX. OF APPLICATION

Emergency stop
Activate for hazardous condition
RED Emergency
or emergency
Start of emergency function
Intervention to suppress abnormal
condition.
Activate in case of abnormal
YELLOW Abnormal
condition
Intervention to restart an interrupted
automatic cycle
Activate in case of condition of
GREEN Safety safety and to prepare a normal
condition
Activate in case of condition that
BLUE Mandatory Put back into operation
requires a mandatory action
No specific For the general start of functions Start (preferential)
WHITE significance with the exception of the
attributed emergency stop (see also note) Stop
No specific For the general start of functions Start
GREY significance with the exception of the
attributed emergency stop (see also note) Stop
No specific For the general start of functions Start
BLACK significance with the exception of the
attributed emergency stop (see also note) Stop (preferential)
NOTE
When an additional method of coding is used (example: structure, form, position) for the
identification of the button actuators, the same white, grey or black colour can be utilized for
various functions (example: white for start and stop actuators).

Use manual
Colours of the light indicators and their meaning with regard to the
conditions of the machine
ACTION OF THE
COLOUR MEANING EXPLANATION EX. OF APPLICATION
OPERATOR
Pressure/temperature above
Immediate action to safety limits
handle a hazardous Drop in voltage
Hazardous
RED Emergency condition (i.e. by
conditions Interruption
activating the
emergency stop) Past stroke past stop
position
Abnormal
Control and/or Pressure/temperature above
condition
intervention (i.e. re- normal limits
YELLOW Abnormal
establishing the
Imminent critical desired function) Release of the safety device
condition
Pressure/temperature within
normal limits
GREEN Normal Normal condition Optional
Authorization to proceed
Indication of the
condition that
Instruction to insert
BLUE Mandatory requires an Mandatory action
preselected values
action of the
operator
Other conditions:
can be used any
time there is a
WHITE Neutral doubt on the use Control General information
of the colours
red, yellow,
green, blue

Use manual
Electrical panel and control panel

The electric command panel provides for the housing of the various selectors and control push
buttons. Specifically:
1) General switch: Activates/deactivates all the functions of the machine.

2) Lamp existence voltage: Indicates there is voltage to the machine.
3) Reset push button.
4) Emergency push button: If pressed, it stops all the functions of the machine.
5) Multi-functional touch-screen.
05
02 04
01 03

Video pages of the operator panel
TEKNOMIX 2000 / 3000 Page 1 Volume 05_VPP_Language _Rev.01

PANEL................................................................................................. 1
VIDEO PAGES OF THE OPERATOR PANEL....................................................
MAIN PAGE .................................................................................................................................................................. 3
SYSTEM PAGE ....................................................................................................................................................... 6
PRODUCTS RECIPIES PAGE ................................................................................................................................ 8
ACTIVE ALLARMS PAGE ..................................................................................................................................... 10
LANGUAGE SELECTION PAGE........................................................................................................................... 12
ALLARMS VISUALITATION PAGE ....................................................................................................................... 13
SAVE / RESET ORIGINAL PARAMETERS PAGE................................................................................................ 14
TEST MODE PAGE ............................................................................................................................................... 17
TANKS TEMPERATURE PAGE ............................................................................................................................ 18
BALANCE TANK PAGE......................................................................................................................................... 20
HEATING TANKS PAGE ....................................................................................................................................... 21
MIX FLOW CONTROL PAGE................................................................................................................................ 24
PASTEURIZATION HEATIG PAGE....................................................................................................................... 26
CIP WASHING PAGE............................................................................................................................................ 29
CHILLED WATER PAGE ....................................................................................................................................... 30
HOT WATER PAGE .............................................................................................................................................. 31
PASTEURIZATION HEATING PAGE .................................................................................................................... 33
MIX EXIT PAGE..................................................................................................................................................... 35
Volume 05_VPP_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Main page
Main page – from icon up left going in clockwise:
• Icon TEKNOICE: Push to enter into main system page or to go back to previous menu
• Icon motor LEFT TANK: activate / deactivate the relevant motor agitator. Flashing icon frame,
indicates intervention of thermic protection. Red motor frame indicates impossibility to start the
motor, whereas, if it is green indicates the consent to go. Red motor indicates condition of
quiet, while green motor indicates working motor.
• Icon motor RIGHT TANK: activate / deactivate the relevant motor agitator. Flashing icon frame,
indicates intervention of thermal protection. Red motor frame indicates impossibility to start the
motor, whereas, if it is green indicates the consent to go. Red motor indicates condition of
quiet, whereas green motor indicates working motor.
• Icon motor POWDERS MIX: activate / deactivate the powders mixing device. Flashing icon
frame, indicates intervention of thermal protection. Red motor frame indicates impossibility to
start the motor, whereas, if it is green indicates the consent to go. Red motor indicates
condition of quiet, whereas green motor indicates working motor.
• Icon motor MIX PUMP: activate / deactivate the circulation mix pump (Mix from balance tank to
heat exchanger) Flashing icon frame, indicates intervention of thermic protection. Red motor
frame indicates impossibility to start the motor, whereas, if it is green indicates the consent to
go. Red motor indicates condition of quiet, whereas green motor indicates working motor.

• Icon motor OMOGENIZER: activate / deactivate activation of homogenizer to be done by

means of panel placed on the homogenizer. Flashing icon frame, indicates intervention of
thermal protection. Red motor frame indicates impossibility to start the motor, whereas, if it is
green indicates the consent to go. Red motor indicates condition of quiet, whereas green
motor indicates working motor.
• Icon motor BALANCE TANK: activate / deactivate the mix feeding pump (mix from tanks to
balance tank). Flashing icon frame, indicates intervention of thermal protection. Red motor
frame indicates impossibility to start the motor, whereas, if it is green indicates the consent to
go. Red motor indicates condition of quiet, whereas green motor indicates working motor.
Beside the motor there is a signal that can be CMD OFF with stopped pump. CMD ON and
green motor icon = working pump. CMD ON and red motor icon = pump in stand by due to the
max level into the balance tank, reached by mix
• Icon motor PAST. HEATING: activate / deactivate the pasteurising heating with re-circulating
hot water pump. Flashing icon frame, indicates intervention of thermal protection. Red motor
frame indicates impossibility to start the function, whereas, if it is green indicates the consent to
go. Red motor indicates condition of quiet, whereas green motor indicates heating in progress.
Icon indicating a hand it is to set automatic/manual functioning, whereas into the inferior case it
is shown pasteurizing mix temperature. PID, if red, indicates impossibility to heat, whereas if it
is green, indicates normal operation conditions
• Icon CHILLED WATER: activate / deactivate mix final cooling, by means of circulation of chilled
water into the exchanger. Red valve indicates by pass active condition, so, no chilled water
passing into the exchanger (washing cycle). Instead, green valve indicates active cooling into
the exchanger with chilled water circulating into the exchanger. CMD OFF and red valve = by-
pass active (washing condition). CMD ON and red valve = by-pass active, waiting to be
abilitated. CMD ON and green valve = cooling in progress.
• Icon HOT WATER shows hot water temperature for pasteurisation
• Icon PAST. HEATING shows mix temperature in pasteurisation
• Icon MIX EXIT shows final mix temperature (exchanger exit)
• Icon washing: activate / deactivate washing function. CIP OFF production, CIP ON washing
• Icon WATER LOADING: start / stop water counting for the mix preparation and shows the set
and actual water quantity.
• Icon TANK HEATING: activate / deactivate tanks heating with relevant hot water circulation
pump. Flashing icon frame, indicates intervention of thermal protection. Red motor frame
indicates impossibility to start the function, whereas, if it is green indicates the consent to go.
Red motor indicates condition of quiet, whereas green motor indicates heating in progress.
Icon indicating a hand it is to set automatic / manual functioning, whereas into the inferior case
it is shown the temperature of hot water in circulation in the selected tank. PID DISAB, if red
indicates impossibility to heat, whereas if it is green, indicates normal operation conditions.

• Icons showing tanks: allow their selection (it is not possible to select both of them, at the same
time) and show the inside mix temperature
• Icon MIX FLOW CONTROL VALVE : Push on the hand or on OPEN or RETURN to select the
3 different working modes.
- Manual (the mix will always go to the ageing vats with any mix temperature)
- Auto (the mix flow is controlled on the base on pasteurising temperature, If equal or higher
to set point, the mix will go to the ageing vats. If lower to set point it will go back to balance
tank.
- By-pass (the mix will always go back to balance tank),
During production, if the mix will go to the ageing vats, the word OPENED becomes green,
whereas the word RETURNING remains red. Instead on, when the mix goes back to balance
tank, the word RETURNING becomes green, whereas the word OPENED remains red.

SYSTEM Page
From the main screen, pushing on icon TEKNOICE opens the SYSTEM page.
Pushing on icon “spanner” opens PRODUCTION DATAS page.

Pushing on MACHINE DATA opens the relevant page, where are shown main data machine, such
as model, serial number electric / pneumatic characteristics, etc…

PRODUCTS RECIPIES Page
From system page, pushing on second icon, opens recipes pages.
In this page it is possible to save the modifications of a recipe, to create a new recipe, to transfer or
delete a recipe.

ATTENTION: the following operations influence the working of the plant. It is therefore advisable to
do them only when the plant is not working and with care.
Save a recipe – push the second symbol, down left (with blue arrow), recipe can be saved on the
screen or on the micro memory card. It is suggested to save on both.
Delay a recipe – push the last symbol (showing a basket); it is possible to delete only from panel or
also from PLC.
Create a new recipe – push the fifth symbol (insert row), it appears an empty row. It is now
possible to insert manually all the values, or (suggested way) pushing the forth symbol to copy all
the parameters of the actually using recipe. Name the new recipe, modifying eventually the
parameters you wish, then save as above mentioned.
Transfer a recipe – select the desired recipe, then transfer it pushing the third symbol on PLC. This
will become operative.

ACTIVE ALLARMS Page
Pushing on third icon of system page you exit from password mode. For example, after digiting the
password to enter into protected pages, to not let other operators not authorized, could modify the
parameters it is enough to push this icon.
Always from system page, pushing the forth icon it opens the active alarms page.

Pushing ALARM HISTORY it opens the relevant page.
While it is possible to cancel the alarms from the list “ACTIVE ALARMS” if already recognized, it is
not possible to cancel those from “ALLARM HISTORY”.

LANGUAGE SELECTION Page
From system page pushing the flags icon, it opens the language selection page.
To change a language you must digit the password and then press on the language you want.

ALLARMS VISUALITATION Page
From system page, pushing the sixth icon, it opens the allarm visualization page.
So, it is possible to choose how to show alarms (never, always, every new alarms).

SAVE / RESET ORIGINAL PARAMETERS Page
From system page, pushing “lamp” icon you run the lamps test, while, pushing the “lifesaver” icon,
you open the save / reset original parameters page.
Pushing on GLOBAL RESET or on GLOBAL SAVE RESET according on what you want to do.
The two functions are under a protection level, higher for the save/reset.

Pushing on GLOBAL RESET, it opens the relevant page.
Push the reset symbol (transfer to PLC) to recall all the original parameters or the ones previously
saved as global.
The function GLOBAL RESET must be used in case of serious anomalies or malfunctioning or
wrong sets into the operator panel or in particular cases such as the replacement of the CPU.

To safe any modification of the original “factory parameters”, push the forth symbol to read from
PLC and than push the second symbol to save these parameters on the panel memory and/or on
micro memory card (in the same already descripted way for the recipies).

TEST MODE Page
From the main page, pushing one of the two icons showing the tanks, opens the TEST MODE.
On this page it is possible to select a different tank and also to visualize the quantity of water
actually dosed (ACTUAL), the quantity of water previously poured (PREV) and the total quantity of
utilized water (TOTAL).
PRECOOLING sets the total pre cooling time referred to the mix in a tank. During this time, the
liquid utilized as cooling agent go on to flow through the heat exchanger even if in the flow meter
has been set a low counter value. This is to grant the pre cooling of the mix during the
pasteurization phase. Of course, once the preset quantity has been reached, the remaining water
will be drained or send to a separate tank for cleaning purposes.
PRESET sets the quantity of water needed to the mix preparation, while LT / IMPULSO sets the
dosing coefficient of the flow meter. According to the utilised liquid and its characteristics
(pressure/temperature), must be set the coefficient that permit to get a dosed quantity equal to the
visualized quantity.
SET FAST / SLOW sets the quantity of water quickly flowing at the beginning of mix preparation in
order to start to add solid ingredients in a shorter possible time.

TANKS TEMPERATURE Page
From the main screen, pushing the small window (down in the tank icon) opens the TEMP SERB
page (left/right depending on the selected icon) where is visualised the graphic recording
temperature of the tanks.
On the TEMP SERB screen pushing the down right icon, showing a potentiometer, opens the
TEST – PRESET CONTROL mode.

In this screen you can set some parameters related to the heating of the tanks.
HHT – very high temperature alarm

HTD – high temperature alarm, that can be set as difference from HHT
LT – low temperature alarm
A HIST – alarms differential
PREH – mix temperature set point
P HIST – differential of PREH
RAW – mix temperature without correction
CORR – mix temperature correction

BALANCE TANK Page
On the main screen, pushing icon BALANCE TANK on the right lower area, opens the page in
which it is possible to set the delay of the feeding mix pump re start (after the stop, due to reaching
of maximum level).
To set the delay of the feeding mix pump re start, push on LEVEL DELAY and set the delay time in
seconds.

HEATING TANKS Page
From the main screen, pushing the icon TANK HEATING in the low right area, opens the specific
Tanks Heating page.

On this screen are shown the heating water temperature and the relevant graphic. It is possible to
set the water temperature set point (in automatic functioning) or the position of the heating valve (in
manual functioning).
Also the high, very high and low temperature alarms are shown.
Pushing on the icon showing a potentiometer, opens the TEST mode.

On this page you can set some parameters related to the tanks heating group.

HT D – high temperature alarm, that shall be set as difference from HHT
Pump stop delay – Pump stop delay
PID CONTROLLER – Controls and setting done by the technical engineer, not to be modified (they
are protected by a high level password)
• Prop: (proportional band) it defines the regulator answer. With low level you get a slow
reaction.
• Int: (integral time) it defines the behaviour of the regulator. With low level you get a fast
reaction.
• Deriv: (derivative) it defines the behaviour of the regulator. With low level you get a slow
reaction.
• Ctrl: (control) reference value for the difference from set point of the alarm.
• CHist: differential for alarm
• Err: value of set point - measure
• Set step: step set variation
• Out step: step command variation during manual functioning
• Blk out: value taken by the regulator when it is blocked (so it is excluded)
• Max set: max set point you can set up
• Min set: minimum set point you can set up

MIX FLOW CONTROL Page
From the main screen, pushing the icon MIX FLOW CONTROL VALVE in the lower left or right
area, opens the PASTEURIZATION FLOW CONTROL.
In this page it is shown the graphic related to the pasteurizing temperature and its flow, (going back
to the balance tank due to the lower temperature or proceeding to the cooling phase).

On this screen you can set some parameters related to the tanks heating group.

HT D – high temperature alarm, that can be set as difference from HHT
CORR – mix temperature correction Heating in the tanks

PASTEURIZATION HEATIG Page
From the main screen, pushing the icon, TANK HEATING in the left lower area opens the specific
Pasteurizing heating page.

On this page are shown the heating water temperature and the relevant graphic. It is possible to
select the water temperature set point (in automatic functioning) or the position of the heating valve
(in manual functioning).
Also the high, very high and low temperature alarms are shown.

In this page you can set the parameters related to the pasteurizing water temperature.
PID CONTROLLER – Controls and setting done by the technical engineer, not to be modified (they
are protected by a high level password)
• Prop: (see description in heating tanks)

• Int: (see description in heating tanks)
• Deriv: (see description in heating tanks)
• Ctrl: (see description in heating tanks)
• Hist: (see description in heating tanks)
• Err: (see description in heating tanks)
• Set step: (see description in heating tanks)
• Out step: (see description in heating tanks)
• Blk out: (see description in heating tanks)
• Max set: (see description in heating tanks)
• Min set: (see description in heating tanks)

CIP WASHING Page
Into the washing CIP page, it is possible to activate / deactivate the washing into the two sections
of the plant (tanks + powders mixer / homogeniser + exchanger). The two functions are
independent and can be run at the same time or separately.
It is possible to set the cycle time to define position of pneumatic valves and consequently the
washing solutions flow.

CHILLED WATER Page
From this screen it is possible to change the delay of cooling activation (by means of chilled water),
once homogeniser has been turned on.

HOT WATER Page
From the main page, pushing on the icon HOT WATER, opens the relevant page.
In this page are shown the heating water temperature and the relevant graphic.
The high, very high and low temperature alarms are also shown.

On this screen you can set some parameters related to pasteurizing water temperature.


PASTEURIZATION HEATING Page
From the main screen, pushing the icon PAST HEATING opens the relevant page.
In this page it is shown the graphic related to the pasteurization heating temperature and also the
high / very high and low temperature alarms, if present.

Pushing the icon on lower right side, showing a potentiometer, opens the TEST mode.
In this screen you can set some parameters related to the pasteurization heating group.


MIX EXIT Page
From the main page, pushing the icon MIX OUTPUT opens the relevant page.
In this page it is shown the graphic related to the mix output temperature (mix coming out from
heat exchanger and going to the ageing vats) and also the high / very high and low temperature
alarms, if present.


Machine maintenance
Machine maintenance
TEKNOMIX 2000 / 3000 Page 1 Volume 06_MM_Language _Rev.01

Machine maintenance
......................................................................................................
MACHINE MAINTENANCE .............................................................................................................................. 1
SAFETY PRECAUTIONS ............................................................................................................................................. 3
INSPECTION ........................................................................................................................................................... 3
RESTORE ............................................................................................................................................................... 3
REDUCING DOWNTIME AFTER A BREAKDOWN........................................................................................... 3
MAINTENANCE WARNINGS ....................................................................................................................................... 4
GENERAL INFORMATION...................................................................................................................................... 5
PERSONNEL QUALIFICATION .............................................................................................................................. 5
MAINTENANCE SUMMARY TABLE............................................................................................................................ 6
WASHING................................................................................................................................................................ 7
SUGGESTIONS FOR WASHING .................................................................................................................... 12
MECHANICAL ....................................................................................................................................................... 13
TIGHTENING CLASS ...................................................................................................................................... 15
TIGHTENING TORQUES (NM)........................................................................................................................ 16
PNEUMATIC.......................................................................................................................................................... 17
THE MOST COMMON ADJUSTMENTS AND MANOEUVRES....................................................................... 19
PRESSURE SWITCH............................................................................................................................................................................... 19
SOLENOID VALVES ................................................................................................................................................................................ 19
PRESSURE REGULATOR....................................................................................................................................................................... 20
FLOW REGULATOR ................................................................................................................................................................................ 20
ELECTRICAL......................................................................................................................................................... 21
ELECTRICAL MOTORS .................................................................................................................................. 23
EXCHANGER ........................................................................................................................................................ 25
TROUBLESHOOTING........................................................................................................................................... 27
OPERATION RECORDING TABLES ......................................................................................................................... 31
DAILY .................................................................................................................................................................... 31
WEEKLY................................................................................................................................................................ 32
MONTHLY ............................................................................................................................................................. 33
EVERY FOUR MONTHS ....................................................................................................................................... 34
EVERY SIX MONTHS ........................................................................................................................................... 35
ANNUALLY ............................................................................................................................................................ 36
Volume 06_MM_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Machine maintenance
Safety precautions
According to the DIN 31051 standard, the concept of “MAINTENANCE” includes the following
fields of activity:
Inspection
Inspection comprises actions intended to recognise the actual condition, or rather, to identify the
reasons and ways with which the wear condition decreases.
Restore
Restore includes the actions designed to obtain the desired condition, namely to compensate for
reduction of performance and to restore the wear condition.
The personnel in charge of running and maintaining the apparatus must be well trained and must
have an in-depth knowledge of the accident prevention rules.
Unauthorised personnel must remain outside the work area during maintenance operations.
The accident prevention precautions must always be strictly observed when running and
maintaining the apparatus, so as to prevent injuries to personnel and damage to the equipment.
These precautions will be quoted and explained in further detail as WARNING and DANGER notes
each time a procedure involving risk of damage or injury is required.
• The WARNING notes precede an operation that may cause damage to the equipment if
performed incorrectly.
• The DANGER notes precede an operation that may expose the operator to risk if performed
incorrectly.
Reducing downtime after a breakdown
It is well to remember that maintenance operations performed properly can reduce downtime
following a breakdown to a minimum. A repair carried out at the right time prevents further
deterioration.
Whenever possible, use original spares and carefully repair the failed component at your plant or
send it for repair directly to Teknoice S.r.l.
Contact the Teknoice S.r.l Technical Service for problems that may arise or to order spares.

Machine maintenance
Maintenance warnings
ATTENTION
Disconnect the power supply to the machine and the pressure in the pneumatic circuit when
performing maintenance operations.
1. Put up “MAINTENANCE IN PROGRESS” signs in highly visible areas before starting

maintenance procedures.
ATTENTION
MAINTENANCE
IN PROGRESS
2. Only authorised personnel are allowed access to the machine.
3. Solvents for any cleaning must be used very carefully, paying special attention to cables.
4. Do not modify or tamper with the machine structure, the operation sequence or anything else
without notifying Teknoice S.r.l. in writing.
5. Maintenance operations must be logged in the tables found in this chapter with date, type of
operation and the signature of whoever performed the operation.
6. All maintenance operations must refer to what is written in this chapter.

Machine maintenance
General information
Record the individual functions to submit for inspection and maintenance in relevant tables or lists
in order to keep a history of the operations carried out and to be checked by collaborators of
different levels of training as well.
This form must show:
• Date;
• Type of operation;
• Signature of whoever performed the operation.
The inspection items must be differentiated in terms of checking frequency, for example on a daily,
weekly, or monthly basis. They must also be carried out shortly before a lengthy system shutdown,
for example before company holidays.
The maintenance and inspection operations prescribed by rules of law are to be carried out
regardless of the goals tied to preservation of functionality as they serve to ensure the safety of the
personnel in charge of operation and to prevent possible material damage. Appropriate
documentation of these operations must be kept.
To repair the machine, the technical documentation and the most important measurement
instruments must be kept within reach at the work place in order to shorten the search for
breakdowns as much as possible.
If the safety devices are removed, check that they have been replaced and are operating
before restarting the machine.
Any cleaning with the use of solvents must be done very carefully, paying special attention to
electric cables. Do not use organic solvents in the proximity of heated surfaces. Using water-based
solvents is recommended.
All maintenance operations must refer to what is indicated in this manual.
Personnel qualification
The maintenance operations can be performed in safety conditions by specialised personnel
qualified for use, preparation and maintenance after the recommendations and instructions
furnished by this manual have been carefully read and understood.

Machine maintenance
Maintenance summary table
No. ASSEMBLY OPERATION EVERY
01 Machine General washing See sheet
02 Machine Mechanical maintenance See sheet
03 Pneumatic system Pneumatic maintenance See sheet
04 Electrical system Electrical maintenance See sheet
05 Exchanger General maintenance See sheet
06 Machine Search and inspection See sheet
07 Electrical motors Inspection and cleaning See sheet

Machine maintenance
Washing
SHEET n. 01
CLEANING WASHING INSPECTION
ELECTRICAL MECHANICAL PNEUMATIC
Assembly: Machine
Operation: General washing
Operator: 1
At the end of production, manually empty and wash the tanks and the mixture filters (Ref. 06), then
proceed as follows to accurately wash:
• Feeding pump (Ref. 03-B)

• Circulation pump (Ref. 03-C)
• Constant level tank (Ref. 05)
• Homogenizer (Ref. 08)
• Exchanger (Ref. 07)
• Stand-by piping (Ref. 10)
10 08
05
03
C
06 07

Machine maintenance
ATTENTION!
Locate the zone to intervene and lock the main switch to the OFF position using the relevant padlock, after having disabled all
components.
Place the “MACHINE UNDERGOING MAINTENANCE – DO NOT SWITCH ON POWER SUPPLY” sign next to the main
switch. Then disconnect the safety devices and any guards.
The operator is working in a risk environment. He/she must therefore follow these rules:
• Personnel authorised for this activity must be knowledgeable of the procedures to be carried out, all potential dangers they
are exposed to during the operation, and proper use of the safety devices installed on the system.
• The operator must also pay attention and act with circumspection.
• Before starting inspection and maintenance operations, maintenance personnel must disable the system and use all safety
and preventive measures contemplated.
1) On the litre counter, set an amount of water equal to about one third of the tank capacity.
2) Select the left tank using the specific tank selection key, open the mains water on-off valve
located on the exchanger and start the litre counter. Enable the tank heating by the relevant
button.
3) At the end of the water loading into the tank, start the agitator of the same tank and add a
maximum percentage of 1% caustic soda to the water contained into the tank.
4) Make sure that the frozen water 3-way valve is in washing position, that is, that no frozen water
is circulating in the exchanger.
5) While heating the washing solution, start the powder mixing pump so as to wash all the piping,
including the pump. Stop the powder mixer pump once the tank heating temperature has been
reached (55°C)
6) Connect the mixture outlet pipe to the discharge.
ATTENTION
A water and caustic soda solution or a high temperature acid solution will come out of this piping.
Be very careful.
7) When the basic solution has reached the preset temperature of 55 °C, open the mixture outlet
valve of the left tank, open the homogenizer by-pass valve, set the mixture flow control selector
to AUTO and start the pasteurization heating, mixture transfer pump, mixture circulation pump
and homogenizer.

Machine maintenance
8) The washing solution will reach the constant level tank and hence, through the circulation
pump, it will flow through the recovery section, the homogenizer, the pasteurization section, the
stand-by piping, the flow control valve, and will return to the constant level tank until the preset
temperature of 85 °C is reached.
9) Once this temperature has been reached, the washing solution will flow from the flow control
valve to the other circuit of the recovery section, to the pre-cooling section, to the cooling
section and then to the unloading mixture output piping. Let all the solution flow, until the tank
is empty, then stop both pumps, the homogenizer and the pasteurization heating.
10) Rinse the left tank to remove any residues of the caustic soda solution, then press the litre
counter run key again.
11) While filling the tank, start the powder mixing pump so as to rinse all the piping, including the
pump.
12) Wait until the end of the litre counter counting, then restart the mixture transfer pump, the
mixture circulation pump and the homogenizer. After a few minutes, set the mixture control
selector to MAN. In this way, the rinsing water continues irrespective of its temperature. Let all
the rinsing water flow, then stop both pumps and the homogenizer.
13) Press the litre counter key again.
14) Wait until the inflow of water into the tank has finished, then start the heating, the left tank
agitator, and add an amount of citric or acetic acid to the water into the tank to allow reaching
an acidity of the solution equal to PH = 4.
15) While heating the washing solution, start the powder mixing pump so as to recirculate the acid
solution in all the piping, including the pump. Stop the powder mixer pump once the tank
heating temperature has been reached (55°C)
16) When the acid solution has reached the preset temperature of 55 °C, open the mixture outlet
valve of the left tank, set the mixture flow control selector to AUTO and start the pasteurization
heating, mixture transfer pump, mixture circulation pump and homogenizer.
17) The washing solution will reach the constant level tank and hence, through the circulation
pump, it will flow through the recovery section, the homogenizer, the pasteurization section, the
stand-by piping, the flow control valve, and will return to the constant level tank until the preset
temperature of 85 °C is reached.
18) Once this temperature has been reached, the washing solution will flow from the flow control
valve to the other circuit of the recovery section, to the pre-cooling section, to the cooling
section and then to the unloading mixture output piping. Let all the solution flow, until the tank
is empty, then stop both pumps, the homogenizer and the pasteurization heating.

Machine maintenance
19) Rinse the first tank to remove any residues of the acid solution, then press the litre counter run
key again.
20) While filling the tank, start the powder mixing pump so as to rinse all the piping, including the
pump.
21) Wait until the end of the litre counter counting, then restart the mixture transfer pump, the
mixture circulation pump and the homogenizer. After a few minutes, set the mixture control
selector to MAN. In this way, the rinsing water continues irrespective of its temperature. Let all
the rinsing water flow, then stop both pumps and the homogenizer.
22) Prepare the left tank with about 200 litres disinfecting solution. Start the powder mixing
pump so as to fill the pipes and the pump with the disinfecting solution. Open the mixture outlet
valve, start the mixture transfer pump, mixture circulation pump and homogenizer and let them
run until the disinfecting solution starts coming out of the mixture outlet piping. Stop both
pumps and the homogenizer, disable the boiler by the relevant switch and set the master
switch to OFF.
23) Leave the disinfecting solution into the machine until its next use, then drain and rinse with
clean water before starting a new production.
ATTENTION
Run a complete washing once a week. On the other days, perform a basic wash and rinsing.
During the entire washing cycle, the homogenizer must operate without pressure to prevent
useless wear of the components.

Machine maintenance
01) Tank
02) Three-way valve
03) Pump
A. Powder mixer pump
B. Feeding pump
C. Circulation pump
04) Powder mixer
05) Constant level tank
06) Mixture filters
07) Main heat exchanger
A. Pasteurization section
B. Recovery section
C. Pre-cooling section
D. Cooling section
08) Homogenizer
09) Mixture by-pass valve
10) Stand-by piping
11) Flow deviation equipment
12) Litre counter
13) Heating temperature controller – Pasteurization
14) Heating temperature controller – Mixture preparation water/tanks
15) Hot water circulation pump
11
08 09
10
04
02 05 07
06
A B C D
03
C
A
B
15
01
12
13
14

Machine maintenance
Suggestions for washing
Washing steps Time Temperature

Pre-washing with disposable water. 5 min. 50/60 °C
Detergent wash: 1% solution of caustic soda with
15 min. 75/85 °C
polyphosphate additives. Recirculate the solution.
Rinsing with disposable water. 5 min. 15/20°C
*Descaling wash: solution with citric or acetic acid, Ph = 3.5
10 min. 75/85 °C
/ 4.5. Recirculate the solution.
*Final rinsing with disposable water. 5 min. 15/20 °C
***Disinfecting solution. *** 15/20 °C
* Whereas the first steps should be carried out each time a production ends, the fifth and sixth step can be carried out only once a
week.
*** At the end of the washing cycle, homogenizer and exchanger may be filled with a disinfecting solution. This must be discharged and
the machine rinsed with clean water, before the next production.
The mentioned times are approximate and the program is valid from the bacteriological point of
view.
The wash drain water must be disposed of according to the current local regulations.
ATTENTION
• Do not use acid or chlorine-containing detergents except for those recommended.

• Hydrochloric acid attacks stainless steel and chromium, generating micro porosities.
• Do not apply temperatures higher than 90 °C.
• Select detergents and disinfectants very carefully, especially as regards concentrations,
temperatures and contact times with the materials the machine is made of.
• For the recommendations of the detergent’s manufacturer, please refer to the relevant
specifications.

Machine maintenance
Mechanical
SHEET n. 02
Assembly: Machine
Operation: Mechanical maintenance
Operator: 1
ATTENTION
To prevent risks to people or to the machine, only specialised personnel should take care of
maintenance.
Before removing the guards, press the emergency button and disconnect the voltage by the master
switch.
For the maintenance of:
• Boiler
• Homogenizer
• Exchanger
Please refer to the relevant technical documentation attached to this manual.

Machine maintenance
ATTENTION!
components.
For the other components, maintenance is limited to few and simple operations listed below.
Frequency Operation
2000 hours (A) Replace all Clamp seals.
Replace the revolving seal of the mixture pump and of the hot water circulation
4000 hours (B)
pump.
Replace throttle valve seals.

Replace agitator motor bearings.
6000 hours (C)
Replace mixture pump motor bearings.
Replace hot water circulation pump motor.

Machine maintenance
Tightening class
The values of the nominal torque and relative tolerances to apply when tightening nuts and bolts,
depending on the applications, in order to ensure the functional aspects are set forth in this
paragraph.
TOLERANCES
TIGHTENING CLASS APPLICATIONS REFERRING TO
NOMINAL TORQUE
Very demanding: for highly stressed

connections subject to vibrations, impacts,
high tractions or brusque movements,
reduction units, racks, connecting rods,
translation stops, alternating loads and drive
I components in general, dynamic suspended ± 5%
loads.
Check to be made every 6 months with

dynamometric wrench.
Demanding: for uses not subject to

excessive vibrations, but where good
certainty of tightness is necessary (casings,
static suspended loads, precision locking, + 5%
II pallets, rollers, gripper supports).
- 15%
Check to be made once a year

(dynamometric wrench recommended).
Not very demanding: for uses subject to

little stress or of secondary importance
(inserts, references, daises, guards).
+ 5%
III
Check to be made every time maintenance - 35%
is carried out on the machine, and the
tightening characteristics can be changed,
depending on the operation performed.

Machine maintenance
TIGHTENING TORQUES (NM)
WRENCH TIGHTENING CLASS

OPENING III II I
OF SCREW STRENGTH CLASS
THREAD SCREW 8,8 10,9 12,9
AND/OR NUT STRENGTH CLASS
NUT 8 10 12
M4 7 2.3 3.3 4
M5 8 4.8 6.8 8
M6 10 8 11.2 13.6
M8 13 20 28 32.8
M10 17 39.2 55.2 66.4
M12 19 68.8 96 116
M14 22 108 152 184
M16 24 168 236 284
M18 27 232 324 388
M20 30 328 464 552
M22 32 440 624 744
M24 36 568 800 960
M27 41 840 1200 1440
M30 46 1160 1600 1920

Machine maintenance
Pneumatic
SHEET n. 03
Assembly: Pneumatic system
Operation: Pneumatic maintenance
Operator: 1
The machine is fitted with a pressure/filter reduction unit, with automatic condensation discharge,
which allows using compressed air even if not previously treated.
The pneumatic system, which controls the homogenisation pressure and the pasteurization water
and mixture flow, does not require special maintenance.

Machine maintenance
ATTENTION!
components.
Through the filter, the feeding line is filtered at 35 µm.
The operating pressure for the working circuit (6 bar) is set by the regulator and displayed on the
attached gauge.
The pressure of the supply network must always be at least 1 bar higher than the pressure of the
working circuit so that any pressure changes cannot jeopardise good operation of the pneumatic
circuit.
Perform a check at the beginning of every working day.
ATTENTION
Never clean the filter transparent le cups with alcohol, but use petrol or oil.

Machine maintenance
The most common adjustments and manoeuvres
Pressure switch
The pressure switch in the figure (similar to that used on the system) must be adjusted to a
pressure of 4 bar in order for the machine to operate properly. It can be adjusted with a screwdriver
or with an Allen wrench. In this way the machine will not start with a pressure lower than the set
pressure.
Solenoid valves
The ISO 1, ISO 2 and ISO 3 type of pneumatic solenoid valves shown in the figure can be
controlled manually by applying pressure in points B, as seen in the figure.

Machine maintenance
Pressure regulator
A pressure regulator allows the pressure on the pneumatic circuit to be adjusted to 6 bar by turning
the knob as seen in the figure and checking the setting on the gauge. Remember that the pressure
of the network supplying the machine must be slightly higher than 6 bar (about one bar higher, so
as to not jeopardise regular machine operation).
Flow regulator
The flow regulator is normally applied close to the use (pneumatic cylinder). Adjustment is made
with a screwdriver and its purpose is to slow down (clockwise) or increase (counter-clockwise) the
speed of the movement.

Machine maintenance
Electrical
SHEET n. 04
Assembly: Electrical system
Operation: Electrical maintenance
Operator: 1
Before starting any production cycle, check the proper operation of:
• Emergency push button

• Light buttons and indicators
• Mode selectors
The check should also include any:
• Photocells
• Limit switches
• Guards
• Other safety device installed.

Machine maintenance
ATTENTION!
components.
Check the filter:
• Clean if dirty
• Replace, if needed
Check the proper operation of the cooling fan.
Replace the filter after 1 year.
ATTENTION
Perform all maintenance operations only with the system stopped and without electric and
pneumatic power supply.

Machine maintenance
Electrical motors
Inspect and clean the electrical motor cooling filter.
For additional explanations, please refer to the technical documentation attached to this manual.

Machine maintenance

Machine maintenance
Exchanger
SHEET n. 05
Assembly: Exchanger
Operation: General maintenance
Operator: 1
As a standard, the exchanger does not require maintenance if the washes have been carried out
regularly and properly.
If required, open the exchanger when cold, to prevent the detachment of the seals if opened when
hot.
Remove the plates for an accurate cleaning or replacement of the seals, proceeding as follows:
1) Completely remove the plate tightening nuts.
2) Slide the front plate on its tracks, so as to leave space to remove the other plates.
3) Tilt the plate to be removed, then lift and remove it.
ATTENTION
All the plates are numbered, during reassembly be careful and insert the plates according to the
progressive numbering.

Machine maintenance
ATTENTION!
components.
4) Remove all the plates, then put them in a 1 - 3 % basic solution with a temperature of 80 - 90
°C and let them immersed for 6 - 8 hours. In these conditions, seals and mastic soften and
make removal easier.
5) The adhesive residues must be fully removed using tools that will not damage the plate
surface.
6) Finally, degrease the surface where you will place the new seals using solvent (chlorine-free)
so as to be ready for the application of the adhesive.
7) Spread a light adhesive layer on the seals and on the relevant seats on the plates. Wait a few
minutes, then insert the seal into the plate channel.
8) The plates with new seals must be stacked so that their weight exerts a specific pressure on
the seals, ensuring perfect adherence to the plate.
9) Place the plates into the exchanger according to the progressive number and tighten the
exchanger to the minimum value indicated on the annexed drawing.
ATTENTION
Never use glues or solvents containing chlorine as they may cause damages to the plates.
For further explanations, please refer to the exchanger documentation.

Machine maintenance
Troubleshooting
SHEET n. 06
Assembly: Machine
Operation: Search and inspection
Operator: 1
PROBLEM CAUSE SOLUTION
a) Bulb failure a) Replace

The voltage on lamp
b) Master switch to OFF b) Set to ON
is off
c) Guards tripped c) Re-engage
a) Faulty running button a) Replace

Agitators not
b) Thermal tripping b) Re-engage/replace
working
c) Agitator motor burnt c) Repair/replace

Mixture transfer
pump not working
c) Pump motor burnt c) Repair/replace

Mixture circulation
pump not working

Homogenizer not
working

Machine maintenance
ATTENTION!
components.

b) Pump thermal tripping b) Re-engage/replace
Heating won’t start c) Circulation pump motor burnt c) Repair/replace
d) Uncalibrated or faulty thermo-regulator d) Calibrate/replace
e) Safety thermostat tripped/faulty e) Re-engage/replace
a) Water valve closed a) Open

Litre counter won’t
b) No setting b) Set the amount of water
start
c) Instrument faulty c) Replace
With boiler: With boiler:

a) No water in the circuit a) Refill
Mixture is not
b) Insufficient gas pressure b) Increase gas pressure/replace
heated and/or
cylinders
takes too long c) Uncalibrated/faulty thermo-regulator
c) Calibrate/replace
d) Defective combustion due to poor
stack drafting d) Check stack

Machine maintenance
With steam: With steam:

a) No water in the circuit a) Refill
Mixture is not
heated and/or takes b) Insufficient steam pressure b) Increase steam pressure
too long
c) Uncalibrated/faulty thermo-regulator c) Calibrate/replace
d) Clogged condensate discharge d) Check/replace
Water leaks from a) Damaged seal a) Replace

hot water circulation
pump b) Damaged revolving seal b) Replace
Mixture leaks from a) Damaged seal a) Replace

pumps b) Damaged revolving seal b) Replace
a) Mixture outlet valve closed a) Open the valve

Mixture won’t reach
b) Mixture transfer pump closed b) Start the pump
constant level tank
c) Mixture filters clogged c) Clean the filters
a) Start the pump

a) Mixture circulation pump off
Homogenizer flow b) Replace (see the homogenizer
b) Damaged valves or seats
rate below standard manual)
c) Dirty exchanger
c) Clean (see the exchanger manual)
a) Insufficient rate a) See previous item

b) Pressure key disabled b) Enable key
Insufficient
homogenization rate c) Uncalibrated/faulty pressure c) Calibrate/replace
regulator
d) Replace (see the homogenizer
d) Damaged homogenization head manual)
a) Plates not tightened properly a) Tighten

Mixture leaks from
b) Dirty and/or clogged exchanger b) Wash
exchanger
c) Damaged seals c) Replace
a) Pre-cooling water missing a) Open water valve

Mixture output b) Pre-cooling water too hot b) Use cooler water or increase flow rate
temperature too
high c) Frozen water tank off c) Start the tank
d) Frozen water temperature too high d) Check operation

Machine maintenance

Machine maintenance
Operation recording tables

These tables must be filled in by the Customer every time the machine undergoes maintenance.
Daily
DAY MAINTENANCE DATE OPERATOR’S SIGNATURE

1.____________________ ___________ ___________________
MONDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
TUESDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
WEDNESDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
THURSDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
FRIDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
SATURDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
SUNDAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
NOTES:
Make photocopies of this page and always keep the tables up to date.

Machine maintenance
Weekly
WEEK MAINTENANCE DATE OPERATOR’S SIGNATURE

1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
NOTES:

Machine maintenance
Monthly
MONTH MAINTENANCE DATE OPERATOR’S SIGNATURE

1.____________________ ___________ ___________________
JANUARY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
FEBRUARY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
MARCH 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
APRIL 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
MAY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
JUNE 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
JULY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
AUGUST 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
SEPTEMBER 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
OCTOBER 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
NOVEMBER 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
DECEMBER 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________

Machine maintenance
Every four months

1.____________________ ___________ ___________________
JANUARY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
APRIL 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
JULY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
OCTOBER 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
NOTES:

Machine maintenance
Every six months

1.____________________ ___________ ___________________
JANUARY 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
JUNE 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
NOTES:

Machine maintenance
Annually
YEAR MAINTENANCE DATE OPERATOR’S SIGNATURE

1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
1.____________________ ___________ ___________________
______ 2.____________________ ___________ ___________________
3.____________________ ___________ ___________________
NOTES:

Volume of diagrams
Volume of diagrams
TEKNOMIX 2000 / 3000 Page 1 Volume 07_VD_Language _Rev.01

Volume of diagrams
DIAGRAMS......................................................................................................
VOLUME OF DIAGRAMS................................................................................................................................. 1
LIST OF DIAGRAMS .................................................................................................................................................... 3
Volume 07_VD_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Volume of diagrams
List of diagrams
For all the diagrams, please refer to the documentation contained in the CD-ROM and/or attached
to this manual.
• Layout: HTST2000
HTST3000
• Washing diagram: HTST2000 washing

HTST3000 washing
• Wiring diagram: HTST2000

HTST3000
TEKNOMIX 2000 / 3000 Page 3 Volume 07_VD_Language _Rev.01

Volume of diagrams
Volume 07_VD_Language _Rev.01 Page 4 TEKNOMIX 2000 / 3000

Volume of spares
Volume of spares
TEKNOMIX 2000 / 3000 Page 1 Volume 08_VS_Language _Rev.01

Volume of spares
SPARES......................................................................................................
VOLUME OF SPARES...................................................................................................................................... 1
STANDARD SPARES................................................................................................................................................... 3
STAINLESS STEEL CSF POWDER MIXER PUMP ................................................................................................ 3
STAINLESS STEEL CSF FEEDING PUMP ............................................................................................................ 3
STAINLESS STEEL CSF CIRCULATION PUMP .................................................................................................... 3
GEA EXCHANGER.................................................................................................................................................. 3
HPM HOMOGENIZER............................................................................................................................................. 3
Volume 08_VS_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Volume of spares
Standard spares
The machine is shipped with a set of standard spares.
They may be used for installation, such as piping, pipe clamps and rubber holders; for the machine
routine operation, or to quickly fix little problems that may occur in production.
Stainless steel CSF powder mixer pump

Stainless steel CSF feeding pump

Stainless steel CSF circulation pump

GEA exchanger
HPM homogenizer
TEKNOMIX 2000 / 3000 Page 3 Volume 08_VS_Language _Rev.01

Volume of spares
Volume 08_VS_Language _Rev.01 Page 4 TEKNOMIX 2000 / 3000

Machine dismantling
Machine dismantling
TEKNOMIX 2000 / 3000 Page 1 Volume 09_MD_Language _Rev.01

Machine dismantling
DISMANTLING......................................................................................................
MACHINE DISMANTLING................................................................................................................................ 1
WARNINGS................................................................................................................................................................... 3
INSTRUCTIONS FOR EXTENDED INACTIVITY .................................................................................................... 3
DEMOLITION........................................................................................................................................................... 3
RESIDUAL RISKS ................................................................................................................................................... 4
Volume 09_MD_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Machine dismantling
Warnings
Before you start any operation on the machine, carefully read the sections “Use manual” and
“Machine maintenance”.
Carefully read the section related to Personal Protection Equipment.
Instructions for extended inactivity

No particular procedure is required for extended rest periods; it is absolutely necessary to
thoroughly clean the machine components, removing any material residues.
Demolition
Once the machine has reached the end of its service lifetime, it must be put out of commission so it
can not be used for the purposes it was designed for and so as to make reuse of its parts and
materials possible.
The machine must be deactivated and demolished safely to prevent the risk of impacts due to the
presence of moving parts or stored energy. Teknoice S.r.l. declines all responsibility for damages
to things or injuries to people caused by reuse of the separate machine parts for functions other
than the original ones.
1. Disconnect the machine from any energy source (e.g.: electric, pneumatic, water, hydraulic,
etc.)
2. Disassemble the various components, if necessary referring to the diagrams and the layout
attached to this manual.
In the case of machine handling, lifting and transport, refer to the section “Transport and
installation” and to the assembly diagrams attached to this manual.
Disassemble the machine according to the various units, using tools and instruments normally
found in maintenance stores, so as to be moved and transported. Separate the potentially
hazardous components, such as:
• Plastic or polymer-based materials, etc...

• Electric components, cables, etc...
• Metal components by type, such as aluminium, steel, etc…
Always bear in mind that the disposal of toxic and harmful waste is subject to special rules,
depending on the country. You must become familiar with these rules before carrying out any
operation of this type.
Contact the Teknoice S.r.l. Technical Service should you have any doubts or need further
information.
TEKNOMIX 2000 / 3000 Page 3 Volume 09_MD_Language _Rev.01

Machine dismantling
Residual risks
The machine does not present residual risks if prepared for demolition according to the procedures
provided in the foregoing section.
Volume 09_MD_Language _Rev.01 Page 4 TEKNOMIX 2000 / 3000

Annexes to the manual
TEKNOMIX 2000 / 3000 Page 1 Volume 10_AM_Language _Rev.01

......................................................................................................
ANNEXES TO THE MANUAL .......................................................................................................................... 1
CERTIFICATES ............................................................................................................................................................ 3
SUPPLIER MANUALS.................................................................................................................................................. 3
Volume 10_AM_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

Certificates
For all the annexes to the “Use and maintenance manual”, please refer to the documentation
contained in the CD-ROM and/or attached to this manual.
Manufacturer/Supplier Documentation:
• HPM CE conformity declaration for Homogenizer B22-08020323
• LOWARA Conformity declaration
Supplier manuals
For all the annexes to the “Use and maintenance manual”, please refer to the documentation
contained in the CD-ROM and/or attached to this manual.
Manufacturer/Supplier Documentation:
• GEA Installation manual - Braze welded plate exchangers
• HPM Use and maintenance manual for Homogenizer B22-08020323
• LOWARA Installation and use instructions - Safety
• BONGIOANNI Bongas1 - Installation and servicing instructions
• CSF INOX Self-priming pumps, series AS

(Powder mixer pump)
Centrifugal pumps, series CL-CLC
(Feeding pump)
Centrifugal pumps, series CS
(Circulation pump)
TEKNOMIX 2000 / 3000 Page 3 Volume 10_AM_Language _Rev.01

Volume 10_AM_Language _Rev.01 Page 4 TEKNOMIX 2000 / 3000

Tekno-Ice S.r.l.
Via Lazio, 37
20090 Buccinasco (MI)
Italy
Tel. 0039.02.4886761
Fax 0039.02.4882153
Web www.teknoice.com

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USE AND

Machine : HTST Pasteurization System

Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

The information contained in this manual is the property of Teknoice S.r.l.

Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Limitation of Manufacturer Liability

Note for the user

General notes on safety

Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Teknoice S.r.l. shall have no further obligations in relation to the above.

Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Description of the fault:

Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

We Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Constituted by the following groups :

Type Q.ty Matricule Code Year

the Directive 2006/42/CE (and successive modifications);

Surname: Maganza Teknoice S.r.l

Data : ___________ ___________________

Teknoice S.r.l. - Via Lazio, 37 - 20090 Buccinasco (MI) - Italy

Machine : HTST Pasteurization System

Type : Teknomix 2000 / 3000

TEKNOMIX 2000 / 3000 Page 1 Volume 01_ECS_Language _Rev.01

CONTENTS IN THIS CHAPTER

Volume 01_ECS_Language _Rev.01 Page 2 TEKNOMIX 2000 / 3000

EC Standards: according to Directives 2006/42/EC and

2. By “exposed person” we mean a person located in a dangerous zone of the machine.

1.1.2 Principles of integration of safety

TEKNOMIX 2000 / 3000 Page 3 Volume 01_ECS_Language _Rev.01

1.1.3 Material and product

1.1.5 Design of the machine for transportation purposes

1.2.1 Safety and reliability of the control systems

1.2.2 Control devices

Volume 01_ECS_Language _Rev.01 Page 4 TEKNOMIX 2000 / 3000

1.2.4 Stop devices

1.2.5 Operating mode selector switch

1.2.6 Control devices

TEKNOMIX 2000 / 3000 Page 5 Volume 01_ECS_Language _Rev.01

1.2.7 Malfunction of the control circuit

1.3.2 Risks of breakage during operation

1.3.3 Risks due to objects falling or being thrown

1.3.4 Risks due to sharp edges and surfaces

1.3.5 Prevention of risks due to moving parts

Volume 01_ECS_Language _Rev.01 Page 6 TEKNOMIX 2000 / 3000

1.3.6 Selections for a protection against risks due to moving parts

1.4.1 General requirements

1.4.2 Particular requirements for safety

1.4.2.1 Fixed guards

See point 1.3.6.

1.4.2.2 Moving guards

See point 1.3.6.

1.4.2.3 Adjustable guards that limit access

See point 1.3.6.

1.5.1 Risks due to electricity

1.5.3 Risks due to different energy

Air For the operation of the pneumatic parts (6 bar).

TEKNOMIX 2000 / 3000 Page 7 Volume 01_ECS_Language _Rev.01

1.5.4 Risks due to errors of assembly

1.5.5 Risks due to extreme temperatures

Data : _ _________