DT-40 PD TOWELETTE APPLICATOR USER MANUAL MESPACK PACKAGING MACHINES

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Aldous Goodwin
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1 DT-40 PD TOWELETTE APPLICATOR USER MANUAL MESPACK PACKAGING MACHINES C/ Mar Adriático 18, Poligono Industrial La Torre del Rector Santa Perpetua (BCN) Spain Tel Fax info@mespack.com

2 Introduction Table of contents 1.- Introduction 1.a- Table of contents 1 1.b- Model 2 1.c- Presentation Technical specifications 2.a- General data 4 2.b- Towelette characteristics 7 2.c- Materials and finishes Safety systems 3.a- Hazards 10 3.b- Preventive measures Installation 4.a- Previous works 14 4.b- Starting operation Format changes 5.a- Unwinding unit 17 5.b- Unreel brake 20 5.c- Connecting bar 21 5.d- Inlet channel 23 5.e- Drag 24 5.f- Knife 25 5.g- Introductor group 27 5.h- Folding machine Maintenance 6.a- Maintenance program 30 1 de 31 1.a

3 Introduction Model Horizontal packaging machine: Machine model Serial no. Delivery date DT-40 PD NOVEMBER 2012 Customer LEK (POLAND) IMPORTANT: We kindly ask our clients to mention the serial number of this machine, in case of technical assistance, or spare parts needs. This serial number corresponds with the number marked on the license plate of the machine, situated in the left lateral of the machine. This will ease the process of servicing and the supply of spare-parts. 2 of 31 1.b

4 Introduction Presentation Dear CUSTOMER: Thank you for purchasing our DT-40-P machine. Our advanced technology and years of experience are both the outcome and the guarantee of the trust that you have placed in the MESPACK brand name. This user and spare parts manual aims to provide concise and detailed instructions on how to install the machine, machine maintenance and format changes. We have included a full list of illustrations of almost all machine parts, in the interest of ensuring that it functions correctly and also to help you with ordering the right spare parts. These service instructions are specifically intended for use by technical personnel and the machine foreman. Please read all the instructions carefully no matter how much experience and knowledge you may have of this type of machinery. We should also like to point out that it is not possible to lay down instructions to address all adverse and unforeseen circumstances which may arise in connection with a machine. The most important factor is that the staff responsible for said machine be vigilant, use common sense and remain calm and patient. Proper functioning of our packaging machine depends above all on proper handling by the operators and it should also be kept thoroughly clean at all times. This will considerably extend its working life. 3 of 31 1.c

5 Technical specifiations General data Horizontal packaging machine, DT-40-P series: The automatic machine MESPACK, series DT-40-P has been created to pack towelettes. Starting from a reel film, machine bends the towelette in several folds, in order to be cut later on, to the required dimension; then folded and dragged to a conveyor belt, where it will be treated. Final machine output will be according to product and size, decided by customer. The DT-40-P is a towelette APPLICATOR of our machines, prepared to produce a special type of towelettes, without being necessarily introduced into a pouch. It is based on a single frame and is adjusted to the customer's needs. All mechanical parts are designed in a modular fashion, which means that the machine set-up can even be adjusted on the customer's premises, switching from the simplest to the most fully equipped machine. Customers are advised to read the manual of the specific machine they have purchased. In this manual MESPACK distinguishes between the different machine models and provides all the necessary information that should be necessary to order spare parts. 4 of 31 2.a

6 Technical specifiations Situation of machine: 5 of 31 2.a

7 Technical specifiations Distribution of machine units: 1.- Machine frame 2.- Towelettes frame 3.- Unwinder 4.- Marker rollers 5.- Folding machine 6.- Rollers way 7.- Ironing (optional) 8.- Towelette knife 9.- Towelette drag 10.- Introducer 11.- Entrance channel 12.- Towelette folder 13.-Towelette reel 14.- Reel brake 15.- unit of pneumatic feeding 16.- Union bars 6 of 31 2.a

8 Technical specifiations Towelette specifications Our machines DT-40-P are able to produce 2 type of towelettes (towellette and swap). Their manufacture will be according to customer specifications. The type of towelette can be different in length and in number of folds. Reel plan for flat pouches The reel plan gives you the reel specifications the customer will be working with, including maximum dimensions and possible combinations CURRENT SWAB SIZE 7 of 31 2.b

9 Technical specifiations Materials and finishes We consider that the materials and finishing employed in the manufacture of our DT-40-P machine deserve an own section in this manual. Given that we have designed these machines with the foodstuff packaging sector foremost in our mind, and given that they will be positioned in areas with high humidity, and that the dosing section will require frequent cleaning, whether because of a change of product or for general cleaning purposes, we have paid particular attention to the problem of corrosion. All units that are part of the unwinding, pouch forming and production sections have undergone the following manufacturing process: 1. TOOLING 2. BLAST CLEANING TO REMOVE PORES 3. POLISHING 4. DESCALING MICRON CHEMICAL NICKEL COATING The above process has its complications, but it is highly effective in preventing corrosion. The saline droplets corrosion test easily exceeds 300 hours, equivalent to over 10 years in a marine environment. Their mechanic parts are made with stainless materials (AISI-304 for the steel and A.A for the aluminium), in order to preserve the products to be packaged and to withstand the wear caused by aggressive cleaning products. 8 of 31 2.c

10 Technical specifiations The frame is painted using a very specific procedure: 1. SANDING COATS OF EPOXY PRIMER COAT OF HARD (MARINE) COATING COMPRISING TWO COMPONENTS: RESIN + HARDENER COAT OF STAINLESS STEEL-COLOUR POLYURETHANE PAINT SPECIALLY PRODUCED FOR MESPACK, MIXED WITH STAINLESS STEEL POWDER. (EXTREMELY CORROSION-RESISTANT). 5. KILN DRYING 9 of 31 2.c

11 Safety systems Hazards In matters of safety, MESPACK complies with all relevant EU directives in order to safeguard the well-being of all personnel who operate and provide maintenance for our machines. These standards are specified in the "EC Declaration of Conformity" in section 1.c of the Introduction. All these regulations are basically intended to avoid contact with the machine, and deal with its functional aspects and basic design principles. The main risks to which the machine operator may be exposed, involve various types of hazards. MECHANICAL HAZARDS: Our machines are essentially mechanically operated. This involves continuous oscillating movements of the majority of their units, which are responsible for folding, producing, filling, dragging and cutting the pouch. There is a risk of cutting or severing, of being snagged or dragged along, and even of being struck by protruding moving units. ELECTRICAL HAZARDS: Our machines are fitted with an electrical unit located inside the machine, which houses the current generators and distributors. Inexperienced personnel must avoid all contact with the machine's electrical and electronic systems. Certain parts of the machine may also be subject to accidental electrical charges as a result of short circuits or power surges. 10 of 31 3.a

12 Safety systems Preventive measures The machines are fitted with the necessary safety devices to ensure that all personnel do not come into contact with the abovementioned dangers. "MACHINE OPEN" PROTECTION DETECTORS: MESPACK machines are fitted with two types of protective device: fixed and moveable. The moveable devices are fitted with anchored detectors, and if the moveable protective device (front Plexiglas door) opens, the machine will stop automatically. The purpose of this system is to safeguard the physical well-being of the personnel operating the machine. Upon proper closure of the doors, the machine will not start up operation automatically, but must be started up again manually. The machine will not start if there are any missing or faulty safety devices. WARNING: DEACTIVATION OF THE ANCHORED MOVEABLE PROTECTIVE DEVICES IS STRICTLY FORBIDDEN. 11 of 31 3.b

13 Safety systems MAINTENANCE WORK: When performing any maintenance and servicing work, make sure you switch off the master switch is located on the control panel in order to turn off the power supply. The compressed air valve, located on the feeder unit on the right-hand side of the machine, must also be shut (turn from "open" to "exh"). EMERGENCY STOPS: The emergency stop is always in operation. The purpose of the emergency stop is to shut down the machine immediately in the event of any unexpected incident or loss of control which may occur while it is in operation. This avoids dangerous situations and minimises unnecessary risks. The emergency stop command takes priority over other commands. The machine is fitted with a clearly identifiable red emergency push button which protrudes above the other push buttons. This allows for easy and swift activation in case of an emergency. When you press the emergency stop button this will stop the machine, and the button will remain in the pushed down position. To re-start the machine, turn the same red button clockwise to return to operation mode. To re-start the machine, press the amber "RESET" button, then "START" (green button). 12 of 31 3.b

14 Safety systems STAFF SAFETY: This machine must be operated only by authorised and properly trained staff. Always observe the following guidelines: * Follow the above instructions for disconnecting the machine when carrying out any functional, maintenance, repair or cleaning work. * The machine operator must not operate the machine when the safety devices are impaired in any way. * The foreman must ensure that the machine is used only by authorised personnel. * The operator must report any factors that may affect the safety of the machine. * The machine must only be used in a good state of repair. * The company purchasing the machine must issue due instructions and carry out regular surveillance to ensure cleanliness and visibility in the workplace next to and around the machine. FAILURE TO OBSERVE THE INSTRUCTIONS LAID DOWN IN THE "SAFETY SYSTEMS" SECTION MAY ENDANGER THE PHYSICAL SAFETY OF INDIVIDUALS. 13 of 31 3.b

15 Installation Previous works POSITIONING: Once you have decided where to install the machine you must ensure that there is sufficient space around the location to allow the machine to be easily and conveniently handled and operated. We recommend you install the machine on a stable and solid surface being as level as possible. 14 of 31 4.b

16 Installation Because of its construction method, the machine does not vibrate, so no precautions need to be taken in this respect when installing it. The first step is to level the machine by using the four adjustable feet located at each corner of the machine. B A To adjust the machine, hold a spanner in position "A" and turn nut "B" clockwise to lower the machine, or anti-clockwise to raise it. Follow this step for the four feet, using a spirit level as a guide. Once the machine is horizontal, check that all the bases work properly. It is advisable to use a torque wrench to ensure proper adjustment. ELECTRICAL CONNECTION AND DIRECTION OF ROTATION: The machine is basically designed for 220/380V. However, the machine may be operated at the voltage required by the customer. Unless otherwise agreed, the machine will be delivered for operation at 380V, plus neutral and earth. We recommend that you consult an expert, or our technical department if you wish to alter the voltage of the machine. 15 of 31 4.b

17 Installation STARTING OPERATION: To start the machine for the first time, press the general switch which is located in the electrical cabinet. The machine normally leaves the factory prepared and adjusted for the customer s stipulated pouch specifications. You should therefore follow the procedure below: 1. First thing to do is to place the reel (towelette paper) on the reel shaft. 2. The paper will be situated between the rollers (This step will be properly developped later) 3. Pulling gently the paper, we will lead it through all machine groups, up to the last knife. It is very important the correct situation of marking rollers and the spatulas, to make the paper reach their destiny properly bent (This step will be properly explained later). 4. We will start the machine with the inching button, trying to make some towelettes. 5. Once we have checked that machine works properly, we will push START for a continuous running. 16 of 31 4.b

Format changes Unwinding unit The unwinding unit is a special group, as we can place a film reel up to a maximum width of 330 mm, due to customer requirements.

18 Format changes Unwinding unit The unwinding unit is a special group, as we can place a film reel up to a maximum width of 330 mm, due to customer requirements. To place the reel, we have to put the shaft A through the reel B. With at least two people we will take the shaft by their ends and place it on the top of the unwinder frame. The shaft should be positioned and leaned on the reel turning bearings. Photo no. 1 B A 17 of 31 5.a

19 Format changes Once situated, we will pull out the paper towards the first fixed top roller C, and following through the rest. For a correct position of the paper pay attention to the next photographies. Photo no.2 C 18 of 31 5.b

Format changes The unwinding group only allows format changes in width of towelette. To change the length we will depend on the drag and knife groups, and we will explain properly.

20 Format changes The unwinding group only allows format changes in width of towelette. To change the length we will depend on the drag and knife groups, and we will explain properly. If we need to produce towelettes with different width, it should not exceed of 330 mm, as this is the maximum reel capacity of the unwinder. Then just place the paper reel of the desired width, and put it through the fixed and compensator arm rollers, as indicated in photo no.1 Towelette format width can also be changed without changing the reel width, as it depends on the situation and quantity of needed folds. The working procedure with marking rollers and spatulas will be shown later. The reel allows us a regulation or displacement for centering the paper. This regulation is advisable in order that paper could reach the correct height at the forwarding bar, arriving to machine inlet channel in perfect position conditions. Just turn the knob D to left or right, as needed, displacing the shaft as well as the reel. D 19 of 31 5.b

Format changes Unreel brake The reel brake group is composed by a piston, the brake, the brake disc (situated in the axis), and two deectors (situated in the unwinder).

21 Format changes Unreel brake The reel brake group is composed by a piston, the brake, the brake disc (situated in the axis), and two deectors (situated in the unwinder).. The reel brake group works as follows: When the detector A does not find paper, the piston C will be activated. That raises the brake and allows the reel turns giving paper to the unwinder. At the moment in which the unwinder have sufficient paper, the detecto B detect it and the brake immobilizes the reel. This way causes a repetitive movement of the unwinder rollers. This process is repeated continuously until the end of the reel. The end of the reel: If the detector D does not detect paper, the machine will stop immediately. When it s stopped, we must to active the brake piston by means of the selector E which allows to release the reel of the brake pressure. Next we raised the cover manually to be able to remove the unwinder and to put a new reel; we return to pass the paper through the rollers, according to the diagram of paper passage and one becomes to put the machine on. Photo nr 3 E C D A B 20 of 31 5.b

Format changes Connecting bar The connecting bar group has to lead the paper to towelette head. It is composed by two subgroups: marking rollers and guide rollers.

22 Format changes Connecting bar The connecting bar group has to lead the paper to towelette head. It is composed by two subgroups: marking rollers and guide rollers. MARKING ROLLERS: The marking rollers mark the paper in order to be easily bent. Change of the format: If it isn t necessary to make a change of reel at the same time, we will process as follows: 1.- Raise the security cover and top rollers by means of the knob A. 2.- Fix the superior rollers by means of anchorage "B". 3.- Move rollers "C" fixed to the axis relaxing the screw until the wished position. 4.- Lower the security cover Photography nr 4 A C B 21 of 31 5.c

23 Format changes GUIDE ROLLERS: The guide rollers A are responsible to give shape and guide the paper folds to the inlet channel. The distance should be decreasing until the last group, where they should hold the paper perfectly. There are three groups of rollers, uniformly separated. These groups can be moved along the connecting bar, by just loosing the fixing handle B. Height of guide rollers should be also regulated, by simply loosing the pin C which connect them to the shaft. Photography nr 5 C A B 22 of 31 5.c B

24 Format changes Inlet channel and the iron (optional) The inlet channel group leads the paper into the dragging unit, in order to be cut later. If we change the reel width or the number of folds, which would affect the towelette width, it will be necessary that inlet channel should be 1,5 or 2 mm wider for each side than the towelette wide. This feature is important because do not allow towelette deviations and makes it to follow straight, until the inlet to rollers way. Ironing group B Once fold the towellete acts a system that consolidates by means of the heat that fold, before happening through the entrance channel that leads the towellete to its later introduction in the pouch. It is important to know that one is in high temperatures and that in addition it exerts a great pressure with which you can be burned and be squashed. Photography nr 6 B A 23 of 31 5.d

25 Format changes Drag The drag group is made up of rollers "A", commanded by a servo motor "B". In order to change the drag length one is due to accede to the Touch screen and modify the parameters of drag according to the length wished towellete. (See photography nr 7) Photography nr 7 B A 24 of 31 5.d

Format changes Knife The towelletes group knifes "A" must be regulated when we want to change the length of the towellete. The change of format in knife only affects the length of the towellete.

26 Format changes Knife The towelletes group knifes "A" must be regulated when we want to change the length of the towellete. The change of format in knife only affects the length of the towellete. Relaxing the crew "B" that subject it, we will be able to be moved the blade throughout support "C" until obtaining the required length, thing that will tolerate, perhaps, a change of rod "D", depending on the format. (See photographies nr 10 and 11) Photography nr 10 A B C 25 of 31 5.e

27 Format changes Photography nr 11 D 26 of 31 5.e

28 Format changes Introductor group For each format it must be selected the introductory sword A adapted to the wide of towellete. This sword raises and low to introduce the towellete in the pouch. In order to be able to fit the race of introduction of the sword, is necessary to adjust the rod B position in the cosmooth "C". Photography nr 12 A C B 27 of 31 5.g

29 Format changes Folder The function of the folding machine "A" is to bend the towellete in its position of length, it can be bended 2, 3 or 4 times. Possibles foldings: If we want a towellete with two foldings is not necessary the folding machine, in this case the towellete denominates ` swap'. Simply with the dubbing of the introduction we obtained the wished thing. If we want a towellete with three foldings we will place this one a third of its length within the folding machine. If we want a towellete with four foldings, the position of the towellete must be centered with the passage of the handle. Photography nr 13 A 28 of 31 5.g

30 Maintenance MAINTENANCE This chapter offers preventive maintenance instructions for MESPACK packaging machines. Follow these instructions carefully in order to ensure proper functioning and work application. The maintenance programme is divided into mechanical and electronic maintenance for daily, weekly, monthly, three monthly, six monthly and yearly time periods. MAINTENANCE PROGRAMME: MECHANICAL MAINTENANCE Daily maintenance: * Check the body of the machine both on the inside and the outside for signs of rust, dents or cracks. If there are any irregularities, inform the maintenance team and repair them immediately. * Check that the machine is in good working order (general overhaul). If there are any irregularities inform the supervisor immediately. * Check that after every certain number of towelettes or operating hours, the correct fold and bend of the paper. If there are any irregularities, pinpoint the problem and correct it promptly by informing the authorized personnel. * Proceed to clean the machine and the working area at the end of every day s work or every shift. We recommend you use compressed air. * Check that the film runs uniformly on the reel; if this is not the case, correct promptly. 29 of 31 6.a

31 Maintenance * Check that the operating pressure is 6 bars or 86 psi. If this is not the case, please adjust the manometer. Weekly maintenance: * Check the lubrication of the camshaft. If necessary, lubricate with an oil that has been recommended by MESPACK. Three-monthly maintenance: * Check that the film passes through the correct channels and that it is not out of them. If this is not the case, please make the necessary adjustments. Six-monthly maintenance: * Grease all the greasers of bearings and any others. * Check that the cap or seal of the electric motors are in place and that all fastening screws are properly fastened. If this is not the case, put the cap in place or change the screws. Yearly maintenance: * Check that all the screws and bolts on the machine are properly fastened. If any of them are loose replace the rounded bolts. Use appropriate tools to tighten the Allen and hexagonal screws. * In case of wear or dents in the cutting/ edging area, rectify the edge of the knives that cut the paper. To sharpen the knives fasten them with a magnetic plate and then use the tangential rectifier to sharpen the cutting side. Be careful not to file away more than 0.05mm to 0.20mm. * Check the state of all mechanical components, i.e. springs, tensors, cams, etc. If any of these are not in proper working order ask for them to be repaired. 30 of 31 6.a

32 Maintenance ELECTRICAL MAINTENANCE Monthly maintenance: * Check that the electrical contacts are clean and free of any corrosion; if this is not the case, clean them with an electrical contact cleaner. * Check that there is no humidity in the electrical system. If this is not the case fix the problem. 31 of 31 6.a

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