CRUST FREEZER MANUAL

(Picture maybe different from actual machine)

Order and Reference Nr:

13, Pioneer Sector 1

Singapore 628424

Tel: + 65 6281-2878

Fax: + 65 6281-2908

Email: dantech@marel.com

Web: www.marel.com/freezing

It is very important that the personnel who operate and work this Crust
Freezer have a proper training and education.

The personnel must be aware and carefully study this Manual.

Ignoring these instructions may invalidate your Warranty.

24/7 HOTLINE: + 65 81 27 61 08

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TABLE OF CONTENTS
1. CRUST FREEZER

1. CRUST FREEZER ........................................................................................................... 3

1.1. Principle of Operation ............................................................................................. 5
1.2. Application / Functions ........................................................................................... 6
1.3. Counter Weight ....................................................................................................... 7
1.4. Drum Motor & Idler Pulley .................................................................................... 7
1.5. Emergency Stop / Switch ........................................................................................ 7

2. SAFETY PRECAUTIONS .............................................................................................. 8

2.1. Safety while Operating Crust Freezer ..................................................................... 8
2.2. Safety prior to maintenance .................................................................................... 8
2.3. Safety Labels ........................................................................................................... 9

3. OPERATING PROCEDURE ......................................................................................... 10

3.1. Before Operation ................................................................................................... 10
3.2. Starting Up and Use .............................................................................................. 11
3.3. After Operation ..................................................................................................... 11

4. CRUST FREEZER HYGIENE AND CLEANING ....................................................... 11

4.1. Crust Freezer Hygiene .......................................................................................... 11
4.2. Cleaning Steps....................................................................................................... 12

5. MAINTENANCE ........................................................................................................... 14
5.1. Crust Freezer Maintenance ................................................................................... 14
5.1.1. Preventive Maintenance .............................................................................. 14
5.1.2. Belt Changing .............................................................................................. 15

6. TROUBLESHOOTING ................................................................................................. 16
6.1. Repairs and Replacements .................................................................................... 16
6.1.1. Tools ............................................................................................................ 17
6.1.2. Storage ......................................................................................................... 17
6.1.3. Removal / Discard ....................................................................................... 17

7. SPARE PARTS .............................................................................................................. 17

7.1. List of Spare parts ................................................................................................. 17
7.2. Ordering of Spare Parts ......................................................................................... 17

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 1. CRUST FREEZER

Marel Singapore Pte. Ltd. FT/CF 500-3000 Series Crust Freezer is

new designed, mechanical refrigeration freezing concept for quick-freezing
the surface of a wide range of delicate food products.

The Dantech Crust Freezer uses an ingenious method to freeze food:

products are conveyed on a thin Teflon belt running over a freezing plate. The
underside of the product gets a stabilizing crust. It is hard enough to allow the
product to be transported onto a regular freezer belt with no mesh marks or
sticking problems. It is perfect for pre-freezing.

Equipped with gas spring, so it is very easy to open and close the cover for
machine cleaning and belt changing. As the belt can be changed from one side,
so production cost can be reduced.

Waterproof stainless steel Electrical Control Panel / Remote Control Panel

with built in PLC, frequency inverter and a touch screen for controlling /
reading of:

 Digital reading of freezing time

 Adjustable of crust freezer belt speed
 Digital reading of freezing plate temperature
 Emergency stop mounted on front of control panel.

Touch Screen

Cover 1 Cover 2 Cover 3 Cover 4

Idler Pulley

Control Panel

Drum Motor Fig. 1 Counter Weight Alignment System

(Picture maybe different from actual machine)

Crust Freezer without Trays

** Open the covers according the sequence: Cover 1  Cover 2  Cover 3 Cover 4
** Close the covers according the sequence: Cover 4  Cover 3  Cover 2 Cover 1
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Outlet Cover Tray Inlet Cover
Fig. 2

Nylon Frame (4PCS)

** When using crust freezer as conveyor, please
layout nylon frame as per left photo.

IMPORTANT NOTE: PLEASE HANDLE

NYLON FRAME WITH CARE!

Tray Handle

Latch

Fig. 3 (Tray Closed) Fig. 4 (Tray Opened)

**Open the tray: Hold the tray handle and press the tray latch (integrated with the tray
handle) to open the tray.

**Close the tray: Hold the tray handle and lift the tray until the tray to be locked.
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 Belt Lifting Rod

Fig. 5 Outlet Cover Handle Inlet Cover Handle Fig. 6

**Attach Outlet / Inlet Cover: Two hands pull outlet / inlet cover handle outwards to
lock the cover.

**De-attach Outlet / Inlet Cover: Two hands pull outlet / inlet cover handle outwards to
unlock the cover.

**Belt Lifting Rod: For easy cleaning and belt dry, please turn the belt lifting rod 90° to
hold the belt before cleaning the machine. It’s better to put additional 2 pieces of nylon plate
on the freezing plate to hold the belt when cleaning the machine.

1.1. Principle of Operation

Fig. 4

The products are manually placed on a thin belt and gently led through the
freezing zone. Freezing plates are mounted under the belt ensuring a fast crust
freezing of the products underside.

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 The unit is equipped with slow mowing fans above the product, which can be
optionally run for better air distribution.

 Belt Auto-align system ensures that the belt runs in a straigh

smooth and trouble free operation.

 Counter weight can be up and down automatically to tighten the

belt. When the freezing plate works (cold down), the belt will be a
little bit shorter, and at the same time, counter weight will be up so
that the belt is tightened.

The unit is delivered on height adjustable stainless steel legs for easy leveling
on unevenness floor.

1.2. Application / Functions

Slicing/Portioning

Improved quality and yield: better slice integrity and reduced fines. Slicing is
considerably eased by rapid pre-freezing of the food surface. Increases slicing rate
and process efficiency. Synergy with Marel Food Systems Portioning/Slicing
Machines (Opticut, I-22, I-36, I-55 etc.)

Minimizing Weight Loss of Product & Maintains Product Quality.

Crust freezing locks/seals the surface of the product instantly with minimal marks
giving the products better quality shape.

Yield is maximized due to the fast freezing which locks/seals the taste and moisture of
product.

Yield is also maximized for cooked products due to the fast freezing that stops the
cooking process.

Fresh products that are Crust Frozen/Sub Cooled have a significantly better shell life.

Avoids Belt Marking.

Crust Freezing delicate products prior to their entry into a main IQF Freezer will
avoid belt markings and to maintain product quality/shape.

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Avoids Products from Sticking onto one Another.

Products will not stick onto one another during the deep/full freezing process should
the overall surface of the product be crust frozen.

This will help increase the belt load of the Main IQF Freezer hence increasing the
capacity of the Main IQF Freezers.

Increases Capacity (Existing) Main IQF Freezer.

The temperature of the product is also brought down during the Crust Freezing
process.

By cooling down the product prior entering a main IQF Freezer, retention time on the
product in the main IQF Freezer will be reduced hence increasing the capacity of the
Main IQF freezer.

Deep Chilling of Products

With an equalized temperature of -1.4°C the drip loss has been stopped and the
products are ready for storage, transport to the supermarket or further processing.

1.3. Counter Weight

This is necessary to tighten the belt. Belt may expand or contract in length due to
temperature and surrounding changes, the counter-weights keeps the belt tight
without continual manual intervention.

1.4. Drum Motor & Idler Pulley

The drum motor drives the belt to transfer the products. This drum motor / idler
pulley are extremely compact, totally enclosed and highly efficient belt conveyor
drive that would be unaffected by dust, water, oil, grease or other harmful substances
– which would be quick and simple to install and require virtually no maintenance.

1.5. Emergency Stop / Switch

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 The start/stop device is placed on the machine.

The supplier of emergency switches, start/stop devices and repair breakers must
install these on the system control panel(s) in accordance with the Machinery
Directive 98/37/EC & 2004/108/EC and the later amendments.

2. SAFETY PRECAUTIONS

2.1. Safety while Operating Crust Freezer

It is very important that all personnel who operate the unit have proper
training and education. The personnel must be aware and carefully study this
manual. Furthermore personnel must wear suitable protective clothing and
ensure that clothing, hair, etc. does not risk getting caught by moving parts.

Be sure to know where the emergency button is placed.

Do not leave tools or loose equipment on the belt. This might cause damage when
the system is started.

Always in case of emergency press the Emergency Button.

2.2. Safety prior to maintenance

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 Safety Switches are only helpful when operating correctly. Check at least once
weekly.

Always lock off isolator when changing belt / cleaning the Freezer.

2.3. Safety Labels

! WARNING ID 12180027
Usually placed at the Spiral freezer doors to warn of moving parts inside the spiral,
and also electrical wires located throughout. It is important to take note of
surroundings during maintenance and always put safety first.

! WARNING ID 12180029
All the manuals provided MUST be read and understood for the best possible safe
working environment.

! CAUTION ID 12180030
This indicates areas where finger and limbs may be subjected to dangers. Chains,

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 belts and sprockets are designed to be hidden from view but still accessible for
cleaning, this is achieved by either placing a cover over these hazardous parts or by
situating them in relatively unreachable locations. This label warns operators to
avoid resting hands, arms on or near these areas.

! WARNING ID 12180031
Located mainly on the electrical control panel. High voltage and currents are
potentially dangerous, even more so during servicing. Steps to ensure safety must be
taken seriously.

! WARNING ID 12180040
Same warning as the above label, except this indicates that servicing or testing may
be carried out without fully disconnecting main power. Personnel working under
such conditions must be specialized and fully trained in all aspects of operations.

3. OPERATING PROCEDURE

3.1. Before Operation

1. Make sure: there is nothing to block or scrape against moving portion of the
machine; everything is in place after any servicing done; the machine
position is correct to the contiguous ones.

2. Verify the cleanness of the machine before production running. If the hygiene
condition does not achieve the criteria, a before-cleaning has to be carried out
until the hygiene requirements are achieved.

3. Conduct a routine checks:

- No maintenance work is being performed on the machine

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 - All guards are in place.

- No fault alarm/emergency switch is on

3.2. Starting Up and Use

Please refer to User Interface Touch-Screen Instruction Manual for instructions on

starting and stopping, speed settings and all aspects of controlling the conveyor.

3.3. After Operation

At the end of production shift, stop the machine and turn off power (controlled via
touch-screen).

4. CRUST FREEZER HYGIENE AND CLEANING

4.1. Crust Freezer Hygiene

CRUST FREEZER HAS TO BE CLEANED AS OFTEN AS POSSIBLE

Recommended Detergent: Ecolab’s Topax 19 / Ecolab’s Topax 13.

In fact the whole system must be kept clean at all times for reasons of hygiene and the safety

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to the system life.

A proper and total drying must take place before a new start of freezing. This to be sure that
left water or moisture will not turn into ice and cause damage.

It is crucial to keep the belt and freezing plate clean at all times. Avoid the possible build up
of dirt and fragments of the products. If not it will be easily lead to damage and this will also
become a factor for more downtime.

4.2. Cleaning Steps

Ensure that the power of Crust Freezer is turning off.

Cleaning of Crust Freezer involve the use and handling of washing solutions and chemicals.

Cleaning crews are advised to wear protection during cleaning operations.

Cleaning should be done in manageable steps to ensure that the whole system is clean.

Before cleaning of Crust Freezer, some preparations and checks must be done.

The unit has to be fully defrosted, if used for freezing.

Never clean under freezing. If so ice will build up from cleaning water and cause
damage to evaporators, fan blades and other steel parts.

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 Pouring water into cold evaporator, lower than 0 °C (32 F), is dangerous, as when ice
buildup will push the evaporator-tubes and cause damage.

General Cleaning Procedure

Open the covers.

After rinsing thru with water, foaming the whole freezer with chemical.
After x time of reaction time of the chemical, rinse the whole freezer with clean water
and ensure the chemical is fully rinsed.
Apply disinfectant onto the whole freezer and x time is given for the disinfectant to
react before rinse it off with clean water.
Avoid use of temperatures over 55 °C (131 F) because some proteins denature in high
temperatures and to be under the corrosive nature of most chemical sanitizers.
Rinse dirt off the machine using water jets or a brush. Work from top and downwards.
Note that high water pressure can spread dirt all over the unit.
Spray the unit with detergent foam or by manufactory recommended cleaning
product.
Be sure to reach all corners and hard-to-reach areas.
Rinse off dirt dissolved by the foaming. Again work from top and downwards.
Use brush on solid dirt.

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Sanitize

All surfaces in contact with the product should be sanitized after operation and
cleaning.

Make sure the surface of the unit is dry before sanitizing. Remains of water will dilute
the sanitizing agent.

For daily sanitization, use agents containing, for example, quaternary ammonium
compounds.

Once a week, sanitize with chlorine (100 ppm) or a comparable agent.

Remark that sanitizer agent with a higher content of chlorine can have a negative
effect to stainless steel and develop rust.

After sanitizing, rinse the unit thoroughly with clean water, to eliminate contact
between sanitizer and raw materials or products in the next operation round.

Let the unit dry.

Cleaning of equipments

Remove all products waste.

Pre-Rinse

Foam the equipments. Foam has to be left on equipment for a period to work and
react with the machinery surfaces.

5. MAINTENANCE

5.1. Crust Freezer Maintenance

5.1.1. Preventive Maintenance

To keep the system running smoothly and optimal, regular preventive measures
are important.

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 These maintenances should be done by trained staff only.

Check that isolator is locked off before service.

Daily:

Inspect for belt damages.

Run the Crust Freezer for at least one complete cycle and control if
there are abnormal conditions.

If abnormalities are found, replace the damaged belt.

Inspect drum motor for wear and idler pulley alignment.

Check if the drive chain is properly tensioned and running well.

5.1.2. Belt Changing

If found belt damaged, please change belt according to follows:

a) Release idler pulley.

b) Lock the counter weight.

c) De-attach the Outlet / Inlet cover.

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 d) Take out the damaged belt then put on the new belt, make sure that the belt
is properly layout.

e) Push back idler pulley.

f) Unlock the counter weight.

g) Attach the Outlet / Inlet cover.

h) Test running the belt (without refrigeration on), adjust idler pulley to align
the belt.

6. TROUBLESHOOTING

Follow safety procedures in Error! Reference source not found. Error! Reference
source not found.

Due to the relative simplicity of the Crust Freezer, troubleshooting is straight forward:

1) Check the belt condition.

2) Check drum motor and idler pulley not jammed by any objects

3) Check the incoming power to the motor

If problems persist, replacement of parts by service personnel may be required.

6.1. Repairs and Replacements

Before carrying out repairs:

1) Disconnect electricity

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 2) Disconnect refrigeration supply.

3) Motor is dismantled and emptied of oil, if necessary.

Disconnection of electricity must be carried out by an

authorized electrician.

6.1.1. Tools

Ordinary tools (metric)

6.1.2. Storage

The spare parts must be stored in a dry and warm room.

6.1.3. Removal / Discard

Crust Freezer is made of stainless steel and plastics. Removal and discard of
waste material from damaged parts must take place in accordance with the
national legislation regarding waste removal.

7. SPARE PARTS

7.1. List of Spare parts

See attachment spare parts list

7.2. Ordering of Spare Parts

To ensure expedient supply of ordered spare parts, please specify following when
placing an order.

1) Order No. (See attached Spare Parts List)

2) Item No. (See attached Spare Parts List)
3) Name and type of spare part

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 4) Number of requested spare parts
5) Delivery address
6) Invoice address
7) Your phone / Telefax No.

Our Address:

Marel Food Systems Pte Ltd, Freezing & Temperature Division

13 Pioneer Sector 1
Singapore 628424

Email : dantech@marel.com
Website : www.marel.com/freezing
Tel : +65 6281 2878
Fax : +65 6281 2908

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Notes:

END OF DOCUMENT

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