Colloid Mill

WINTECH PHARMACHEM PHARMACHEM EQUIPMENTS PVT. LTD. Plot 1, Hirji Estate, Behind Excom House, Off Saki Vihar Road, Saki Naka, Andheri (East), Mumbai ± 400 072, India

Tel : -91-22-91-22- 56992254 / 5693 5693 5778 Telefax : 5693 5693 5778 Mobile : 0-9322247017 0-9322247017 / 9322688397 9322688397 Email : winphar [email protected] [email protected] / winpharma@hot [email protected] mail.com Website : www.wintechpharmachem.com

OPERATIONAL MANUAL

FOR

COLLOID MILL

GMP MODEL

CLIENT

HOVID BHD

ADDRESS MACHINE

121,JALAN TUNKU ABDUL REHMANM,30010 IPOH PERAK, MALAYSIA COLLOID MILL

MODEL

GMP

JOB NO.

WPL/2003-04 /

YEAR OF MANUFACTURING P.O. NO.

140380 / 1.11.2004

PLEASE FURNISH ABOVE INFORMATION IN CASE OF ANY DIFFICULTY, COMPLAINTS ABOUT THE MACHINE OR ORDERING OUT SPARES. PLEASE READ AND UNDERSTAND THE INSTALLATION , OPERATION AND MAINTENANCE MANUAL CAREFULLY.IN CASE OF ANY DOUBT PLEASE FEEL FREE TO WRITE TO US. CONTENTS SUBJECT TO REVISION WITHOUT NOTICE. C A UT I ON :

FAILURE TO COMPLY WITH INSTRUCTIONS MAY RESULT IN DAMAGE TO EQUIPMENT AND PERSONNEL.

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WINTECH PHARMACHEM EQUIPMENTS PVT. LTD. Plot 1, Hirji Estate, Behind Excom House, Off Saki Vihar Road, Saki Naka, Andheri (East), Mumbai ± 400 072, India

Tel : -91-22- 56992254 / 5693 5778 Telefax : 5693 5778 Mobile : 0-9322247017 / 9322688397 Email : [email protected] / [email protected] Website : www.wintechpharmachem.com

SR.NO.

DESCRIPTION

1.

INSTRUCTION FOR UNPACKING AND CHECKING

2.

INTRODUCTION AND WORKING PRINCIPLE

3.

APPLCIATIONS

4.

TECHNICAL SPECIFICATION

5.

INSTALLATION

6.

DO AND DON¶T

7.

CHECKS

8.

GENERAL PROBLEMS, THEIR CAUSES AND REMEDIES.

9.

RECOMMENDED SPARES

10.

GENERAL ASSEMBLY DRAWING

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1.

INSTRUCTION FOR UNPACKING AND CHECKING

Colloid Mill is dispatched in assembled condition in wooden case. 1.1

Unpack the case carefully under the supervision of a responsible person and remove the contents without trying to force open any package.

1.2

Check contents with the packing note.

1.3

Should any shortage be observed in the first check, the case, the individual package, also the packing material should be thoroughly searched for a second time in the presence of person who will certify the shortage report.

1.4

In case of breakage or damage the nature and extent of each article, components, it should be immediately brought to the notice of supplier within a week of the receipt of the consignment in writing.

1.5

All the parts and components should be thoroughly cleaned of packing material before assembly / installation with particular reference to moving parts.

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2.

INSTRUCTION AND WORKING PRINCIPLE :

The machine is designed for easy homogenization, emulsification, dispersion, mixing etc. Colloid Mill is used for the processing of highly viscous to liquid product in various applications. The principal works on stator / rotor. The product is fed to the opereting area of rotor which rotates at the speed of approx. 2800 rpm & the product is processed by high shear, pressure & friction between the stator and rotor. Due to this the product is exposed to intense vibrations which exert their force on it by means of pressing & releasing actions. The process for the product is continuous & it can be re-circulated if required. The angular gap becomes narrower towards the discharge section due to the slight deviating tapering of the milling surfaces of stator & rotor. Three way cock assembly is provided so that liquid can be re-circulated & if product is viscous it can be processed in one pass by fixing discharge spout. Viscous product can be reprocessed as per your requirement again by charging the material again in hopper. The out put depends upon the milling gap, viscosity, feed size & hardness of the product to be processed. Shaft entry is sealed by a single Mechanical seal so as to prevent the motor from any leakage of processed material in any circumstances. The unit can be used for small, medium & large scale production.

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3.)

APPLICATIONS :

A.

Pharmaceutical Industry : For Ointment,Starch Solution,Extracts,Creams,Emulsions,Paste,Colour Solution,Lotions.

B.

Chemical Industry: Colouring,Latex Emulsions,Detergents,Shoe Polish,Textile Coating Car shampoos,Stlants,Plastics ,Pvc and paper Coating etc.

C.

Cosmetic Industry : Bath additives,Emulsions,Face milk,make up,lipstick base,ointment,soaps,toothpaste,creams lotions etc

D.

Food Indutry : Ketchups paste,extracts,drinks,soups,milk product,cream cheese.

4.)

TECHNICAL SPECIFICATION :

MODEL OUT PUT PARTICLE SIZE REDUCTION MOTOR HOPPER CAPACITY

WCM 3 (PLAIN OR WATER JACKETED) 120 TO 12000 KGS. PER SHIFT 5 TO 10 MICRONS 2 HP, 2800 RPM, 380 V, 50 HZ, 3 PHASE, A.C. MOTOR 15 LTRS

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5.

INSTALLATION INSTRUCTION FOR COLLOID MILL

Colloid Mill has been put into position, leveled and bolted down (if required) it should be thoroughly cleaned to remove anti-rust, grease and dust etc. Open the conical shaped hopper by removing the bolts of the flanges and check for any foreign material in the Stator Rotor assembly. Check the direction of Rotor and it should be as per the arrow marked on the machine. If there is any change, change the direction by changing the three phase wiring connection at input supply point. Apply small amount of any food grade oil at the surfaces of Mechanical seal. An actual running period is given to each machine before it leaves the works. However, an additional running-in-period can be given if desired. (The machine should run after checking inside the hopper of any foreign particles left in, -failure to do this would all probability, cause damage to Rotar /Stator) 5.1

Removal of 3-Way Cock Assembly

Unscrew two bolts while holding the 3-way cock assembly to allow assembly to remove from mill. (In water Jacketed Model, PVC Pipe connections to 3-way cock Assembly are to be removed first) Take care that Neoprene rubber packing at housing should remained there without any damage. 5.2

Fitting of 3-Way Cock Assembly

Clean well, rubber packing at housing, as well as 3 way cock assembly pipes from inside bores to remove direct or any foreign material, clean rectangular machine face meeting with rubber packing at housing, so that leakage due to dirt between meeting faces can be avoided. Keeping two bolts away by swinging, place gasket packing on housing position 3-way cock. Assembly as shown in the figure at housing so that hole of pipe and the discharge matches properly. Tighten the bolts evenly to match faces without any leakage. Flow of processed material can be done by operating the two ball valves provided in the pipeline. In case of water jacketed model connect the PVC pipe with circulating pipe jacket as shown in schematic diagram of water jacket pipe connection. While connecting PVC pipes of water jacketed model, it is essential to take care that water or liquid media must feed from bottom Nozzel to the Jacket and discharges from top nozzle of the jacket. 5.3

Adjustment of Milling GAP

De-lock two handles by unscrewing at least two full revolutions. Turn Adjusting ring by handles clock wise to decrease the milling gap (grinding clearance between stator and rotor) and vice versa. After adjusting required clearance, lock again two handles by screwing in and Tightening to avoid disturbing of adjusted milling gap by vibration effect of mill.

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Once by try and error method, set right milling gap for specific product which gives required end product. For that particular product, when to adjust again, it is advisable to make a note and marking on the machine for easy and quick set right time.

5.4

Adjustment for Actual Production

Check Hopper from inside so that no foreign materials or unwanted things lying there, take care, if any, first. Close the cock with cock handle. Start Colloid Mill by Green Push Button µON¶ situated at main body of the machine. Check the direction of rotation by peeping in hopper and it should be as per arrow mentioned on the machine. Note : If the direction of the rotor will be opposite, the spring of the mechanical seal will tend to open and thus may cause leakage.

Start the colloid Mill with right direction of rotation, pour water about 10 litres to rinse the mill. Adjust milling gap from minimum to maximum in such a way and set at any one point. Now mill can be used for production. To decide upon adjustment of milling gap & arrangement, check the product as follows: a.

Viscosity - e.g. Liquid (Water Form), slightly viscous (condensed milk) Viscous (Cream Form) or Pasty (ointment)

b.

Feed Size & Hardness of Product.

c.

Required end product

For liquid and slightly viscous product Fitting of 3 way cock assembly is recommended. It facilitates circulating as well as draining. For viscous and pasty product, fitting of Discharge spout is recommended where re-circulation is not possible. Adjustment of milling gap & time period of re-circulation through 3 way cock assembly depends upon Feed size, and final requirement of end product. It can be decided by try and error method at least once for particular product. For next time, one can preset milling gap with the help of recorded marking. Once the batch is over. Drain off the product, close the cock pour in hopper suitable solvent, run few minutes to circular solvent through 3 way cock to clean thoroughly all over. Drain off of the solvent. Now press µOFF¶ red push button to stop the colloid mill. After completion of processing or changing from one product to another, it is essential to clean thoroughly the Colloid Mill to avoid contamination problems.

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6.

Do and Don¶t

Don¶t run machine without reading instruction manual. Follow instruction manual strictly. Do not give power connection without checking correct direction of rotation. Do not run the machine after pouring the hopper. Do not leave machine with product overnight. Do not keep drain open while pouring product in hopper.

7.

Checks

Check that no foreign material of metal particles in the mill. Check that Colloid Mill is clean before and after use. Check close position of cock before feeding the product. Check that mill is run first and then product is fed. Check that mill is stopped after product is drained off. Check whether container is in position at drain pipe or at discharge spout when product has no drain through without circulation. Check for the mechanical seal time to time that its faces or edges are not broken. Check that both the bolts of discharge line and the cone flanges are tighten evenly to avoid leakage. Do not try hard to rotate the gap adjustment handle without loosening it otherwise it may cause damage to the assembly. Do not open the gap adjustment handle complete otherwise the there could be leakage from the gasket fitted at the conical hopper flange.

8.

Recommended Spares

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We recommend that you should maintain following materials in stock to avoid any shutdown due to some breakdown, general wear n tear. a.

Single dry mechanical seal

9.

General Problems, their causes and Remedies.

Problems

2 Nos.

Causes 1) Main Electric Supply fault.

Remedies 1)Check individual phase & Voltage in line or

2) Faulty Electrical Connection.

1) Check overload relay, avoid loose connection, verify connection

Direction of Rotation is not as per Direction Arrow fitted on Mill Leakages Cock Leaks

1) Faulty Electrical Connection

1) Interchange two phase wires after switch off the main supply.

1) Setting Disturb

1) Tighten gently Hex Head Bolt such that cock can be turn with light force with cock handle. 2) Replace the gasket.

leakage at Electric Motor Or At Mill base

2) µO¶ Rings warn out at mechanical seal 1) seal face damaged or worn out 2) Product Kept overnight. 1) Foreign particles in mill or 2) Bearing Back-lash increasing due to warn out effect or setting disturbed. 1) Viscous Product

1) Replace oil seal by expert. 2) To avoid such practice

Colloid Mill does not start

Noise At Milling Zone Or Bearing Housing

Product not Circulating properly

Not getting required Micron-size or not achieving uniform distribution of product ingredients

Foreign Particles found with

2) Clogging of product in circulating pipe 3)Cock position is not set properly. 4) Direction of Rotation is not OK 1)Milling GAP not properly set 2)No sufficient circulation or Processing time is provided. 3)Hard product or infeed extraordinary big particle size. 1)Mill was not thoroughly clean

1) Remove immediately 2) Call expert

1) Change circulating pipe to disharge spout or Reduce Viscousity if possible. 2)Remove clogging. 3)Set true position 4)correct the direction of rotation 1)Let sufficient time for milling. 2)Let sufficient time for milling. 3) Keeping different milling gap, product to be processed in stages, instead of one pass. 1)Adhere to cleaning practice.

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before use. 2)Product taken in dirty container 3)Rotor coming in contact with stator due to foreign metal particles or Increased bearing clearance.

product

2)Adhere to cleaning practice. 3) Call expert.

COLLOID MILL

COLD WATER INLET

RECIRCULATION PIPE

HOPPER

JACKET COLDWATER OUTLET

OUTLET MILLING GAP ADJUSTMENT

PROCESS CHAM ER MECHANICAL SEAL

MAIN MODY

CASTOR WHEELS

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Colloid Mill

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