Manual

434, Pillow Crimper, Oct.
2009, Rev0
OPERATION & AFTERCARE MANUAL

Pillow Crimper
Baker Perkins Ltd.

Manor Drive
Paston Parkway Telephone: +44(0) 1733 283000
Peterborough Facsimile: +44(0) 1733 283001
PE4 7AP Website: www.bakerperkinsgroup.com
England E-mail: bpltd@bakerperkinsgroup.com
www.bakerperkinsgroup.com -1
434, Pillow Crimper, Oct. 2009, Rev0
USER NOTES
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Contents Links - click to view

Section Page
1 Pillow Crimper ........................................................................................................................................................ 7

1.1 Contact Information .........................................................................................................................................................................................8
1.2 Operation Manual History ................................................................................................................................................................................8
2 FAXBACK Form ....................................................................................................................................................... 9
3 EC Machinery Directive..........................................................................................................................................11
4 Equipment Specification ........................................................................................................................................13

4.1 Contract Reference Number..........................................................................................................................................................................13
4.2 Machine Number ...........................................................................................................................................................................................13
4.3 Noise Level ....................................................................................................................................................................................................13
4.4 Electrical Power Supply .................................................................................................................................................................................13
4.5 Other Utility Supply Details - e.g. Gas, Air.....................................................................................................................................................14
4.6 Specification Detail ........................................................................................................................................................................................14
5 Safety ....................................................................................................................................................................17
5.1 WARNINGS, Cautions, Notes and Hints .......................................................................................................................................................17
5.2 General ..........................................................................................................................................................................................................18
5.3 Purpose of use ..............................................................................................................................................................................................19
5.4 Electrical Lock Out and Tag Out of Isolator ...................................................................................................................................................20
5.5 Emergency Shutdown....................................................................................................................................................................................20
5.6 Guards and Safety Devices ...........................................................................................................................................................................21
5.7 Installation Safety Precautions ......................................................................................................................................................................23
5.8 Commissioning Safety Precautions ...............................................................................................................................................................23
5.9 Operation Safety Precautions........................................................................................................................................................................23
5.10 Cleaning and Maintenance Safety Precautions.............................................................................................................................................26
5.11 Running the Equipment Without Safety Systems ..........................................................................................................................................28
5.12 Health and Safety ..........................................................................................................................................................................................30

5.13 Personal & Food Hygiene..............................................................................................................................................................................31
5.14 De-Commissioning ........................................................................................................................................................................................32
6 Hazards..................................................................................................................................................................33
6.1 Equipment Hazards .......................................................................................................................................................................................33
6.2 Machine Specific Hazards .............................................................................................................................................................................35
7 Baker Perkins Customer Support ...........................................................................................................................37

7.1 Customer Training .........................................................................................................................................................................................37
7.2 Plant Automation Systems.............................................................................................................................................................................37
7.3 Customer Support..........................................................................................................................................................................................38
8 Glossary of Terms ..................................................................................................................................................41
9 General Information - Baker Perkins Equipment ....................................................................................................43

9.1 General ..........................................................................................................................................................................................................43
9.2 Machine Markings..........................................................................................................................................................................................44
9.3 Prolonged Storage.........................................................................................................................................................................................44
9.4 Installation .....................................................................................................................................................................................................45
10 Installation ............................................................................................................................................................47
10.1 General ..........................................................................................................................................................................................................47
10.2 Pillow Crimper................................................................................................................................................................................................48
11 Pillow Crimper .......................................................................................................................................................49

11.1 General Description .......................................................................................................................................................................................49
11.2 Detailed Description.......................................................................................................................................................................................49
11.3 General Operating Procedures......................................................................................................................................................................53
11.4 Pillow Crimper Operating Instructions ...........................................................................................................................................................54
12 General Maintenance.............................................................................................................................................59
12.1 General ..........................................................................................................................................................................................................59
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12.2 Safety Devices...............................................................................................................................................................................................60

12.3 Running After Adjustment or Repair ..............................................................................................................................................................60
12.4 Routine Maintenance.....................................................................................................................................................................................60
12.5 Electrical Maintenance...................................................................................................................................................................................62
12.6 Maintenance Log or Record ..........................................................................................................................................................................65
13 Quick Reference Maintenance Schedule ................................................................................................................67
14 Detailed Maintenance............................................................................................................................................71
15 Equipment Cleaning and Hygiene ..........................................................................................................................77

15.1 Initial Cleaning (after installation)...................................................................................................................................................................77
15.2 Cleaning During Production...........................................................................................................................................................................78
15.3 Safety and Cleaning Equipment ....................................................................................................................................................................79
15.4 Cleaning and Disinfection Procedure ............................................................................................................................................................80
15.5 Points To Note ...............................................................................................................................................................................................81
15.6 Access To Equipment For Cleaning ..............................................................................................................................................................82
15.7 The Cleaning Process ...................................................................................................................................................................................83
16 Specific Cleaning and Hygiene ...............................................................................................................................89

16.1 Machine Specific Cleaning ............................................................................................................................................................................90
16.2 Pillow Crimper................................................................................................................................................................................................91
17 Standard Lubrication .............................................................................................................................................93

17.1 General ..........................................................................................................................................................................................................93
17.2 Bearing Lubrication........................................................................................................................................................................................94
17.3 Recommended Lubricants.............................................................................................................................................................................94
17.4 Lubrication Oils - (Industrial Grades) .............................................................................................................................................................96
17.5 Lubrication Greases - (Industrial Grades)......................................................................................................................................................98
17.6 Lubrication Oils - (Automotive Grades)........................................................................................................................................................100
17.7 Lubrication Greases - (Automotive Grades) ................................................................................................................................................102
17.8 High Temperature Greases .........................................................................................................................................................................104
17.9 General Lubrication Schedule .....................................................................................................................................................................105
17.10 Lubrication Table for SEW Drives................................................................................................................................................................106
18 Lubrication Details............................................................................................................................................... 107

18.1 SEW Gearboxes ..........................................................................................................................................................................................107
18.2 Pillow Crimper Drives ..................................................................................................................................................................................108
19 Baker Perkins Spare or Replacement Parts........................................................................................................... 109
20 Index of Parts Lists and Drawings ........................................................................................................................ 111
21 Index of Other Makers Leaflets............................................................................................................................ 113
22 Customer Feedback ............................................................................................................................................. 115
23 Conversion Table ................................................................................................................................................. 117
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1 Pillow Crimper
Copyright
No part of this publication may be reproduced, transmitted, transcribed, stored in any retrieval system or translated
into any human or computer language by any means or in any form, without the prior written permission of Baker
Perkins.
Contravention of the owner’s copyright may also reduce the ability of Baker Perkins to provide effective support
for its equipment.
Baker Perkins Baker reserves the right to make changes without notice to both this publication and to its products
described within.
All possible care has been taken in the preparation of this publication, but Baker Perkins accepts no responsibility
for any inaccuracies which may be found. If you find any errors, or would like to make suggestions for
improvement, then please write to Baker Perkins at the address given below. Phone and fax numbers are also given.
Baker Perkins has a policy of continuous development and improvement of documentation and any comments you
may have will be welcome.
www.bakerperkinsgroup.com Pillow Crimper - 7

1.1 Contact Information
Non USA USA

Baker Perkins Ltd. Baker Perkins Inc.
Manor Drive 3223 Kraft Ave. S.E.
Paston Parkway Grand Rapids
Peterborough MI 49512-2027
PE4 7AP USA
United Kingdom
Telephone: +44 (0) 1733 283000 Tel.: +1 (616) 784 3111
Facsimile: +44 (0) 1733 283001 Fax: +1 (616) 784 0973
Email: bpltd@bakerperkinsgroup.com Email: bpinc@bakerperkinsgroup.com
1.2 Operation Manual History

Rev C.Goodacre Original Documentation Language: English (UK) 01/11/2007
Rev. No. Author Details Date
This Manual belongs to: Alfonzo Rivas & Cia
Pillow Crimper - 8
2 FAXBACK Form
NOTE: During the first month
Fax to: Baker Perkins of the warranty - if the
equipment IS NOT being
Fax no: +44 (0)1733 283001 commissioned by Baker
FAO: Technical Support Centre Perkins, this form must be
completed and returned to us,
Thank you.
Machine no: 434/1SF0931
Type: Pillow Crimper
Startup date: ..........................................................................................
We confirm that we are in receipt of the operating manual for the above machine.
Company using machine:
......................................................................................... Signed for and behalf of the company:

.........................................................................................
......................................................................................... Signed..............................................................................
.........................................................................................
......................................................................................... Date.................................................................................
www.bakerperkinsgroup.com FAXBACK Form - 9

Comments, spare parts requirements, training requirements:-
FAXBACK Form - 10
3 EC Machinery Directive
EC MACHINERY DECLARATION OF CONFORMITY OR INCORPORATION

(Directive 98/37/EC and 89/336/EEC)
We hereby certify that the machinery detailed below, has been designed and
manufactured to comply with all the relevant provisions of the EC Machinery
Directive, as amended and the National Laws and Regulations adopting this Directive.
Machine description: Pillow Crimper
Machine number: 434/1SF0931
Manufacturer: Baker Perkins Ltd
Address: Manor Drive

Paston Parkway
Peterborough
PE4 7AP
ENGLAND
For EC contracts, an original certificate for this machine is retained

in the technical construction file at the above address and may be
requested by the end user.
Date: November 2009
www.bakerperkinsgroup.com EC Machinery Directive - 11

Certificates of Conformity - EC Plant Installations

The equipment detailed in this manual is designed and manufactured in accordance with the Machinery Directive
98/37/EC and will be CE marked in accordance with this directive. The supplied equipment also conforms to BS EN
ISO 12100-1:2003 Safety of Machinery Parts 1 and 2.
All Baker Perkins machinery has been designed and constructed to meet the Health & Safety requirements covered
under EEC directives. However, as not all of the equipment in a final installation of a plant may be supplied by Baker
Perkins, under the supply of machinery (Safety Regulations 1993) Baker Perkins would issue "A Declaration of
Incorporation" to cover the supply of all Baker Perkins machines (including any merchanted equipment). The same
is applicable where Baker Perkins supply a unit machine to fit into an existing plant.
You should be aware that under the above regulations, it would be your responsibility to arrange for "A Declaration
of Conformity" to be issued for the final plant installation comprising the equipment supplied by Baker Perkins plus
all equipment supplied by others.
The installed plant will not in its entirety comply with the Supply of Machinery Regulations until this declaration of
conformity has been issued.
Declarations of Incorporation
When a machine has been supplied with "A Declaration of Incorporation" it should be noted that residual hazards
in addition to those detailed in the Hazard Section of this manual may exist or be created at installation by an end
user. Please contact Baker Perkins for advise if required.
EC Machinery Directive - 12
4 Equipment Specification
4.1 Contract Reference Number

• SF0931
4.2 Machine Number

This Manual covers the following equipment :-
• 434/1SF0931 - Pillow Crimper & Control Panel
4.3 Noise Level
The noise level for this machine should be measured and recorded by the customer after final installation and
! CAUTION commissioning (this is mandatory under CE Regulations). Baker Perkins advise ear protection to be worn where
noise levels exceed 80 dB(A) to comply with EC Regulations.
4.4 Electrical Power Supply
Voltage Phase Cycles Neutral Spec.

Power 440 3 60 Yes + / - 10%
Control 24v DC
Some panel components may operate at a high voltage.

! CAUTION
www.bakerperkinsgroup.com Equipment Specification - 13

Power Consumpsion
• Crimper Rolls Main Drive - 1.5kw
• Infeed Conveyor - 0.18kw
• Outfeed Conveyor - 0.18kw
4.5 Other Utility Supply Details - e.g. Gas, Air

• Pneumatic components are fitted to the machine, a filtered air supply at 6.0 bar (87 psi) will be required.
Entrained moisture should be avoided by the use of a local water separator if found necessary.
4.6 Specification Detail

Multi-stream Pillow Crimper (Wide Unit)
The pillow crimper is designed to form the pillow shape and seal the ends. The pillows remain in ropes and are then
transferred to a dryer by the customers elevating conveyor where the product is dried. The ropes will break up into
individual pillows when cooled. The Pillow Crimper is used to crimp and seal up to 8 streams of centre filled tubes.
The unit is made from stainless steel and comprises:
• Infeed conveyor with independent variable speed AC drive.
• Adjustable infeed guides to help keep the streams separate as they leave the cooker extruder and present
them correctly for crimping.
• Hold down roll fitted above the infeed conveyor.
• Two synchronised rotating crimper rolls for pillows (pitch 24mm). The rolls will have replaceable blades (not
machined out of one piece). Each roll has an eject mechanism to prevent product streams wrapping around
them.
• The rolls are driven via an independent variable speed AC drive. Engineer adjustment is provided on one side
of the machine to allow the gap between the rolls to be adjusted while running in order to give the optimum
crimp/cut. This adjustment is fitted with a lockable cover for supervisor access. A mechanism is provided to
allow rapid roll gap adjustment between start-up (open) and operating (closed) positions.
Equipment Specification - 14
Continued......
• Two off air knives at roll discharge, complete with filter/regulator for air filtration to 0.2 microns.
• Stainless steel mesh guards ensure that the product is visible at all times. The guards are interlocked for
safety.
• Stainless steel mesh bottom covers.
• Discharge conveyor with independent variable speed AC drive, to transfer product to the next piece of
downstream equipment.
• The unit is mounted on lockable castors for mobility.
• On machine electrics IP55 or better.
• Maximum linear speed of 50m/min.
Control Panel
Controls for the infeed conveyor, crimper rolls and discharge conveyor are located in the stainless steel machine
mounted panel. Complete with a stainless steel control station isolated on rubber mountings.
The machine is sold for the processing of standard filled pillows at linear speeds of up to 50m/min.
Note
The Baker Perkins warranty does apply to "wear parts" such as anvil/crimp blades, pusher rods and bearings.
www.bakerperkinsgroup.com Equipment Specification - 15

Equipment Specification - 16
5 Safety
5.1 WARNINGS, Cautions, Notes and Hints

This manual highlights warnings, cautions, notes and tips as described below:-
THIS IDENTIFIES A HAZARD WHICH COULD LEAD TO PERSONAL INJURY. USUALLY AN INSTRUCTION WILL BE GIVEN,
! WARNING TOGETHER WITH A BRIEF EXPLANATION AND THE POSSIBLE RESULT OF IGNORING THE INSTRUCTION.
This identifies a hazard which could lead to damage to the equipment, damage to other equipment or
! CAUTION environmental pollution. Usually an instruction will be given, together with a brief explanation and the possible
result of ignoring the instruction.
Note This highlights additional information which may be helpful, but where there are no special safety implications.
www.bakerperkinsgroup.com Safety - 17
5.2 General
This manual is intended to help you use the equipment safely and effectively. Baker Perkins equipment is designed
to comply with relevant safety legislation, and includes safety features to help prevent injury or damage. However,
all machines can be dangerous if misused.
BEFORE ATTEMPTING TO USE THE EQUIPMENT DESCRIBED IN THIS MANUAL, YOU MUST READ, UNDERSTAND AND
! WARNING FOLLOW ALL THE SAFETY INFORMATION AND INSTRUCTIONS CONTAINED IN THE MANUAL.
FAILURE TO FOLLOW ALL THESE WARNINGS, CAUTIONS AND OPERATING INSTRUCTIONS COULD LEAD TO SERIOUS
INJURY TO YOURSELF OR OTHERS OR TO DAMAGE OF THE EQUIPMENT.
IF THERE ARE ANY WARNINGS, CAUTIONS OR OPERATING INSTRUCTIONS THAT YOU DO NOT UNDERSTAND, DO
NOT USE THE EQUIPMENT. CONTACT YOUR SUPERVISOR AND ARRANGE FOR PROPER TRAINING ON THE USE OF
THE EQUIPMENT.
IF IN DOUBT - ASK!!!
IT IS THE RESPONSIBILITY OF THE USER TO AUTHORISE PERSONNEL TO OPERATE OR MAINTAIN THE EQUIPMENT
! WARNING AND TO ENSURE THAT THOSE PERSONNEL HAVE RECEIVED TRAINING TO ENABLE THEM TO CARRY OUT THEIR
WORK SAFELY AND EFFECTIVELY.
Keep these instructions available for use by all concerned with the operation and maintenance of the machine.
Safety - 18
5.3 Purpose of use
THIS EQUIPMENT IS ONLY TO BE USED FOR THE PURPOSE FOR WHICH IT WAS SPECIFICALLY DESIGNED.
! WARNING ATTEMPTING TO USE THE EQUIPMENT FOR ANY OTHER PURPOSE MAY CAUSE INJURY OR DAMAGE.
This equipment has been designed for use in the food production industry and is specified to handle food
materials. In no circumstances must any hard material, foreign object or substance be allowed to enter the
processing equipment.
These instructions are written to support the equipment usage determined at the time of sale. If at any time there
is a change in use of the equipment from the original specification, appropriate safe operating procedures must be
established. It is strongly recommended that Baker Perkins is consulted both in the proposed new usage of the
equipment and in developing the new instructions.
5.4 Electrical Lock Out and Tag Out of Isolator

A "main disconnect switch" is incorporated on all Baker Perkins equipment where complete electrical controls are
provided by Baker Perkins The function of the main disconnect switch is to provide a means of disconnecting and
locking out customer supplied electrical power from the equipment when performing set up, maintenance or
cleaning services to the equipment. Electrical power is disconnected and locked out by placing the main disconnect
switch in the OFF position and securing it in that position using a padlock. Electrical power can be re-connected by
removing the padlock and placing the main disconnect switch in the ON position. A tag out procedure should be
used to record and monitor lock outs.
5.5 Emergency Shutdown

Before using the equipment, you must know how to shut it down in an emergency.
DO NOT ATTEMPT TO USE THIS EQUIPMENT UNLESS YOU KNOW HOW TO SHUT IT DOWN IN AN EMERGENCY.
! WARNING YOU MUST BE ABLE TO STOP THE EQUIPMENT QUICKLY IN AN EMERGENCY TO AVOID THE POTENTIAL DANGER OF
SERIOUS INJURY TO YOURSELF OR OTHERS IN EMERGENCY SITUATIONS.
To stop the equipment in an emergency, press one of the red Emergency Stop pushbuttons located around the
equipment. The following illustration shows an Emergency Stop pushbutton.
These are often referred to as E-Stops.
Safety - 20
These E-Stops are usually located at each main control panel and at various other positions around the equipment.
It is your responsibility to familiarise yourself with the location and operation of the E-Stops on the equipment you
are working on. When an E-Stop is pressed all movement stops as quickly as possible.
Use the Emergency Stop only in the case of an emergency to equipment or personnel. The E-stop is very hard on
! CAUTION the equipment and it must not be used for routine stops.
DO NOT RESTART THE EQUIPMENT AFTER AN EMERGENCY STOP SHUTDOWN UNTIL THE REASON FOR THE
! WARNING EMERGENCY STOP IS CLEARLY UNDERSTOOD.
NEVER RESTART THE EQUIPMENT UNTIL YOU ARE COMPLETELY SATISFIED THAT IT IS SAFE TO DO SO.
5.6 Guards and Safety Devices

Suitable guards and safety devices are incorporated in the design of all Baker Perkins equipment. The general
principles followed in the design of the guards and safety devices follow those recommended by the standards
relevant to the country of sale, for example
• the UK Health and Safety Executive and other relevant European and British Standards.
• The US Occupational Safety and Health Administration (OSHA) and other relevant United States standards.
Safety guards are provided on all Baker Perkins equipment where foreseeable potential hazards may be present to
the operator or other personnel. The purpose of safety guards is to provide a physical barrier which will prevent
the personnel from gaining access to hazardous areas on the equipment when the equipment is running. Two (2)
types of safety guards are installed by Baker Perkins.
1 Permanent Safety Guards: Permanent safety guards are installed on the equipment using fasteners which cannot
be removed without tools. Removal of these safety guards should only be required for maintenance purposes by
qualified maintenance personnel. Always disconnect, lock out and tag out electrical power to the equipment
before removing permanent safety guards. Always make sure that permanent safety guards are replaced and
secured to the equipment using the same type of fasteners.
2 Interlocked Safety Guards: Safety guards which can be removed or lifted (without tools) to gain access for set up
and/or cleaning purposes are policed by electrical interlocks. Removing or lifting a guard policed by an electrical
interlock will interrupt electrical power to the equipment control circuits, disabling or shutting down all the
equipment drives. Replacing the guard will restore electrical power to the equipment drive. For most machines it
will be necessary to restart the drive by operating the start push-button.
THE ELECTRICAL INTERLOCKS OR INTERLOCKED SAFETY GUARDS MUST NOT BE TAMPERED WITH OR BY-PASSED IN
! WARNING ORDER TO RUN THE EQUIPMENT WITH THE CORRESPONDING SAFETY GUARD REMOVED OR LIFTED.
These protective features are tested as far as possible or practical at Baker Perkins before the equipment is
dispatched. Further operational checks are carried out during commissioning.
THE COMPONENTS USED IN SAFETY SYSTEMS SHOULD NOT BE REPLACED BY ANY ALTERNATIVE, OR THE METHOD
! WARNING OF THEIR FUNCTION ALTERED IN ANY WAY. TO DO SO MAY COMPROMISE THE SAFE OPERATION OF THE
EQUIPMENT AND CAUSE A DANGER OF INJURY OR DAMAGE
THE USER IS RESPONSIBLE FOR CARRYING OUT REGULAR INSPECTIONS TO VERIFY THE CORRECT OPERATION OF ALL
! WARNING SAFETY SYSTEMS.
WHEN THE EQUIPMENT IS IN OPERATION ALL SAFETY GUARDS AND SYSTEMS MUST BE PROPERLY IN PLACE AND
! WARNING OPERATIONAL.
ALL ELECTRICAL ENCLOSURE DOORS, NOT EQUIPPED WITH AUTOMATIC INTERLOCKS, MUST BE LOCKED TO
PREVENT ACCESS BY UNAUTHORISED PERSONNEL.
Accidents can be prevented by following these safety precautions, and insisting that those working with you do the
same.
Safety - 22
5.7 Installation Safety Precautions

The engineer installing the equipment must ensure that all guards are secured in position and that the safety
devices and systems are set to operate correctly before the equipment is put into use or handed over to the
customer for production.
Customer's should not re-use the eye bolts supplied with Baker Perkins machines. The eye bolts should only be
! CAUTION used to lift the machine they are supplied with.
5.8 Commissioning Safety Precautions

1 Before starting equipment the moving parts must be checked for freedom of movement by rotating by hand where
possible or practical. Where necessary, direction of rotation of drives must be confirmed before they are connected
to ‘direction of rotation sensitive’ mechanisms.
2 Correct lubrication of the equipment must be checked before it is put into motion.
3 Before equipment is put into service its insulation resistance must be tested to detect any problems in the electrical
system which may have occurred due to dampness or damage caused by transposition or storage.
5.9 Operation Safety Precautions

1 Before starting the equipment, especially after a shutdown during which cleaning or maintenance activities have
taken place, inspect the equipment to ensure that it has been correctly assembled, all guards and safety systems are
in place and that there are no signs of work still ongoing on the equipment. In particular inspect the equipment for
any tools or other items which may have been left on or around it.
2 Prior to making the equipment operational, make sure that all maintenance or cleaning activities have been
completed and that the “TAG OUT” and “LOCK OUT” procedures are carried out correctly. All “LOCK OUT” and
“TAG OUT” tags must be removed by the person authorised to do so.
3 Always keep the area around the equipment clean and tidy. Obstructions can cause accidents. Clean up any
spillages immediately.
4 Always be alert when operating the equipment. Your own actions are your best defence against the dangers of
accidents and injury. Immediately investigate any signs of abnormal operation. If necessary, shut the equipment
down until the cause of any abnormal operation is investigated by relevant qualified personnel.
5 All personnel not authorised to be within the operating zone should be warned and moved outside the operating
zone prior to starting the equipment.
6 The equipment should always be run within the specified limits for speeds, pressures, temperatures, etc.
7 The equipment should always be attended while in operation. Keep alert and observe indicator lights and warnings
that are displayed on the machine.
8 Do not place fingers, hands or any part of your body into the equipment or near moving parts when the equipment
is not isolated from all power sources.
9 Stopping the equipment.
WHEN STOPPING THE EQUIPMENT, KEEP CLEAR OF ANY MOVING PART. REMEMBER THAT ROTATING EQUIPMENT
! WARNING WILL CONTINUE MOVING FOR SOME PERIOD AFTER POWER HAS BEEN SHUT OFF.
SERIOUS INJURY COULD RESULT IF A LIMB IS CAUGHT BY A MOVING PART.
DO NOT STOP THE EQUIPMENT BY OPENING AN INTERLOCKED GUARD. THIS MAY EXPOSE YOU TO DANGEROUS
! WARNING MOVING PARTS.
STOP THE EQUIPMENT FIRST, WAIT FOR IT TO COME TO REST, AND THEN OPEN THE GUARD.
10 Permanent Guards
DO NOT ATTEMPT TO GAIN ACCESS TO THE MACHINE UNDER ANY CIRCUMSTANCES BY REMOVING A PERMANENT
! WARNING GUARD. THIS MAY EXPOSE YOU TO THE DANGER OR SERIOUS INJURY.
Permanent guards are often secured by fasteners or bolts which require the use of hand tools in order to remove
them.
Safety - 24
This means that only a “responsible” person may remove them, and this person must take responsibility for safety in
this situation.
In the majority of cases this will mean that the machine must be isolated and the “LOCK OUT” and “TAG OUT”
procedures are followed. When this is not the case refer to the section “Running the equipment without safety
systems”.
11 All air, hydraulic and electrical power must be disconnected and when the machine is not in use.
12 This equipment requires proper periodic preventive maintenance to keep it working at peak performance. You
must be satisfied that periodic preventive maintenance has been carried out before you operate the equipment.
IF YOU ARE NOT SATISFIED THAT PREVENTIVE MAINTENANCE HAS BEEN CARRIED OUT AND THAT THE EQUIPMENT
! WARNING IS IN A SAFE CONDITION, DO NOT USE IT.
CONTACT YOUR SUPERVISOR.
OPERATING EQUIPMENT WHICH HAS NOT BEEN MAINTAINED PROPERLY COULD LEAD TO SERIOUS PERSONAL
INJURY.
13 Faulty equipment.
IF YOU HAVE ANY REASON TO THINK THAT THE EQUIPMENT IS OPERATING DANGEROUSLY, STOP IT (USING THE E-
! WARNING STOP IF NECESSARY).
INFORM YOUR SUPERVISOR.
CONTINUING TO OPERATE EQUIPMENT WHICH YOU BELIEVE MIGHT BE DANGEROUS COULD LEAD TO SERIOUS
PERSONAL INJURY.
If you have any reason to think that the equipment is operating below its usual standard or abnormally in any way,
! CAUTION you must report this to your Supervisor as soon as possible.
Continuing to use equipment which you believe is operating below standard could lead to damage to the
equipment or other equipment and adversely affect the products.
Be especially aware of unusual noises or vibrations.
14 For equipment with programmable logic controls, do not attempt to re-program or alter the programming
established by Baker Perkins unless approved and supervised by qualified Baker Perkins personnel. Any attempt to
do this could result in damage to the equipment and may create unsafe operating conditions on the equipment.
5.10 Cleaning and Maintenance Safety Precautions

Lock Out/Tag Out Procedures
The user is responsible for ensuring that safe procedures are in place for isolation of the equipment, and that these
procedures are used before any cleaning or maintenance tasks are commenced. All power sources should be locked
out and tagged indicating by who, for what and why the power has been removed.
BEFORE ATTEMPTING CLEANING OR MAINTENANCE OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT IT IS
! WARNING ISOLATED FROM ALL POWER SOURCES:-
- ELECTRICAL SUPPLY.
- PNEUMATIC SUPPLY.
- HYDRAULIC SUPPLY.
ENSURE THAT THE LOCK OUT PROCEDURES HAVE BEEN APPLIED.
ENSURE THAT ANY EQUIPMENT WHICH OPERATES AT ELEVATED TEMPERATURES HAS COOLED TO A SAFE WORKING
TEMPERATURE BEFORE STARTING WORK.
FAILURE TO CARRY OUT THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY.
UPON COMPLETION OF ANY CLEANING OR MAINTENANCE ACTIVITIES ENSURE THAT ALL PERSONNEL ARE CLEAR
! WARNING OF THE MACHINE, COMPONENTS ARE CORRECTLY ASSEMBLED AND THE EQUIPMENT IS SAFE TO OPERATE. DO NOT
RUN THE EQUIPMENT UNLESS ALL GUARDS ARE SECURELY FITTED IN THEIR CORRECT POSITION. IF PARTS ARE NOT
CORRECTLY INSTALLED, OR GUARDS ARE NOT FITTED PROPERLY, SERIOUS INJURY CAN RESULT.
TEST ANY SAFETY SYSTEMS BEFORE PUTTING THE EQUIPMENT BACK INTO PRODUCTION.
LOCK ALL ELECTRICAL ENCLOSURES THAT DO NOT HAVE SAFETY INTERLOCKS SUCH THAT ACCESS TO THEM IS BY
! WARNING AUTHORISED PERSONNEL ONLY.
Carefully check that all screws, bolts, nuts and other fixings are securely replaced.
Safety - 26
After any parts have been reset or replaced, the equipment should be turned over by hand, if possible or
! CAUTION practical, before applying power. This prevents serious damage occurring to the equipment if parts have
been incorrectly fitted or set.
BEFORE TURNING OVER EQUIPMENT BY HAND, CAREFULLY ANALYSE THE HAZARDS WHICH MAY BE CREATED BY
! WARNING THIS ACTIVITY AND TAKE ALL NECESSARY PRECAUTIONS TO MINIMISE THE RISK OF INJURY TO YOURSELF OR TO
OTHERS.
Compressed Air
Some cleaning and maintenance operations involve the use of compressed air. Treat compressed air with respect, it
can be dangerous if misused. The user is responsible for issuing guidelines for the safe use of compressed air.
COMPRESSED AIR MOVES PARTICLES THAT CAN CAUSE SERIOUS EYE INJURIES. ALWAYS WEAR PROPER EYE
! WARNING PROTECTION AND DO NOT USE MORE THAN 15 PSI (103 KPA) OF PRESSURE.
Regulations
be aware of any local regulatory requirements for safety. For example, OSHA states that “All safety devices on
ovens shall be inspected at intervals of not less than twice a month by an especially appointed, properly instructed
bakery employee, and not less than once a year by representatives of the oven manufacturer”.
Make contractual arrangements with Baker Perkins for inspections of all Baker Perkins equipment as appropriate.
Tools
Always use the proper tool for the job.
Work Practices
When servicing or maintaining equipment it is strongly recommended that personnel never work alone. A “safety
buddy” should always be standing by in case there is an accident.
There should be an adequate number of people present at all times work is taking place who are medically
qualified. This includes normal operation as well as maintenance or cleaning activities.
5.11 Running the Equipment Without Safety Systems

In normal circumstances the equipment should not be operated unless all safety systems are fully
operational. However, on very rare occasions and for very specific tasks, it may be necessary to run the equipment
with some guards or safety devices removed.
Some electrical maintenance activities may require that the power is turned on.
THESE SITUATIONS ARE POTENTIALLY VERY DANGEROUS AND GREAT CARE MUST BE TAKEN TO EXECUTE THIS
! WARNING WORK AS SAFELY AS POSSIBLE.
Most accidents involving machinery are avoidable and happen due to lack of thought and by not taking suitable
safety precautions for the task being undertaken.
Note The user is responsible for implementing safe working practice and procedures for this type of situation and the following
notes are given for guidance only.
1 Is it absolutely necessary to have the power on or to operate the equipment without safety devices to carry out this
particular task?
Have all possible methods of safely carrying out this work been thoroughly evaluated?
2 The person who is to do the work must be an employee that the user has authorised and who has received training
to be able to carry out the task safely and effectively.
3 The person who is to do the work must carefully assess the risks and take all possible or practical precautions
against injury or damage.
This person is responsible not only for his own safety but also for the safety of others.
Safety - 28
4 Your own skill, care and self discipline are your best protection. Use safe working practice at all times. Examples of
safe working practice would be:
• Use suitable protective equipment.
For example when working close to moving parts a close fitting single piece overall suit in good repair should
be worn. This should have no loose ends and no external pockets except a hip pocket. It should be worn in
such a way that it covers all loose ends of clothing.
Goggles, gloves and ear defenders are other examples of protective equipment which may be required.
• Only remove those guards that are absolutely necessary for carrying out the task.
• Another person who has been instructed in emergency procedures should be immediately available within
sight or sound.
• Take steps to prevent anyone else being endangered.
Use safety barriers or temporary guarding to ensure the safety of others.
5.12 Health and Safety

The user should carry out an assessment of the risks to health and safety from the use of this equipment, including
the precautions to be taken to minimise any risks identified.
MAKE SURE THAT YOU UNDERSTAND THE RISKS AND WHAT PRECAUTIONS YOU SHOULD TAKE TO MINIMISE THEM
! WARNING BEFORE WORKING ON THE EQUIPMENT.
Issues to be considered include:-

1 Compliance with any relevant local safety regulations and codes.
2 Protection of employees against any bodily injury. Examples include:
• Hardhats
• Safety Glasses
• Ear Protection
• Gloves
• Overalls
• Dust masks
• Fume and Dust Extraction
3 Protection of employees against exposure to various hazards. For example hot surfaces are a particular hazard with
ovens.
4 Maintaining clear visibility of DANGER, WARNING & CAUTION labels on the equipment.
Safety - 30
5.13 Personal & Food Hygiene

You are working with food which is usually for human consumption. Therefore, it is essential that you maintain the
highest standards of hygiene within the process area.
YOU SHOULD HAVE RECEIVED TRAINING IN PERSONAL AND FOOD HYGIENE FROM YOUR EMPLOYER. IF YOU HAVE
! WARNING NOT, DO NOT USE THE EQUIPMENT OR ENTER THE PROCESS AREA.
ARRANGE TRAINING WITH YOUR SUPERVISOR OR TRAINING MANAGER.
WORKING IN THE PROCESS AREA WITHOUT AN ADEQUATE UNDERSTANDING OF HYGIENE CAN LEAD TO
CONTAMINATION OF FOOD.
Below is a list of basic hygiene rules. This list is not a substitute for proper training by the user, and is issued here for
guidance only.
• Wash your hands thoroughly before entering the process area.
• Remove your watch and any loose jewellery before entering the process area.
• If suffering from an illness or infection, obtain a Doctor’s approval before working.
• Leave all medicines, pills and tablets which you need during the day in the First Aid station, securely locked away if
necessary.
• Wear all provided protective clothing and headgear in the way instructed or recommended by your employer.
• Avoid touching your nose, ears and mouth when you are in the process area.
• Don’t carry small loose items in your overall pockets.
• Never take food or drinks into the process area.
• Keep all tools in a box or bag.
5.14 De-Commissioning
The equipment should be decommissioned by skilled personnel trained in safe working practices for the installation
and decommissioning of large industrial process equipment. The aim is to decommission the equipment such that it
does not present any danger to personnel or the environment.
The following points should be noted.
1 Blunt all sharp objects.
2 Remove all doors and hatches.
3 Secure or release hinged lids.
4 Do not torch or burn PTFE coatings.
5 Disassemble all gear trains.
6 Release pre-tensioned springs.
7 Disconnect all electrics.
8 Remove the drive motors.
9 Slacken all drive belts
10 Disconnect any cooling water hoses
11 Disconnect all air supplies
12 Drain any water jackets.
13 Drain lubricants from all gear boxes, hydraulic systems, oil baths etc. and dispose of correctly.
14 Handle any batteries with great care due to the acid contained within them.
Dispose of correctly.
15 Clearly and indelibly mark the equipment to show that it has been decommissioned and must not be put back into service.
Safety - 32
6 Hazards
6.1 Equipment Hazards

The following information has been provided to highlight the potential hazards of the Cream Feed System & Pillow
Crimper. All personnel must become familiar with these points before operating, cleaning or maintaining the
equipment.
! WARNING
Generic Hazards for ALL machine types -

1 Do not run the equipment without safety guards and covers. This may allow access to moving or dangerous parts
which could cause injury.
2 Do not run the equipment without fully operational safety and E-stop systems. Without these protective systems
there is a danger of injury and / or damage to the equipment.
3 Beware faulty or bypassed interlocks. These may allow access to moving or dangerous parts which could cause
injury
4 Keep your hands clean and grease free to prevent the danger of them slipping whist operating the machine
controls and causing injury.
www.bakerperkinsgroup.com Hazards - 33
5 Beware of nip and abrasion points on the machine which present the danger of injury. Although Baker Perkins
provides safety guards so far as reasonable and practical there may be areas of the equipment which present a
danger of entrapment or abrasion injuries, such as:
• Where rolls come together
• Conveyors and belts as they pass over or round rollers
• Scrapers, knives etc. pressing against conveyors and rolls
• Equipment which moves during normal operation
Reciprocating actions on conveyors etc.
Pneumatic cylinders and associated mechanisms
Conveyor tracking and tensioning mechanisms
• Parts of the equipment which are moved by the operator
• Moving parts such as conveyors, (in particular the edges), and rolls.
6 Do not reach into parts of the equipment not normally accessible to an operator. The access to moving parts
through the open areas of the equipment could cause severed/broken appendages.
7 Stored (or Potential) energy:
Energy may be stored in various systems such as Mechanical, Pneumatic, Hydraulic or Electrical. This can be
hazardous if released in an uncontrolled manner.
Hazards - 34
6.2 Machine Specific Hazards

Pillow Crimper
1 Operator and maintenance personnel should be aware that live electrical connections are present in the control
panel, terminal boxes, junction boxes and other electrical devices and connections. The connections and boxes
comply to a minimum standard of IP54 and EMC. The main control panel is fitted with a lockable isolator so that all
electrical devices can be safely serviced. Appropriate hazard warning symbols are fitted to the equipment where
applicable and extreme care must be taken when approaching these areas.
2 Operators and maintenance personnel should be aware that a nip point exists between the crimp rolls. To avoid the
risk of injury, hinged mesh guards are fitted above the infeed and discharge sides of the crimp rolls. The guards are
interlocked to stop the machine when they are raised. Also, guards are fitted under the infeed and discharge sides
of the crimp rolls. These are also interlocked to stop the machine when they are removed.
3 Personnel should note that the crimper is very heavy. Take care when manoeuvring, two people may be needed.
4 When turning the crimper rolls by hand:
• To avoid injury, care must be taken during hand rotation as the blades are sharp and brittle.
• Wear stout leather gloves, place palms onto the top of the upper roll and rotate slowly in the direction of
running. Take care not to get anywhere near the roll nip point with fingers.
5 Ensure the castors are in the locked position before operating the machine.
ATEX Directive
It is the customer's responsibility to define the probability of the existence of an explosive dust atmosphere in each
area of the plant where unit machines are to be sited - zone 20, 21, 22, or unclassified.
The equipment in this manual is specified on the basis of it being sited in an unclassified area. Should the zone
identification change, modifications to the equipment specification may be required - contact Baker Perkins.
www.bakerperkinsgroup.com Hazards - 35
Hazards - 36
7 Baker Perkins Customer Support
7.1 Customer Training

Baker Perkins can supply training programmes in support of this equipment. The objectives of the training can be:
• Improved Operational Performance, and Efficiency
• Rapid Equipment Optimization
• Reduced Start-up Costs
• Improved Maintenance Performance
• Safety Awareness
• Hygiene Awareness
• Assists In Meeting Employer's Legal Obligations For Training.
For further information on this service, please contact Baker Perkins at the address given at the front of this
manual.
7.2 Plant Automation Systems

Plant automation systems from Baker Perkins can be retro fitted to provide benefits in overall process and business
efficiency. The systems deliver these benefits by giving operators, engineers and supervisors accurate and relevant
information from anywhere in the plant. The information is presented using the most understandable text or
graphical method e.g. real time trend, summary sheet etc. This enables decisions to be made based on a complete
picture of the process rather than only the parts that can be seen.
www.bakerperkinsgroup.com Baker Perkins Customer Support - 37

Not only do "InTouch" systems provide a much greater range of information they also have a number of features
that can help operators, supervisors and engineers interpret it quickly and correctly to reduce costs, improve
quality and increase business efficiency. These include:
• Touch screen interfaces with clear graphics and intuitive operation.
• Recipe management for controlled access to process and machine setting information
• Alarm information that reduces the time taken to trouble shoot problems
• Trend graphs that help operators identify and respond quickly to process variations
• Baker Perkins automation systems are customized to suit individual applications using industry standard
"Wonderware" software.
7.3 Customer Support

Baker Perkins is committed to delivering the highest standard of service to its customers and is continually striving
to improve the quality and range of services it provides.
Baker Perkins and its customers have the benefit of an international network of wholly owned subsidiaries and
agents located in all of the major markets of the world. Customer Service is co-ordinated from the Baker Perkins
headquarters in Peterborough, England. These facilities feature a 'state of the art' parts warehouse providing over
2000 cubic metres of shelf space.
Baker Perkins maintains a comprehensive stock of replacement parts available for immediate delivery. This stock is
complemented by a fast track manufacturing ability and supported by an engineering archive containing records
from the turn of the previous century!
A 24 hour breakdown service ensures that urgent customer requirements are satisfied at any time of the day or
night. Baker Perkins' extensive range of technical services includes:
• Plant audits - Product and process support - Refurbished machinery - Equipment upgrade packages -
Preventive and predictive maintenance planning - Machine inspections and repairs - Service contracts - Plant
relocation - Product design services.
Baker Perkins Customer Support - 38

Baker Perkins' service team is dedicated to supporting its customers to ensure that Baker Perkins' products give
superior performance at a low cost of ownership.
Baker Perkins Customer Support would be delighted to hear from you and to give you whatever assistance you
require - please contact us.
Contact Details
Non USA USA

PE4 7AP - UK USA
Phone: +44 (0)1733 283222 Phone: +1 616 784 3111
Fax: +44 (0)1733 283010 Fax: +1 616 784 0973
www.bakerperkinsgroup.com Baker Perkins Customer Support - 39

Baker Perkins Customer Support - 40

8 Glossary of Terms
In this operation manual, certain terms, phrases and abbreviations are used which may be unfamiliar. The following
list of terms and their definitions is therefore offered to assist the reader.
Term Definition
CIP Clean In Place. A device, system or method used to clean or washout the
equipment without disconnecting it. Sometimes known as Wash In Place.
Drg No. Drawing Number. The number assigned to a particular picture associated
with a Parts List.
HMI Human Machine Interface. Many machines are fitted and controlled from
electronic operator control facias. The unit is then connected to the PLC (see
below) in the control panel. It is sometimes referred to as an "OIT" - operator
interface terminal.
KA Key Assembly. The top level parts list of a plant which includes a number of
individual unit machines.
KP Key Plan. The top level parts list of a individual unit machine (as picked up on
a plant parts list.)
SA Sub Assembly. An assembly of components, usually picked up by another

assembly.
Megger An electrical device used to generate high voltages for testing the insulation
resistance of electrical circuits.
OML Other Manufacturers Leaflet. A leaflet or instruction manual for an item of

equipment not manufactured by Baker Perkins, but fitted wholly or in part to
the equipment supplied by Baker Perkins; e.g. A Drive Motor.
www.bakerperkinsgroup.com Glossary of Terms - 41

Term Definition
PL Parts List. A list of all the components supplied on a particular machine. A

Parts List is commonly used for cross referencing with drawings to identify a
component; e.g. when ordering spares.
Pic. Picture. This is an abbreviation of the word ‘picture’ and is likely to appear
after a number or title in the parts list index. It is used to indicate that the
particular number or title referred to, is a drawing, rather than a parts list.
PLC Programmable Logic Controller. A microprocessor (computer) based

electronic device, used to control a system or process.
SRL Standard Recommended Lubricant. One of the lubricants preferred by

either Baker Perkins or a supplier for use in the equipment.
Glossary of Terms - 42
9 General Information - Baker Perkins Equipment
9.1 General
The Baker Perkins warranty applies in so far as the equipment is operated within the rating and service conditions
for which it was specifically provided. The equipment must be installed, operated and maintained in accordance
with good practice and the instructions contained in this Manual.
Unauthorised modification of machinery supplied by Baker Perkins will invalidate the warranty. We will not be held
liable for any personal injury, problems or damages arising from modifications that have not been approved by us.
The client must prevent the existence of any destructive external conditions, such as:
• Loads due to excessive speeds or throughputs
• Severe shock loading
• Mechanical or thermal overloads
• Environment - temperature and humidity outside design specifications
• Power and fuel supplies outside design specification
• Other conditions of which Baker Perkins has not been fully advised.
Adequate installation, operation, maintenance, and safety instructions must be given by the user to all personnel
responsible for the operation and / or maintenance of the equipment as appropriate to support safe and effective
working.
www.bakerperkinsgroup.com General Information - Baker Perkins Equipment - 43

9.2 Machine Markings

A metal number plate that displays the CE logo (if applicable), Baker Perkins logo and address, machine name,
machine number, year/contract number, power consumption in kW, and any patent details, is secured on each
machine. The location of this number plate varies with each machine and it is usually indicated on the Key Plan
drawing in the Parts Lists section of this manual. The machine name, machine number and year/contract number
should be quoted when ordering spare parts.
9.3 Prolonged Storage

If installation and / or operation of the equipment is to be delayed for more than one month after factory
shipment, special rust preventative precautions should be taken. The precautions can be taken by Baker Perkins if
full information concerning storage conditions is provided at the time of ordering or alternatively by the user in the
field. Baker Perkins’ warranty on the equipment can be modified by agreement to accommodate the storage
period.
If prolonged storage is necessary, it should be indoors and preferably in a dry area having a relatively constant
temperature. When outdoor storage is unavoidable units should be raised off the ground on skids and should be
covered by a tarpaulin or an equivalent protective covering.
Protection for Storage
1 Coat all non-painted surfaces with an anti-corrosion compound. Stainless steel and nickel plated components do
not require any additional protection.
2 Attach bags of desiccant inside all the electrical enclosures, to prevent any deterioration of the electrical
components.
3 Ensure that the gearboxes are filled with the correct oil.
General Information - Baker Perkins Equipment - 44

Attention During Storage

Turn over all rotating equipment at least two complete turns of the output shaft at regular intervals, (every two
weeks), to prevent damage being caused to bearings, bushes etc. caused by parts remaining stationary for extended
periods.
9.4 Installation
Rotation Of Machines
Some equipment is designed to operate in one direction only, especially that having cam operated movements and
tensioned chain drives, and may suffer serious damage if the drive motors are run with incorrect direction of
rotation. Before operating the equipment check for correct direction of motor rotation. Disconnect the belt, chain
or coupling where possible.
When using a portable machine in an area with several power sockets, ensure that each socket is similarly
connected to the mains supply thus producing the same rotation at each point.
Before starting any new equipment, the moving parts must be checked for freedom of movement by rotating by
hand where possible or practical.
Insulation Test
Transportation or storage may result in dampness or damage to the electrical system. Insulation tests should be
carried out using a suitable instrument to determine that the electrical system insulation is acceptable.
Do not connect the test instrument to any parts of the electrical system which may be damaged by the high
! CAUTION voltages involved in the test. For example:
Low voltage systems
Electronic equipment
Thermistors
www.bakerperkinsgroup.com General Information - Baker Perkins Equipment - 45

Before Initial Start Up

Do not run the equipment until all lubrication requirements have been carried out.
! CAUTION
Note Before despatch all exposed polished parts and machined faces are coated with a rust preventative compound. This may be
removed by rubbing with an edible oil followed by washing with a detergent solution.
Carefully check all areas of the equipment to ensure that all debris, swarf etc. that may have been left over from the
installation period is removed and that the equipment is in a clean and tidy condition and is safe to start. In
particular check the condition of the electrical control enclosures to ensure that there is no debris which may cause
short circuits or other problems.
Check that the wiring is in a safe and tidy condition and that any modifications that may have been made during the
commissioning period are installed to the correct standards and that they are documented.
General Information - Baker Perkins Equipment - 46

10 Installation
BEFORE INSTALLING THE EQUIPMENT, ENSURE THAT YOU HAVE READ AND UNDERSTOOD THE SAFETY SECTION OF
! WARNING THIS MANUAL.
10.1 General
The Baker Perkins warranty applies in so far as the unit(s) is/are operated within the rating and service condition for
which it was/they were specifically sold. The client must prevent the existence of any destructive external condition,
which might typically include loads due to critical speed, severe shock loading, mechanical or thermal overloads or
other conditions of which Baker Perkins was not fully advised. Also, the unit(s) must be installed and maintained in
accordance with instructions contained in this service handbook.
Adequate installation, maintenance, and safety instructions must be given by the user to personnel directly
responsible for the operation of the equipment.
Rotation of Machines
Most machines are designed to operate in one direction only, especially those having cam operated movements
and tensioned chain drives and may suffer serious damage if the motor is run in the wrong direction.
When using a portable machine in an area with several power sockets, ensure that each socket is similarly
connected to the main supply thus producing the same rotation at each point.
Before starting any new equipment, the moving parts must be checked for freedom of movement by rotating by
hand where possible.
Before Initial Start-Up
Do not run the machine until all the lubrication instructions have been carried out (refer to the Maintenance and
! CAUTION Lubrication sections of this manual).
www.bakerperkinsgroup.com Installation - 47
Before despatch all exposed polished parts and machined faces are coated with a rust preventative compound. This
may be removed by rubbing with an edible oil followed by washing with a detergent solution.
10.2 Pillow Crimper

• See the Wiring Diagram on page 112 for connection details
The Pillow Crimper is supported on a set of four swivel castors and can be wheeled into position. The castors should
be locked to prevent movement of the machine during production.
The following services are also required:
• A filtered air supply at 6.0 bar (87 psi).
Lubricant
• See “Pillow Crimper Drives” on page 108 for details
Conveyor Belts
Check the belts have sufficient tension, use the adjusting screws each if required, see “Pillow Crimper Conveyor Belt
Tensioning and Tracking” on page 71.
The infeed roll height should be adjusted to suit the product:
height adjusters
Installation - 48
11 Pillow Crimper
11.1 General Description

The Pillow Crimper is a mobile unit used to crimp
and seal up to eight streams of centre-filled
tubes. It is controlled from a machine-mounted
control panel.
The photographs and images shown in the
following text may differ from the specific machine
on this contract, but the information is valid.
See drawing no. SA10950 for more detail on
components.
11.2 Detailed Description

The Pillow Crimper unit comprises four sub-
assemblies:
• The Infeed Conveyor
• Upper Crimping Roll
• Lower Crimping Roll
• Discharge Conveyor.
The crimping rolls are mounted in removable
bearing housings that allow the rolls to be removed view with side guard removed
from the machine. The conveyors consist of
removable stainless steel decking and plug-in drive
drums.

The streams of product from the extruding machine are fed to the Crimper by the horizontal Infeed Conveyor. They
then pass between blades mounted on a pair of rolls that crimp and form the pillows.
The Crimping Rolls
optional Phasing Discs

DETAILS HERE
Each roll incorporates either a set of straight or trapezoidal blades. The lower roll is fitted with anvil blades, against
which the blades of the upper roll act to crimp, seal and cut the product, thus producing individual "pillows". The
machine can also be set to only crimp and seal which will produce long "ribbons" of pillow shaped product.
Stripper rods are mounted on an eccentric ring to move in and out relative to the blades, effectively removing the
product from the blades.
Once the streams have been crimped they are fed from the unit onto the Discharge Conveyor and ultimately onto
the next part of the process.
An air knife is fitted above the ingoing product stream to "skin" the surface and minimise picking up on the cutting
rolls. A second knife is located below the roll/discharge conveyor transfer to discourage pillows from passing
through the gap. Both air supplies are individually controlled to optimise performance. The circulating air also helps
to disperse steam released from the product and thus reduce condensation build-up.
Pillow Crimper - 50
Upper and Lower Air Knives
UPPER AIR KNIFE LOWER AIR KNIFE
The infeed conveyor, crimping rolls, and discharge conveyor are driven by separate motors; Stop/Start buttons are
housed on the control panel. A master variable speed dial controls the speed of the crimping rolls. The speed of
either conveyor can be trimmed above or below the master speed by separate speed dial controls. Further
adjustment of the master speed maintains any speed differential with the conveyors.
Safeties
Safety switches are fitted to both mesh hinged upper covers and also the mesh cross covers below the conveyors.
Whenever one of these guards is open, provided the electrical supply is connected, the PANEL LIVE lamp will
continue to be lit but all drives will be inoperative. In addition, three bolt-operated safety switches are fitted to the
machine as shown in the following illustration. In order for the covers to be opened, the bolt must be unscrewed.
This action inhibits the drive and provides a delay before the operator can open any of the guards therefore giving
time for the machine to come to a halt.

Control Facia
master speed
trim
start
stop
conveyor speed
trim conveyor speed
trim
E-Stop
Overload Trips
In the event of any of the drive motors being "overloaded", the electrical supply to that motor will be disconnected
and the warning lamp will be lit on the control panel.
Rotating the Crimping Rolls By Hand
ENSURE THAT THE PILLOW CRIMPER IS DISCONNECTED FROM THE ELECTRICAL SUPPLY - SEE PAGE 20.
! WARNING
To rotate the rolls by hand, first lower the bottom roll with the hand lever (shown on page 55). Wearing stout
leather gloves, place palms onto the top of the upper roll and rotate slowly in the direction of running. Take care
not to get anywhere near the roll nip point with fingers. Care must be observed during hand rotation as the blades
are not only sharp but also brittle and could break with rough handling.
Pillow Crimper - 52
11.3 General Operating Procedures

Refer to the Control Panel drawings in the Parts Lists and section of the manual for push button, speed control and
temperature control details.
Before commencing production, the following procedures should be undertaken.
1 Ensure that all equipment incorporating its own power supply (i.e. not powered by the Extruder etc.) is plugged in
and the direction of rotation (where applicable) is correct.
2 Slide the Pillow Crimper into position and secure it in place by locking the wheels. Only use the hand rails provided
to move the Pillow Crimper. The Pillow Crimper operating procedures are provided at the end of this section.
3 Switch on all the control panels, using the isolator switches, and ensure that the "Panel Live" Lamps are lit.
4 Ensure that the correct die inserts are fitted to the Extruder die assembly for the required product.
5 Wheel the Creamer Feed system into position and connect the feed pipes to the die assembly. Fill the cream
hopper with the required amount of cream. From the Cream Feed Control Panel, start the cream stirrer.
Start-up Plant
1 As soon as the Extruder has stabilised, and the product is emerging at the desired rate and consistency -
2 Start the Pillow Crimper infeed conveyor, rolls and discharge conveyor.
3 From the Cream Feed Control Panel, start the cream auger drive and cream pumps. Adjust the speeds as necessary.
4 Ensure that the machinery in the next process is ready to receive the product.
• Adjust the conveyor speeds to match the speed of the "ribbons" being extruded.
Shut Down
1 Stop the feed to the Extruder and the Extruder itself.
2 From their respective control panels, stop the Cream Feed system, Pillow Crimper, and any other equipment in the
process.

3 Carry out any appropriate Washout procedures as detailed in the Cleaning section.
11.4 Pillow Crimper Operating Instructions

Start-up
1 Wheel the Pillow Crimper into place in the line and lock the four castors.
2 Connect the air and electrical supplies.
3 At the control panel, switch the main Power Isolator to ‘On’.
4 Check that all guards are fully closed.
Note The machine will not start with one or both guards partially or fully open.
5 At the pneumatic regulators, open the shut-off valves to operate air knives.
6 At the control panel, set the master speed control to 70% and the conveyor trim controls to 50%.
7 Lower the hand lever to open up the Crimper cutter roll gap. Check the hand wheel reading to ensure that
excessive crimp/cut pressure is not subsequently applied.
Pillow Crimper - 54
Control Side - Cover Removed
LOCK CATCH
ROLL GAP HAND LEVER

HAND WHEEL
8 For multiple streams, angle the guide fingers towards but not touching the conveyor.
9 Lift the roller to the upper position.
CAUTION 10 Wearing heat and steam resistant gloves grab all product streams and thread them over the guide fingers, under the
roller and onto the conveyor.
11 Lower the roller onto the product so that the product streams are pulled into the machine. You can adjust the
height of the roller using the screws provided.
12 Divide the streams of product into their lanes through the guide fingers adjusting the fingers into a more vertical
position if necessary.

13 Once the ribbons are through the rolls and onto the discharge conveyor, raise the hand lever to apply the crimp/
cut pressure.
14 Adjust the crimper roll speed until the ribbon tension from the extruder is correct.
15 Trim the infeed and discharge conveyor speeds to handle product correctly. Generally the discharge conveyor will
be set to run slightly faster to take product away from the rolls.
16 Adjust cut/crimp pressure if necessary to achieve separate pillow forms. To achieve the maximum life of the blades,
the pressure should be the minimum required to achieve the desired results.
Shut-down
1 Manually break the ribbons of extruded product as it enters the Infeed Conveyor.
2 At the crimper control panel facia, press the Stop button.
3 At the pressure regulators, close the shut-off valves to the air knives.
4 Switch off the main Power Isolator.
Pillow Crimper - 56
Setting the Crimping Roll Gap

By adjusting the roll gap it is possible for the machine to produce either individual cut pillows or ribbons of crimped
pillows.
Different product recipes may also require adjustment to the gap/cut pressure setting.
Setting can be done 'on the run' and is achieved by turning the hand wheel on either side of the machine. Both
hand wheels are connected together so adjustment of either has the same effect.
Crimping Roll Gap Stops
It should be noted that roll stops are provided, positioned on both lower bearing blocks; they consist of a bolt and
lock-nut. The purpose of the stop is to both prevent excessive cut pressure being applied by the hand wheel and
also to maintain a residual pressure within the mechanism to reduce the loading/unloading vibration cycle as the
blades come into and out of contact. These stops must be adjusted to enable the machine to 'just' cut through the
product and are an engineer setting. If it is found that it is not possible to cut through the product by increasing the
hand wheel pressure, it is likely that the stops are set too 'high', thus preventing the rolls from coming together.
Conversely, excessive vibration may be caused by the stops not touching the upper bearing housing allowing over
pressure on the blades i.e. set too 'low'.

Pillow Crimper - 58
12 General Maintenance
BEFORE ATTEMPTING MAINTENANCE OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT YOU HAVE READ
! WARNING AND UNDERSTOOD THE SAFETY SECTION OF THIS MANUAL.
BEFORE ATTEMPTING MAINTENANCE OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT IT IS ISOLATED
! WARNING FROM ALL POWER SOURCES:-
- PNEUMATIC SUPPLY.
- HYDRAULIC SUPPLY.
ENSURE THAT THE LOCK OFF PROCEDURES HAVE BEEN APPLIED.
IT MAY BE POSSIBLE FOR THE EQUIPMENT TO APPEAR “SWITCHED OFF” BECAUSE IT IS NOT MOVING.
! WARNING TURNING THE SPEED CONTROL TO ZERO CAN CREATE THIS EFFECT ON EQUIPMENT THAT IS ACTUALLY STARTED.
ALWAYS FOLLOW THE LOCK OFF PROCEDURES.
12.1 General
After the machinery has been running for one month, check that all the nuts, screws, setscrews, taper pins etc are
tight. These should then be checked over periodically. Include all electrical terminals in these checks.
Refer to the Other Manufacturers Leaflet (OMLs) section of the manual for information on equipment not
manufactured by Baker Perkins.
www.bakerperkinsgroup.com General Maintenance - 59

12.2 Safety Devices

All safety devices must be checked for correct operation at weekly intervals.
DO NOT RESTART THE MACHINE UNTIL ALL GUARDS HAVE BEEN SECURELY REFITTED AND SAFETY SYSTEMS
! WARNING CHECKED FOR CORRECT OPERATION.
12.3 Running After Adjustment or Repair

Before attempting to run the machine under power, make certain that any components which have been the
subject of adjustment or replacement have been correctly fitted. Check closely to see that all screws, nuts, pins,
bolts etc. have been replaced and that they are all secure.
After any parts have been reset or replaced, the machine should be turned over by hand, if possible, before
supplying power. This precaution will prevent the possibility of damage being caused by the incorrect fitting or
setting of parts.
If after maintenance it is necessary to run any part of the equipment under power with any guard removed or safety
device by-passed for access for tuning, then every precaution must be taken by the engineer to ensure that safe
working practice is employed. In particular it is essential that any unauthorised personnel cannot approach the area
exposed. If necessary, temporary guarding or safety barriers must be erected.
12.4 Routine Maintenance

Regular maintenance is essential to prevent expensive stoppages of production. It is impractical to give a definitive
time schedule between maintenance inspections as local conditions will vary. However, Baker Perkins recommend
that regular preventative maintenance be carried out and any items requiring attention dealt with as soon as
possible to prevent any further damage.
Not carrying out preventative maintenance increases the possibility that the equipment will fail during production
causing expensive downtimes.
This section lists items that should be included in the users’ preventative maintenance schedule.
General Maintenance - 60
For more information on operation and maintenance of equipment not manufactured by Baker Perkins, refer to the
relevant manufacturers leaflet in the Other Makers Leaflets section.
Mechanical Components
Welded Components
Where components are subject to stress and load, it is important that they are checked regularly (weekly) for
integrity and general condition of the welds. Failure to carry out these inspections could result in serious damage to
the machine if a weld fails.
Driving Chains and Belts
Should be checked regularly (weekly) for general condition and tension, adjustment being made if necessary.
Motors and Drives
Regular attention (monthly) should be paid to the mountings to ensure they have not worked loose, and that the
drive alignment is correct. Adjust and tighten if necessary.
Steam Lines and Fittings
Particular care must be taken to ensure any steam leaks are located and repaired as soon as possible.
Steam is dangerous and presents the risk of injury to personnel working in the area.
Air Lines and Fittings
Regular inspection (monthly) of the pneumatic system should be made and any leakages corrected. Any air
lubricators should be topped up with lubricant and filters should be checked and cleaned - details of these and
other associated items will be found in the Other Makers Leaflet section.
Seals and Gaskets
Replace any seals or gaskets that show signs of deterioration or damage. When assembling ensure that any nuts etc
are tightened evenly so that the seal and housing are drawn square to the shaft.
Bearings
When replacing a bearing always ensure that it is correctly lubricated. Note that many bearings are sealed units
requiring no further lubrication.

Conveyor Belts
Should be checked regularly (weekly) for general condition. The belt tension and belt tracking should also be
checked at the same time to ensure maximum belt life. Where automatic belt tensioning and tracking systems are
fitted they should be checked for correct operation.
12.5 Electrical Maintenance

General
Components with moving parts should be inspected at intervals related to their frequency of operation.
Pitting of electrical contacts after a short period of service is normal bedding-in and is not detrimental to their
operation. Modern contacts have a special finish and must not be ‘dressed’.
Silvered contacts will oxidize and become black and should not be polished since this would remove some of the
coating.
Cleaning
Cleanliness is normally covered by the action of cleaning down the machine in general. However dust can
accumulate inside panels and other enclosures.
Every six months these should be cleaned using a vacuum system. If this is not available use a hand blower or a
compressed air line. Avoid excessive use of compressed air because entrained moisture could be as harmful as the
removed dust. Also be aware that the air will blow the dust somewhere else!
In dust (flour etc) areas door seals should be checked to prevent the dust ingress to control gear.
Inspection
The normal mechanical life of relays and contactors is approximately five million operations. Baker Perkins
therefore recommends that those components which are subjected to frequent switching be checked and, if
necessary, replaced after approximately five million operations.
Control equipment situated in dusty atmospheres should be inspected more frequently, with particular attention
being paid to the condition of the door seals to prevent the ingress of dust to the equipment.
Relays not subjected to frequent operation e.g. those in alarm and safety circuits should be inspected and tested
regularly (weekly).
A formal test procedure should be set up in the bakery to ensure regular testing of all safety systems.
Inspection requirements for relays and contactors are related to the frequency of operation is as follows:
Type Frequency Action

Low Duty Operated less than once an hour Inspect every 6 months
Normal Duty Operated more than once an hour but less than Inspect every 3 months
once per minute
High Duty Operated more than once a minute Inspect every month
Safety Duty n/a Inspect and test weekly
In components which have sealed or enclosed contacts inspection is limited to the mechanical action and visible
moving parts.
Other Electrical Equipment

Connections and Leads
Every six months check all terminals for tightness, security and that they are safe. Check that all insulating and
safety shrouds are securely in place and in good condition.
Check that flexible cables have freedom of movement, particularly on devices which move frequently, eg tier
selector booms.
Check that the insulation of cables has not been cracked or abraised by moving parts, either mechanical or by
opening doors or covers.

Fuses
No inspection required.
If one power fuse ruptures on a three phase supply then the other two should be renewed also. Always replace
fuses on a three phase system as a set of three.
Earth Leakage Protection Devices
Where these are installed a regular (monthly) operation check should be carried out.
Clutches and Brakes
Refer to the manufacturers instructions for inspection requirements with due regard to the frequency of operation.
Transistorised / Solid State Devices
The life of transistorised and solid state devices is indefinite. In the event of failure of a transistor device, circuit or
component, it is recommended that repair should not be attempted. Renew the complete unit or plug-in board.
Sophisticated tooling is generally necessary to implement repairs on this type of equipment and tampering with it
may invalidate any warranty from the manufacturer.
Limit Switches
The actuator should be regularly inspected (monthly) for freedom from wear or damage. The operation and
alignment should be checked and adjusted if needed. Inspect the rod or roller and any rubber seal round the
plunger actuator. Renew the switch after approximately one million operations.
Reed Switches
Reed switches are sealed, and no regular inspection is required except to check that the mounting is secure.
Damage to the contacts can be caused if the switch is operated without the spark suppression components which
are included in the control circuit.
Photo Electric Detectors
Lamp and cell units should be firmly mounted to maintain correct alignment of the beam.
Dirty lenses can reduce the sensitivity of operation. Regularly clean the lenses with a clean cloth. The required
interval will depend upon operational conditions.
Proximity Detectors (Inductive or Capacitive)

These are solid state devices and require no periodic maintenance, except to check that the mounting is secure with
the correct sensing gap and to wipe them clean. The frequency of cleaning will depend upon operational
conditions.
Plug-In Timers
The plug-in timer is transistorised and contains a relay similar to the normal plug-in relay with similar life and
maintenance requirements.
12.6 Maintenance Log or Record

It is essential for the user to record all maintenance activities on the equipment. Such a log will assist in identifying
any persistent problems, keep track of consumable and spares items used and also act as a means of
communication from one group of maintenance engineers to another.
A sample chart for this log is included for your convenience.

MAINTENANCE RECORD
Machine No:...................................................................................................
Particulars of Work Done Date Signature
13 Quick Reference Maintenance Schedule
The following chart is to be used as a quick scheduling guide for the general maintenance of the Equipment. As
various tasks need undertaking, refer to the Detailed Maintenance and Lubrication sections of this manual, or other
makers manuals, as these sections supersede the tasks shown below.
Task Suggested
Description Frequency
Cream Feed System
Inspect lip seals, chains and pump rotors for damage Monthly
Clean all accumulated dirt from around the air inlets of the drive motors. Every Three
Months
Apply one or two shots of the appropriate grease to motors with hydraulic grease nipples for fan and/or Every Three
motor bearings (refer to the relevant manufacturers information in the OML section of the Manual). Months
Pillow Crimper
Check the general condition of all the Pillow Crimper driving chains and adjust the tension as necessary. Every Week
Lubricate the chain with a lubricant chosen from the Lubrication section of the Manual.
Check the general condition of the Pillow Crimper blades, sharpen/replace as required. Every Week
Clean and adjust the Pillow Crimper belt scrapers. Every Week
Inspect the general condition of the Pillow Crimper conveyor belts (e.g. tension, tracking and cleanliness), Every Month
Wipe clean and make adjustments as necessary.
www.bakerperkinsgroup.com Quick Reference Maintenance Schedule - 67

Task Suggested
Inspect the Pillow Crimper compressed air pipework. Remove and clean the filters and bowls in soapy Every Month
water.
Drain, flush and re-fill gear units Six Monthly

GENERAL
Inspect the various safety devices on the machines for correct operation Every Day
Clean all machine outer surfaces Every Day
Empty all crumb and catch trays Every Day
Inspect the general condition of the various gear units. Check particularly the oil level within the units (if Every Week
oil loss has occurred investigate immediately). Check also that any seals or gaskets incorporated are
undamaged
Clean dirt and debris from all fan cowls, including geared motor drives Every Week
Check the general condition of the pipework and fittings and rectify any damage Every Week
Inspect the air lines and fittings, including lubricators and filters, for leakages, damage and ingress of dirt. Every Week
Repair/replace as required
Remove any internal scrap collection trays and empty them. Wash trays and any PU coated conveyor belts Every Week
with a soft cloth and Food Safe Sanitising solution - and dry
Inspect and replace when necessary all seals and gaskets Every Week
Check the general condition of any steel or wire bands (ovens) Every Week
Quick Reference Maintenance Schedule - 68

Task Suggested
Ensure that drive motor mountings are secure and that any cooling fan air inlets are cleaned of all dirt to Every Month
prevent overheating
Inspect any cartridge or panel-type air filters and replace as necessary. Every Month
Check the condition of all Fenner drive belts Every Month
Recharge all the motor fan bearings with two shots of a high temperature grease chosen from the Every Three
“Standard Recommended Lubricants” chart in the Lubrication section of the manual Months
Check the general condition of all the driving chains and adjust the tension as necessary. Lubricate the Every Three
chains with a lubricant chosen from the “Standard Recommended Lubricants” chart in the Lubrication Months
section of the Manual
Apply one or two shots of food quality grease to any pumps that are fitted Every Three
Months
Apply oil liberally to all the BORB’s (Bronze oil-retaining Bushes). Allow some of the oil to be absorbed, Every Six
then clean off the surplus Months
Completely drain the oil in the various gear units and flush through with a light flushing oil. Take this After the first
opportunity to inspect seal, bearing and gland condition on all the units. Refill the units to their correct 500 hours of
level using the lubricant recommended in the Lubrication section of the manual running
www.bakerperkinsgroup.com Quick Reference Maintenance Schedule - 69

Task Suggested
Water tanks/jackets - drain, then flush with a proprietary sanitising agent and refill Every 1-2
Years Or
10,000
Running
Hours
Change the Panel Oxidation Inhibitor every one or two years as indicated on the capsule Every 1 or 2
Years
Examine all RHP self lube bearings to ensure that they do not require replacement Every 1 or 2
Years
Quick Reference Maintenance Schedule - 70

14 Detailed Maintenance
Pillow Crimper Conveyor Belt Tensioning and Tracking

To tension the conveyor belts, turn the hexagon headed screws situated inside the frame on either side of the drive
drums. Tension the belt evenly across its width. Tracking is achieved by using the same screws and by adjusting the
appropriate side to centralise the running of the belt. Do not over-tension the belt. Minimum tension to maintain
drive and tracking stability will extend conveyor life.
Removal of Crimping Rolls
The machine is designed to allow the rolls to be removed for both servicing and to change the type of crimping
rolls.
1 Lower the anvil roll with the hand lever.
2 Open the upper hinged mesh covers and remove the infeed cover.
3 Remove the stainless steel side covers.
4 Disconnect the chain drive.
5 Retract the conveyor decking by lifting off support pins and pulling back. It may be necessary to reduce the belt
tension. Back-off both tension screws a known amount, i.e. five turns so that when re-fitting the tension can be
easily returned to the original setting.
6 On the upper roll, remove the four hex head bolts retaining the bearing housing.
7 Carefully sling around the roll and lift out of the machine using a hoist, crane or similar lifting device.
8 On the lower roll, remove the four hex head bolts retaining the bearing housing cap.
9 Carefully sling around the roll and lift out of the machine using a hoist, crane or similar lifting device.
10 To refit, reverse the above procedure ensuring that the keyways on the end of the rolls are correctly aligned to
maintain accurate phasing of the blade to anvil. (Upper roll - keyway vertical down, lower roll - keyway vertical up).
www.bakerperkinsgroup.com Detailed Maintenance - 71

Sharpening the Crimper Blades

The Blades on the Upper and Lower Crimping Rolls will both require sharpening, as a pair, on several occasions
throughout their lives, whenever they become worn, or deformed sufficient to cause production problems. To re-
grind both kinds of blades requires a certain amount of stripping and re-building of the crimping roll assemblies.
Procedures for approaching this task are detailed below. Read through them first to ensure the correct sequence of
operations is followed, and also to check whether any of the procedures may be unnecessary.
Sharpening Straight Crimping Blade Rolls
Refer to Drawing Nos: upper - SA10953 & SA10922
1 Remove the Crimping Rolls as detailed previously.
2 Once removed, if the diameter is less than 182mm or is likely to be after re-grinding, then the rolls should be
scrapped and a new pair ordered from Baker Perkins.
Note Grind the upper roll assembly before the lower roll assembly.
3 If the roll is within re-grinding limits, remove the bearings and housings by removing the bearing lock nuts and
extracting the bearing/housing from the shaft. if fitted with a squirrel cage, the cams will also be removed with the
housings, releasing the squirrel cage rods.
4 With the roll stripped down, place on centres on a suitable cylindrical grinder.
5 Once mounted on centres, check the bearing journals for run-out. The total run-out should be less than 0.02mm. If
the measurement is in excess of this, the roll may have been damaged and advice should be obtained from Baker
Perkins. If the run-out is acceptable, a minimum clean up skim should be undertaken to clean the outer diameter of
the roll.
6 Once ground, measure the diameter across the blades to ensure that it is not below the minimum permissible
dimension as stated on the drawing. If the measured diameter across the blades from the upper roll is satisfactory,
make a note of the dimension, as the anvil blades from the lower roll must be ground to the same diameter.
7 Refit the bearing housings and bearings. It is easier to refit the squirrel cage rods with the rolls in-situ in the
machine.
Detailed Maintenance - 72
8 Refit the rolls as detailed previously.

Sharpening The Rake Angle - Straight Blades
It can be seen from the shape of the upper roll crimping blades that once the outer diameter has incurred a certain
amount of machining and reaches the mid point of 186mm dia, the rake angles of the blades will require re-
machining to thin out the crimping edge of the crimping blade. The procedure for implementing this task is
detailed below.
1 With the rolls removed from the machine, grind each blade in turn on a suitable grinding machine until the
crimping edge on the crimping blade is 1.0mm and the crimping edge on the anvil blade is 3.0mm.
Note As the angled face of the blade is re-ground only once at this point in its life, it should be noted on the Maintenance Record
Sheet.
2 Having sharpened the blades on both the upper and lower crimping rolls, refit into the machine as previously
detailed.
Setting the Crimper Rolls - Phasing
ENSURE THAT THE PILLOW CRIMPER IS DISCONNECTED FROM THE ELECTRICAL SUPPLY.
! WARNING
Take great care to avoid damaging the blades by inadvertent contact between blades on opposing rolls, especially
whilst the blades are un-synchronised, and when adjusting chain tensions.
1 Back off the cut pressure handwheel to give approximately 1.0mm gap between cutter and anvil blades.
2 Remove the cover on the control side to expose the drive chain.
3 Carefully rotate the machine by hand until the upper roll keyway is at the bottom and the lower roll keyway is at
the top.
4 If it is not possible to align the keyways, slacken the locking screws on the phasing jockey plate and turn the
adjusting screw. This will rotate one roll relative to the other.

5 Once the keyways are aligned, an accurate check on blade synchronisation can be made by passing a soft malleable
material, i.e. solder wire, through the nip.
6 Gradually reduce the blade gap until a witness mark can be seen on the solder. If mis-alignment is visible, make
further adjustment of the phasing jockey plate.
7 When the blade/anvil phasing is correct, re-tighten the locking screws on the phasing jockey plate.
Setting the Crimper Rolls - Parallel
Should it be seen that there is a change of blade gap across the roll width, i.e. not parallel, the machine can be
adjusted to correct it.
Note This procedure is not normally necessary and the effect may be due to other factors such as incorrect setting of the roll stop
screws or a non parallel re-ground roll. Check for other causes before deciding to adjust the setting.
1 Rotate the machine by hand to align a cutting and anvil blade.

2 Insert a feeler gauge into the blade gap and wind on the pressure whilst moving it across the blade. If it is not
parallel, the feeler gauge will be nipped at one side of the roll and free at the other.
3 Remove the screws in the handwheel cross-shaft coupling.
4 Rotate one handwheel relative to the other in the appropriate direction. This allows one side of the roll to be
moved relative to the other.
5 Repeat the feeler gauge check and adjust the handwheels until the nip is even across the width of the roll,
indicating the rolls are now parallel.
6 Rotate the cross-shaft coupling to align the nearest set of holes and replace the screws. Re-synchronise the
handwheel dials by loosening the dial and rotating it until they both indicate the same numerical value. The value
should be zero at metal to metal contact of the blades.
Removal of Stripper Rods

The stripper rods can be replace with the rolls in situ.
1 On the upper cam block at each end of the roll, remove the two screws and lift off the wedge insert piece to
expose the cam track.
2 Rotate the roll one pitch at a time and extract the stripper rods.
3 Inspect the plastic stripper rod sleeves for wear and replace if necessary. The sleeves can be pulled off the rods and
the replacement pushed back on.
4 Replacement of the rods is the reverse of the above procedure, rotating the roll one pitch at a time.
5 Replace the cam block wedge insert.
6 The same procedure applies to the lower roll with the cam block wedge insert situated underneath. Remove the
lower guards to gain access to this area.

15 Equipment Cleaning and Hygiene
BEFORE ATTEMPTING CLEANING OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT YOU HAVE READ AND
! WARNING UNDERSTOOD THE SAFETY SECTION OF THIS MANUAL.
BEFORE ATTEMPTING CLEANING OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT IT IS ISOLATED FROM
! WARNING ALL POWER SOURCES:-
- PNEUMATIC SUPPLY.
- HYDRAULIC SUPPLY.
IT MAY BE POSSIBLE FOR THE EQUIPMENT TO APPEAR “SWITCHED OFF” BECAUSE IT IS NOT MOVING. TURNING THE
! WARNING SPEED CONTROL TO ZERO CAN CREATE THIS EFFECT ON EQUIPMENT THAT IS ACTUALLY STARTED. ALWAYS
FOLLOW THE LOCK OFF PROCEDURES.
15.1 Initial Cleaning (after installation)

Before despatch from Baker Perkins, all exposed polished parts and machined faces are coated with a rust
preventative compound. This may be removed by rubbing with an edible oil, followed by washing with a detergent
solution.
All ferrous surfaces must be thoroughly dried after cleaning - failure to ensure all moisture is removed could result
! CAUTION in corrosion. THIS IS APPLICABLE FOR THE LIFE OF A MACHINE.
www.bakerperkinsgroup.com Equipment Cleaning and Hygiene - 77

15.2 Cleaning During Production

Regular and thorough cleaning of the equipment is important for hygienic operation.
What is Cleaning?
Cleaning describes the process of changing a soiled surface to one that is safe for food handling. It involves the
input of energy for a given length of time. The types of energy used in the process may be classified as:-
• Mechanical - the more energetic the application, the more effective the process.
• Chemical - the stronger the chemical, the more powerful the action.
• Thermal - the more heat means faster reactions.
Note The user is responsible for implementing adequate cleaning procedures for the equipment and for safe working practice. The
following notes are given for guidance only.
Equipment Cleaning and Hygiene - 78

15.3 Safety and Cleaning Equipment

Ensure that you have access to the correct safety and cleaning equipment and that it is clean and in good condition,
such as the following items:
• Eye protection - goggles or safety glasses
• Rubber gloves
• Clean mop and bucket
• Scouring pads
• Non woven disposable cloths
• Hand scraper
• Hand brush
• Floor brush
• Compressed air line
• Detergent in hot water
• Disinfectant mixture in hand spray
(e.g. Typically a Proprietary Odourless, Food Safe Sanitiser)
• Warning signs
e.g. Slippery floor, Danger men at work, etc.
EYE PROTECTION MUST BE WORN WHEN THERE IS THE RISK THAT DUST, DEBRIS OR CLEANING SOLUTIONS MAY
! WARNING DAMAGE THE EYES.
GLOVES MUST BE WORN TO PROTECT THE HANDS WHEN USING CLEANING SOLUTIONS.
! WARNING

Note No cleaning utensil that has been used for other purposes, e.g. washing the floor, should be used to clean food production
equipment.
15.4 Cleaning and Disinfection Procedure

Purpose
To ensure that any machinery used for the purpose of food production is cleaned and/or disinfected in compliance
with the Food Safety Act 1995, for equipment in the UK, and/or any other relevant legislation for equipment
elsewhere.
To ensure that the operation or function of the machine is not impaired by product residues remaining in or on the
machine after use. To ensure that food products of the highest quality and microbiological standards are achieved.
Overview
There are a number of reputable hygiene chemical suppliers that can supply the correct cleaning and disinfection
agents. Cleaning and disinfection equipment may also be available from these suppliers.
The choice of chemical agent required to clean and disinfect Baker Perkins machines has to be correct. The
materials of construction, function and operation of the machine may be seriously damaged by unsuitable agents.
Because the range of hygiene products in terms of chemical types and formulation is vast it is impossible to outline
all the possible products and procedures required to clean and disinfect all Baker Perkins machines.
Scope
This section is a guideline designed to outline a general cleaning and disinfection routine together with the
considerations needed to be taken at each stage to choose the correct product and application equipment.
Limitations
Because the possible choices and systems available are numerous it is important to contact a reputable supplier of
cleaning and disinfection chemicals who can advise on the correct products, equipment and systems required. The
next section gives a general procedure of “the process of cleaning and disinfection”.

Procedure
Any equipment which presents an electrical or heat risk to hygiene operatives must be isolated from the power
supply and heated surfaces cooled. If the cleaning and disinfection method has to be carried out with electricity
and heat in line then the correct health & safety measures should be enforced. It would be advisable to carry out a
risk assessment for this purpose.
Remove Apply Rinse Apply Rinse

gross debris detergent disinfectant
d r y!
a nd
15.5 Points To Note

Ingredient Systems
Where ingredient feed systems are supplied, it is important to maintain them in a sanitary condition. A HACCP
(Hazard Analysis Critical Control Points) survey should be undertaken after installation.
Water or Liquid Ingredient Systems
Tanks and pipes should be drained, flushed and sanitised at regular intervals. The frequency of cleaning required
will depend upon the ingredients, usage and site conditions.
For example, a system in constant use in a cool environment may only require weekly cleaning. A system used for
only part of the day in a warm environment may require daily cleaning.
Dry Ingredient Systems
Hoppers, feed pipes, connecting socks, filters and other equipment associated with the ingredient supply system,
must be emptied, cleaned and sanitised on a regular basis, determined by the sanitation hazards identified by the
user.

Non-Stick Coatings
When washing down PFA/PTFE coated surfaces with high pressure spray systems - the spray nozzle should not
! CAUTION be held closer than 300 mm to the coated surface. High pressure water can enter through small scratches in the
surface and cause the coating to lift (or rust if a mild steel component).
Washing down a coated surface with hot water is permissible, but steam should not be used in any circumstances.
Water temperature should not exceed 60 deg. C - detergents should not be used.
Cast Steel and Ferrous Metals
Some components manufactured from ferrous materials cannot have protective coatings due to the nature of the
application on a machine. Care must be taken after any cleaning procedures to ensure that if such components
come in contact with moisture - they are thoroughly dried. After drying, Baker Perkins recommends applying a light
film of vegetable oil as protection.
15.6 Access To Equipment For Cleaning

Note that gaining access to equipment for cleaning may expose various hazards. It is the responsibility of the user to
assess any hazards and establish safe working practices accordingly.
For example, flour silos present an explosion hazard due to air borne flour particles. Safety precautions must be
implemented to avoid the risk of injury to personnel and damage to equipment.
Process vessels, jacketed tanks and the cleaning chemicals themselves are possible sources of hazards. Again, it is
the users responsibility to assess the potential hazards and implement safe working procedures.

15.7 The Cleaning Process

Five steps to Hygienic Cleaning.
• Remove debris
• Clean - by applying physical energy, chemicals or heat
• Rinse
• Disinfect
• Rinse - AND DRY.
1 Any water sensitive control panels must be protected from water ingress by appropriate means.
2 As much debris as possible should be manually removed from machine surfaces to include underneath and behind
panels as build up of debris in concealed places can also lead to pest problems. The method chosen must not cause
physical damage to the surface being cleaned.
Note Product debris left on machine surfaces will impair the effectiveness of hygiene chemicals used.
3 Once debris has been manually removed, any fine debris may be removed by either rinsing with water, or blown off
with compressed air.

4 A suitable detergent can then be applied to remove the remaining soil. The type of detergent chosen will depend
upon a number of factors, for example:
• The type of soiling e.g., if it is of a fatty origin, alkaline or caustic detergents are required, if it is scale then
acid based detergents are required. If the soiling level is low neutral detergents may be used.
• The construction material the detergent is to be applied to, i.e. is the detergent compatible with the surface
in terms of damage or corrosion.
• The temperature of the surface the detergent is applied to as it may release irritating vapours and will
increase the corrosive effect.
• Application of detergent; can it be foamed or does it require manual application, especially for water
sensitive areas. Can detergent be used at all or does it require dry cleaning?
• The type of detergent application equipment required, e.g. the pressure used, as high pressures may cause
chemical and water ingress.
Note It is important to consider the above choice very carefully, in consultation with the approved suppliers of the hygiene
chemicals and Baker Perkins.
5 The detergent will then require removal by rinsing with water or use of a damp cloth if a water sensitive area is
being cleaned.
Note The thorough removal of detergent is paramount. Any residue remaining on surfaces will impair the effectiveness of
subsequent disinfection. It may also continue its corrosive effects or be harmful to personal who may come into contact with
it or its vapour.

6 A suitable disinfectant can then be applied as directed by the supplier. The considerations when choosing a
disinfectant are for example:
• The type of micro-organism
• The construction material the disinfectant is to be applied to, i.e. is the detergent compatible with the surface
in terms of damage or corrosion
• Application of the disinfectant, e.g. the pressure of application as high pressure may cause chemical ingress
• The temperature of the surface the disinfectant is applied to as it may release irritating vapours and will
increase the corrosive effect if the disinfectant is of a corrosive nature
• Application procedure, e.g. is rinsing required?
7 If the time for the cleaning and disinfection process is limited, then there are products available which contain both
detergent and disinfectant. These are called “sanitisers”. The debris removal and rinsing are still required, and
possibly a final rinse, but the same questions regarding the choice of product outlined in points 4 and 6 need to be
asked.

Summary
The cleaning and disinfection system chosen for Baker Perkins machinery requires careful consideration. The wrong
system may cause damage to the control, working components and construction materials of the machine.
It is important to consult with other parties involved when considering a cleaning and disinfection system/practice,
for example:-
Baker Perkins / Engineers: they will know about the construction, safety and tolerance of working components
and whether the machine will be able to withstand various chemical treatments.
The hygiene chemical supplier: the chemical supplier has experience in the types of products required to clean
and disinfect production machinery and the required procedures.
Technical/Hygiene Managers: they need to be involved as they will be responsible for operatives carrying out the
cleaning and disinfection procedure.
Production Management: they will need to know how cleaning and disinfection will effect production timing and
down time.
Laboratory Managers/QC: as they will be testing the machine for microbiological acceptance they need to be
familiar with the procedure and how they can obtain their samples and determine test points.
Once the cleaning and disinfection system/practices have been finalised, they should be incorporated into a
cleaning schedule for documentation purposes.
This is useful for ISO 9000 or HACCP (Hazard Analysis Critical Control Points) systems.

Further Points To Consider -

1 Ensure that all shut down and lock off procedures have been correctly carried out as detailed in the Safety Section.
2 Make arrangements for the necessary guards to be removed to allow access for cleaning.
3 Make arrangements for any necessary dismantling of the equipment to facilitate cleaning
4 Clean all surfaces, paying particular attention to any ledges and any trap areas. Include areas around drive units,
under conveyors and extraction hoods (where fitted).
Note The paint used on Baker Perkins equipment will not maintain its full gloss and finish if cleaned with scouring powders or
strong alkaline cleansers. The use of ordinary soap and water or one of the modern synthetic detergents is therefore
recommended.
5 If using compressed air be aware that this will blow the deposits away but that they will end up somewhere else! If
possible it is always best to collect deposits with a vacuum system.
6 Some items, once removed from the equipment, are best cleaned by using a steam lance.
ENSURE THAT SAFETY PROCEDURES FOR THE USE OF STEAM LANCES ARE IN PLACE AND ADHERED TO BY
! WARNING OPERATORS.
STEAM CAN CAUSE SERIOUS INJURY.
Note After cleaning a component with steam, wait for it to cool down before fitting it back into the equipment. The raised
temperature may cause fitting problems with close tolerance components.
7 Clean all drip trays.

8 When the job is finished, clean all cleaning and safety equipment.
9 Arrange for equipment re-assembly and for the guards to be replaced.
10 Remove all waste, ensuring that the equipment and surrounding area is left in a clean and tidy condition.

11 Before restarting the equipment make sure that it is has dried from the cleaning procedure. This is particularly
important for ingredient feed or sprinkler systems where moisture could impair performance or react with the
ingredients, (e.g. salt) causing corrosion of steelwork.
ON COMPLETION OF CLEANING PROCEDURES, ALWAYS ENSURE THAT ALL PERSONNEL ARE CLEAR OF THE
! WARNING EQUIPMENT. CHECK THAT ALL EQUIPMENT IS PROPERLY ASSEMBLED AND ALL SAFETY GUARDS ARE IN PLACE
BEFORE TURNING ON THE POWER SOURCES.
More Information -
Suppliers of typical cleaning/hygiene chemicals would be:
Th. Goldschmidt Ltd. Holchem Laboratories Ltd.

Tego House Premier House
Chippenham Drive 175 Grane Road
Kingston Haslingden
Milton Keynes Rossendale
MK10 0AF Lancashire
ENGLAND. BB4 5ER
Tel. +44 (0)1908 582250 ENGLAND.
Fax +44 (0)1908 582252. Tel. +44 (0)1706 222288
Email: info@goldschmidt.com Fax +44 (0)1706 221550.
Email: info@holchem.co.uk

16 Specific Cleaning and Hygiene
BEFORE ATTEMPTING CLEANING OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT YOU HAVE READ AND
! WARNING UNDERSTOOD THE SAFETY SECTION OF THIS MANUAL.
BEFORE ATTEMPTING CLEANING OF ANY DESCRIPTION ON THE EQUIPMENT ENSURE THAT IT IS ISOLATED FROM
! WARNING ALL POWER SOURCES:-
- PNEUMATIC SUPPLY.
- HYDRAULIC SUPPLY.
IT MAY BE POSSIBLE FOR THE EQUIPMENT TO APPEAR “SWITCHED OFF” BECAUSE IT IS NOT MOVING.
! WARNING TURNING THE SPEED CONTROL TO ZERO CAN CREATE THIS EFFECT ON EQUIPMENT THAT IS ACTUALLY STARTED.
ALWAYS FOLLOW THE LOCK OFF PROCEDURES.
www.bakerperkinsgroup.com Specific Cleaning and Hygiene - 89

16.1 Machine Specific Cleaning

It is important to keep the production area and equipment clean for the sake of hygiene, and safety, and to prevent
dust getting into the electrical parts of the machinery.
Cleaning To Be Done Immediately
Liquid spills are a safety hazard to you and other people in the area. So clean or mop up any spilled liquids
immediately. While the floor is slippery be sure to use hazard cones to warn people and prevent accidents.
Any dry ingredients that fall on the floor near the crimper should also be swept up as soon as possible.
Dispose of waste packaging as soon as it is emptied and don't leave dirty cloths on the floor or equipment.
Cleaning Done During All Shifts
There are a few cleaning and clearing jobs that need to be done regularly during each shift.
At regular intervals:
• Wipe down the outer surfaces of the machine with a damp cloth so that it is always clean and dust free.
• Dust down the front of the machine control panel.
At the end of a shift:
• Wash the floor round the machine thoroughly.
Weekend and Monthly Cleaning
Weekly cleaning is usually done at the end of the last production shift or before a different product is to be run on
production. Once a month there are a few additional cleaning operations that are added to those done every
weekend.
Specific Cleaning and Hygiene - 90

16.2 Pillow Crimper
ENSURE THAT THE PILLOW CRIMPER IS DISCONNECTED FROM THE ELECTRICAL SUPPLY.
! WARNING
Use a vacuum cleaner to remove cereal dust deposits from the crimper. An engineer should remove the guards to
allow any build up of product dust to be removed. Ensure all covers are secured back in place. To clean the blades,
use a suitable stiff brush to remove any product and vacuum off the deposits. The roll can then be wiped with a
damp cloth (soaked in mild detergent solution or food safe sanitising solution) to remove all traces of the product.
Finally, wipe the blades with a damp cloth (soaked in clean water) - Then thoroughly dry any parts that has been
cleaned.
Never “hose down” the machine
Rotating the Crimping Rolls by Hand
To rotate the rolls by hand, first lower the bottom roll with the hand lever. Wearing stout leather gloves, place
palms onto the top of the upper roll and rotate slowly in the direction of running. Take care not to get anywhere
near the roll nip point with fingers. To avoid injury, care must be taken during hand rotation as the blades are not
only sharp but also brittle and could break with rough handling.
ON COMPLETION OF CLEANING PROCEDURES, ALWAYS ENSURE THAT ALL PERSONNEL ARE CLEAR OF THE
! WARNING EQUIPMENT. CHECK THAT ALL EQUIPMENT IS PROPERLY ASSEMBLED AND ALL SAFETY GUARDS ARE IN PLACE
BEFORE TURNING ON THE POWER SOURCES.
www.bakerperkinsgroup.com Specific Cleaning and Hygiene - 91

Specific Cleaning and Hygiene - 92

17 Standard Lubrication
Note Baker Perkins recommend the use of NSF authorised synthetic Food Grade lubricants, for all components where incidental
food contact may occur. Note that the lubrication charts that follow, detail both NON Food Grade and Incidental/direct
Contact Food Grades lubricants.
• For more info - www.nsf.org
17.1 General
Regular lubrication, using lubricants of the correct specification and in the correct quantities and locations, is
essential for the reliable operation and long service of the equipment.
It is extremely important to use only high grade lubricants of the correct viscosity and specification, and to check
and change them at the recommended intervals. Where possible, mixing of lubricants should be avoided.
Initial Running
Before first starting any machine, each gearbox, oil bath etc., must be checked and, if necessary, filled to the
! CAUTION correct level with a recommended lubricant. A careful check should be made to ensure that all lubrication
requirements have been carried out.
Refer to the Recommended Lubricants, Lubrication Details and Other Maker’s Leaflets section for further
information.
www.bakerperkinsgroup.com Standard Lubrication - 93

17.2 Bearing Lubrication

Ball/Roller Bearings with Provision for Relubrication
Packed with grease at assembly, these bearings need little further attention other than the occasional addition of a
small amount of grease. If examination becomes necessary, clean and flush out the bearing with an environmentally
safe, approved quick drying solvent and if the bearing is serviceable, re-pack with new grease.
Note Do not pack the bearing too tightly with grease as this can cause overheating and possible breakdown of the bearing. The
ideal is to have a little grease always in contact with the races.
Sealed Ball Bearings

This type of bearing is lubricated for the life at the time of manufacture and no provision is made for relubrication.
If the bearing is running loudly it should be replaced rather than refilled.
NSK - RHP Self Lube Bearings
These bearings are factory charged with the correct type and quantity of grease at the time of manufacture and
seldom require recharging.
If the bearings do however require more grease, (due to excessive loads or operating temperatures for example),
they can be recharged with two or three shots of grease chosen from the Recommended Lubricants chart through
the hydraulic grease nipple provided.
17.3 Recommended Lubricants

This is a general list of lubricants.
Reference should also be made to the Other Maker’s Leaflets for lubrication information on equipment not of
Baker Perkins manufacture.
Baker Perkins cannot recommend the use of any type or grade of lubricant not quoted by either themselves, or
where applicable by the manufacturer of the specific piece of machinery.
Although for a particular application equivalent grades from different manufacturers are specified, this does not
Standard Lubrication - 94
mean that the lubricants are identical in all respects.
Note The mixing of lubricants should always be avoided.
Note If abnormal operating conditions exist and you are in doubt of what lubricant to use, consult Baker Perkins for advice at the
address given in this manual.
The recommended lubricants are listed in the following categories:-
• Lubrication Oils - Industrial Grade, food contact/non contact grades

• Lubrication Greases - Industrial Grade, food contact/non contact grades
• Lubrication Oils - Automotive Grade

• Lubrication Greases - Automotive Grade
• High Temperature Greases
Always check a lubricants specification against local regulations before use.

! CAUTION

17.4 Lubrication Oils - (Industrial Grades)
Temp
Application Food Contact Grades NON Food Grade
°C
Oil cans Up to Mobil DTE FM 150 Mobilgear 627
Transmission +50 Shell Cassida Fluid HF 100 BP Energol CS 100
Chain Slipstream CL 150 Duckhams Garnet 100
High Speed Gears Castrol Vitalube GS 150 or Rocol Sapphire Hi-Torque
Vitalube Chain Spray 100
Rocol Foodlube Hi-Torque 150 Kluberoil GEM 1 - 150
or
Rocol Foodlube Chain Spray
Kluberoil 4 UH1 - 150N
High Speed Gears 50 - 80 Mobil DTE FM 220 Mobilgear 630
Shell Cassida Fluid GL 220 BP Energol CS 220
Slipstream CGL 320 Duckhams Garnet 220
Castrol Vitalube GS 320 Rocol Sapphire Hi-Torque
Rocol Foodlube Hi-Torque 320 220
Kluberoil 4 UH1 - 220 Kluberoil GEM 1 - 220
Medium Speed 50 - 80 Mobil DTE FM 460 Mobilgear 634
Gears Shell Cassida Fluid GL 460 BP Energol CS 460
Slow Speed Gears Slipstream CGL 320 Duckhams Garnet 460
High Speed Castrol Vitalube GS 320 Rocol Sapphire Hi-Torque
Worm Gears Rocol Foodlube Hi-Torque 320 460
Oil Cans Kluberoil 4 UH1 - 460N Kluberoil GEM1 - 460
Transmission
Chains
Temp
°C
Conveyor Chain Up to Mobil DTE FM 32 Mobil DTE 24
Air Line +70 Shell Cassida Fluid HF 32 BP Energol HPL-HM32
Lubricators Slipstream BG.6 Oil Grade Duckhams Zircon 32
Small Hydraulic Castrol Vitalube HS 32 Saphire Hi-power 32
Pressure Systems Rocol Foodlube Hi-Power 32 Kluber Airpress 32
Kluber Summit HySyn FG 32
Light Grade Food Up to Mobil Whiterex 408
Quality Oil +70 Slipstream CL 46
Shell Ondina 15 or EL
Castrol Dovidol Light/Special
Rocol Foodlube Hi-Power 32
Kluberoil 4 UH1 - 15
Heavy Grade Up to Mobil DTE FM 460
Food Quality Oil +70 Slipstream CL 46
(Incidental food Shell Ondina 68 or MH
contact) Castrol Dovidol Heavy
Rocol Foodlube Hi-Torque 320
Kluberoil 4 UH1 - 320N

17.5 Lubrication Greases - (Industrial Grades)
Temp
°C
Grease Guns Up to Mobilgrease FM 102 Mobilgrease HP222
Stauffers +130 Shell Cassida Grease 2 BP Energrease HTG2
Rolling Bearings Slipstream WB 2 gel Duckhams Admax LEP2
Castrol Vitalube HT 2 Rocol Sapphire 2
Rocol Foodlube Universal 2 Kluberplex BEM 41 - 132
Klubersynth UH1 64 - 62
Rolling Bearings 130 - 185 Mobilgrease FM series Mobiltemp SHC 100
Shell Cassida HD2 BP Energrease LS3
Slipstream WB 2 gel Duckhams Admax 3
Castrol Vitalube HT 2 Rocol Sapphire Premier
Rocol Foodlube HT Grease 2 Kluber Petamo GHY 133N
Open Gears Mobilgrease FM series Mobil SHC46M (up to
Shell Cassida Grease 2 200oC)
Slipstream WB 2 gel Mobil SHC 6800
Castrol Vitalube HT 2 BP Energrease OG
Rocol Foodlube Multi Paste Duckhams Laminoid
Klubersynth UH1 84 - 201 Rocol Tuflube Allweather
Kluber Grafloscan CSG 0
Ultra
Temp
°C
Lift & Tilt Screws Mobilgrease FM 102 Mobilgrease HP322 special
Shell Cassida Grease 2 BP Energrease LS3
Slipstream WB 2 gel Duckhams Admax LEP2
Castrol Vitalube HT 2 Rocol Tuflube Allweather
Rocol Foodlube Universal 2 Kluberpaste ME 31 - 52
Food Quality Grease Mobilgrease FM 003/101/102
(Incidental food Shell Cassida RLS and EPS
contact) Slipstream WB 2 gel
Optimol Obeen range
Rocol Foodlube Universal 2

17.6 Lubrication Oils - (Automotive Grades)
Note Being automotive grades the following are likely to be more expensive but may be more readily available than the industrial
grade lubricants.
Application Temp (°C) Supplier Type

Shell Oil Helix standard
Oil Cans Castrol GTX
Transmission Chain Up to +50 Deusol CRH20W/50
High Speed Gears Mobil Mobil Super
Duckham Fleetol or Multi-V
Texaco Havoline 15W/40
BP Oil Visco 2000
Vanellus M20/50
Shell Oil Dentax 90
High Speed Gears 50 - 80 Castrol ST 90
Mobil Mobilube HD90
Duckham Fleetmesh 90
Medium Speed Gears Up to +50 Texaco Geartex RO90
BP Oil Energear 90 EP
Medium Speed Gears 50 - 80 Shell Oil Vitrea Oil M460
Slow Speed Gears Up to +80 Castrol EPX 85 / 140
High Speed Worm Gears 60+ Alpha ZN460
Oil Guns Mobil Mobilube HD140
Transmission Chains Duckham Fleetmesh 140
Texaco Geartex RO140
BP Oil Energear 140 EP


Conveyor Chain Shell Oil Tellus 37
Air Line Lubricators Castrol Hysprin AWS32
Small Hydraulic Pressure Up to +50 Mobil Mobil DTE 24
Systems Duckham Zircon 32
Texaco Rando HD32
BP Oil Energol HLP - HM 32
Kluber Kluber Summit HySyn FG32

17.7 Lubrication Greases - (Automotive Grades)

Shell Oil Retinax A
Grease Guns Castrol LMX Grease
Staufers Up to +130 Mobil Mobilgrease HP222
Rolling Bearings Duckham Admax Lep 2
Texaco Marfak All Purpose EP2
BP Oil Energrease L2
Rocol Rocol Sapphire Premier
Kluber Kluberplex BEM 41 - 132
Shell Oil Retinax DX
Castrol LMX Grease
Mobil Mobiltemp SHC100
Rolling Bearings 130 - 185 Duckham Admax B3
Texaco Ultra Temp 2
BP Oil Energrease B2
Rocol Rocol Sapphire Premier
Kluber Kluber Petama GHY 133N
Shell Oil Retinax CD
Castrol Impervia CL Grease
SRG Grease
Open Gears Mobil Mobilgrease Special
Duckham Laminoid 1
Texaco Marfak 0
BP Oil Energrease AO
Rocol Tuflube Allweather
Kluber Grafloscan CSG - 0 Ultra


Shell Oil Retinax A
Castrol LMX Grease
Lift & Tilt Screws Mobil Mobilgrease Special
Duckham Admax Lep 2
Texaco Multifak All Purpose EP2
BP Oil Energrease L2
Rocol Dry Moly Paste
Kluber Kluberpaste ME 31 - 52

17.8 High Temperature Greases
Supplier Type Supplier Type
Standard Grades Food Contact Grades

BP Oil Energrease HTG2 BP Oil None approved to USDA H1
Castrol Spheerol BNS Castrol Vitalube HT 2 +200 ºC
Duckhams Admax B3 Duckhams None approved to USDA H1
Kluber Petamo GHY 133 N Kluber Kluber Paraliq GTE 703
Mobil Mobilgrease 28 Mobil Mobilgrease FM 102 +200 ºC
Rocol Sapphire Premier Rocol Foodlube Sapphire Endure +280 ºC
Shell Darina R2 (UK only) Shell Cassida HD2 +165 ºC
Darina R
Texaco Ultra Temp Slipstream WB 2 Gel +200 ºC
None of these recommended high temperature greases should be mixed or used with any other make or grade of
! CAUTION grease. If there is any doubt before using, ensure that the components are thoroughly cleaned of any existing
grease.
Note It is strongly recommended that a separate grease gun containing a special high temperature grease is used for that one
grease and no other. Always have separate marked guns for food grade and non food contact greases.

17.9 General Lubrication Schedule

It is essential that a lubrication schedule for the equipment is put in place and implemented by the user.
The required frequency of lubrication checks and changes is dependant upon the operating conditions of the
equipment. The following schedule is given as a guide which will be appropriate for most installations. However the
frequencies should be amended if the equipment operates continuously and / or in a harsh environment, for
example high ambient temperatures.
Item Frequency Lubricant

Heavy Duty Gears Every Day Lubricate/Grease
Driving Chains Every Week Oil as required
Light Duty Gears Every Week Lubricate/Grease
All Gearboxes Every Week Check oil levels and
replenish if necessary
Fan & Motor Every Three Months One or two shots only of
Bearings the appropriate grease
All Gearboxes Every Six Months Change the oil
Bronze Oil-Retaining Every Six Months Apply oil liberally, allow
Bushes some to be absorbed by
the bush, then clean off
the surplus oil.

17.10 Lubrication Table for SEW Drives

Many of the machines supplied by Baker Perkins are fitted with geared motors/gearboxes manufactured by SEW
Eurodrive. The SEW standard lubrication table details lubrication manufactures equivalent grades.
• Click HERE to view table

18 Lubrication Details
18.1 SEW Gearboxes

Many of the machines built by Baker Perkins are WORKING INSTRUCTIONS PARTS LIST PAGE 1
fitted with SEW Eurodrive geared motors. These have ----------------------------------------------------------------------------------------------------
PARTS LIST NO DESCRIPTION DRAWING NO DATE
ID plates fitted - they detail the lubricant type and
FE2859 S/O ELECS - X-SCRAP CONVEYOR 12-JAN-2006
quantity. Consult the manufacturer’s documentation, ----------------------------------------------------------------------------------------------------
located in the OML section for more detail. If the POS P MATERIAL ID NO DESCRIPTION QUANTITY DIM 1
plate is not visible, the electrical parts list details the ----------------------------------------------------------------------------------------------------
motor as shown in the example. 20 CROSS SCRAP CONVEYOR
21 D 8513-6235E 0.55kW GEARED MOTOR 400V-3PH-50Hz FOOT MTG 1
ID Plate: R27 DT80 K4 TF. MTG M1. OUTPUT SPD 206rpm
24HR EMERGENCY TEL. 01924 896911. WITH PTC THERMISTORS. SEW EURODRIVE
TYP FA47/6 0190S4 30 PLUGS AND SOCKETS
SER 30.01244792.01.0001.03.04 31 D 2521-496K RITTAL BOX DIMENSIONS 200 X 200 X 80. 1
RPM 25.0 / 1 400 i 56.49 SHAFT O 35
ASSY M3 FLANGE O COS O 0.77 STAINLESS STEEL SURFACE. SATIN BUFF, WEIGHT
kW 1.1 ED S1 INSL F IP 55 2.7KG. TYPE KL1523.
V 220 / 380 A/Y Hz 50 A 5.10 2.95
BRAKE V BRAKE Nm RECTIFIER 32 2 8165-311J MALE PLUG 6 POLE +E HARTING 0933-006-2601 1
CUST REF 8525-6164E n / 33 2 8165-312G FEMALE SOCKET INTERIOR 6 POLE + E PART 1
LUBE CPL 220 1.10
S.E.W. - EURODRIVE LTD. NORMANTON. ENGLAND. NO.43.22.06.40 - HTS
GEARBOX LUBRICATED BY MOBIL LUBRICANTS 34 2 8165-313E ANGLED SIDE ENTRY HOOD PART NO 1
0930-006-1540 / 0900- 000-5014 HARTING
35 2 8165-315A PANEL MTG BASE WITH SINGLE LOCKING LEVER 1
AND SPRING COVER PART NO. 42.52.06.00 - HTS
36 .
8000 J.T. SHAW
**************** END OF PRINT - PARTS LIST NO FE2859 *****************
www.bakerperkinsgroup.com Lubrication Details - 107

18.2 Pillow Crimper Drives
Unit Capacity Lubricant

Conveyor Drive Motors Oil Filled for Life See OML Section for information
Interoll / Joki 113S
Cutter/Crimper Drive Motor 2 Litre Shell Omala 220
SEW Eurodrive DV100M4-KAF47 M2 mounting
The Kelston screw jacks lifting the lower crimping roll may require a small amount of extra grease. Every six months
use a hand grease gun to apply such as:
• Rocol MTS 1000 or Castrol Kenol BN2
Other Areas
Apply a small amount of food grade grease to the slideways:
If the drive chain looks dry, apply such as Rocol Spray Lubricant.
Lubrication Details - 108

19 Baker Perkins Spare or Replacement Parts
When ordering, please quote the following typical details:
Information Example
The Machine Name MP40PH Extruder
The Machine Number 703/1NF0202
The Description of the Part Die Plate
The Drawing number or Code number of the part 4977-108N
The Quantity Required 1
Quoting all the above will assist Baker Perkins to supply the parts quickly. The machine details can be found on the
Machine Number Plate, example:
www.bakerperkinsgroup.com
Baker Perkins
Baker Perkins Ltd
Peterborough
England
machine name Accurist Divider quote

machine number 271/1AF0601 for
year/contract 2006 spares
kW
patents
www.bakerperkinsgroup.com Baker Perkins Spare or Replacement Parts - 109

Use the parts lists and drawings to find the part details. If a required item is less clearly defined, please also quote
the number of the picture drawing on which it is shown. Fax the drawing or sketch with the part highlighted can be
useful in identifying the part. A photograph of the required part can be emailed to us.
Please contact the Baker Perkins Customer Services Department to discuss your requirements. Our experienced
staff will help to service your requirements efficiently and will give you any assistance you may need.
Contact Baker Perkins Support
Non USA USA

All Machine Types Biscuit, Snack & Confectionary
PE4 7AP - UK USA
Phone: +44 (0)1733 283222 Phone: +1 616 784 3111
Fax: +44 (0)1733 283010 Fax: +1 616 784 0973
Baker Perkins Spare or Replacement Parts - 110

20 Index of Parts Lists and Drawings
Parts Lists Description Drawing No.

434/1SF0931 Key Parts - Multistream Pillow Crimper SA10950
SP11661 Common Parts - Pillow Crimper SA10950
SP11664 Set of Sideframes
SP11659 Set of Rolls - 24T Parallel SA10953
SP11660 Set of Bearing Housings - Squirrel
SP11663 Squirrell Cage - 24T SA10922
SP11794 Set of Covers - St.St.
SP11669 Crimper Pneumatics (Festo) SA10955
SP13143 Product Infeed Guide - 6 Stream
SP11933 Cutter / Crimper Support Frame
SP13175 Key Parts - Wide Pillow Crimper (CE) English
434/1SF0931/1E KP; Elecs; Pillow Crimper
SE2716 EPL; On Machine; Pillow Crimper
SE2715 S/O Conduit - Cutter Crimper
SE2489 S/O Panel Support Parts
434/1SF0931/P1 KA CP Pillow Crimper
spreadsheet Control Panel Parts List SD2189
www.bakerperkinsgroup.com Index of Parts Lists and Drawings - 111

Index of Parts Lists and Drawings - 112

21 Index of Other Makers Leaflets
Note Additional OML’s and Manuals are supplied with the Control Panel.
Manufacturer Equipment
Elobau Magnetic Safety Switches
Exair (if fitted) Air Knife
Fenner Taper Lock Bush
Guardmaster Centurion Time Delay Bolt
INA Needle Bearings
Interoll / Joki 1700 Series Roller

113S Motorised Drum
Kelston J04 100kn Screw Jack
Norgren General Pneumatic Components
Ondrives P60 Gear Reducer Unit
Renold Roller Chain
Rosta Chain Tensioner
SEW Eurodrive Gear Unit

Motor
Timken Roller Bearings
Walker / Habasit Conveyor Belt Care
www.bakerperkinsgroup.com Index of Other Makers Leaflets - 113

Index of Other Makers Leaflets - 114

22 Customer Feedback
Please print & fax back to:

Fax +44 (0)1733 283001
FAO: Chris Goodacre
Technical Publication Quality Survey

How do you feel about the contents and quality of Baker Perkins operation manuals? We are providing this survey
so that you (our Customer) can directly effect and help us improve the quality and content of our products. Our
manuals must meet the needs of you, the user. By filling out this form you can help us provide the most useful,
thorough and accurate manuals available.
Take the time to make a photocopy of this form so that you will have the original form for future feedback use.
Please review the manual, or any previous manuals, then complete this form. Please fax this form to Baker Perkins.
RATE THE OVERALL QUALITY OF THIS MANUAL BY CIRCLING YOU RESPONSE BELOW
(1)=Unsatisfactory, (2)=Poor, (3)=Average, (4)=Above Average, (5)=Excellent
Helpfulness Of The Table Of Contents: 1 2 3 4 5

Clarity: 1 2 3 4 5
Ease Of Use: 1 2 3 4 5
Accuracy And Completeness: 1 2 3 4 5
www.bakerperkinsgroup.com Customer Feedback - 115

Quality/Accuracy of Engineering Drawings: 1 2 3 4 5

Quality/Accuracy of Parts Lists: 1 2 3 4 5
Quality Compared To Other Companies’ Manuals: 1 2 3 4 5
Quality Compared To Other Baker Perkins Manuals: 1 2 3 4 5
What did you like most about this manual?

Anything missing ?
What did you like least about this manual?
Do you prefer a manual on CD ROM? YES or NO
Would you like to access BP manuals and Drawings on the Internet? YES or NO
Who uses this manual?:
Where are the manuals stored?:
Contract No.: Equipment or M/C No.:

Company:
Contact: Title:
Phone Number: E-mail:
Customer Feedback - 116

23 Conversion Table
Unit To Convert Multiply

Length millimetres to inches 0.03937
inches to millimetres 25.4
metres to feet 3.2808
metres to yards 1.0936
metres to fathoms 0.5468
feet to metres 0.3048
yards to metres 0.9144
fathoms to metres 1.8288
kilometres to miles 0.62137
miles to kilometres 1.60934
Area hectares to acres 2.4711
acres to hectares 0.404686
sq kilometres to acres 247.105
sq kilometres to sq miles 0.3861
acres to sq kilometres 0.004047
www.bakerperkinsgroup.com Conversion Table - 117

Unit To Convert Multiply

Weight grams to ounces 0.03527
ounces to grams 28.3495
kilograms to pounds 2.20462
pounds to kilograms 0.4536
Speed kilometres/hour to miles/hour 0.62137
miles/hour to kilometres/hour 1.6093
miles/hour to knots 0.8684
Energy kilometres/litre to miles/gallon 2.82481
miles/gallon to kilometres/litre 0.35401
Temperature ° Celsius to ° Fahrenheit multiply by 9/5, and add 32
° Fahrenheit to ° Celsius subtract 32, and multiply by 5/9
Pressure lb/in2 to bar 0.06895
bar to lb/in2 14.5
Conversion Table - 118

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434, Pillow Crimper, Oct.

OPERATION & AFTERCARE MANUAL

Baker Perkins Ltd.

Contents Links - click to view

1 Pillow Crimper ........................................................................................................................................................ 7

2 FAXBACK Form ....................................................................................................................................................... 9

4 Equipment Specification ........................................................................................................................................13

5.12 Health and Safety ..........................................................................................................................................................................................30

7 Baker Perkins Customer Support ...........................................................................................................................37

8 Glossary of Terms ..................................................................................................................................................41

9 General Information - Baker Perkins Equipment ....................................................................................................43

11 Pillow Crimper .......................................................................................................................................................49

12.2 Safety Devices...............................................................................................................................................................................................60

13 Quick Reference Maintenance Schedule ................................................................................................................67

15 Equipment Cleaning and Hygiene ..........................................................................................................................77

16 Specific Cleaning and Hygiene ...............................................................................................................................89

17 Standard Lubrication .............................................................................................................................................93

17.10 Lubrication Table for SEW Drives................................................................................................................................................................106

18 Lubrication Details............................................................................................................................................... 107

19 Baker Perkins Spare or Replacement Parts........................................................................................................... 109

20 Index of Parts Lists and Drawings ........................................................................................................................ 111

21 Index of Other Makers Leaflets............................................................................................................................ 113

22 Customer Feedback ............................................................................................................................................. 115

23 Conversion Table ................................................................................................................................................. 117

www.bakerperkinsgroup.com Pillow Crimper - 7

1.1 Contact Information

Non USA USA

1.2 Operation Manual History

Rev. No. Author Details Date

This Manual belongs to: Alfonzo Rivas & Cia

Type: Pillow Crimper

Startup date: ..........................................................................................

......................................................................................... Signed for and behalf of the company:

www.bakerperkinsgroup.com FAXBACK Form - 9

Comments, spare parts requirements, training requirements:-

EC MACHINERY DECLARATION OF CONFORMITY OR INCORPORATION

Machine description: Pillow Crimper

Machine number: 434/1SF0931

Manufacturer: Baker Perkins Ltd

Address: Manor Drive

For EC contracts, an original certificate for this machine is retained

www.bakerperkinsgroup.com EC Machinery Directive - 11

Certificates of Conformity - EC Plant Installations

4.1 Contract Reference Number

4.2 Machine Number

4.3 Noise Level

4.4 Electrical Power Supply

Voltage Phase Cycles Neutral Spec.

Some panel components may operate at a high voltage.

www.bakerperkinsgroup.com Equipment Specification - 13

4.5 Other Utility Supply Details - e.g. Gas, Air

4.6 Specification Detail

www.bakerperkinsgroup.com Equipment Specification - 15

5.1 WARNINGS, Cautions, Notes and Hints

5.3 Purpose of use

5.4 Electrical Lock Out and Tag Out of Isolator

5.5 Emergency Shutdown

5.6 Guards and Safety Devices

5.7 Installation Safety Precautions

5.8 Commissioning Safety Precautions

5.9 Operation Safety Precautions

5.10 Cleaning and Maintenance Safety Precautions

5.11 Running the Equipment Without Safety Systems

5.12 Health and Safety