INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°1

TABLE OF CONTENTS

CHAPTER 1 : Technical Data

CHAPTER 2 : Installation of the machine

2.1. Transport of the machine

2.2. Connecting the electricity
2.3. Connecting the air
2.4. Fixing the machine to the floor
2.5. Take away conveyor
2.6. Distance from machine to machine
2.7. Air suction hood

CHAPTER 3 : Preparation of raw materials

3.1. The different grains

3.2. Addition of moisture
3.3. Grains specifications and quality

CHAPTER 4: Setting up the machine

4.1. Description of the machines and its parts

4.2. Alignment of the die
4.3. Position of the upper die
4.4. Setting of the feeding system
4.5. Hydraulic pressure regulation
4.6. Position of the reedcontacts on the hydraulic cilinder
4.7. Position of the reedcontacts on the pneumatic cilinder

CHAPTER 5: Working with the machine

5.1. Switching on the machine

5.2. Individual control panel on the machine
5.3. Setting the parameters on the display
5.3.1. Individual machine parameters
5.3.2. Start-up values
5.4. Start-up procedure
5.5. Alarm Messages on the screen
5.6. Cleaning the dies
5.7. Shut down procedure
5.8. Trouble shooting
5.9. Maintenance

Spare partslist
Hydraulic drawings
Pneumatic drawings
Electrical drawings

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°2

CHAPTER 1 : TECHNICAL DATA

• Identification : Incomec Cerex Grain Processor

• Electricity : 3*380 or 3*220 VAC 50 or 60 Hertz

• Maximum Power consumption :

Model Power Consumption

CEREX-6-LR 11,1 kW
CEREX-3-SQ 8,6 kW
CEREX-21-MI 8,6 kW
CEREX-44-MB 11,1 kW
Other shapes To be specified

• Air Consumption : approximately 150 Normal-litre per minute

• Dimensions : Width 535 mm

Length 1235 mm
Height 2150 mm

• Weight : 550 KG or 1210 Lbs.

• Manufacturer : INCOMEC-CEREX N.V.

Industrielaan 18A
B-9660 Brakel
Belgium

Tel: + 32 55 43 16 20
Fax: + 32 55 42 73 08

E-mail: info@incomec-cerex.com

Website: http://incomec-cerex.com

________________________

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°3

CHAPTER 2 : INSTALLATION OF THE MACHINE

2.1. Transport of the machine

• The machines are delivered on a EURO-pallet.

• Remove plastic and cardboard protection.
• Machines are bolted to the pallets through the holes in the machine structure, which are
later used to fix the machines to the floor.
• The machine is strapped to the pallet with a steel strap: be careful when cutting the
steel strap, because it is under a lot of tension and thus can cause injuries when cut.
• The machine now has to be lift from the pallet by means of a forklift with sufficient loading
capacity.
• To lift the machine from the pallet,place a a steel rectangular or square tube under the
mounting plate of the two top cylinders.
• Put a ribbon of sufficient capacity around this tube and and slowly lift the machine from its
pallet.
• Remove the pallet and and put the machine to its place.

2.2. Electrical connection

• The machine needs to be connected to

the power supply by means of a cable of
sufficient section according to the
maximum power consumption of the
machine type.
• This cable is connected to the machine
by means of the supplied female plug
which is connected to the the male plug
underneath the electrical control box at
the back of the machine.
• This connection cable has to be
protected by the necessary fuses.

2.3. Air Connection

• Each machine has to be connected to

the air supply with a tube of sufficient
section (6mm exterior/4mm interior).
• The air-supply to the machine can be
switched off by pulling up the special
valve at the back of the machine.
• The remaining air is then removed out of
the cylinders for safety reasons.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°4

2.4. Fixing the machine to the floor

• The machine has to be bolted to the floor to avoid that the machine will change its
position while working. For this purpose, there are two holes in the floorplate of the
machine.
• Use a bolt of sufficient diameter to fix the machine to the floor.

2.5. Take-away conveyor

• In front of the machines a take away conveyor is installed.

• This conveyor needs to be placed sufficiently high and a chute needs to be installed to
guide the cakes to the conveyor when they are ejected.
• The chutes are preferably fixed to the conveyor by hinges which makes it possible to put
the chute in a different position, thus preventing the cakes to fall on the conveyor (for
instance when adjusting or after cleaning the machine during production

2.6. Distance between the machines

• The machines should be placed at a centerdistance of at least 900mm.

• The distance from the back of the machines to the wall needs to be at least 600mm in
order to be able to open the door of the electrical control box at the back of the machine.

2.7. Air suction hood

• An air suction hood needs to be installed above the line of machines to have a sufficient
removal of the fumes created by the baking process.
• It is advisable to have a fan with a capacity of at least 1000 cubic meters of air per hour
and per meter length of the air suction hood.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°5

CHAPTER 3 : PREPARATION OF THE RAW MATERIALS

3.1. The different grains

Several starchy grains can be used on the grain processors and also mixes of several
varities.
Also other ingredients can be used, like pelletised products made of wheat -, potato-, corn-,
rice-flower and starches .

Base Grains:

• 100% rice ,brown or white ,whole or broken

• 100% wheat
• 100% degermed broken popcorn
• other ingredients to be added (percentages of mixes and processing conditions may vary
and may be subjected to testing on site)
broken corn
rye
oats
buckwheat
soybean
millet
barley
peas
sesame
amaranth
quinoa
other starchy grains
salt
dry spices (*)

(*)These dry spices will loose a lot of their intial taste due to the temperatures during the
baking process. It is therefore recommended to apply spices or flavors after baking the
cakes by means of the CEREX coating system.

!!! NO PRODUCTS CONTAINING SUGARS CAN BE ADDED TO THE MIXES !!!

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°6

3.2. Addition of moisture

• The moisture of the grains should be checked and if necessary water should be added to
achieve the desired moisture level.
• The desired moisture percentages for the different grains should be tested on site.
• Normally,a good percentage of moisture for both wheat and rice should be in between 15
and 16 %.
• It is necessary to give the grains a sufficient mixing action while adding the water to
improve the even distribution.
• After adding the water to the grains one should give the grains some time to absorb the
moisture to the heart of the kernel.
• It is recommended to add moisture separately to different kind of grains because of the
difference in water absorbing characteristics. One kind of grains might absorb much more
moisture than another kind.
• The addition of some lecithine to the water before mixing it with the grains might give the
finished cake a smoother surface. It will also help to keep the dies clean for a longer
period and will facilitate the removal of the cakes from the dies (anti sticking agent).

3.3. Grain specifications and quality

• The INCOMEC CEREX GRAIN PROCESSOR can use a lot of different raw materials to
make cakes with.
• It is recommended to do some tests with different varities of the same grains because
there might be a lot of difference in the finished cake.
• The raw material should certainly NOT CONTAIN:
Stones
too small pieces
dust
foreign materials..

• When using wheat,best results are achieved with pearled wheat (4 to 8 %)

• Pop corn should be degermed and broken to a regular size (size five)
• In most cases, a better quality of raw materials will lead to a better quality of finished
product and less waste.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°7

CHAPTER 4 : SETTING UP THE MACHINE

4.1. Description of the machine and its parts

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°8

The main components of the machine can be seen on the drawing.

• Floorplate
• piedestal
• hydraulic group
• hydraulic coils
• central greasing system
• electric control box rear
• electric control box front
• pressure transmitter
• hydraulic cilinder
• die
• feeding system
• feeding hopper

Hydraulic group

• Motor
• pump
• filter
• 4/3 valves with coil
• pressure regulator
• pressure dial
• shut off valve for pressure dial

Hydraulic cylinder and pressure transmitter

• front cylinder
• rear cylinder
• reed contacts
• pressure transmitter
• upper lever
• lower lever
• stop bolts
• safety bar

Die

• lower die
• upper die
• ring die
• heating elements
• temperature sensors(PT100)
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Feeding system

• feeding plate
• cilinder for moving forward feeding plate
• cilinders for opening the holes in the feeding plate
• reed contacts on cylinders
• speed regulator for air cylinders moving ring die
• feeding hopper
• grain level sensor

Upper block

• safety screen
• safety switch
• linear cylinder for movement of blower
nozzle
• blower nozzles for cleaning
• cilinders for moving ring die

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°10

4.2. Alignment of the die

• As soon as the machine is installed properly, the upper and lower die must be aligned in
order to create the same pressure and baking conditions all over the die surface.
• The die must be clean, because the material in between this die can disturb the alignment
procedure.
• The following steps should be followed and can only be done by a technician who takes
care of the following safety procedures.

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS SHOULD BE

REMOVED TO ALIGN THE DIES.

PUT BACK SAFETY GUARDS AFTER ALIGNING THE DIE.

1. Loosen up al four nuts above and underneath the upper block, so the upper block and die
can move freely when lifted up by the lower die.

2. Shut off air pressure.

3. Start the hydraulic motor.

4. By pushing in the buttons on the hydraulic valves on the right hand side of the machine (if
seen from the front side) the under die will start to go up, thus taking also up the upper die
and upper block at which the upper die is fixed.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°11

5. The lower die should be pushed upwards until the two levers of the pressure transmitter
reach a position of two to five degrees before vertical position.

6. The upper nuts can now be lowered against the upper block and lightly tightened,thus
aligning the upper die against the lower die.The lower nuts can now also be tightened
lightly so the upper die and block are immobilised.

4.3. Position of the upper die

When the machine will work with material,the upper die will probably have to be raised in
order to reach the same position of the levers (2 to 5 degrees before vertical position).
However, it will now be necessary when raising or lowering the upper die, to rotate the upper
nuts the same amount of (partial) rotations (in the same direction!)

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°12

4.4. Setting of the feeding system

The following steps should be followed and can only be done by a technician who takes care
of the following safety procedures.

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS SHOULD BE

REMOVED TO SET THE FEEDING SYSTEM.

PUT BACK SAFETY GUARDS AFTER SETTING THE FEEDING SYSTEM.

• The complete feeding system can be adjusted by means of several screws.

• When loosening the screws XX it is possible to adjust the height of the feeding system.
• The feeding system should be at a position that it doesn’t touch neither the lower nor the
upper die.The feeding plate also has to push out the finished cakes which is also impor-
tant for the exact height of the feeding system.
• When loosing the screws YY it is possible to move back- or forward the feeding system.
• The exact position is when the holes of the feeding plate will drop the material right in the
center of the die when the cylinder which is moving the feeding plate is in its most forward
position.
• The hopper can be regulated also. It is done by means of the nuts ZZ.
• It is necessary to have a very small space in between the under side of the hopper and
the surface of the feeding plate in order to prevent the hopper from damaging the feeding
plate.
• By raising the hopper a little bit ,it is possible to put a little bit more grains in the holes and
thus to influence the weight of the cakes a little bit.
• Of course the space in between the hopper and the feeding plate has to stay small
enough in order to prevent the grains from being spilled.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°13

4.5. Hydraulic pressure regulation

The following steps should be followed and can only be done by a technician who takes care
of the following safety procedures.

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS SHOULD BE

REMOVED TO REGULATE THE HYDRAULIC PRESSURE.
PUT BACK SAFETY GUARDS AFTER REGULATING THE HYDRAULIC PRESSURE.

• To regulate the hydraulic pressure from the pump the settingscrew has to be turned
clockwise (raise pressure) or counterclockwise (lower pressure).
• One of the buttons on the hydraulic valves at the left hand side of the machine (seen from
the front) should be pushed in to see the actual pressure on the pressure dial.
• The settingscrew has to be turned while pushing in this button so one can see how much
the hydraulic pressure will be.
• Normally it has to be in between 80 and 120 bars.The pressure will depend a.o.on the
weight of the cakes, the grains that are used the position of the upper die. It will be also
decided after the first tests on site with the appropriate grains.
• Once the pressure is set, the locking nut should be tightened in order to prevent the
setting screw from changing its position.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°14

4.6. Position of reedcontacts on the hydraulic cilinder

The following steps should be followed and can only be done by a technician who takes care
of the following safety procedures.

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS SHOULD BE

REMOVED TO POSITION THE REEDCONTACTS ON THE HYDRAULIC CILINDER.
PUT BACK SAFETY GUARDS AFTER REGULATING THE REEDCONTACTS ON THE
HYDRAULIC CILINDER .

• The reedcontacts are numbered 2,3,4 and 5.

• Starting from the front side of the machine they are placed in the following order:
5,4,2,3
• The several positions of the lower die are determined by the positions of these
reedcontacts.

Bottom position

Contacts nr° 2 and 4 are lit.

The lower die falls to this position when the alarmbutton is switched to the
‘ON’position.
These two contacts have to be lit to be able to restart the machine.
In case contact nr° 2 is not lit one needs to push in the button lower button on the
hydraulic valve at the right hand side of the machine.
The hydraulic cilinder most towards the back of the machine will than move out and
the contact n° 2 will lit up.
As soon as this occurs, release the button.
It will be possible now to restart the cycle.
The alarmbutton is normaly swiched to the ‘ON’ position when one wants to clean
the under die.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°15

Middle position

Contacts nr° 3 and 4 are lit. In this position, th e feed slide is ejecting the cake and
filling in the new load of grain.

Crushing and baking position

The contact nr° 5 will be lit. In this position th e grains are crushed and baked during
a certain time.(Pressure time and baking time)
After baking the cake the hydraulic cilinder most towards the front side of the
machine will move from reedcontact nr°5 to reedcont act nr° 4 thus creating an
expansion chamber and allowing the grains to expand.

Ejecting position

Reedcontact nr° 4 and nr° 3 will be lit and the ca ke will be ejected.
After ejecting the cakes, the lower die will go down a little bit to form a cup in which
the new load of grains will be dropped and the cycle will start again.

RESUMED:

Reedcontact nr° 5 :will decide how big the expansi on chamber will be and thus the
thickness of the cake (together with the Thickness Time parameter)

Moving it towards the front of the machine=bigger expansion chamber and thicker cake.
Moving it towards the back of the machine=smaller expansion chamber and thinner cake
When moving it too much towards the front of the machine, the under die will drop too
much and will drop out of the ring die and the grains will escape together with a loud
explosion noise.
When moving it too much towards the back of the machine, the expansion chamber which
is created will be not enough, and the cake will explode a second time as soon as the die
is opening up.
Reedcontact nr°4 : is always placed at the end of the stroke (completely inwards) of the
hydraulic cilinder C.
Reedcontact nr°2 : the position the cilinder B wil l move to when the alarm stop button is
switched to’ON’ (Cilinder C will also move to the most inwards position reedcontact nr°4)
Reedcontact nr°3 : the position the cilinder B wil l move to when moving forward the
feeding plate. (Cilinder C will be at the most inward position). The positioning of this
contact should be adjusted so that the surface of the under die is a little bit higher than the
top surface of the ring die and thus the finished cakes can easily be removed.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°16

When it is too much towards the front of the

machine the cakes will be stuck in the ring die
and break when ejecting them.

When it is too much towards the back of the

machine the under die will be too high and the
feeding slide will hit the under die and the
pneumatic cycle will be interupted and the
machine will stop working and go into alarm
condition.

4.7. Position of reedcontacts on pneumatic cilinders

The following steps should be followed and can only be done by a technician who takes care
of the following safety procedures.

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS SHOULD BE

REMOVED TO POSITION THE REEDCONTACTS ON THE PNEUMATIC CILINDERS.
PUT BACK SAFETY GUARDS AFTER REGULATING THE REEDCONTACTS ON THE
PNEUMATIC CILINDERS

The reedcontact on the pneumatic cilinder which is moving the feeding plate forward
should be placed on the end of the stroke of this cilinder (reedcontacts 0 and 1)
The reedcontact on the pneumatic cilinder which is opening the holes in the feeding plate
should be lit when the holes are totaly closed (reedcontact 0’).
The two reedcontacts 0 and 0’ are connected in serial and when one of these two reed-
contacts is not in the right position neither of them will light up. The machine will not start
its cycle.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°17

CHAPTER 5 : WORKING WITH THE MACHINES

5.1. Switching on the machine

• Switch on the air supply of the machine.

• Switch on the electrical switch from the PLC and also on the electrical control panel at the
back of the machine.
• Close the safety guard on the front of the machine.
• Start up the hydraulic motor.
• Check if the under die is in the ring die.
• If not, put the under die in the ring die :

- Switch the ‘alarm stop’ button from ‘OFF’ to ‘ON’ and back to ‘OFF’
- Push the ‘ start ‘ button and the under die will go up and enter in the ring die.
- Push the ‘stop’ button to stop the cycle as soon as the under die is inside the ring die.

• Switch the button ‘heating’to ‘ON’ : the machine will start to heat up.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°18

5.2. Individual control panel on the front of the machine

On this control panel there are several buttons

1. START CYCLE:
Starts the cycle if the under die is in the exact position,and all other cylinders are in the
exact starting position.

2. STOP CYCLE:
Stops the cycle IMMEDIATELY if pressed and will put the aircilinders back in their original
start position and will immobilise the hydraulic cylinder in its current state. It is
recommended to stop the machine when the cakes are ejected and before the new load of
grains is dropped.

3. ALARM STOP:
When switched from ‘OFF’ to ‘ON’ the lower die will drop to its lowest position, and the
ring die will move upwards around the upper die. This switch is used to put the under die in
a position to be able to clean it. It is also switched from ‘OFF’ to’ON’ and back to do a reset
of the machine to be able to restart it when the machine is not in restart position (hydraulic
cylinders are not in the correct position to be able to restart the machine)

4. HEATING:
When switched from ‘OFF’ to ‘ON’ the dies will start to heat up untill the desired tempe-
ratures are reached.

5. SAFETY STOP:
will stop the cycle immediately: aircilinders move back to their initial position and hydraulic
cylinders are immobilised.The hydraulic motor is also stopped and heating is switched off.
This safety button is switched back to ‘OFF’ position by giving it a quart turn.

6. START/STOP HYDRAULIC:
Will start/stop the hydraulic motor.When the motor is running the indication light will
lit up.

7. ALARM FAULT LIGHT:

This light will flash when the machine is in alarm condition or when the grain level in the
hopper has dropped below minimum level.
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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°19

5.3. Setting the parameters on the display

5.3.1. Individual machine parameters

The individual parameters which can be set on the display are;

T1 : Temperature upper die (Max:325°C)

T2 : Temperature bottom die (Max:325°C)

Baking time : Time during which the grains are heated in between the
closed dies (hydraulic cylinders are immobilised, no
hydraulic pressure applied)
Max:7.5 sec(or 750 in 0.01 sec.)

Pressure Time : Time during which the grains are crushed in between the
Dies (hydraulic pressure applied)
Max:150 in 0.01 sec.

Thickness Time : After the dies have created an expansion chamber, there is
the possibility to let the under die rebounce during a certain
time to reduce the thickness of the cake or to make the
surface flatter.The higher the thickness time, the more the
bottom die will rebounce and the thinner the cake will be.
Putting the thickness time to 0 will prevent the bottom die
from rebouncing.
Max. 20 in 0.01 sec.

Cup Time : When the cakes are ejected ,the bottom die will drop during
a certain time to create a cup in which the grains will be
dropped.The higher the cup time, the deeper the cup.
Max. 25 in 0.01 sec.
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The setting procedure for the parameters is the following:

Move the cursor to the parameter you want to set by means of the arrow buttons.
Once the cursor is at the right position, you can give in the value by means of the numeric
buttons.
The new value is now entered by pushing the enter button.

5.3.2. Start Up Values

The Start Up values can not be set for each individual machine but are set for all the
machines linked to the same PLC.

The parameters on the screen are the following:

Min.Baking Time
Min.Pressure Time
Number of cycles
Numberof cycles cleaning.

The meaning of the first three of these parameters is the following:

When the machine is stopped for a time longer than two minutes, the surface temperature of
the dies will be higher as when the machine is constantly working. The surface is not
anymore cooled by the cold grains coming into contact with the die surface.
When the machine is restarted, the temperature will be higher and the cakes will be baked
too much.
To overcome this difficulty, the PLC will automatically take a shorter baking and pressure
time and will gradually build up untill the baking time and pressure time set on the individual
machine parameter screen is reached. It will build up gradually in as much steps as the
number of cycles you have set1. A normal value for this parameter would be five cycles.

The parameter ‘number of cycles cleaning’ will decide after how much cycles the cleaning
system will clean the die one time.

5.4. Start Up Procedure

• As soon as the machine is switched on properly and heated up (takes at least three
quarter of an hour)the grains can be filled into the hopper.
• Make sure to close the safety screen in front of the machine and push the start button.If
the machine is not in the right position, the machine will not respond to this start signal.
• The machine then needs to be reset by turning the ‘alarm’ switch from ‘off’ to ‘on’ and
back to ‘off ’.
• The under die will drop down, the ring die will go up and then back down.
• The under die is not anymore in the ring die so push the start button to start the machine
cycle.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°21

5.5. Alarm messages on the screen

Several alarm messages can appear on the screen. They can be cleared from the screen by
pushing the appropriate “acknowledged” button.

The last alarm messages will be stored automatically in the alarm messages file.

• No grainlevel

Will appear as soon as the grain level in the hopper will drop below its minimum
level. You now have five minutes to fill up the hopper,otherwise the machine will stop
automatically after ejecting the last cakes.

• Temperature Upper /Lower die too High/Low

The difference between the setpoint temperature and the actual temperature is too big.

• Interrupt pneumatic cycle

It takes too long for one of the air cilinders to move from one end of its stroke to the other
end.

It could mean that there is a mechanical cause that is blocking the free movement of one of
the air cilinders.
It could also mean that the air pressure has dropped.

• Interrupt hydraulic cycle

It takes too long before one of the reedcontacts is lit up.

This means that for some reason the hydraulic movement is blocked. This could have either
a mechanical cause or the hydraulic group may not be switched on.

• Hydraulic motor

This means that the thermal overload protection of the hydraulic motor has switched of.

The power supply to the motor should be checked.

The current in all three phases must be the same as the one indicated on the motor
identification tag.
The setting of the thermal overload protection should be the same as the current indicated on
the motor identification tag.

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INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°22

5.6. Cleaning the dies

TAKE CARE OF MOVING PARTS BECAUSE THE FRONT SAFETY GUARD HAS TO BE
OPENED FOR CLEANING THE DIE. BY SWITCHING THE ‘ALARM STOP’ BUTTON IN
THE ‘ON’ POSITION, THE RING DIE WILL GO UP AND THE UNDER DIE WILL DROP TO
ITS LOWEST POINT.

THE WHOLE DIE AND THE AREA AROUND IT IS EXTREMELY HOT.

TAKE CARE WHEN CLEANING AND WEAR HEAT RESISTANT GLOVES WHEN
WORKING IN THIS AREA OF THE MACHINE.

The dies have to be cleaned as soon as too much dirt has built up in between the ring die
and the lower die. This will prevent the upper surface of the lowerd die to be higher than the
upper surface of the ring die.
The cakes will break when ejected and the machine will start producing bad cakes and even
stop cycling.

• To remove this dirt, one has to use the hook tool.

• Open the front safety guard and place the’alarm stop button’ in the ‘ON’ position.
• The ring die will go up and the under die will drop to its lowest point.
• The hook tool can now be used to remove the carbonised dirt from the under die.an air
gun can be used to blow away the carbonised pieces.
• This carbonised dirt also has to be removed from the underside of the ring die and if
necessary from the upper die.

___________________________________________________________________________________________________
Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004
INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°23

After a long time working with the machines, a carbonised layer can appear on the die
surface. This layer will act as an insulator and prevent a good heat transfer to the grains
when being crushed and baked. This might influence the quality of the cakes in a negative
way.

• To remove this layer, one should use a flat piece of wood.

• Around it one should wrap a strip of sand paper (P200!!) on which there are some drops
of a water,oil ,lecithine mixture to make the sandpaper softer. (60% of water,30% of
oil,10% of lecithine).
• The surface of the die can be cleaned.
• The sandpaper and wooden piece should be kept FLAT in order not to round of the edges
of the dies or damage the thin layer of coating on the dies.
• After cleaning the dies ,remove the remaining dirt with a piece of absorbing paper by
means of the same wooden piece.

• After cleaning, close the front safety guard back again and place the lower die back into
the ring die by switching the ‘ Alarm stop ‘button back to ‘OFF’ and by pushing the ‘Start’
button and ‘Stop’ button .

IMPORTANT REMARK!!!:

The excess building up of too much dirt in between the ring die and under die can have
several causes:

the moisture level of the grains is too high

the temperature of the dies is too high
the pressure is too high
the cup is to deep and there are grains which drop out of the cup
………..

___________________________________________________________________________________________________
Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004
INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°24

The building up of a carbonised layer too soon can also have several causes:

too high moisture of the grains

too high temperature of the dies
too much pressure created on the grains when crushed and baked
one of the components mixed with the grains is creating a lot of carbonisation
there are a lot of sugars within certain grains…

In general, the building up of this carbonisation on the surface of the dies can be reduced
drastically by using a little bit of lecithine in the water the grains are moisturised with.

The down time of the machine for cleaning will reduce drastically when using the right
moisture, temperature, grains, pressure, mechanical machine-settings.. and preferably a
little bit of lecithine in the water.

5.7. Shut down procedure

Before shutting down the machine, it is necessary to clean the die with the hook tool and to
blow it of with an air gun to remove the carbonised pieces. If necessary, the die surface
should also be cleaned with sandpaper and the water/oil/lecithine emulsion.

The lower die is placed back into the ring die.

• Put the ‘Heating’ button into the ‘off ‘ position.

• Shut down the hydraulic motor
• Switch off the electric control panel at the back of the machine.
• Switch off the air supply to the machine.
• Switch off the PLC and display

Make sure to remove the remaining grains from out of the hopper. The grains will dry out and
make it very hard to restart the machine the next day. The grains can be removed by using a
vacuumcleaner.

BE AWARE THAT THE DIE OF THE MACHINE AND THE AREA AROUND THE DIE WILL
STAY VERY HOT UNTILL THE MACHINE HAS BEEN SWITCHED OFF FOR A COUPLE
OF HOURS.

5.8. Trouble shooting

1. The machine is not heating up

• Check if the power supply is OK

• Check if the temperature parameters on the screen are set to the desired temperature
• Check if the PLC is switched on.
• Let an electrician check the fuses in the electrical control box at the back of the
machine.
• Check if the temperature sensor is not broken or detached.The temperature on the
screen will then read ***
___________________________________________________________________________________________________
Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004
INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°25

2. The hydraulic group can not be switched on

• Check if power supply is OK

• Check if the thermal overload protection is still switched on.

3. The hydraulic cilinder is not moving ,even when the buttons on the hydraulic
valves are pushed in manually and the motor is running

• Check the oil level of the hydraulic group

4. The machine is not starting its cycle when pushing the ‘Start ‘ button

• Check if power from machine and PLC are switched on.

• Close the safety guard on the front side of the machine
• Reset the machine by switching the ‘Alarm Stop’ button from ‘OFF’ to ‘On’ and back to
• ‘Off ’; Push the ‘ start ‘ button again.
• Check if the necessary reedcontacts are lit (See section ‘Position of reedcontacts on
hydraulic and pneumatic cilinders ‘ )
• Check if air is switched on.

5. When pushing the ‘start’ button,the machine moves forward the feeding plate and
goes back without dropping the rice.

• Fill up the hopper with grains

6. The cakes are not strong enough

• Check if the desired temperature is reached for both upper and under die. If
necessary make the temperature higher.
• Check if the hydraulic pressure is OK.
• Check if the position of the upper and under lever is a little bit before vertical position
when crushing the grains.
• Check if the moisture of the grains is OK

7. The cakes have a burnt taste and smell

• Check the temperature and reduce if necessary

• Lower the baking time if necessary.

8. The cakes don’t look the same.

• Check the weight of the individual cakes.If too much difference,it can mean that the
holes in the feeding plate are (partially) plugged.Check and clean if necessary.
• The alignment of the dies is not correct. Check and adjust

___________________________________________________________________________________________________
Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004
INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°26

9. The cakes are burnt on one side.

• The grains are not dropped right in the center of the die.Check and adjust the feeding
system.
• The surface of the dies is (partially) dirty.Clean if necessary.

10. The material is squirting out of the die when crushing and baking

• Check the temperature of the dies.Lower if necessary

• Moisture is too high. Lower the moisture of the grains.
• The pressure is too high.Lower hydraulic pressure.
• The two levers are going beyond their optimal position.Lower the upper die.

11. The grains are dropping out of the cup

• Reduce the ‘cup time’ parameter.The cup is too deep

12. The grains spill on the ring die

• Make the ‘cup time’parameter higher.The cup is not deep enough

13. The cup is deep enough,but the grains spills on the ring die when the under die and
ring die start to go up.

• The speed of the air cilinders making the ring die go up is to slow compared to the
speed of the under die going up. Increase the speed of the air cilinders moving the
ring die up by turning the adjustable speed regulator.

14. The under die drops out of the ring die when expanding the cakes, thus generating
the loud noise of an explosion.

• The position of reedcontact n°5 is not correct (S ee section on positioning of

reedcontacts on hydraulic and pneumatic cilinders )

15. The cakes are expanded a second time when the die is opening to eject the cakes

• The position of the reedcontact n° 5 is not correc t .The cakes have not enough room
to expand and will expand a second time in a very uneven way when the die is
opening to eject the cakes. (See section on positioning of reedcontacts on hydraulic
cilinder )

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Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004
INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°27

16. The machine is unable to keep its temperature when it is producing cakes, the
cakes are not baked uniformly

• Ask a skilled electrician to check if all of the heating elements are still functioning (by
means of an ampere-clamp)

17. One of the reedcontacts does not light up anymore.

• Check if the reedcontact is not lighting up anymore even when the clinder is moving in
front of this specific reedcontact.
• Change the reedcontact with a new one and check if it is functioning well.

5.9. Maintenance

1. The machine has a central greasing system.

• All necessary greasing points are connected to the progressive distributor and will be
greased one after another as long as grease is pumped in the central grease nipple.
• As long as the system is not plugged up, it is possible to pump grease inside the
distributor.
• It is much more effective to grease the machine at a small time interval with a small
amount of grease than to grease it with a big amount of grease and a long time
interval.
• The machines should be greased every eight hours of production.
• A full automatic greasing system with electric pump is optionally available .
• The grease used in our factory is a foodgrade and temperature resistant grease :
MOLYKOTE VG 02

2. It is advisable to blow of the machine by means of an air gun to prevent the dirt or dust
to attach to the machine frame, dies, feeding system etc..at least once every eight
hours.

3. The hydraulic oil and filter should be changed once a year when the machines are
used in a full continuous system. If not, the oil changing interval can be longer (for
instance approximately three years on an eight hour per day system)

Most suppliers of hydraulic oil will do an analysis FOR FREE to check if the quality of
the oil is still OK. Have the quality checked regularly!!

___________________________________________________________________________________________________
Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004
INCOMEC-CEREX GRAIN PROCESSOR Operating Manual page n°28

The hydraulic oil used in our factory is:

UNIL HFO 46
3 microns filtered hydraulic oil.

Check the level in the oil reservoirs regularly!

4. Due to the smoke and vapour created by the baking process and fine dust inside the
grains it is possible that there is building up some dirt underneath the feeding plate or
inside the holes of the feeding plate.

If this is the case:

• take out the feeding plat

• wash it with some water and soap
• dry the feeding plate
• put it back to its original place.

5. When using dry and clean air it is not necessary to use oil lubrication on the air supply.
it is even not recommended since the air is used to clean the die, and thus this oil
might end up in the finished product !!

6. The air-filters in the ventilation inlest of all electric control boxes have to be cleaned
once per month. The can be washed out and dried afterwards or they can be cleaned
with an airgun.
After some time it will be necessary to replace them with new filters.
Not regularly cleaning the filters may result in a lack of ventialtion inside of the electric
control boxes and thus excessive heating with damage to the electric and electronic
components as a result.

__________________________

___________________________________________________________________________________________________
Tel. : +32 55 431620 e-mail : info@incomec-cerex.com date: 03/06/2004