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Page 1: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

6000000802 1206 GB

600

Food Processing Machinery

Desinewing MachineOperating Instructions

Page 2: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

GB

Nordischer Maschinenbau Rud. Baader GmbH + Co.KGPostfach 1102 D-23501 LübeckGeniner Str. 249 D-23560 LübeckPhone +49 / 451 / 5302-0Telex 26839Internet www.baader.come-mail [email protected]

Fax:Sales +49 / 451 / 5302-492Project Eng. +49 / 451 / 5302-494R & D +49 / 451 / 5302-495Shipping +49 / 451 / 5302-483Purchasing +49 / 451 / 5302-493

Preface

Preface

This operating manual is dedicated to the personnel responsible for the operation and mainte-nance.

Set up, commission and operate the machine only when having perfect knowledge of this operat-ing manual and by strictly observing the instructions given therein.

Nordischer Maschinenbau Rud. Baader GmbH + Co. KG

will not assume any liability for damages due to the nonobservance of the operating manual, insufficiently trained personnel, improper handling of the machine as well as its application in other fields than those specified in the operating manual!

In case of arbitrary modifications by removing or mounting parts or any conversion of the machine without our approval, our conformity declaration (EC directive) will become invalid.

Do not use other than genuine BAADER spare parts!

It is absolutely necessary to observe the legal safety regulations for food processing machinery which are in force in your country!

This operating manual is our intellectual property and may neither be copied, reproduced or made available to third parties without our written approval, nor may it be misused!

Page 3: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

GB 1

600Table of Contents

Table of Contents

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3 Outline drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

6 Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

7 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

9 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

10 Setting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

11 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

12 Selection of the perforated drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

13 How to treat the squeezing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

15 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

17 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

18 BAADER 600 with DMM 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

19 Country-related list of cleaning agents and disinfectants . . . . . . . . . . . . . . . . . . . .35

20 HENKEL sales partners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

21 Lubricants and preservatives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

22 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Page 4: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

2 GB

Meaning of the pictograms

Meaning of the pictograms

Important note!

In case of non-observance, impairments of the machine or of property assets cannot be ruled out!

Particular attention is required - danger of bodily injury!

Danger to life in way of unprotected electrical systems!

Page 5: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

GB 3

600Safety instructions

Safety instructions

Important for machine operators!

Non-specified use as well as improper operation of the machine can result in serious bodily inju-ries and severe material damages. It is absolutely necessary that the operators observe the fol-lowing safety instructions!

• Read the operating instructions prior to starting up the machine!• Unauthorized, untrained personnel must not put the machine into operation and/or carry out

any work at the machine!• Wear tight-fitting working cloth, especially around arms!• Tie long hair together and cover!• Do not wear any finger rings!• Do not reach into running machine!• Do not use the machine to put any article on it!• Do not run the machine unattended!• Switch off the machine, put the main switch to 0-position and secure it:

- in case of failure of the functional sequence- prior to cleaning- prior to maintenance- prior to lubrication

• Warning signs attached to the machine must at any time be legible for the operators! Defective or missing warning signs have to be replaced immediately!

• Have repair work carried out by qualified personnel only strictly observing these operating instructions!

• The safety devices installed by the manufacturer must not be bypassed, modified or removed!• Spraying by means of sprays of any kind whatever in electrical enclosures and control gears is

prohibited; explosion hazard!

Page 6: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

4 GB

Safety instructions

Safety instructions

Fit all hoods and covers prior to commissioning the machine.Verify the proper functioning of all safety devices!During operation, the machine must stop when …… setting the main switch (1) to 0-position

The machine shall not be commissioned when …

… the intermediate wall (2) is not in operating position!… the storage bin (3) is not in operating position!… the front panel (4) is not in operating position!… the squeezing belt (5) is not fitted!… the perforated drum (6) is not installed!… the scraper (7) is not installed!… a perforated drum with holes of more than 5 mm is installed and the safety

guard provided is not fitted to the machine!

The parking brakes (8) of the castors shall only be released for displacing the machine! After the machine has been displaced, the brakes must be applied again!

In the event of power failure, the main switch of the machine will be set automatically to 0-posi-tion! Once the power is available again, the main switch must be set to position I in order to restart the machine.

5

2

4

7 1

3

6

8

Page 7: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

GB 5

600General

1 General

The BAADER 600 is used for separating soft components from solid components according to a press-separation method.

For instance fish filets from skin and bones, meat and poultry from sinews and cartilages, dairy products from their packages, fruits and vegetables from the skin, pips and stones.

1

Page 8: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

6 GB

Technical data

2 Technical data

Throughput rate* : up to 400 kg/h as a function of the initial product and the size of the holes in the perforated drum

Power consumption : 1.5 kW

Dimensions- width : approx. 1200 mm- depth : approx. 910 mm- height : approx. 1140 mm (max. 1603 mm)

Weight : 220 kg

Operator requirements : 1 person

Noise measurement (evaluation according to DIN 45635) Workplace level (LpA) : 70 dB(A)

* The throughput rate of the machine is contingent upon the raw product to be processed (fish, meat, poultry, fruits or vegetables, packages, etc.), furthermore on the preparation, tempera-ture of the raw product, on the type of feeding, the adjusted pressure of the squeezing belt and on the size of the holes in the perforated drum.

Page 9: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

GB 7

600Outline drawing

3 Outline drawing

1 Power connection2 Initial product3 Final product4 Waste

2

878

3

4

4

1

2

4

1170

502

1046

291

1577

422

1144

R480

567

731

602

1550

R592

682

657

3

2

2

Page 10: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

8 GB

Transport

4 Transport

Lift the machine from the front or back (figure 3, arrows) using a forklift truck or elevating-platformtruck.If none of these industrial trucks is available, then the machine can be lifted from the pallet bymeans of two squared timbers each of approx. 1500 mm in length.

Transport the machine with the necessary care!

Only the load lifting devices provided or equivalent approved ones shall beused!

After the transport, the castors previously removed must be refitted to the machine. Arrange thecastors with the parking brakes (fig. 3, item 1) as shown in figure 3.

The parking brakes of the castors shall only be released for displacing themachine! After the machine has been displaced, the brakes must be appliedagain!

31

Page 11: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

GB 9

600Set-up

5 Set-up

The location provided for the machine must be horizontal!The machine must be readily accessible from all sides for ease of operation and maintenance(figure 4).After the machine has been set up, apply the parking brakes of the castors.

The parking brakes of the castors shall only be released for displacing themachine! After the machine has been displaced, the brakes must be appliedagain!

4

800 mm

800 mm

400

mm

800

mm

Page 12: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

10 GB

Power connection

6 Power connectionThe machine is equipped with a cable of 5 m in length with Euro plug.If national standards require the plug to be changed, then the machine must be connected to the mains according to the circuit diagram taking into account the provisions of the local power sta-tion and the standard EN 60204 as well as VDE 0100 in order to comply with the legal safety reg-ulations.Seal the cable bushes and screw so that they are watertight.

The electric gear of the machine connected to the mains contains hazardous alive, blank parts, and during operation, moving and/or rotating parts if the main switch is put to ”ON” position! Removal of any covering is prohibited! Improper operation or insufficient maintenance can result in serious bodily injuries and severe material dam-ages!

Consequently, the persons who are responsible for the safety of the machine, have to ensure that ...… any work to be carried out on the machine is only entrusted to qualified personnel,… the operating instructions as well as all information required for carrying out works are always

available to this personnel who will be bound to strictly observe the contents of such informa-tion,

… any work on the machine or in its vicinity by unqualified personnel is prohibited.

Spraying by means of sprays of any kind whatever in electrical enclosures and control gears is prohibited; explosion hazard!

Verification of the motor's sense of rotationWhen looking into the drum, the sense of rota-tion of the perforated drum is clockwise (figure 5).

If the mains power is not applied to the machine, the main switch cannot be set to position I but will return automatically into position 0 when released!

5

Page 13: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

GB 11

600Safety devices

7 Safety devicesIn order to prevent accidents and personal injuries, it is absolutely necessary to observe the safety reminders at the beginning of this operating manual!It is prohibited to bypass, modify or remove the safety devices installed by the manufacturer!In the event of power failure, the main switch of the machine will be set automatically to position 0. Once the power is available again, the main switch must be set to position I in order to restart the machine!

If a perforated drum with holes of more than 5 mm is installed in the machine, the safety guard provided must be fitted to the machine! It is prohibited to operate the machine without this safety guard when using a perforated drum with this hole size!

Page 14: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

12 GB

Operation

8 OperationThe machine processes the initial product con-tinuously.The material to be separated is loaded via the bin (fig. 6, item 1).The squeezing belt (fig. 6, item 2) presses the initial product against the perforated drum (fig. 6, item 4) during which process the soft compo-nents are pressed through the holes into the inner drum space. A conveyor screw (fig. 6, item 4) discharges the components pressed through the holes from the perforated drum.The solid components remain on the outer drum shell. They are removed by a scraper (fig. 6, item 5) and discharged via a chute (fig. 6, item 6).The use of another perforated drum may be required as a function of the initial product. Perforated drums with different hole diameters are available (cf. section 12).

When separating meat from sinews, the fibre structure of the meat remains intact, as the initial product is neither chopped nor triturated or ground. The brief passage through the holes results only in a minor warming of the product.

6

4

53

1

2

6

Page 15: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Commissioning procedure

9 Commissioning procedureIt is absolutely necessary to disassemble and clean the machine prior to commissioning.

9.1 Disassembly

• Set the main switch to position 0 and protect it using a padlock

• Remove the conveyor screw (fig. 7, item 1)• Remove and disassemble the scraper (fig.

7, item 2) including the axle• Relief the belt pressure by means of quick

release- Lift the tensioning lever (fig. 8, item 1)

and lower laterally from the sliding block (fig. 8, item 2)

• Completely reduce the belt tension and remove the lever (fig. 7, item 3)

• Loosen the drum nut (fig. 7, item 4; fig. 9, item 1) and remove it together with the disk (fig. 9, item 2) from the perforated drum

2

14

3

7 12

8

9

1

2

GB 13

Page 16: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Commissioning procedure

• Fit the extractor (fig. 10, item 1; supplied with the machine) to the perforated drum (fig. 10, item 2) and withdraw the drum with the necessary care

Consider the weight of the perfo-rated drum!

• Loosen and remove the nuts (fig. 12, item 1)• Hinge down the front panel (fig. 12, item 2)

(fig. 11, item 1)• Hinge up the storage bin (fig. 12, item 3) (fig.

11, item 2)• Remove the squeezing belt, pressure device

(fig. 13, item 1) and the rollers (fig. 13, item 2)

• Remove the tensioning roller (fig. 13, item 3)• Adjust the belt tensioning eccentric (fig. 14,

item 1) and the pressure roller (fig. 14, item 2) so in relation to the intermediate wall (fig. 14, item 3) that the latter can be pulled up

• Clean the machine as described in section 15.3.1

Cleaning agents endangering the envi-ronment are to be disposed of accord-ing to the applicable regulations!

2 1

10

2

1

11

11

1

12

3

12

13

2

1

3

14

1

2

3

4

14 GB

Page 17: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Commissioning procedure

9.2 Assembly• Push the intermediate wall (fig. 14, item 3;

fig. 15, item 1) against the housing and make sure that it is level with the locating flange (fig. 15, item 2) for the perforated drum

• Fit the pressure device (fig. 15, item 3) of the housing side

• Grease the belt tensioning eccentric (fig. 15, item 4) and the axles (fig. 15, item 5) using special BAADER grease GLS 380/N3 and mount the rollers (fig. 15, item 6)

• Fit the tensioning roller (fig. 15, item 7)• Fit the outer pressure device (fig. 15, item 8) • Fit the squeezing belt pressing it under the

drum fastening bolts (fig. 15, item 9)• Swivel the storage bin into operating posi-

tion

• Swivel the front panel into operating position and secure it by means of the nuts

The inner surface of the front panel must be level with the offset of the perfo-rated drum!

• Insert the centring piece (fig. 16; provided with the standard tools) for the perforated drum

• Place the perforated drum with the fitted extractor on the squeezing belt• Push the perforated drum over the centring piece on to the square (fig. 15, item 10)• Remove the extractor from the perforated drum• Remove the centring piece• Fasten the perforated drum by means of the disk (fig. 17, item 1) and the nut (fig. 17, item 2),

during which operation the disk is fixed with the bolt (fig. 15, item 9)

3

7

28

101

2

4655

9

15

16 17

2

1

GB 15

Page 18: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Commissioning procedure

• Install the conveyor screw (fig. 18, item 1)• Insert the scraper and press it with the adjusting screw (fig. 18, item 2) against the perforated

drum (cf. section 10.1)• Fit the belt tensioning lever (fig. 18, item 3)• Adjust the tension of the squeezing belt (section 10.2.2)• Adjust the belt pressure (section 10.2.1)• Remove the cap from the vent plug (fig. 19, item 1) of the gear motor (fig. 19, item 2)• Verify the proper functioning of all safety devices; cf. safety reminders at the beginning of this

operating manual!• Briefly run the machine and grease in order to remove any penetrated water from the bearings

It is prohibited to bypass, modify or remove the safety devices installed by the manufacturer! The machine shall not be commissioned when …

… the intermediate wall (fig. 18, item 4) is not in operating position!… the storage bin (fig. 18, item 5) is not in operating position!… the front panel (fig. 18, item 6) is not in operating position!… the squeezing belt (fig. 18, item 7) is not fitted!… the perforated drum (fig. 18, item 8) is not installed!… the scraper (fig. 18, item 2) is not installed!… a perforated drum with holes of more than 5 mm is installed and the safety

guard provided is not fitted to the machine!

6

1

23

7

8

4

5

18 19

12

16 GB

Page 19: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Setting instructions

10 Setting instructions

10.1 Scraper• Turn back the adjusting screw (fig. 20,

item 1) • Push the scraper with the support (fig. 20,

item 2) between front panel (fig. 20, item 3) and intermediate wall (fig. 20, item 4)

• Push the axle (fig. 20, item 5) through the front panel, support and intermediate wall

• Turn the axle to secure it with the pin behind the front panel

• Turn the adjusting screw (fig. 20, item 1) clockwise in order to press the support with the scraper against the perforated drum The perforated drum and the product to be processed determine the pressure exerted by the scraper on the drum

Any too high pressure would result in an unnecessarily high wear of scraper and perforated drum!

• Loosen the nut (behind the intermediate wall, fig. 20, item 6) of the black stop bush (fig. 20, item 6)

• Adjust the stop bush so that the scraper is of a lateral distance of 1 mm each from the interme-diate wall and the front panel

• Retighten the nut

20

2

4

1 3

5

6

GB 17

Page 20: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Setting instructions

10.2 Squeezing belt

10.2.1 Belt pressure• Lift the tensioning lever (fig. 21, item 1) and

press the pressure roller (fig. 21, item 2) against the perforated drum

The manual force determines the yield!

• Turn the spindle (fig. 21, item 3) with the star handle (fig. 21, item 4) until the sliding block (fig. 21, item 5) is positioned under the ten-sioning lever

By lifting and lowering the tensioning lever by passing the sliding block, a quick pressure relief of the pressure roller is possible.

Before rest periods and prolonged standstills of the machine, the quick pressure relief should be carried out in order to reduce the load on the squeezing belt!

10.2.1.1 Standard values for pressure setting (force applied to the tensioning lever)Fish lowMeat highPoultry mediumDairy products lowFruits, vegetables lowWarm products low

10.2.2 Belt tension• Loosen the clamping lever (fig. 22, item 1)• Turn the tensioning lever (fig. 22, item 2) to

the right thus adjusting the tension of the squeezing belt

• Tighten the clamping lever

Adjust the belt tension only by applying slight manual force! Any too high belt tension would result in an unnecessarily high wear of the squeezing belt and should therefore be avoided!

3

4

1

5

2

21

2

1

22

18 GB

Page 21: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Setting instructions

10.3 Back-up bearings

The back-up bearings on the eccentric bolts are factory-set to a distance of 0,2 – 0,4 mm from the bearing surface of the perforated drum. If this distance is increasing, the respective back-up bearing has to be readjusted (see fig. 23):• Unscrew the cover (fig. 23, item 1)• Unscrew completely the bearing (fig. 23, item 2) with the eccentric bolt (fig. 23, item 3)• Remove the compensating washers off the pivot or out of the boring (fig. 23, item 4) and screw

down the eccentric bolt again• Measure the clearance between the perforated drum (fig. 23, item 5) and the back-up bearing.

Set the distance of 0,2 mm – 0,4 mm by pinning up compensating washers onto the thread of the eccentric bolt (0,1 mm 24°)

• Screw down the eccentric bolt and inspect the clearance again; if necessary, repeat the proce-dure

Examine the clearance after each grinding of the perforated drum; if necessary, readjust! The compensating washers are included in the accessories.

0,2-

0,4

mm

0,2-0,4 mm

5

21

3

4

1

5

120°

120°

23

Position of the eccentric bolt within this range!

Position of the eccentric bolt within this range!

GB 19

Page 22: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

20 GB

Operating conditions

11 Operating conditions

11.1 Pre-shreddingThis is required for …

… the perfect infeed of the initial product

… the separation process of the soft and solid components of the ini-tial product

The finer the pre-shredding …… the higher will be the yield… but the final product will be less

pure- examine figure 24 and cf. section 12 –

11.2 Loading the initial product into the machine• As evenly as possible• Feed the finely pre-shred initial product as a flat spread mass• Continuously feed larger pieces one after the other• It is absolutely necessary to avoid dry running!

Accumulations of initial product and/or lump formations prevent the perfect infeed and would overload the machine!

11.3 Temperature of the initial productIt shall be within a range of 0°C and 5°C.

As far as meat is concerned, temperatures above 8°C would result in a deterioration of the initial product!

24

shredding finecoarse

+

-

purity

yield

Page 23: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Selection of the perforated drum

12 Selection of the perforated drum

12.1 Processing of fish

12.2 Processing of meat

If a perforated drum with holes of more than 5 mm is installed in the machine,the safety guard provided must be fitted to the machine!It is prohibited to operate the machine without this safety guard when using aperforated drum with this hole size!

Hole diameter Initial product Preparations

3 mm TrimmingsBones

5 mm Filets

Whole fish crushing

Hole diameter Initial product Preparations

2 mm Meat quality 1Meat quality 2

Meat grinder with perforated disk 13-20 mm and 2 pre-cutters with knife in between

Separation of bones from large soft pieces

Meat grinder with perforated disk 13 mm and 2 pre-cutters with knife in between

3 mm(standard)

Normal up to extremely sinewy meat (= quality 3 meat) pork, beef and the like as well as remainders

Meat grinder with perforated disk 20-30 mmCutter with 3 bowl revolutions

5 mm Meat quality 2 Meat grinder with coarse adjust-ment (2 pre-cutters with knife in between)

8 mm Meat quality 3 Pieces of the size of a palm

GB 21

Page 24: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Selection of the perforated drum

12.3 Processing of poultry

If a perforated drum with holes of more than 5 mm is installed in the machine,the safety guard provided must be fitted to the machine!It is prohibited to operate the machine without this safety guard when using aperforated drum with this hole size!

Hole diameter Initial product Preparations

1.3 mm Residual meat from poultry bones

In agreement with the BAADER company

3 mm Turkey drumsticks Trimmings from turkey and chicken meat

Meat grinder with perforated disk 30 mm

5 mm Pieces of the size of a palm, divided into two

Meat grinder with 2 pre-cutters with knife in between

8 mm Pieces of the size of a palm

22 GB

Page 25: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

D 23

600How to treat the squeezing belts

13 How to treat the squeezing belts

13.1 Squeezing belt in the machine

13.2 Squeezing belts outside the machine• Store in a cool and dark space

Storage temperature squeezing belt blue: 10 - 15°CStorage temperature squeezing belt white: 5 - 10°C

• Storage periods of more than two years are not to be recommended!

• It is absolutely necessary to avoid dry running!• Never run a new squeezing belt with full pressure!• Pointed and sharp-edged raw material damages the squeezing belt!

When processing poultry, the squeezing belt is exposed to an extreme load by pieces of bones and must be replaced before the surface layer cracks due to incisions!

• Do not tighten the squeezing belt too much; release the tension of the squeezing belt when the machine is in standstill condition!

• Wear of the squeezing belt is contingent upon the product, pretreatment of the product, selection of the perforated drum and of the set pressure!

• Clean with lukewarm water (max. 60°C) only. Do not use any cleaning agents containing chlorine!

Page 26: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

24 GB

Troubleshooting

14 Troubleshooting

In the event of failure of the sequence of operations, switch off the machine, set the main switch to position 0 and protect it using a padlock!

Symptom Cause Remedy

The initial prod-uct is not fed in

The perforated drum is not clean

Correct the adjustment of the scraper Replace the scraper

The squeezing belt is smeared

Clean the squeezing belt

The squeezing belt is worn Replace the squeezing belt

The drum shell is not cleaned

The scraper is not correctly positioned

Readjust the scraper

The scraper is worn Replace the scraper

The machine is blocked

Foreign matters in the machine

Reduce the pressure of the scraper and pres-sure roller. Remove the conveyor screw, per-forated drum and front panel. Remove the foreign matters.

Belt edges are broken

The front panel is not cor-rectly positioned

Disassemble and clean the machine. Make sure that the perforated drum is correctly positioned between intermediate wall and front panel! The inner surface of the front panel must be level with the offset of the per-forated drum!

The belt is punched through

Bones in the initial product Replace the belt

The life of the squeezing belt is too short

Pressure on the squeezing belt too high

Reduce the pressure on the squeezing belt

Slipping of the pressure roller, high yield losses

The pressure roller is con-taminated

Disassemble and clean the machine (cf. sec-tion 15)

The front panel is not cor-rectly positioned

Make sure that the perforated drum is cor-rectly positioned between intermediate wall and front panel! The inner surface of the front panel must be level with the offset of the per-forated drum!

The squeezing belt is worn Replace the squeezing belt

The squeezing belt is stopped

Too low pressure on the squeezing belt

Increase the pressure on the squeezing belt

Yield losses The hole edges of the on the outer drum surface are no longer sharp

Regrind the outer surface of the drum (ser-vice offered by all BAADER agencies)Replace the perforated drum

Page 27: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Cleaning

15 CleaningClean the complete machine at regular intervals of 8 operating hours. When using low-pressure cleaning devices, do not direct the jet into bearings.

15.1 Rest periods• Relief the belt pressure by means of quick

release- Lift the tensioning lever (fig. 25, item 1)

and lower laterally from the sliding block (fig. 25, item 2)

• Set the main switch into position 0• Remove product remainders and wash

down the machine from all sides with a pow-erful water jet

15.2 Pre-cleaning

Run the machine with the slowest speed and clean it with a corresponding safety distance from all moving components:

- with drinking water, max. 60°C!- from top to bottom!- with low pressure, max. 30 bar!

Keep the safety distance! Make sure that clothing, hose, cleaning device or the like do not get caught by the moving components of the machine; danger of serious bodily injuries and damages to the machine! Do not run the machine unattended!

After pre-cleaning, stop the machine, set the main switch to position 0 and secure it!

15.3 Main cleaning

The main switch shall be in position 0 and be secured! Observe the safety instructions at the beginning of this operating manual! Wear protective clothing during cleaning and sanitation operations! Observe the specific national regulations for the cleaning agents and disinfectants used!

12

25

GB 25

Page 28: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Cleaning

15.3.1 Cleaning schedule

The following cleaning schedule does not apply to squeezing belts! For cleaning the squeezing belt, do not use cleaning agents containing chlo-rine, but drinking water max. 60°C!

* In order to avoid white deposits, P3-topax 17 should not be foamed on hot surfaces.

15.4 End of cleaningAfter cleaning, run the machine briefly and grease to remove any water that might have pene-trated the bearings.

Cleaning agents that are ecologically harmful are to be disposed of properly!

15.4.1 Hardened perforated drums

Hardened materials are less resistant to corrosion! We recommend to completely spray removed perforated drums after cleaning and disinfection using BAADER preservatives (cf. section 15.5) wich are recognized as physiologically safe.

Operation Cleaning Agent Device/Method Remarks Main cleaning

2 - 5% P3-topax 17* (Henkel)

foam with low-pres-sure foaming device

from bottom to top, reaction time 15 minutes

For removing calcareous deposits, use 1 time per week cleaning foam 2 - 5 % P3-topax 56 (Henkel) instead of P3-topax 17

from bottom to top, reaction time 15 minutes

drinking water, max. 60°C

rinse with low pres-sure, max. 30

carefully from top to bottom

Check visualSanitation 1% P3-topax 91

(Henkel)low-pressure spray-ing, max. 30 bar

from top to bottom, reaction time abt. 10-15 minutes since contingent upon germe spectrum; refer to product data sheet

rinsing drinking water, abt. 20°C

low pressure, max. 30 bar

rinse again carefully

26 GB

Page 29: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Cleaning

15.5 Preservation

Prior to any longer standstill, protect the machine using food-approved preservatives!

Recommended preservatives:- Preservation spray BKS; ref. no. 51100201 (400 ml can)- Preservation liquid BKS; ref. no. 51100200 (5 l container)

This preservative is NSF-H1 approved.

Before resuming production, remove the preservative from all areas in contact with the product:- with drinking water, max. 60°C!- from top to bottom!- with low pressure, max. 30 bar!

GB 27

Page 30: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

28 GB

Maintenance

16 Maintenance

Spraying by means of sprays of any kind whatever in electrical enclosures and control gears is prohibited; explosion hazard! Prior to performing maintenance operations, switch off the machine, set the main switch to position 0 and protect it using a padlock!

16.1 Squeezing beltVerify the squeezing belt at regular intervals for possible damages and wear.

Immediately replace damaged or worn squeezing belts!

16.2 ScraperVerify the scraper at regular intervals for possi-ble damages and wear.If the scraper (fig. 26, item 1) is worn to the extent that the scraping area has a width of 4 mm (figure 26), then it must be replaced!

Broad scraping areas of the scraper require high adjusting forces which would result in premature wear of the outer surface of the perforated drum!

16.3 Perforated drumVerify the perforated drum at regular intervals for possible damages and war.

The hole edges in the outer area of the drum must be sharp. Rounded hole edges would deteriorate the function; the perforated drum must be replaced!

Regrinding of worn perforated drums is offered by all BAADER agencies.Regrinding interval: as a function of the visual inspection, reduction of throughput rate and yield.

16.4 Spur gearsVerify the spur gears (figure 27) every 200 operating hours and/or 6 months for wear.

1

max

. 4m

m

26

27

Page 31: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Lubrication

17 LubricationPlace the main switch into position 0!

17.1 Grease lubricationThe machine has been lubricated with BAADER Special grease GLS 380/N3.This grease is of the GRAS type, semi-synthetic and highly seawater resistant. It complies with the German Food and Consumer Goods Acts (LMBG § 5, art. 1, clause 1) and is authorized according to USDA H1. We recommend to use this lubricant in the future as well.When using other GRAS lubricants, the troublefree functioning of the machine cannot be guaran-teed anymore because of the considerable differences in quality of the lubricants available on the market!

Do not blend with mineral lubricants! Please note that mineral lubricants do not comply with the provisions of the Food and Consumer Goods Acts and may thus not be used!

Make sure that only clean grease gets to the lubrication points! The complete lubrica-tion system (zerk fitting, mouth of grease gun, hand lever press and the coupling, if required) should be free of any impurities! The maximum lubricant pressure at the mouth of the grease gun should not exceed 150 bar!

Whenever cleaned, the machine is to be lubricated as well to remove any water that might have penetrated the bearings.

GB 29

Page 32: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Lubrication

17.1.1 Lubrication plan

17.1.2 Gear motorClean roller bearings filled with grease after 3000 operating hours and fill with new grease. Only one third of the cavities between the roller bodies shall be filled with grease!

17.1.3 Spur gears Clean the spur gears (figure 29) including the adjacent spaces every 400 hours and/or 2 years. Subsequently, apply special grease GLS 380/N3 to the spur gears.

Item fig. 28 Lubrication point Lubrication interval Lubricant

1 Grease nipple (centralized lubrication) 8 operating hours

Special grease GLS 380/N3

2 Grease nipple (centralized lubrication) 40 operating hours

3 Supporting bearing Prior to each cleaning as well as when starting production

4 Pressure eccentric 8 operating hours

5 Various axles Apply grease prior to production

13 3

4

5

2

28

29

30 GB

Page 33: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600Lubrication

17.2 Oil lubrication

17.2.1 Gearbox of the gear motorLubricant: mineral gear oil ISO VG 220Required quantity: 0.7 litresChange interval: 3000 operating hours, at least every 2 years

Venting/fillingOil levelOil drain

Lubricant change:• Remove the drain plug and the vent plug• After the old lubricant has been drained,

clean the gearbox using an appropriate flushing oil. Prior to filling in new oil, make sure that all flushing oil residues are removed!

• Turn in the drain plug• Fill in the indicated amount of lubricant

Checking the amount of lubricant: When the gearbox is at rest and the oil level screw removed, the oil must reach the upper edge of the threaded bore

• Turn in the vent plug

30

GB 31

Page 34: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600BAADER 600 with DMM 10

18 BAADER 600 with DMM 10

18.1 GeneralIn conjunction with the DMM 10 machine, the BAADER 600 is best suitable for the recovery of residual meat. The meat adhering to the bone is coarsely removed by the DMM 10 and fed via a piping to the BAADER 600. In the BAADER 600 the sinews and bones are separated from the meat using a perforated drum tuned to the residual meat.

18.2 Set-Up

BAADER 600

3339

31

DMM 10

166

580 mm

902

423

943

878 17

425

6

ø84

636

686

1695 18

7042

60

32 GB

Page 35: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600BAADER 600 with DMM 10

The BAADER 600 and the DMM 10 can be set up in a 90° arrangement (fig. 31) or in a straight line (fig. 32). The spiral hoses are then to be shortened (fig. 33) according to the respective dimensional draw-ing.

Align the machines horizontally and fit the piping in accordance with the respective dimensional draw-ing.

For the spiral hoses, the feeding direction must be observed; it is marked on the hoses.

BAADER 600

5151

32

DMM 10

166

1260 mm

902

943 11

62

423

174

256

ø60

63668

6

915

89

1695 18

70

1396

1680

878

33

GB 33

Page 36: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600BAADER 600 with DMM 10

18.3 Safety devices

It is prohibited to bypass, modify or remove the safety devices installed by the factory!

it is absolutely necessary to observe the safety instructions at the beginning of this operation manual, as well as of the separate operation manual of the DMM 10 machine!

18.4 Start-up procedurePrior to starting up the BAADER 600 and the DMM 10, observe all information contained in the individual operation manuals, e.g. reinstallation of the parts dismantled for cleanup, as well as subsequent cleaning of the machine prior to resuming operation.

18.5 CleanupCleanup is to be performed as described in section 15.

34 GB

Page 37: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

D 35

600Country-related list of cleaning agents and disinfectants

19 Country-related list of cleaning agents and disinfectants

CountryProduct

P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91

Brazil Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac

Canada Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac

France P3-topax 12 P3-topax C 80 P3-topax M acide P3-topax M55 P3-sterylmouss P3-triquart

Germany P3-topax 12 P3-clint RI P3-topax 56 P3-zinnfest flüssig P3-topax 99 P3-topax 91

Greece P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91

Italy P3-topax 12 P3-topax 17 P3-topax L54 P3-topax 68 P3-topax SAN P3-topax 91

Japan P3-topax 12 P3-topax 56 P3-topax 68 P3-topax 99 P3-triquart

Namibia Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac

Netherlands P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-triquart

Norway TP 12 TP 17 Tp 56 TP 68 TP 99 Triquart AP

Poland P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91

Russia P3-topax 12 P3-clint RI P3-topax 56 P3-zinnfest flüssig P3-topax 99 P3-topax 91

South Africa Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac

Spain P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91

United Kingdom P3-FBC foam P3-rik P3-topax 56 P3-topax 68 P3-triquart

Ukraine P3-topax 12 P3-clint RI P3-topax 56 P3-zinnfest flüssig P3-topax 99 P3-topax 91

USA Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac

Page 38: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

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HENKEL sales partners

20 HENKEL sales partners

Actual data see below:

http://www.ecolab.com

• Click on Global Directory• Select the Continent• Select the Country• Click on Contact

Page 39: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

D 37

600Lubricants and preservatives

21 Lubricants and preservativesLu

bric

ants

and

Pre

serv

ativ

es fo

r BA

AD

ER M

achi

nes

Lubr

icat

ing

grea

ses

Oils

Pres

erva

tives

Bea

ring

grea

seFl

uid

grea

seG

reas

e sp

ray

Gea

r oils

Hyd

raul

ic o

ilSp

ray

Flui

d

Des

igna

tion

GLS

380

/N3

GLS

367

/N00

0FL

C 6

5C

LP 6

8C

LP 4

60H

LP 6

8B

KS

BK

S

NLG

I2

000

2-

--

--

ISO

-VG

--

-V

G68

VG

460

VG

68-

-

Col

our

whi

tebr

own

trans

pare

ntye

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ish

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pare

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App

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l/ cl

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US

DA

/H-1

NS

F-H

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SF-

H1

NS

F-H

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SF-

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NS

F-H

1N

SF-

H1

NS

F-H

1

Avai

labl

e pa

ckag

e si

zes

400

gca

rtrid

ge5

kgbu

cket

400

ml

can

5 l

cani

ster

30 l

cani

ster

5 l

cani

ster

400

ml

can

5 l

cani

ster

Art

icle

cod

e51

5001

0351

5001

5151

1001

8651

1001

4651

2001

2551

1001

4651

1002

0151

1002

00

Avai

labl

e pa

ckag

e si

zes

18 k

g (+

)+

-+

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--

Art

icle

cod

e51

5001

02+

-+

++

--

Impo

rtant

! Lu

bric

atin

g gr

ease

s an

d oi

ls s

hall

not b

e m

ixed

with

eac

h ot

her,

as th

ere

is a

risk

of c

hem

ical

dec

ompo

sitio

n!

+ ot

her p

acka

ge s

izes

on

requ

est

Not

e:

Gre

ase

or o

il fil

led

gear

boxe

s an

d ge

ar m

otor

s th

e lu

bric

ants

of w

hich

are

not

indi

cate

d in

this

list

mus

t be

lubr

icat

ed in

acc

orda

nce

with

th

e in

form

atio

n in

sec

tion

Lubr

icat

ion!

Page 40: Desinewing Machine Operating Instructions · The BAADER 600 is used for separating soft components from solid components according to a press-separation method. For instance fish

600

38 D

Notes

22 Notes