kflexsystems allspecss

Product Specifications vers. 8/27/2014 1:28:00 PM of 33

K-Flex Systems Product Specifications

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of 33 vers. 8/27/2014 1:28:00 PM Product Specifications

Contents

1. SLAT BELT CONVEYORS MODEL SBC-K10SF ........................................ 5 1.1 DRIVE UNIT AND TAIL UNIT ................ 5

1.1.1 Belt Washing Tank ...................... 5 1.1.2 Drive Shaft ................................. 5 1.1.3 Drive Motor ................................. 5 1.1.4 Drive Housing ............................. 5 1.1.5 Plumbing Housing ....................... 5 1.1.6 Tail Unit ...................................... 6

1.2 SIDE FLEXING K10-SF SLAT BELT ........ 6 1.3 SLIDE BED AND RETURN TRACKS .......... 6 1.4 CONTROL PANEL DETAILS ................... 6

1.4.1 Motor Controls ............................ 6 1.4.2 Panel .......................................... 6 1.4.3 Buttons ....................................... 6 1.4.4 Main Disconnect .......................... 6 1.4.5 Programmable Logic

Controller ................................... 6 1.4.6 Wiring ........................................ 6 1.4.7 Voltage Connection ..................... 7 1.4.8 Wiring and Conduit ...................... 7 1.4.9 Splash shield ............................... 7 1.4.10 Accumulation switches ................. 7

1.4.10.1 Through beam ......... 7 1.4.10.2 Diffuse Reflection ..... 7

1.4.11 Auto Index Feature ..................... 7 1.4.12 Remote Start Stop Station ........... 7

2. POWER ROLLER CONVEYORS ........... 8

3. MODEL HRA-30B HOSE CLEANING STATION ......................... 9

4. DUAL BELT ACCUMULATING CONVEYORS ................................... 10 4.1 821 SLAT BELT

SPECIFICATIONS ........................ 10 4.2 RACKING BENCH STYLE ............... 10 4.3 STAND ALONE STYLE .................. 10

5. LOOP DRIVE SYSTEMS ................... 11

6. MODEL CTC-WB10 POLY CORD CONVEYORS ................................... 12 6.1 GENERAL SPECIFICATIONS — DISH

ROOM TYPE ................................... 12 6.2 CONTROL PANEL DETAILS ................. 12

6.2.1 Motor Control Center (MCC) ....... 12 6.2.2 Wiring and Conduit .................... 13 6.2.3 Splash shield ............................. 13 6.2.4 Accumulation switches ............... 13

6.2.4.1 Through beam ....... 13 6.2.4.2 Diffuse Reflection ... 13

6.2.5 Auto Index Feature ................... 13 6.2.6 Remote Start Stop Station ......... 14 6.2.7 Plumbing Housing ..................... 14

7. GRAVITY ROLLER SYSTEMS ........... 15 7.1 ROLLERS .................................... 15

7.1.1 Model GC-200P .......................... 15 7.1.2 Model GC-200SS ........................ 15

8. RACKING BENCH DETAILS ............. 16 8.1 GENERAL CONSTRUCTION .......... 16 8.2 DISPOSAL TROUGH ......................... 16 8.3 TRAY RAIL .................................... 16 8.4 LIVE CORD CONVEYOR ..................... 16 8.5 MOVABLE RACKING STATIONS ............ 16 8.6 AUTO PLATE RINSE (APR) ................ 16 8.7 STACKING PLATES ........................... 17

9. TRAY AND PLATE MAKE-UP CONVEYORS ................................... 18 9.1 MODEL SBC-D1 SLAT BELT TRAY

ASSEMBLY CONVEYOR SPECIFICATIONS ............................. 18 9.1.1 Electric Distribution

Raceway ................................... 18 9.1.2 821 Belt Specifications ............... 19

9.2 MODEL CTC-D1 CORD TYPE TRAY ASSEMBLY CONVEYOR ...................... 19 9.2.1 Cord Material ............................. 19 9.2.2 Load ......................................... 19 9.2.3 Slide Beds and Skirt Panels ......... 19 9.2.4 Drive Housing ............................ 19 9.2.5 Electric Utility Distribution

Raceway ................................... 19 9.3 K-LINE TRAY ASSEMBLY

CONVEYORS ............................... 19 9.3.1 Drive unit .................................. 20 9.3.2 Belting ...................................... 20 9.3.3 General Construction.................. 20 9.3.4 Electric Utility Distribution

Raceway ................................... 20 9.4 SLIM-LINE SANDWICH AND

PLATING CONVEYORS ................. 20

10. MODEL MCR-1248 MAGNETIC CUTLERY REMOVER ....................... 22

11. TRAY-STAC TRAY ACCUMULATOR CART ..................... 23

12. POWERSKATE TRAY ASSEMBLY CONVEYORS ................................... 24 12.1 DISHWASHING SYSTEMS ................... 24 12.2 POWERSKATE SPECIFICATIONS .. 25

13. VERTICAL TRAY CONVEYORS — FLOOR TO FLOOR ........................... 26 13.1 APPLICATION ............................. 26


13.2 DESCRIPTION ............................. 26 13.3 OPERATION ................................ 26 13.4 TYPICAL SPECIFICATIONS ........... 27 13.5 OPERATION OF SYSTEM .................... 27 13.6 TRAY DEPOSIT CONVEYOR ................ 28

13.6.1 Pin conveyor chain .................... 28 13.6.2 Slide Beds ................................. 28 13.6.3 Enclosure .................................. 28 13.6.4 Drive Unit ................................. 28 13.6.5 Automatic Tray Loading

into Vertical .............................. 28 13.6.6 Loading End Protection

Devices ..................................... 28 13.7 VERTICAL INDEXING

CONVEYOR ................................. 28 13.7.1 Framing .................................... 28 13.7.2 Shafts ....................................... 28 13.7.3 Flight Chains ............................. 28 13.7.4 Sprockets.................................. 29 13.7.5 Flight Guides ............................. 29 13.7.6 Flights ...................................... 29 13.7.7 Drive Motor ............................... 29 13.7.8 Mechanical Overload

Protection ................................. 29 13.8 UNLOAD CONVEYOR AT LOWER

FLOOR ....................................... 29 13.8.1 Drive unit and Tail unit .............. 29

13.8.2 Side Flexing K10-SF Slat Belt ........................................... 30

13.8.3 Slide Bed and Return Tracks ....................................... 30

13.9 CONTROL SYSTEM AND FIELD WIRING...................................... 30 13.9.1 Wiring and Conduit .................... 31 13.9.2 Auto Index Feature .................... 31 13.9.3 Maintenance Switches ................ 31 13.9.4 Motor Disconnect Switches ......... 31

14. WRS-KF-419B WASTE RECLAMATION SYSTEM ................. 32 14.1 GENERAL SPECIFICATIONS ................ 32

14.1.1 Non-destructive Food Waste Capture ........................... 32

14.1.2 Effectiveness ............................. 32 14.1.3 Lowest Industry Sound

Pollution .................................... 32 14.1.4 Vibration ................................... 32 14.1.5 Cleanliness ................................ 32 14.1.6 Safety ....................................... 32 14.1.7 Waste Trough ............................ 32 14.1.8 De-watering tank &

Housing .................................... 32 14.1.9 De-watering Cylinders ................ 32 14.1.10 Re-circulation pump ................... 33 14.1.11 Control System .......................... 33 14.1.12 Screen Cylinder Lift .................... 33 14.1.13 Utilities required ........................ 33


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1. SLAT BELT CONVEYORS MODEL SBC-K10SF Provide Slat Belt Conveyor as shown on plan and details. Unit shall consist of the following main components:

• Drive Unit And Tail Unit

• K-Flex Side Flexing Slat Belt

• Slide Beds And Return Tracks

• Control Panel

1.1 Drive Unit and Tail Unit

1.1.1 Belt Washing Tank Drive unit shall incorporate a belt washing tank formed of welded 14 ga S/S with coved horizontal corners. Provide lift off waterproof doors in side of wash tank for total easy access for cleaning and servicing. Doors shall have positive self-latching S/S handles. A perforated strainer pan shall be located in sump to catch any debris washed off conveyor belt. Provide (3) removable S/S spray arms with die-stamped spray jets to effectively clean belting. A 1-1/2” S/S drain connection is required as shown on plan.

1.1.2 Drive Shaft provide S/S drive shaft with positive greaseless S/S spring seals to prevent any moisture from entering bearings. Shaft shall use no keyways at any point and all sprockets shall be driven from shaft by collet type couplings. Drive sprockets shall be machined S/S. Flange bearings on outside of tank shall have S/S housings, lubricated for life.

1.1.3 Drive Motor Gear motor shall consist of a wash down BISC gearbox with an all S/S motor, c-flange of 3 phase design with S/S junction box. Chain driving conveyor drive shaft shall be special waterproof construction, superior to ordinary S/S chains and shall be fitted with an automatic take-up for attention-free maintenance.

1.1.4 Drive Housing Housing shall be constructed of 16 ga S/S with double wall 18 ga door panels. Panels shall be laminated foam construction for maximum sanitation. Drive housing and tank assembly shall be sealed to slide-bed with clear silicone sealer on final assembly. Construction and forming of housing shall be so designed to eliminate the requirement for any angle iron framing.

1.1.5 Plumbing Housing A plumbing enclosure shall contain mixing and shut-off valves for belt washer, solenoid valve and detergent pump. Detergent shall drip feed on return belt as it enters the return track to provide maximum time and concentration of cleaning action. Provide check valves and vacuum breakers as required. All exposed piping shall be stainless steel or chrome plated. Unfinished copper piping is not allowed. 1/2” hot and cold water connection required at shut-off valves.


1.1.6 Tail Unit tail unit shall contain a removable drawer-type scrap pan to catch any debris from the belt return tracks. Tail sprocket shall be UHMW with special lubed-for-life bearing on S/S shaft with dual spring take-up. A 1-1/2” drain connection is required as shown on plan.

1.2 Side Flexing K10-SF Slat Belt Slat belting shall be 10” wide K-Flex K10SF (pat no 3627109) plastic plate tops attached to a S/S side flexing chain. Slats shall have special rollers attached to eliminate any sliding friction between belt and track as belt turns corners. Slat and belt assembly shall closely fit the track in slide bed to minimize any collection of debris in track if cleaning is not regularly attended. Slats to have overlapping feature to prevent any objects from getting under belt. Standard color is Royal Blue but custom colors are available.

1.3 Slide Bed and Return Tracks Slide beds shall be formed from 14 ga S/S with all corners coved to ¾” radius. Belt tracks shall be closely fitted to profile of K-Flex belt to eliminate any build-up of debris. Slide bed Tracks shall have special UHMW wear guides along each side for the belt to ride on to minimize friction and eliminate wear. Return belt tracks shall be totally self-cleaning and shall never require cleaning attention of any kind. No drain connections are required, regardless how long the conveyor may be designed, except at drive and tail unit connections.

1.4 Control Panel Details

1.4.1 Motor Controls All motor controls shall be located inside Motor Control Center (MCC). Motor controls shall be variable frequency devices and deliver 3 phase 230 volts to each motor as required to vary the speed of the belt from 10-40 ft/min.

1.4.2 Panel Panel shall be fabricated of 14 ga S/S and fitted with waterproof gasketing. Control panel shall be mounted above conveyor on S/S posts, however, other options are available.

1.4.3 Buttons Push buttons and other user interface devices shall be located on hinged down front panel with clearly labeled integral nameplates. “Stick-on” or individual plates are not acceptable.

1.4.4 Main Disconnect Provide a main disconnect with interlock, belt wash selectors, sealed speed adjustment knob, indicating lights and diagnostics.

1.4.5 Programmable Logic Controller All devices will be controlled by a programmable logic controller (PLC).

1.4.6 Wiring All wiring shall conform to UL standards for appliances and meet all local codes.


1.4.7 Voltage Connection Standard voltage connection is 120 VAC but other voltages are available.

1.4.8 Wiring and Conduit Wiring outside the control panel will be performed in totally sealed, all plastic flexible conduit and fittings. PVC covered metal conduit is not allowed. If control panel must be shipped separated from conveyor, provide a PosiKon socket and terminal assembly for all incoming wiring on the back of the control panel.

1.4.9 Splash shield All K-Flex Control centers can be fitted with a pull down clear polycarbonate splash cover to positively prevent direct hose-down of the panel.

1.4.10 Accumulation switches The operation of all photocells is user selectable at the control panel by selecting OFF or AUTO on the selector switch.

Most conveyor systems require some sort of stopping mechanism to prevent over-running of conveyor in the event product is not removed at the terminal point. The best system for this is photoelectric. Two types are available:

1.4.10.1 Through beam

This is the most reliable but not the easiest to apply. It means there is a “sender” and a “receiver, and there must be a physical place to mount these which will be interrupted by the object on the conveyor. There is practically no limit to the range of these photocells.

1.4.10.2 Diffuse Reflection

This type is actually a proximity sensor and it senses light be reflected back to the photocell from the object on the conveyor. This is easiest to install but the range of sensitivity is limited to about 10”.

1.4.11 Auto Index Feature This feature uses photocells to effectively advance the conveyor at the tray deposit area. When this mode is selected on the control panel, anyone setting a tray down on the tray deposit breaks the through-beam of the photo cell causing the belt to “index” or move ahead enough to place another tray on the space provided.

1.4.12 Remote Start Stop Station Any K-flex conveyor can be equipped with a “touch less” start-stop auxiliary station. This very small device can be fitted in cramped or small locations, has no moving parts and is completely waterproof. Size is only 2” x 1” x 3/8” and can be fitted on rims and edges or set into its own mini-enclosure.


2. POWER ROLLER CONVEYORS Provide Power roller Conveyor Model PRC-200B as shown on plan with the following features:

• Low pressure accumulation

• 1.9” S/S rollers, 22” BFR, 5-1/2” o.c.

• Parallel geared gear motor, ½ hp 3 phase, waterproof

• Positive anti-squeak side channel bearings

• Nylon drive sprockets

• Lubricated for life bearings

• Tail driven

• 2-year unconditional guarantee

1. The power rollers shall be designed to transport full racks of dishes or stacks of trays and shall function as a low pressure accumulating conveyor.

2. Special molded side rail flange bearings prevent squeaking without any continuing lubrication.

3. Main body channels and covers shall be fabricated from S/S with a minimum of visible screws and fasteners.

4. Structure shall be designed to hold racking stations (see details) without stress or deflection.

5. Entire unit can be hosed cleaned.


3. MODEL HRA-30B HOSE CLEANING STATION Provide where shown on plan a Model HRA-30B HOSE CLEANING STATION.

1. Unit shall be designed to stow away when not in use. 2. Assembly shall be mounted to a leg of the dish table. 3. Unit shall be universally adaptable and able to easily mount to existing leg or slip over a

leg of new construction 4. Provide a ½” x 30 ft NSF approved white dairy hose with live swivel connections each

end with spray end fitted with an industrial water gun made from anodized aluminum with a blue PVC cover and large trigger handle used to adjust volume of spray and spray pattern.

5. Swivel and reel assembly shall be constructed of 12 ga and 14 ga polished stainless steel. Cheeks of reel shall be 12 ga and fillet welded to the radius bottom of cradle.

6. Front of reel cradle shall contain a convenient valve connected to chrome plated lever to turn water pressure on/off. ON-OFF indicating labels shall be laser cut into front cheek.

7. All brass and copper plumbing on the reel shall be concealed and nickel plated including valves and piping.

8. Angle swivel frame shall be double sided 14 ga stainless and shall contain the plumbing with convenient connections for dairy hose and supply line. Connection for supply line from vacuum breaker shall be positioned close to swivel axis to minimize torsion on the connection hose which will be constructed of ½” Teflon with a stainless steel braid and JIC flare fittings. Specify clockwise or counter clockwise swing.

9. Provide a 12 ga stainless wall bracket assembly containing the main mixing and shut off valves. All connections and plumbing to be a minimum of ½” pipe size. Mixing valves shall be chrome plated and contain integral check valves and be so marked. Provide pre-tinned ½” solder field supply connections under each valve.

10. Valve assembly to be connected to ½” Fisher chrome plated vacuum breaker with polished ½” x 24” stainless steel riser pipe to above top of customer’s backsplash. Output of vacuum breaker to be returned under table with ½” polished stain. Steel pipe and chrome brass fittings and connect to rotating cradle with a ½” S/S and Teflon flexible hose. Provide an 18 ga stainless encrustion angle plate with elliptical pipe holes to neatly trim cut-out in back-splash return.


4. DUAL BELT ACCUMULATING CONVEYORS Provide dual belt accumulating conveyor where shown on plan. Unit shall be K-Flex Model SBC-D10 and shall be long and shall conform to all general specifications of Model SBC-K10SF except for design of slat belt. All D10 units shall incorporate a spring loaded safety plate the full width of belt where belts enter the drive unit belt washer to prevent any items from entering wash tank.

4.1 821 SLAT BELT SPECIFICATIONS Model SBC-D10 conveyors shall incorporate a double 10” slat belt. Slat belt shall be all plastic construction with S/S connecting pins. Belt shall be molded links of Delrin and Teflon and designed for automatic spray washing.

4.2 RACKING BENCH STYLE Accumulating conveyor shall be integrated into the racking bench as shown on plan and cross sections. Top belts shall be suspended above the sloped bottom on 1” square S/S rails covered in UHMW for ease of hose cleaning and completely eliminate the need to ever clean under the belt tracks. Return belts shall be fitted into self cleaning tracks identical to all K-Flex Slat Belt Models. Bed under top belts shall be sloped minimum of 5 degrees to the waste trough. Provide backsplash and raised rims as required.

4.3 STAND ALONE STYLE Provide double belt accumulating conveyor as shown on plan, 34” wide by long. Unit shall be self-contained with raised rims all around. General specifications shall be similar to Model K10SF. Provide 12” aprons or skirting on both sides and an access door to tail unit. Control center shall be mounted above slide bed as shown on S/S posts. Conveyor unit is supported on S/S legs and rails with adjustable feet or may be mounted on 5” polyurethane swivel casters with brakes. Provide standard hinged safety plate at belt openings and though-beam photoelectric accumulation sensor.

Belt track or guide in top bed shall be totally self cleaning and shall be easily hosed down to remove any debris. Return belt tracks shall be the standard K-Flex self cleaning design.


5. LOOP DRIVE SYSTEMS 1. Provide conveyor system as shown on drawings consisting of an oval footprint using K-

Flex model SBC-LD10. 2. Conveyor shall have no return belt and shall be able to accumulate trays along the entire

length and use the standard K10sf slat belting. 3. General specifications and construction details shall be similar to Model SBC-K10SF and

shall incorporate a loop drive system with all the standard features including a belt washer.

4. System shall be designed to allow trays to circulate around the oval until operators remove or attend to trays.


6. MODEL CTC-WB10 POLY CORD CONVEYORS

6.1 General Specifications — Dish room type 1. Provide dual poly-cord conveyor as shown on plan. 2. Unit shall be designed to transport trays from cafeteria to dish room. 3. Cords shall ride in black UHMW tracks formed to reduce friction to a minimum. 4. If conveyor is required to make a corner, provide removable Micro-Roller curves to form

a curved conveyor track with a nominal 22” center line radius. 5. Micro Rollers shall be machined from special low-friction plastic and set into an anodized

aluminum frame. 6. There shall be no pinch points anywhere on the system. 7. The double assembly of Micro-Roller curves shall be easily removed from the bed and

washed by hand or in a dishwasher. 8. A belt washer shall be provided in the drive unit consisting of (3) spray manifolds with

pierced jets to effectively wash any contamination off the belt immediately as it enters the drive compartment.

9. Provide a lift out perforated scrap pan to catch any debris from the washing units. 10. Drive housing shall be constructed of 16 ga S/S with double wall 18 ga door panels.

Panels shall be laminated foam construction for maximum sanitation. 11. Drive housing and tank assembly shall be sealed to slide-bed with clear silicone sealer on

final assembly. Construction and forming of housing shall be so designed to eliminate the requirement for any angle iron framing.

12. Wash tank shall be constructed of 14 ga S/S with all horizontal corners coved. 13. Provide waterproof access door with positive S/S latch to allow complete inspection and

servicing of the wash tank. 14. As belt exits tank, provide multiple Teflon wipers to completely remove any moisture

from the belt before wrapping the drive pulleys. 15. All pulleys within wash tank shall have sealed stainless steel bearings. 16. A single 1-1/2” waste connection is required under the wash/drive unit. 17. Drive motor shall be all stainless steel and gearbox shall be waterproof BISC

construction. 18. Dual Drive pulleys shall be nylon encapsulated with .045” coating of gray nylon to give

maximum corrosion resistance and provide maximum traction for the wrapped cords. 19. Cord material shall be ½” polyurethane with Dacron cores. 20. Welded joints in cords shall be the overlap type. Butt joint welds will not be accepted. 21. Conveyor shall be designed to carry a 6 lb/ft loading and shall operate smoothly without

oscillations or pulsing of conveyor under full load. 22. Return belt cords shall be supported with special cord bushings to safely return cords to

drive unit and shall be totally accessible for inspection.

6.2 Control Panel Details Control panel for cord type dish room systems shall be identical to SBC type controls and all features described for the SBC model are available for the CTC models.

6.2.1 Motor Control Center (MCC) 1. All motor controls shall be located inside Motor Control Center (MCC).

2. Panel shall be fabricated of 14 ga S/S and fitted with waterproof gasketing.


3. Push buttons and other user interface devices shall be located on hinged down front panel with clearly labeled integral nameplates. “Stick-on” or individual plates are not acceptable.

4. Provide a main disconnect with interlock, belt wash selectors, sealed speed adjustment knob, indicating lights and diagnostics.

5. Motor controls shall be variable frequency devices and deliver 3 phase 230 volts to each motor as required to vary the speed of the belt from 10-40 ft/min.

6. All devices will be controlled by a programmable logic controller (PLC).

7. Control panel shall be mounted above conveyor on S/S posts, however, other options are available.

8. All wiring shall conform to UL standards for appliances and meet all local codes.

9. Standard voltage connection is 120 VAC but other voltages are available.

6.2.2 Wiring and Conduit Wiring outside the control panel will be performed in totally sealed, all plastic flexible conduit and fittings.

PVC covered metal conduit is not allowed. If control panel must be shipped separated from conveyor, provide a PosiKon socket and terminal assembly for all incoming wiring on the back of the control panel.

6.2.3 Splash shield All K-Flex Control centers can be fitted with a pull down clear polycarbonate splash cover to positively prevent direct hose-down of the panel.

6.2.4 Accumulation switches Most conveyor systems require some sort of stopping mechanism to prevent over-running of conveyor in the event product is not removed at the terminal point. The best system for this is photoelectric. Two types are available:

6.2.4.1 Through beam

this is the most reliable but not the easiest to apply. It means there is a “sender” and a “receiver, and there must be a physical place to mount these which will be interrupted by the object on the conveyor. There is practically no limit to the range of these photocells.

6.2.4.2 Diffuse Reflection

this type is actually a proximity sensor and it senses light be reflected back to the photocell from the object on the conveyor. This is easiest to install but the range of sensitivity is limited to about 10”.

The operation of all photocells is user selectable at the control panel by selecting OFF or AUTO on the selector switch.

6.2.5 Auto Index Feature This feature uses photocells to effectively advance the conveyor at the tray deposit area. When this mode is selected on the control panel, anyone setting a tray down on the tray deposit breaks the through-beam of the photo cell causing the belt to “index” or move ahead enough to place another tray on the space provided.


6.2.6 Remote Start Stop Station Any K-flex conveyor can be equipped with a “touch less” start-stop auxiliary station. This very small device can be fitted in cramped or small locations, has no moving parts and is completely waterproof. Size is only 2” x 1” x 3/8” and can be fitted on rims and edges or set into its own mini-enclosure.

6.2.7 Plumbing Housing A plumbing enclosure shall contain mixing and shut-off valves for belt washer, solenoid valve and detergent pump. Detergent shall be injected into the wash water as it is sprayed on the belts. Provide check valves and vacuum breakers as required. All exposed piping shall be stainless steel or chrome plated. Unfinished copper piping is not allowed. 1/2” hot and cold water connection required at shut-off valves.


7. GRAVITY ROLLER SYSTEMS Gravity conveyors can be used to convey trays, racks or tubs of dishes.

K-Flex rollers, other than skate wheels, require a pitch of ¼” per foot to move by gravity.

Skate wheels will gravitate with 1/8” per foot depending on load being conveyed.

Gravity rollers should be spaced so a minimum of (3) rollers are securely under the load at all times. A typical spacing for 20 x 20” dish racks would be 5-1/2” and 4” o.c. for 14 x 18” trays.

7.1 ROLLERS

7.1.1 Model GC-200P 1. Provide gravity rollers as per layout drawings.

2. Rollers shall be 1.9” Royal Blue PVC plastic with stainless steel ball bearings.

3. Provide hex aluminum axels anodized and secured between 12 ga S/S side bars with 5/16 hex bolts.

4. Floating or non-secured axels will not be accepted.

5. If curved conveyor is required, provide triple rollers to assist the rack movement around corner.

6. Outside rail shall be fabricated to act as a guide.

7. If roller sections are set into a table depression or trough provide support pins to keep frame rails off bottom of pan to assist in clean-up.

8. Roller frame sections shall be of convenient length to allow for easy removal and cleaning.

9. Cleaning can be done by machine washing or hose cleaning without any affect on the ball bearings or shafts.

7.1.2 Model GC-200SS Same as above except the roller tube is constructed of polished 1.9” stainless steel.


8. RACKING BENCH DETAILS The design and engineering of conveyor machinery is important for cleanliness and longevity but the design of racking benches or work processing centers interfaces the user with the machines in a manner that is extremely important to provide an efficient and comfortable working environment. Thus, for a properly designed system, it is clear “inches make a difference” and care must be taken to assure tasks can be completed with a minimum of effort.

8.1 GENERAL CONSTRUCTION Provide Process Center with 14 ga stainless steel tops all corners coved to a 5/8” radius. Slope bottom of bench to disposal trough a minimum of 5 degrees. Where conveyors cross the work area, suspend or support belts on laser cut standoffs welded to beds or tops. Support the bench on “bulkhead” structures designed to hold return belts, electrical and plumbing lines in a concealed manner. Bulkheads are mounted to 1-5/8” S/S legs and cross rails and fitted with S/S adjustable flanged or bullet feet.

8.2 Disposal Trough Disposal trough shall be 8-3/4” wide and built into racking bench and sloped to pulper with a minimum of 1/8”/ft. Re-circulated water inlet shall be fully welded and be the width of the trough with a 3/8” opening which will completely flush to trough, Sides of trough shall be sloped to avoid any flat areas. Provide 12 ga S/S connection flange to pulper as specified.

8.3 Tray Rail (used in cart systems)-Provide tray set down rails suspended off the sloped walls of the disposal trough to hold trays during breakdown. Rails shall allow wastes to be scrapped trough and alongside the rails with absolute minimum obstructions. Rails shall be S/S 5/8” half rounds supported on 12 ga bar stock set on laser cut supports neatly welded to the sloped sides of trough.

8.4 Live Cord Conveyor (as used in tray return systems). Provide Cord Type tray conveyor suspended over the disposal trough. Rails shall be a maximum of 1” wide and shall contain the return belt within the structure. Wastes can be injected to the trough between and around these rails. Support belt guides on laser cut brackets, welded to the sloped sides of the trough.

8.5 Movable Racking Stations Provide racking stations to hold single 20 x 20 racks at angle and height for easy loading of cups and glasses from trays. Construction shall be of 12 ga S/S and tubes and of open construction. Racking station shall be easily moved with out pinching or removed completely according to the needs of the operators.

8.6 Auto Plate Rinse (APR) This device consists of a mini spray head located under the racking stations to pre-rinse plates and wares of any wastes. Two versions are available:

MO-manually operated valves and PE-photo electric operated valves. All piping shall be stainless steel or nickel plated brass. Spray head should be located above grated stacking plates and disposal trough. Manual (MO)valves shall have large formed S/S


handles with ON-OFF laser-cut into handles. PE models shall have photo sensor contained in a tubular support adjacent to spray head to turn valve on or off in the presence of an object being held under spray pattern. All units shall have nickel plated mixing valves with checks to prevent cross flow located under the racking bench.

8.7 Stacking Plates Provide grated stacking plates approximately 7-1/2” wide under racking stations to allow operators to stack various plates and dishes prior to sending them to the dishwasher. Plates shall be formed of 16 ga S/S with ¼” square bars, 1-7/8” on centers, welded to the 16 ga pan frame and smoothly polished. Plates shall be easily removed for general clean-up operations.


9. TRAY AND PLATE MAKE-UP CONVEYORS Nearly any model K-Flex Conveyor described in these specifications can be used for tray or plating conveyors as well as the (2) models specifically designed for this task:

• Model SBC-D1 Slat Belt

• Model CTC-D1 Cord Conveyor

• K-Line belt conveyor

• Slim Line belt conveyor

K-Line belt conveyor and Slim Line belt conveyor are conveyors drive units that are specifically designed for tray or plating conveyors and use a neoprene/PVC covered Dacron belt in the classic example of an assembly conveyor. We recommend these (2) models for primary consideration in this type environment.

9.1 Model SBC-D1 Slat Belt Tray Assembly Conveyor Specifications This slat belt conveyor can be successfully used in tray assembly work but must be equipped with the standard belt washing system as described in previous specs simply because slat belts have many areas hard to clean except with a properly designed wash system. Belt groove in slide bed top and return belt under top shall be totally self cleaning and need no manual attention

Specifications of this drive unit are identical to specs on model SBC-D10.

1. Slide beds shall be constructed of 14 ga S/S with raised rolled rim. Boxed edges, or marine edge as selected. Provide a ¼” high raised center section under the belt to prevent any spilled wastes from getting under the conveyor belt.

2. Provide non-removable skirt panel to cover return belt. Provide hinged safety plate at terminal end of conveyor that will allow trays to smoothly exit powered belt to un-loading platform.

3. Provide a 20” raised starting deck at tail end of conveyor so trays can be placed in a holding position while being prepared with certain basic items. Belt shall slide out from under this deck and there shall be no belt opening in bed to allow trays to be slid from loading platform to live belt with minimum effort.

4. At terminal end or unloading end provide a through-beam set of accumulation photo cells and an un-load deck similar to the staring deck. Standard SBC motor control panel shall be located under unloading deck. Control shall have settings to rapidly stop the conveyor during accumulation and controlled acceleration when restarting.

9.1.1 Electric Distribution Raceway Provide an electrical utility distribution chase the entire length of conveyor suspended from the leg structure. Unit shall have sloped top for easy cleaning and receptacles as designated on electrical plan and schedule.

All receptacles to be wired to a 200 amp 3 phase, 4W load center in housing under tail unit. Flush mounted circuit breaker panel shall be e-nickel plated with a brushed finish to match S/S housing. Provide locking door with (3) sets of keys


9.1.2 821 Belt Specifications Model SBC-D1 conveyors shall incorporate a single 10” slat belt. Slat belt shall be all plastic construction with S/S connecting pins. Belt shall be molded links of Delrin and Teflon and designed for automatic spray washing.

9.2 Model CTC-D1 Cord Type Tray Assembly Conveyor Provide double strand polycord conveyor as shown on plan. Unit shall incorporate K-Flex Model CTC-D1 cord conveyor. Belt washer is not required or needed. Provide multi-level Teflon wipers to clean belt of any contamination and a removable scrap pan in drive unit housing.

Cords shall operate in black UHMW full length guides. Provide a 20” raised starting deck at tail end of conveyor so trays can be placed in a holding position while being prepared with certain basic items. Belt shall slide out from under this deck and there shall be no belt opening in bed to allow trays to be slid from loading platform to live belt with minimum effort.

At terminal end or unloading end provide a through-beam set of accumulation photo cells and an un-load deck similar to the staring deck. Motor control panel shall be located under unloading deck and control shall have settings to rapidly stop the conveyor during accumulation and controlled acceleration when restarting.

9.2.1 Cord Material Cord material shall be ½” polyurethane with Dacron cores. Welded joints in cords shall be the overlap type. Butt joint welds will not be accepted. Return belt cords shall be supported with special cord bushings to safely return cords to drive unit and shall be totally accessible for inspection

9.2.2 Load Conveyor shall be designed to carry a 6 lb/ft loading and shall operate smoothly without oscillations or pulsing of conveyor under full load.

9.2.3 Slide Beds and Skirt Panels Slide beds shall be constructed of 14 ga all coved S/S with standing rolled rim, box channel or marine edges. Provide 10” skirt panels for full length of conveyor.

9.2.4 Drive Housing Drive housing shall be formed from 16 ga S/S with double foam filled doors

9.2.5 Electric Utility Distribution Raceway Provide an electrical utility distribution chase the entire length of conveyor suspended from the leg structure. Unit shall have sloped top for easy cleaning and receptacles as designated on electrical plan and schedule.

All receptacles to be wired to a 200 amp 3 phase, 4W load center in housing under tail unit. Flush mounted circuit breaker panel shall be e-nickel plated with a brushed finish to match S/S housing. Provide locking door with (3) sets of keys.

9.3 K-LINE TRAY ASSEMBLY CONVEYORS The K-Line series conveyor offers a truly effective belt conveyor for use in tray make-up in hospitals. Using new materials and designs, K-Flex has developed an in-expensive version of the oldest conveyors. These units run quiet and are simple to maintain. Belt


can be cleaned of spills with conventional kitchen cleaners and the smooth crack free finish makes clean-up easy.

9.3.1 Drive unit Drive unit shall be constructed of all S/S formed structures and shall have a 16 ga enclosure with double wall foam-filled 18 ga door panels. Drive pulley shall be 6-1/2” diameter neoprene covered crowned roller set on pillow block ball bearings with a S/S shaft. Provide a corrosion proof drive chain with spring take-up connected to a BISC wash down gear reducer and all S/S 3 phase drive motor. Provide a removable belt scraper to effectively remove any debris from belt and deposit in removable scrap pan.

Belt take-up shall be accomplished in the tail unit with spring take-ups and hinged tail pulley. Return belt shall be carried on S/S rollers set in adjustable brackets and fitted with S/S silent ball bearings and be designed for easy belt tracking.

9.3.2 Belting Belting shall have a smooth PVC plastic finish and available in white, blue or green. PVC covering shall be over a 2 ply Dacron fabric core and laced with S/S alligator #6 lacing. Where belt wraps around drive pulley provide a spring loaded S/S hinged safety plate to prevent any object from entering opening in slide bed.

9.3.3 General Construction At terminal end or unloading end provide a through-beam set of accumulation photo cells and an un-load deck similar to the staring deck. Motor control panel shall be located under unloading deck and control shall have settings to rapidly stop the conveyor during accumulation and controlled acceleration when restarting.

Slide beds shall be constructed of 14 ga all coved S/S with standing rolled rim, box channel or marine edges. Center section of slide bed under belt shall be raised ¼” to prevent any spills from entering the underside of the belt and allow for quick and easy clean-up. Provide 10” skirt panels for full length of conveyor.

9.3.4 Electric Utility Distribution Raceway Provide an electrical utility distribution chase the entire length of conveyor suspended from the leg structure. Unit shall have sloped top for easy cleaning and receptacles as designated on electrical plan and schedule.

All receptacles to be wired to a 200 amp 3 phase, 4W load center in housing under tail unit. Flush mounted circuit breaker panel shall be e-nickel plated with a brushed finish to match S/S housing. Provide locking door with (3) sets of keys.

9.4 SLIM-LINE SANDWICH AND PLATING CONVEYORS The K-Flex Slim-Line conveyor series was designed specifically for preparation of sandwiches and other plated items such as salads and entrees. The design is fixed and usually no options are available. The unit is available in 10-12-14-16 ft lengths. It can be fitted with 14 ga s/s sectional removable shelf covers that can be pulled up and over the slide bed to allow the conveyor to convert to a flat top utility table. The unit comes self-contained on 5” swivel and locking polyurethane casters and is fitted with a 10 ft cord and plug assembly with Hubbell #2757P and matching #2753C connector body. No service receptacles are incorporated in the standard PC unit, however low amperage plug- ins can be provided at an additional charge. Consult K-Flex for details.


1. Slide bed shall be constructed of 16 ga S/S and skirt panels shall be integrally formed as part of the slide bed. The portion of slide bed under the conveyor belt shall be raised ¼” to prevent any spills from entering the underside of the belting and make clean-up simple and easy.

2. The entire slide-bed and belt/motor assembly shall hinge upward on counterbalanced S/S gas spring to expose the entire works of the conveyor for easy cleaning of all parts.

There is no enclosure for a drive unit as the drive is contained within the drop skirts of the top slide bed. The cross section is 8-1/2’’deep.

3. Drive motor shall consist of a PVC crowned pulley with the drive motor closely coupled. There are no chains or sprockets.

4. Belt take-up shall be accomplished at the tail end with spring take-ups and sliding tail pulley.

5. Return belt shall be carried on PVC rollers set in adjustable brackets and fitted with S/S silent ball bearings and be designed for easy belt tracking.

6. Provide removable belt scraper to clean belt and a removable scrap pan. Each side of drive adjustment area shall have a clear lexan view port for inspection of drive and belt scraper area.

7. At terminal end above unloading deck provide a set of through beam photo cells to rapidly stop belt when sensing any object interrupting beam. Belt speed shall be adjustable from 5 to 30 ft./minute at motor control panel located under tail end of conveyor. Control system shall allow operators to select “AUTO INDEX” feature where conveyor belt will “JOG” for a pre-determined distance, STOP for a pre-selected time and restart again after the time interval.

8. Belting shall have a smooth PVC plastic finish, 10” wide and available in white, blue or green.

9. PVC covering shall be over a 2 ply Dacron fabric core and laced with S/S alligator #6 lacing. Where belt wraps around drive pulley provide a spring loaded S/S hinged safety plate to prevent any object from entering opening in slide bed.

10. Slide bed under belt shall be raised ¼” to prevent any spillage from going under and allow for easy clean-up.


10. MODEL MCR-1248 MAGNETIC CUTLERY REMOVER MCR units automatically remove magnetic cutlery from a cafeteria tray as it passes underneath the MCR belt.

Best results are obtained by placing the MCR at or near the last breakdown station on the disassembly line of the work center, although it can be located at nearly any location.

Unit should be mounted no with no more than 6” clearance above tray conveyor belt line. A portable soak sink is usually used in conjunction to the MCR and a 20 x 20 silverware basket is placed in the sink to allow for easy pick-up; the MCR is positioned perpendicular to the breakdown flow and as cutlery is held by the magnet inside and under the belt, when the cutlery reaches the end of the conveyor where the magnet is not present it falls into the sink or portable basin.

1. MCR unit is constructed with a S/S body and corrosion proof machine parts. 2. A cleated white 12” wide PVC Dacron belt shall surround a PM magnet which is exposed

on the underside and covered with a hinged cover on top and ends. 3. Magnetic flux shall weaken as cutlery is moved to drop off point above soak sink. 4. Entire unit shall be designed for hose cleaning. 5. Provide legs for mounting to tray return conveyor bed as shown on plan. 6. A S/S drive pulley shall contain the drive motor and take-up pulley shall be all plastic 7. Provide built in start-stop buttons and motor controls. 8. No lubrication of any kind is required at any time. 9. Power requirements are 120 VAC, ¼ HP. 10. Size of unit shall be about 15” wide, 6” high x 48” long. 11. Weight is about 350 lbs.


11. TRAY-STAC TRAY ACCUMULATOR CART K-Flex has developed a tray accumulator cart, specifically for soiled trays coming off the end of a tray conveyor scrapping line. Most competitive units available today simply cannot take the severe service and wash-down requirements of soiled tray lines which many times dump waste and liquids over the accumulator as the tray unloads. Models available are STAC-1418 for 14 x 18 trays. Model STAC-1520 for 15 x 20” trays. Capacity of each unit is 60 standard trays. Customized versions are available to conform to special needs and requirements.

The STAC unit is specifically designed to cope with this environment and can be completely hose cleaned or cleaned in a cart washer which is nearly impossible to accomplish with competitive units.

1. Unit shall be constructed with 16 ga S/S body and uprights with foam filled double wall re-enforced 14 ga bottom plate with 4” swivel casters with brakes.

2. Tray carrier shall be precision balanced to the tray load with S/S chain, sprockets and special high-tech bearings to effect a smooth vertical movement that responds to each tray placement.

3. Provide sufficient S/S springs that can be connected to balance any tray load as required. 4. Provide lift off access panels for complete inspection on back and front sides. 5. Rubber bumpers shall protect exposed corners and large plastic heavy duty handles shall

be mounted to top for easy mobility


12. POWERSKATE TRAY ASSEMBLY CONVEYORS Conveyors of various types are used in the Food Service Industry to assist production of many tasks. Investment costs and sanitation play key roles in selection of what conveyor will be used.

Fabric belts, slat belts, and cord belts have all been used but are costly and difficult to clean or keep clean. To keep the investment to a minimum, gravity and skate wheel conveyors have often been the only unit an institution could afford.

Even though there is a marked gain in sanitation there is a corresponding loss of efficiency due to the elimination of a powered drive system.

In hospital patient tray preparation work, an assembly line is used to make up each patient tray. One of the biggest problems associated with any belt conveyor is the fact that spillage can and does occur during the assembly process and food can get in, under and around the belt conveying causing clean-up at the end of the work period. Thus, the “skate wheel” conveyor presents an increase in sanitation, however, the trays must be pushed along, bumping and tailgating against each other as they move down the line.

The answer to all these problems is the ingenious POWERSKATE tray assembly conveyor. This conveyor encompasses the sanitation of simple “skate-wheels” with the distinct advantages of a powered “belt” by motorizing the individual wheels.

Any food products that miss the mark during tray assembly and fall on the conveyor simply fall to the bottom pan of the conveyor and are never transferred down the line as would be the case in any belt conveyor. Clean-up after the work period is simple and easily accomplished by wiping the bottom of the bed with standard cleaning products.

Additional features can include an “auto start” zone. In tray assembly work, a loader person places the tray on a “dead-plate” of powered belt conveyors and standard common items such as tray liners, silverware, serviettes, salt and pepper, etc, are placed on the tray and then pushed onto the powered belt in a not-too-smooth fashion. The proposed improvement features a “loading zone” where the powered skate wheels are normally in a stopped position. When the preliminary loading is complete the operator presses a conveniently located button and the wheels are momentarily engaged transferring the tray to the powered line for loading of additional items. The operator can in the same movement reach for another tray speeding up the loading process.

12.1 Dishwashing Systems Dishwashing systems have long used skate wheels during the disassembly process for economics, effectiveness and simplicity. Even though a powered belt may bring the cafeteria trays in from the cafeteria a line of skate wheels may form the last segment of the system in an advantageous manner. These are located in a “racking bench” along with other devices to allow dish-wares to be effectively cleaned, pre-rinsed and transferred to the dishwasher for final sanitizing.

Usually the skate wheels are suspended over a “disposal trough” or flume where refuse from the tray can be conveniently deposited downward in the gaps between trays for transferring to the disposal system. In this respect skate wheels have a clear advantage over slat belts or fabric belts and transferring of spilled or misplaced waste products by the use of a continuous belt is non-existent.

Since movement of the tray is dependent on the operators only, the trays do not maintain uniform spacing and tailgate each other closing the gap where refuse and wastes are deposited into the disposal trough.


The use of POWERSKATE therefore allows the skate wheels to become a powered conveyor and trays uniformly move along the breakdown line or racking bench. The proposed design requires no more space than non-powered skate wheels and for all purposes even the appearance is identical. Thus, all the advantages of skate wheels are now available with the obvious values of a powered belt along with the absolute ultimate in sanitation.

12.2 POWERSKATE SPECIFICATIONS 1. Provide tray assembly conveyor as shown on plan. Unit shall be 28’-6” long x

16-3/4” wide and designed to smoothly convey 13” x 21” x 1” trays. Working surface of tray bottom shall be 42” above the floor level. Conveyor top shall be fabricated from 16 ga #4 finish stainless steel with all corners coved to ¾” radius for easy cleaning. To reduce the product loading reach to a minimum there shall be 4” clearance under the conveyor runway to the top of the side equipment which will allow cold holding equipment to be placed under the conveyor up to 5” on each side.

2. Transport system shall be designed so any spills or misplacement of food product off the trays or plates will not be transferred by the conveying media. Trays shall be conveyed by 2” diameter polyurethane powered skate wheels, projecting into runway of conveyor on stainless steel tubular extensions, 5-1/2” on centers. There shall be no clean-outs or belt scrapers of any kind nor a requirement for any cleaning device.

3. Driving system shall be so designed that any skate wheel or group of skate wheels or a tray can be stopped or held from turning with minimal pressure. Channel edge which contains the drive system shall be a maximum of 4-3/4” high so side and top of tray shall be ¼” below the top rim of conveyor.

4. Provide drive unit enclosure from 16 ga S/S with double wall foamed panel doors. Motor Control panel shall be recessed under loading end of conveyor with a foot operated auxiliary switch on the unloading end. Foot pedal shall be on 6 ft cord and plug into a special receptacle at that location. Speed of conveyor shall be user-adjustable at the motor control from 5 to 20 ft/min. and shall be equipped with a “soft start/stop” feature.

5. At starter end of conveyor the first (4) skate wheels form a loading zone and are normally not rotating. When a tray is placed in the zone and loaded with condiments, silverware and tray liners it is dispatched by loader brushing the sensor plate when reaching for a new tray. Stationary skate wheels begin to turn for a preset time interval releasing the tray to the down stream line of the conveyor. Wheels stop rotating and wait for new signal. This feature is user selectable at the motor control panel.

6. At the loading or terminal end of the conveyor, provide a flush mounted photo-electric limit/accumulation sensor to stop conveyor after adjustable delay time. This sensor can be turned “off” or “auto” at the motor control panel. Provide also a mechanical stop in the form of a S/S cross rod to stop trays from going off end of conveyor. If photo sensor is turn to “off” or operates with a longer “delay”, driving system shall allow minimum (4) loaded trays to “tailgate” without any danger of overlapping . This feature allows the main line of the conveyor to keep running if the loader/checker is required to accumulate trays during this process.

7. Under the center line of the conveyor provide an electrical raceway formed from 16 ga S/S with required receptacles mounted on either vertical face or under the


bottom, facing floor. Provide a sloped roof with “drip eves” integral with side faces. Provide a 100 amp 120/208 volt 3 phase load center at loader end of conveyor in a stainless steel enclosure. Panel door shall be nickel plated and brushed to match the stainless enclosure. Each receptacle shall be wired back to the panel with proper sized wire in accordance to National and Local Electrical Codes. Owner will provide “drop cord” for direct connection to main lugs in Load Center;

8. Support drive unit on S/S legs with flange feet that can be secured to floor. Provide 8” x 2-1/2” x 14 ga. stainless steel tubular pedestal floor supports under main run of conveyor to allow side equipment to be located anywhere without leg interference. Electrical raceways shall butt up against face of pedestal. Bottom of pedestal shall mount on ¼” thick S/S plate with beveled edges all #4 finish. Plate shall be 1” wider on sides than the tubular pedestal and shall be secured to floor with flush stainless concrete anchor fasteners.

9. Provide double sided sloped over-shelf above conveyor 24 ft long where shown on plan. Shelf to be fabricated from 16 ga S/S with 1” turned-up hem at each bottom side. Each sloped side shall measure 13” at a 15 deg angle. Provide full length enclosed fluorescent lighting under shelf at centerline. Shelf to be supported on 1” square S/S tube supports approximately 10” clearance to the top rim of conveyor.

10. Provide a movable starter station measuring approximately 62” x 18” and designed to straddle the starting end of conveyor. Provide an elevated sloped shelf with cut-outs holding (9) 1/3 size steam table pans. Station shall be fabricated with 1” square S/S tubular frame. Provide 16 ga work surfaces at conveyor height and (2) shelves on each side for starter items. Mount unit on adjustable S/S feet.

11. Warranty and guarantee: Conveyor shall carry manufactures warranty for two years parts and one year parts and labor.

13. VERTICAL TRAY CONVEYORS — FLOOR TO FLOOR

13.1 APPLICATION This type of conveyor is used to carry trays from a cafeteria lo the dish room where the dish room is on a floor lower than the cafeteria.

13.2 DESCRIPTION The down feeding tray handling system which features (3) different conveyors probably represents the most efficient means of transporting trays in a floor-to-floor cafeteria to dish room application.

The system consist of an automatic loading “pin” conveyor, an indexing vertical conveyor and an unloading conveyor, usually a SBC slat belt. The system is fully automatic and virtually free of jam-ups and trouble spots common to other types of vertical tray systems.

13.3 OPERATION A tray is placed on the slider bed of the pin conveyor in the cafeteria. A “pusher pin” projects through a slot in the conveyor bed and is constantly moving. The pin conveyor


is mechanically linked to the vertical conveyor making it impossible to get out of “synchronization”. The pin contacts the tray and pushes it towards the vertical conveyor.

The vertical conveyor, by means of an index drive, stops “flights” at intervals on the exact level of the tray on the pin conveyor. During the dwell period of the vertical conveyor the constantly moving pin conveyor pushes a tray onto the flights now at rest. As soon as the tray is completely inserted into the vertical, it indexes down bring a new set of flights at a level to load from the pin conveyor. Dwell and index times make up one complete cycle, each taking 50% of the time

The trays continue to descend in the vertical conveyor and are deposited on the continuously moving unload conveyor belt. To insure proper and complete unloading, the flights stop indexing approximately 1” below the unload platform holding the unload conveyor belt system. Thus it can be seen that the load-to-unload height is critical. It must be an given number of feet (12” spaces) minus 1”. This will insure the flights which are on 12” center, will always place a tray on the unload conveyor and come to a rest 1” below this landing platform.

While mechanically integrated, the loading and unloading operations are constantly monitored by electronic sensors. These devices sense any misplacement of a tray on the loading conveyor or any tray that may not properly unload at the lower level.

Automatic loading and unloading devices on any machine eliminate 95% of the possible danger to people as well as providing a more efficient and faster overall operation.

One of the biggest problems in vertical tray handling systems is breakage of wares. While not exactly hazardous, it is costly and every hospital dietician, even in small hospitals, tries to keep it to a minimum. Breakage will occur whenever people come into contact with breakables. Eliminating as much “people handling” as possible is the obvious solution, but care must be taken to ensure that any “automatic” system does not create more hazards than it cures.

The K-Flex Floor-to-Floor Automatic Tray Handling System has many safety features that have been refined and modified over the 40 years since first engineered and designed by the founder of K-Flex Systems. Modern technology has lead to more reliable and faster acting controls which has had a major impact on safety and performance of these systems.

13.4 TYPICAL SPECIFICATIONS Conveyor contractor to provide and install the following equipment as per plans and drawings:

• Tray deposit pin conveyor

• Automatic top loading vertical conveyor

• Unload conveyor at lower level

• Control system and field wiring

• Fire doors

• Instructions and In-Service Demos

• 2 year Warranty

13.5 Operation of System


14” x 18” cafeteria trays shall be placed on the pin conveyor in the dining room and automatically transfer to the vertical conveyor. Trays are then lowered to the lower dish room level and automatically unloaded.

System has handle 12 trays per minute.

13.6 Tray Deposit Conveyor

13.6.1 Pin conveyor chain Concealed, pre-lubricated #2060 WP with nylon rollers and Delrin pusher pins riding on UHMW guide ways.

13.6.2 Slide Beds Slide beds to be formed with tray slide ribs from 14 ga S/S with all corners coved to 5/8” radius, welded, ground and polished at all joints. Drop edges shall be integrally formed as part of the slide bed.

13.6.3 Enclosure Provide ¾” plastic laminate removable panels over galvanized frame with S/S trim and reveals as shown on elevations.

13.6.4 Drive Unit Special cut e-nickel plated sprockets, stainless steel precision 303 shafts, taper lock hubs, precision take-up for tail unit, ball and needle sealed bearings. This conveyor shall be driven by the vertical conveyor.

13.6.5 Automatic Tray Loading into Vertical During normal tray loading operation, tray shall remain totally horizontal and shall not stop or hold at any time. Tray shall be smoothly inserted into vertical by means of the pusher pins during the dwell position of the vertical conveyor cycle .

13.6.6 Loading End Protection Devices Provide photoelectric sensors to detect any misplacement of trays during loading process at the entrance of the vertical conveyor. Provide sensors to detect any object covering pusher pins or if trays are “piled” on conveyor. All sensors will be monitored at the Motor Control Center (MCC) and a diagnostic display will be clearly visible and any malfunction will immediately stop both pin and vertical conveyors.

13.7 VERTICAL INDEXING CONVEYOR

13.7.1 Framing Welded angle iron frame –hot dipped galvanized. Built in modules for assembly into a tower at job site. Provide ribbed stainless steel lining to run the entire height of the vertical conveyor with splice plates at all module joints.

13.7.2 Shafts Shafts shall be machined from precision ground 303 stainless steel

13.7.3 Flight Chains Pre-lubricated, 2060 WP chain, 8500 lbs tensile with attachments to hold flights


13.7.4 Sprockets All sprockets shall have hardened teeth and e-nickel plated with locking hubs.

13.7.5 Flight Guides Nylon covered stainless steel

13.7.6 Flights Nylon covered stainless steel with UHMW guide plates

13.7.7 Drive Motor Worm and helical combination with fail-safe magnetic brake. Speed of motor adjusted by variable frequency drive control. 208 volt 3 phase, 1 hp.

13.7.8 Mechanical Overload Protection In addition to electronic overload protection in motor control, provide a torque limiter on the drive “jack shaft” to prevent damage in the event of a malfunction not detected by the electronic systems.

13.8 UNLOAD CONVEYOR AT LOWER FLOOR Provide SBC-K10SF slat belt conveyor to remove trays from vertical conveyor. Belt shall extend through vertical conveyor landing platform between flights to receive trays.

13.8.1 Drive unit and Tail unit Belt washer—drive unit shall incorporate a belt washing tank formed of welded 14 ga S/S with coved horizontal corners. Provide lift off waterproof doors in side of wash tank for total easy access for cleaning and servicing. Doors shall have positive self-latching S/S handles. A perforated strainer pan shall be located in sump to catch any debris washed off conveyor belt. Provide (3) removable S/S spray arms with die-stamped spray jets to effectively clean belting. A 1-1/2” S/S drain connection is required as shown on plan.

Drive Shaft—provide S/S drive shaft with positive, greaseless S/S spring seals to prevent any moisture from entering bearings. Shaft shall use no keyways at any point and all sprockets shall be driven from shaft by collet type couplings. Drive sprockets shall be machined S/S. Flange bearings on outside of tank shall have S/S housings, lubricated for life.

Drive Motor—gear motor shall consist of a wash down BISC gearbox with an all S/S motor, c-flange of 3 phase design with S/S junction box. Chain driving conveyor drive shaft shall be special waterproof construction, superior to ordinary S/S chains and shall be fitted with an automatic take-up for attention-free maintenance.

Drive housing—housing shall be constructed of 16 ga S/S with double wall 18 ga door panels. Panels shall be laminated foam construction for maximum sanitation . Drive housing and tank assembly shall be sealed to slide-bed with clear silicone sealer on final assembly. Construction and forming of housing shall be so designed to eliminate the requirement for any angle iron framing.

Plumbing Housing—a plumbing enclosure shall contain mixing and shut-off valves for belt washer, solenoid valve and detergent pump. Detergent shall drip feed on return belt as it enters the return track to provide maximum time and concentration of cleaning action. Provide check valves and vacuum breakers as required. All exposed piping shall be


stainless steel or chrome plated. Unfinished copper piping is not allowed. 1/2” hot and cold water connection required at shut-off valves.

Tail unit—tail unit shall contain a removable drawer-type scrap pan to catch any debris from the belt return tracks. Tail unit will be carefully installed in vertical conveyor structure to allow for cleaning of both units and not interfere with any servicing of the system. Tail sprocket shall be UHMW with special lubed-for-life bearing on S/S shaft with dual spring take-up. A 1-1/2” drain connection is required as shown on plan.

13.8.2 Side Flexing K10-SF Slat Belt Slat belting shall be 10” wide K-Flex K10SF (pat no 3627109) plastic plate tops attached to a S/S side flexing chain. Slats shall have special rollers attached to eliminate any sliding friction between belt and track as belt turns corners. Slat and belt assembly shall closely fit the track in slide bed to minimize any collection of debris in track if cleaning is not regularly attended. Slats to have overlapping feature to prevent any objects from getting under belt. Standard color is Royal Blue but custom colors are available.

13.8.3 Slide Bed and Return Tracks Slide beds shall be formed from 14 ga S/S with all corners coved to ¾” radius. Belt tracks shall be closely fitted to profile of K-Flex belt to eliminate any build-up of debris. Slide bed Tracks shall have special UHMW wear guides along each side for the belt to ride on to minimize friction and eliminate wear. Return belt tracks shall be totally self-cleaning and shall never require cleaning attention of any kind. No drain connections are required, regardless how long the conveyor may be designed, except at drive and tail unit connections.

13.9 CONTROL SYSTEM AND FIELD WIRING All motor controls for vertical conveyor and unloading conveyor shall be located inside Motor Control Center (MCC). Motor controls shall be variable frequency devices and deliver 3 phase 230 volts to each motor as required to vary the speed.

Panel shall be fabricated of 14 ga S/S and fitted with waterproof gasketing.

Push buttons and other user interface devices shall be located on hinged front door with clearly labeled integral nameplates. “Stick-on” or individual plates are not acceptable.

Provide an inside pocket to hold drawings and diagrams for maintenance personnel.

Provide auxiliary control panel in dish room to operate the unloading conveyor belt wash and local control requirements.

Provide a main disconnect with door interlock, sealed speed adjustment knobs, indicating lights and diagnostics.

All devices and sensors will be controlled by a programmable logic controller (PLC).

Control panel shall be mounted on the wall inside vertical conveyor room, however, other options are available.

All wiring shall conform to UL standards for appliances and meet all local codes.

Standard voltage connection is 120/208 VAC single phase but other voltages are available.

It is the responsibility of the conveyor contractor to install and field wire the conveyor system into a turn-key operation.


13.9.1 Wiring and Conduit wiring outside the control panel will be performed in totally sealed, all plastic flexible conduit and fittings. Conduit in the dish room shall be PVC or PVC covered galvanized with sealed fittings or all plastic sealed flexible conduit. Wiring shall be PVC covered tinned copper machine tool wiring with clearly labeled terminal strips and connection points.

13.9.2 Auto Index Feature this feature uses photocells to effectively advance the pin conveyor at the tray deposit area. When this mode is selected on the control panel, anyone setting a tray down on the tray deposit breaks the through-beam of the photo cell causing the system to “index” or move ahead enough to place another tray on the space provided. This will continue to operate until the entire vertical conveyor is full and trays have reached the bottom unloading platform.

13.9.3 Maintenance Switches Provide strategically located maintenance switches in the conveyor loading room for service. These shall be key operated to prevent un-authorized personnel from using this feature. Provide an EMERGENCY STOP button clearly visible on the tray deposit

13.9.4 Motor Disconnect Switches Provide all plastic enclosed rotary type waterproof motor disconnects at each motor for maintenance and service personnel safety. A separate circuit will notify the Motor Control Center a switch is “open” and therefore the conveyor cannot operate. The location will be indicated on the diagnostic board in MCC.


14. WRS-KF-419B WASTE RECLAMATION SYSTEM

14.1 General Specifications Provide a waste handling system to process the food wastes from cafeteria trays with the following specifications:

14.1.1 Non-destructive Food Waste Capture Food wastes will not be ground or destroyed with industry lowest minimum dilution into the conveying water.

14.1.2 Effectiveness Less than 1% solid waste particles will be allowed to enter building drainage system. System shall retrieve and capture all particles as small as grains of rice.

14.1.3 Lowest Industry Sound Pollution System shall operate at a decibel rating of less than 45db. (normal conversation is 50db)

14.1.4 Vibration Entire system shall operate vibration free regardless of loading.

14.1.5 Cleanliness There will be no hidden cavities of ground up food wastes. Entire system can be cleaned in less than 15 minutes to factory condition.

14.1.6 Safety System shall contain no high velocity spinning cutters and the in-advertent admission of silverware or metal objects shall have no effect on the performance in any way. Pump motor shall stall to a harmless state if obstruction in pump impeller occurs.

14.1.7 Waste Trough This shall be fabricated of 14 ga. S/S and shall connect to industry generic flanges on the dishtable racking bench trough which form an integral part of this system. All troughs shall be 8” wide and pitched at 1/8” per foot. A full width sluice box with an opening of ¼” shall be welded into the high end of the trough and design to inject a smooth laminar flow of water into the trough. Provide pipe hangers to neatly hold the recirculation line in a hidden position. Unit overall dimensions are 42"L x 27"W x 34"H. (overhead gantry 6'-5" AFF)

14.1.8 De-watering tank & Housing Constructed of 14 ga S/S with all coved horizontal and vertical corners, integral welded to drain table top and polished to smooth #4 finish. Tank levels are automatic and the central drain is fully automatic operations.

14.1.9 De-watering Cylinders Two (2) fluid straining cylinders to be constructed of molded PVC top ring and molded bottom perforated base ring with the cylinder body constructed of seamless high strength Kevlar/Nylon tight weave. Cylinder perforation mesh to be -1/64" inch perforation.


14.1.10 Re-circulation pump Pump shall be cast/machined from stainless steel with semi-open S/S impeller, high grade ceramic seals and a TEFC 3 phase direct coupled motor. Redundant safety and overload protection. Nominal operating draw shall be less than 1.5 amps at 60 gallon per minute recirculation.

14.1.11 Control System Provide control panel on pedestal mounting. Control system shall provide fully automatic operation with a single activation with no manual attention required. The automatic fill system with correct amount of water and start the pump after an over-fill period to insure sufficient water has been added. Safety features will include an automatic shut-off if tank loses water or if the cylinder screen are not in place or has not been reset from the cleaning position to the operating position. The operator can select auto-pulse feature when desired and the unit shall automatically pause operation allowing exchange of the cylinder screen. The unit shall be controlled by a PLC Computer with diagnostic indicator lights to alert the operators of any malfunction or stoppage of the system.

14.1.12 Screen Cylinder Lift Constructed of 14 ga S/S gantry with on board lift and lower functions, rolling frame and 300 lb lift capacity with auto-shut off safety feature. Typical full screen weight at fullest point is 35 lbs.

14.1.13 Utilities required 120 volt 15 amp , ½” hot and cold water supply, 1-1/2” waste connection

kflexsystems allspecss

Documents

line tray assembly conveyors

drive unit

slat belt specifications

vertical tray conveyors

tray rail

tray deposit conveyor

drive housing

drive motor