Maintenance

Maintenance Schedule
To keep the system running smoothly and in optimal condition, regular preventive measures are
important.
This chapter describes preventive maintenance of the Spiral Freezer and various adjustment that may
have to be made.
CAUTION!
These maintenance procedures must be performed only by trained staff. Check that the isolator has
been locked off and always inform a co-worker before gong inside the drum/ cage. For more safety
instructions, see the Safety during Maintenance section in this document.
Table 14 Preventive Maintenance Schedule
Description Frequency
CALIBRATION
Calibrate air temperature sensor Quarterly
Calibrate refrigerant suction temperature sensor Quarterly
Calibrate belt speed Quarterly
Calibrate overdrive Quarterly
Check parameters of variable frequency drive Quarterly
SAFETY
Check emergency stop button Quarterly
Check belt lift sensor Quarterly
Check product height limit sensor (if installed) Quarterly
Check drum drive chain proximity sensor Quarterly
Check freezer doors emergency push handle Quarterly
Check the earth wiring connection Quarterly
LUBRICATION
Check oil level in drum drive gear box Weekly
Change take up motor gear lubricant Annually
Change drum drive gear box lubricant Annually
Lubricate drum drive chain and tensioner systems Monthly
Lubricate all the conveyor bearings Monthly
MECHANICAL WEAR & TEAR
Check that the conveyor belt is properly tensioned Half-Yearly
Check and ensure the condition of the drum drive
chain
Half-Yearly
Check conveyor wear strip for wear and tear Half-Yearly
Check conveyor bearing for wear and tear Half-Yearly
Check nylon bearing bush
(for in-feeds / inspection conveyors)
Half-Yearly
Check conveyor sprockets for wear and tear Half-Yearly
Check conveyor motor for wear and tear Annually
Check inner door rails Annually
Check that the drum top and bottom bearings are
lubricated
Monthly
Check the evaporator tubing for any rust or
abnormal conditions
Monthly
Check cable trunking conditions Half-Yearly
ELECTRICAL
Check door heater Half-Yearly
Check the settings of overload relays Half-Yearly
Ensure incoming power connectors are securely
fastened
Half-Yearly
Measure current drawn by fan motors.
Ensure it remains below rated current on motor
nameplate.
Half-Yearly
Measure current drawn by drives.
Ensure it remains below rated current on motor
nameplate.
Half-Yearly
Check insulation of the electric drive with Ohm-
meter
Half-Yearly
Check cable conditions within the freezer Monthly
Check lighting in the freezer Monthly
Check the touch screen functionalities Monthly
Check control panel:
Door seals
Ventilation fans and thermostat
Ensure panel does not over heat
Monthly
Check the PLC for any abnormal conditions Monthly
Download the fault logs and study through the
fault alarms
Weekly
INSULATION PANEL
Ensure the skirting rivets are securely fastened Half-Yearly
Ensure the silicone is not torn off, especially on the
joint to the floor
Half-Yearly
Check insulation panels from any damage Half-Yearly

NOTE
The following are recommended grease and lubricant for specific components of Marel equipment:
Klubersynth UH1 14-31 Bearings
Kluberpaste UH1 84-201 Fasteners
Kluberoil 4 UH1-15/spray Roller chains (freezing)
Kluber Summit HySyn FG-32 Gearbox (freezing)
Kluberoil 4 UH1-220N Gearbox (non-freezing)

Maintenance Procedures
Procedures for maintaining individual parts of the Spiral Freezer are described in the following.

Drive Chain & Center Drive Gear Motor
NOTE
For freezer with a center drive gear motor, please see the attached service manual for Center Drive Gear
Motor.

A well-planned and systematic maintenance procedure assures extended operations of the system. On
the other hand, failure to take necessary precautions generally lead to downtime.
To minimize the wear and tear of the drive chain and sprocket, it is advisable to lubricate the chain,
sprocket, and drive shaft weekly.




Figure 44 Drum drive chain and related components

Chain Lubrication
Be sure to follow the lubrication schedule closely. If the chain is covered with dirt and debris, clean it
with degreaser and re-lubricate it.

Chain Tension
Adjust the chain accordingly to maintain the proper sag in the slack span. If elongation exceeds the
available adjustment, try to make some adjustment in the Chain Tension unit.

Chain Wear
Measure the Chain Wear elongation. The elongation must not exceed the functional limits or be
greater than 3%. If that happens, you must replace the entire chain.
NOTE
3 % is the same as 30 millimeter in 1 meter or 0.36 inches in 1 foot.
Do not run a Chain worn beyond 3% because the chain will not engage the Sprockets correctly
and cause damage.
Do not connect a new section of chain to another worn section as it can run roughly and create
damage to the drive.
Sprocket Teeth Wear
Check for roughness or binding when the Chain runs in and out of the Sprocket.
Check the Sprocket for damage in the teeth section and hooked tooth tips.
If the Sprocket teeth are damaged, you must change the Sprocket.
Do not run a new Chain on worn or damaged Sprocket.
Do not run worn and damaged Chain on new Sprockets.
It is recommended that the Chain and Sprockets be changed at the same time.
Sprocket Alignment
Check for notable wear on the inside surface of the Chain roller link.
Check the Sprocket alignment and realign when needed.
Drive Interference
Check for any interference between the drive and other parts of the system.
When interference is found, correct the issue immediately as this can result in abnormal and
destructive wearing on the Chain.
If the edges of the Chain link plates comes in constant contact against a rigid object, fatigue on
link plate as well as Chain failure can happen.
Check and eliminate any buildup of debris or foreign materials between the Chain and Sprocket.
Chain Failure
Inspect the Chain for any cracked, broken, or deformed parts.
If problems are found, replace the entire chain even if some parts of the Chain look to be OK.
Remember, a Chain is never stronger than its weakest link.

Bearings
To ensure that your Spiral Unit is working optimally, remember to maintain all the bearing properly by
observing the following:
Careful installation of the bearings
Daily monitoring and control
Proper lubrication
The fundamental purpose of the bearings is to reduce friction and wear between the rotating parts that
are in contact with one another in the systems. The length of time the machine will retain its original
efficiency will depend on the proper selection and careful maintenance of the bearing.
Bearings can be found in the following areas:
In-feed unit
Drum/ Cage drive unit (top and bottom)
Take Up area




Figure 45 Different bearing locations on the Spiral Freezer

Fan Motor
The insulation resistance of the windings must be measured prior to initial startup of the motor and
after longer periods of storage or standstill.

CAUTION!
While measurement is being taken and immediately afterwards, some of the terminal carry dangerous
voltage and must not be touched.
The minimum insulation resistance of new, cleaned, or repaired windings with respect to the
ground is 10M Ohm.
The critical insulation resistance is calculated by:
Multiplying the rated voltage Un, e.g. 069 VAC. With Constant factor 0.5 M Ohm/Kv.

Rcrit = 0.69kV 0.5 M Ohm/kV means: 0.345 MV.

The minimum insulation resistance of the windings to ground is measured with 500 VDC.
The winding temperature should then be approximately 25
o
C 15
o
C (77
o
F - 59
o
F).
The critical insulation resistance should be measured with 500 VDC + the winding at operating
temperature.
After long period of operation, the minimum insulation may drop to critical insulation resistance. As long
as the measured value does not fall below the calculated value of critical insulation resistance, the
motor may continue to operate. But if it falls below, the motor must be stopped immediately.

Fan Motor Bearings
Under normal operating conditions, a new motor with proper grease suitable for low temperature down
to -40 degree C (-40 F), will have a bearing life of:
Horizontal mount or 1800 rev/min approx. 40.000 hours
Vertical mount or 3600 rev/min approx. 20.000 hours

Lubrication
Daily, weekly and yearly lubrication of the machine is done with the use of the Grease Inlet and through
a tube that reaches the top and bottom bearing houses.





Figure 46 Grease inlet nipples

Regular lubrication is best:
To resist wear of the pin-bushing joint
To cushion impact loads
To dissipate heat generated
To flush away foreign materials
To lubricate chain sprockets contact surfaces
To delay rust or corrosion

Drive Chain Lubrication Procedure
Drive Chain consists of a series of connected travelling metallic bearings. They must be properly
lubricated to obtain the maximum service life of the chain.
NOTE
Many slow-speed drives operate successfully with little or no additional lubrication other than the initial
factory lubrication.

Before starting lubrication procedure, turn the gear motor off
Open the Drive Chain cover and use high-pressure warm water to clean the chain
Use a regular brush to remove stubborn dirt and worn-out grease
Wipe it with dry cloth or use an air gun to blow the Drive Chain dry
When the chain is dry, start and stop the gear motor to run the chain around 300mm each time
Turn the motor off and carefully apply grease on the chain using a grease brush
NOTE
If Drive Chain or Sprocket needs replacing, it is best to replace them at the same time.







Cleaning
Cleaning in General
The following sections contain general instruction for good cleaning practices which Marel considers
appropriate for Marel equipment. The instruction are not a proposal for a complete cleaning plan for
the users. The best available practices should be used at all times.
We recommend that you request an introduction to recommended cleaning agents and their use, from
a qualified distribution of cleaning solutions. Selecting a sanitizer depends on the type of equipment to
be sanitized, the hardness of the water, the application equipment available, the effectiveness of the
sanitizer under site conditions, and cost.
Only approved sanitizers should be used in food processing plants. Lists of approved sanitizers are
published by the authorities in most countries: see for example the Code of Federal regulations in USA.
Request technical advice from a reputable sanitizer manufacturer, if you have questions on which
sanitizer to use, as well as questions on the appropriate solution strength.
It is very important that the Spiral Freezer is thoroughly cleaned every day after operation
In general, do not use excessively strong solutions of detergent. Chlorine disintegrates belts and
strong base solutions (pH > 3) corrode aluminum parts, air cylinders for example. The use of
chlorine may cause rust spots to appear on the stainless steel.
High-pressure water jets can easily damage sensitive mechanisms in the equipment. Therefore,
do not use high-pressure water jets on the controller display, product sensor and load cell, the
electrical cabinets, or motor. Instead, use low water pressure (tap water), or clean these parts
by hand and pour water over to rinse.
General Cleaning Steps
Cleaning of Spiral Freezer units involve the use and handling of washing solutions and chemicals.
Cleaning crews are advised to wear protection during the whole cleaning operations.
The cleaning process should be done in manageable steps to ensure that the whole system is clean.

IMPORTANT
Make sure that the power is disconnected or that the main power switch is locked in OFF-position
before cleaning.

The unit is equipped with two spray bars for belt washing after every operation
Internal pipe work for the spray bars are included, along with flexible hoses to connect with an
external washing source.
The unit is also equipped with spraying manifold for drum and structure washing after
operation. Pipe work for the washing system is also included along with a flexible hose
connecting to an external washing source.
Units with the CIP system have built-in water connection and cleaning control
Be sure to have coupling between your own hose and the units hose connection

Materials Used in Marel Equipment
The materials listed here are common in Marel equipment. Use the list to determine the chemical
tolerance of individual parts of the equipment.
NOTE
Specific recommendations on types and strength of solution used for cleaning or sanitization should, at
all the time, come from a qualified distributor of cleaning solutions.
Table 15 List of Materials
Material Used In Resistance to Detergents
Metals:
Stainless steel Frames, various parts High (in normal conditions, for
example temperatures between
-20 to +30
o
C/-4 to 86
o
F
Aluminum Load cell brackets and spacers,
load cells, pneumatic cylinder
ends
Low, to strong base solutions
Plastics:
Polyethylene (PE) Guides High
Polycarbonate (PC) Displays and keyboards Limited, to strong base solutions
Polypropylene (PP) Modular conveyor belts High
Acetyl (POM) Modular conveyor belts High, may develop precipitations
caused by chlorine
Polyvinylchloride (PVC) Endless belts of layered PVC and
PUR canvas
Low, especially to minimally
diluted solutions Polyurethane ( PUR)

Water and Temperature
Water can contain a significant number of microorganisms. Therefore, inspection of water used
for cleaning should be part of a HACCP plan. All impurities in water can influence the
effectiveness of a detergent or sanitizer.
Water hardness is the most important chemical property which directly effects cleaning and
sanitizing efficiency. The pH value for normal water ranges from pH 5 to pH 8.5
Soils soluble in water are sugars, some starches and most salts
Always use clean water for rinsing and cleaning. Never rinse or clean with seawater.
Rinse with cold water, except when working with fat products. In that case use 40-55
o
C (104-
131
o
F) hot water to dissolve the fat. Some fats have a melting point below the recommended
40-55
o
C, so you should adjust the water temperature accordingly.
Be careful when using hot water. Some proteins denature in high temperatures and may
become difficult to remove.
Avoid temperatures above 55
o
C (131
o
F) because of the corrosive nature of most chemical
sanitizers.

Detergents
The pH value of detergents used on Marel equipment should preferably be pH 12-13.
Strong base solutions are the main ingredients in most cleaning agents, for example potassium
hydroxide (KOH) or caustic soda (NaOH). Because of its corrosive effects, caustic soda is not a desirable
detergent for Marel equipment. If possible, use detergent solutions with KOH instead.
Always use detergents according to the detergent manufacturers instructions.
Do not use a detergent containing sodium hypochlorite for daily cleaning. Sodium hypochlorite
is a common ingredient in detergents, but as it contains chlorine it should be used with great
care because of chlorines corrosive effect on stainless steel.

Daily Cleaning
Cleaning is the complete removal of food soils using appropriate detergent chemicals according to
instructions. It is important that cleaning personnel have an understanding of the nature of the different
types of food soils and the chemistry of their removal.
Use high alkaline foaming detergent, 1% solution, pH 12-13. For regular daily cleaning. Avoid
using a detergent containing a high amount of sodium hypochlorite for daily cleaning. The
foaming detergent must be selected carefully and should contain some corrosion inhibitors and
preferably potassium hydroxide (KOH) instead of sodium hydroxide (NaOH)
Spray the detergent on all surface areas and leave it, to work for a time specified by the cleaning
agents manufacturer. Then rinse the detergent off with clean, cold water.
To kill any remaining bacteria, you must finish the daily cleaning procedures by spraying the
surface with an approved chemical sanitizer.

NOTE
Quaternary ammonium compounds (QACs) are widely used in the food processing industry. Keep in
mind, however, that while these are effective against most bacteria may also develop tolerance against
QACs, which should therefore not be used for an extended period of time unless they are rotated with
compounds of a different type.

Sanitization
When choosing a sanitizing agent, please note that chlorine corrodes the stainless steel and
disintegrates PVC and PUR belts, especially at higher temperatures. Chlorine is, however, an effective
sanitizer, so occasional use of chlorine may be necessary to control the growth of microorganisms.

Marel recommends the following sanitization procedure:
Spray the sanitizer on surfaces and leave to work according to manufacturers instructions.
Make sure you spray into all corners and hard-to-reach areas.
After sanitizing, always rinse the equipment carefully with cold and clean water before
resuming processing.
Use chlorine or a comparable sanitizer on the equipment once a week after performing the
regular cleaning procedure with a high alkaline foaming detergent.
Make sure the strength of chlorine, if used, does not exceed 200 ppm
On days when chlorine or a comparable sanitizer is not used, use other sanitizers recommended
for food processing instead.


NOTE
Rotating different sanitizers (for example chlorine, peracid or acid-anionic) in your sanitization
program may ensure more effective sanitization.

As chlorine evaporates very quickly, its sanitizing effect will fade soon after it is sprayed on the
equipment. Letting chlorine stay on the equipment will not improve the sanitizing effect, but
only damage the equipment. Quaternary ammonium compounds are considerably more stable
than chlorine and are active for a much longer time . Therefore, the benefit of leaving QACs on
the equipment for an extended period of time is much greater.


Training Staff
It is important that new cleaning personnel receive the proper training and are made aware of
the proper cleaning procedures for this machine. Demonstrate the Cleaning procedures for new
personnel using the instructions in the following sections. Make sure the cleaning personnel are
familiar with safety rules concerning the use of cleaning agents.

Cleaning Procedures
Before you start cleaning the Spiral Freezer, follow the instruction below to ensure maximum
safety during the cleaning.

Preparation
Before cleaning the Spiral Freezer unit, some preparations and checks must be done.
The unit has to be fully defrosted
The room and suction temperature must be more than +5
o
C (41
o
F)
Do not clean while freezing. If so, ice will build up from the cleaning water and cause
damage to evaporators, fan blades, and other steel parts.
Do not pour water colder than 0
o
C (32
o
F)into cold evaporator as it can cause ice
buildup. This can push the evaporator tubes and cause damage
Some Spiral units are supplied with the CIP program which interlocks with the room temperature. This is
to prevent potentially damaging situations. However, the cleaner must still take a few more steps:
Remove large wastes and inspect the unit thoroughly to make sure they have all been removed
Remember that stubborn residues may have to be cleaned further as it may not be removed
even with high-pressure cleaning


Rinsing the Environment
1. First you must thoroughly rinse nearby walls and floor to prevent cross-contamination from
the environment after Spiral Freezer has been cleaned.
2. If possible, do not use water temperatures over 55
o
C (131
o
F) to avoid heat denatured
proteins.

Rinsing the Spiral Freezer
1. Rinse soils off the machine using water jets or a brush. Rinse thoroughly from the top down with
clean water.
2. Avoid high water pressure in order not to spread the soils all over the machine
3. If possible, do not use water temperatures over 55
o
C (131
o
F) to avoid heat denatured proteins
Sanitizing
1. All surfaces in contact with the product should be sanitized every day of operation
2. Make sure the surface is as dry as possible before sanitizing, because water remaining from the
washing process will dilute the sanitizing agent.
3. For the daily sanitization, use sanitizing agents containing, for example, quaternary ammonium
compounds. Once a week, sanitize with chlorine ( 200 ppm) or a comparable sanitizing agent.
4. After sanitizing, rinse the Spiral Freezer thoroughly with clean water to eliminate contact
between sanitizer and raw material or products in the next production round. This also helps
prevent corrosion of the stainless steel by aggressive sanitizers and prevents the forming of an
undesirable chemical film.
NOTE
A sanitizer agent with high content can damage can have a negative effect to stainless steel and cause
rust to develop on steel.

Final Inspection
After cleaning, quality control personnel should evaluate the result of the cleaning process:
1. By stroke of hands make sure that places where visual control is difficult are clean
2. Regularly measure cleaning results by counting the microorganism, for example using RODAC
cups or ATP measurements
3. After cleaning and sanitizing, make sure that all surfaces dry as well as possible.

Special Cleaning Instructions
Cleaning the Spiral Conveyor
The spiral conveyor is an important part of the freezer unit and requires special care during cleaning:
Dry Clean
1. Remove large pieces of waste, dirt or food from the belts surface
2. Remove compacted debris from all of the belts support system (e.g. sprockets, idler wheels,
and support rails)
3. Clear the conveyor belt by working from top-to-bottom and from inside-edge-of-belt towards
outside edge-of-belt.
4. Use the same pattern in subsequent cleanings
Apply Detergent
1. Use appropriate foam mixture to belt and support system at 40-80 psi/ 3-5 bar
2. Foam can remain on the belt and support system for about 10-15 minutes
NOTE
Detergent foam should not be allowed to dry as dried chemical is difficult to remove and may support
growth of bio films

Rinse and Inspect
1. Rinse with water pressure at 150-225 psi / 10-15 bar and temperature at 52-54
o
C
2. Inspect the belt and support system to make sure that it is free of dirt, water, film, and other
residues
3. Use sight, touch , and smell during inspection

Pre-operate the Belt
1. Make sure that all cleaning chemicals have been removed from the conveyor belt, sprocket,
idlers, and support rails
2. Remove any water that has pooled on the floor
3. Run the conveyor belt slowly to help dry it and its support system

Sanitize the Conveyor
All surfaces in contact with the products should be sanitized daily after every operation and cleaning.
1. Make sure the surface of the unit is dry before sanitizing
2. For daily sanitization, use agents such as quaternary ammonium compound
3. Once a week, sanitize with chlorine, maximum 100 ppm; or a comparable agent
4. After sanitizing, rinse the conveyor thoroughly with clean water to avoid contact of sanitizer
with raw materials or products in the next operation
5. Let the conveyor dry

Sanitize the Belt
1. Apply appropriate sanitizers at no rinse concentrations, according to the manufacturers
recommendations
2. Run the belt while applying sanitizer to be sure that all parts of the belt and support system are
adequately covered with sanitizer
3. Leave the sanitizer to work for a few minutes as directed on the usage instructions
4. Rinse the belt while continuously allowing it to run
5. Rinse and flush the floor of any sanitizer that has pooled on the floor

Cleaning Evaporator and Fans
Whenever possible, the evaporators should be emptied of excess refrigerant before cleaning to
avoid an increase in pressure due to the sudden and huge rise in temperature. This can later be
pumped back to the holding tank
In case an emptying suction process is not possible, water and other cleaning materials must
have a temperature which does not go above inside pressure of 12 bars. Anything higher may
cause ruptures in the pipe work
Refrigerant pressure-temperature tables are available in the appropriate steam and saturation
tables. Consult plant refrigeration experts/ engineers to determine the safe working limits

NOTE
To avoid damaging the sensitive parts of your evaporator unit, it is necessary to take utmost care
especially when using pressurized water. If uncertain, it is best to get the services of a third party
vendor to perform a thorough cleaning of your evaporator and fans

Continuous Belt Washing System
The Continuous Belt Washing System is an optional feature that can be added to the Spiral Freezer
to further ensure that health and safety requirements are met.





Figure 47 Example of a belt washing system

The typical belt washing system is located at the inlet of the Spiral unit. It cleans and dries the
returning belt before it is loaded with the products.
The belt washing system works by:
Submerging the returning belt in warm water, with our without foam
Removing dirt off the belt with water spray
Shaking the belt to get rid of water
Drying the belt by a jet of hot air