Manual Cerex en

INCOMEC-CEREX GRAIN Operating page n°1
TABLE OF CONTENTS
CHAPTER 1 : Technical Data
CHAPTER 2 : Installation of the machine
2.1. Transport of the machine

2.2. Connecting the electricity
2.3. Connecting the air
2.4. Fixing the machine to the floor
2.5. Take away conveyor
2.6. Distance from machine to machine
2.7. Air suction hood
CHAPTER 3 : Preparation of raw materials
3.1. The different grains

3.2. Addition of moisture
3.3. Grains specifications and quality
CHAPTER 4: Setting up the machine
4.1. Description of the machines and its parts

4.2. Alignment of the die
4.3. Position of the upper die
4.4. Setting of the feeding system
4.5. Hydraulic pressure regulation
4.6. Position of the reedcontacts on the hydraulic cilinder
4.7. Position of the reedcontacts on the pneumatic cilinder
CHAPTER 5: Working with the machine
5.1. Switching on the machine

5.2. Individual control panel on the machine
5.3. Setting the parameters on the display
5.3.1. Individual machine parameters
5.3.2. Start-up values
5.4. Start-up procedure
5.5. Alarm Messages on the screen
5.6. Cleaning the dies
5.7. Shut down procedure
5.8. Trouble shooting
5.9. Maintenance
Spare partslist
Hydraulic drawings
Pneumatic drawings
Electrical drawings
Tel. : +32 55 e-mail : info@incomec- date:

CHAPTER 1 : TECHNICAL DATA
 Identification : Incomec Cerex Grain Processor
 Electricity : 3*380 or 3*220 VAC 50 or 60 Hertz
 Maximum Power consumption :
Model Power
Consumption
CEREX-6-LR 11,1 kW
CEREX-3-SQ 8,6 kW
CEREX-21-MI 8,6 kW
CEREX-44-MB 11,1 kW
Other To be specified
shapes
 Air Consumption : approximately 150 Normal-litre per minute
 Dimensions : Width 535

mm
Length 1235
Height mm
2150
mm
 Weight : 550 KG or 1210 Lbs.
 Manufacturer : INCOMEC-CEREX N.V.

Industrielaan
18A B-9660
Brakel
Belgium
Tel: + 32 55 43 16 20
Fax: + 32 55 42 73 08
E-mail: info@incomec-
cerex.com Website:
http://incomec-cerex.com


CHAPTER 2 : INSTALLATION OF THE MACHINE
2.1. Transport of the machine
 The machines are delivered on a EURO-pallet.

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

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

connected to the air supply

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

2.4. Fixing the machine to the floor
 The machine has to be bolted to the floor to avoid that the

machine will change its position while working. For this purpose,
there are two holes in the floorplate of the machine.
 Use a bolt of sufficient diameter to fix the machine to the floor.
2.5. Take-away conveyor
 In front of the machines a take away conveyor is installed.

 This conveyor needs to be placed sufficiently high and a chute needs
to be installed to guide the cakes to the conveyor when they are
ejected.
 The chutes are preferably fixed to the conveyor by hinges which
makes it possible to put the chute in a different position, thus
preventing the cakes to fall on the conveyor (for instance when
adjusting or after cleaning the machine during production
2.6. Distance between the machines
 The machines should be placed at a centerdistance of at least 900mm.

 The distance from the back of the machines to the wall needs to be at
least 600mm in order to be able to open the door of the electrical
control box at the back of the machine.
2.7. Air suction hood
 An air suction hood needs to be installed above the line of machines to

have a sufficient removal of the fumes created by the baking process.
 It is advisable to have a fan with a capacity of at least 1000 cubic
meters of air per hour and per meter length of the air suction hood.

CHAPTER 3 : PREPARATION OF THE RAW MATERIALS
3.1. The different grains
Several starchy grains can be used on the grain processors and also
mixes of several varities.
Also other ingredients can be used, like pelletised products made of
wheat -, potato-, corn-, rice-flower and starches .
Base Grains:
 100% rice ,brown or white ,whole or broken

 100% wheat
 100% degermed broken popcorn
 other ingredients to be added (percentages of mixes and processing
conditions may vary and may be subjected to testing on site)
► broken corn
► rye
► oats
► buckwheat
► soybean
► millet
► barley
► peas
► sesame
► amaranth
► quinoa
► other starchy grains
► salt
► dry spices (*)
(*)These dry spices will loose a lot of their intial taste due to the
temperatures during the baking process. It is therefore recommended to
apply spices or flavors after baking the cakes by means of the CEREX
coating system.

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

!!!

3.2. Addition of moisture
 The moisture of the grains should be checked and if necessary water

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

raw materials to make cakes with.
 It is recommended to do some tests with different varities of the
same grains because there might be a lot of difference in the
finished cake.
 The raw material should certainly NOT CONTAIN:
► Stones
► too small pieces
► dust
► foreign materials..
 When using wheat,best results are achieved with pearled wheat (4 to 8

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

INCOMEC-CEREX GRAIN Operating page

CHAPTER 4 : SETTING UP THE MACHINE
4.1. Description of the machine and its parts

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

 Floorplate
 piedestal
 hydraulic group
 hydraulic coils
 central greasing system
 electric control box rear
 electric control box front
 pressure transmitter
 hydraulic cilinder
 die
 feeding system
 feeding hopper
Hydraulic group
 Motor
 pump
 filter
 4/3 valves with coil
 pressure regulator
 pressure dial
 shut off valve for pressure dial
Hydraulic cylinder and pressure transmitter
 front cylinder
 rear cylinder
 reed contacts
 pressure transmitter
 upper lever
 lower lever
 stop bolts
 safety bar
Die
 lower die
 upper die
 ring die
 heating elements

 temperature sensors(PT100)

Feeding system
 feeding plate
 cilinder for moving forward feeding plate
 cilinders for opening the holes in the feeding plate
 reed contacts on cylinders
 speed regulator for air cylinders moving ring die
 feeding hopper
 grain level sensor
Upper block
 safety screen
 safety switch
 linear cylinder for movement
of blower nozzle
 blower nozzles for cleaning
 cilinders for moving ring die

4.2. Alignment of the die
 As soon as the machine is installed properly, the upper and lower die
must be aligned in order to create the same pressure and baking
conditions all over the die surface.
 The die must be clean, because the material in between this die can
disturb the alignment procedure.
 The following steps should be followed and can only be done by a
technician who takes care of the following safety procedures.
TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS SHOULD BE

REMOVED TO ALIGN THE DIES.
PUT BACK SAFETY GUARDS AFTER ALIGNING THE DIE.
1. Loosen up al four nuts above and underneath the upper block, so the
upper block and die can move freely when lifted up by the lower die.
2. Shut off air pressure.
3. Start the hydraulic motor.
4. By pushing in the buttons on the hydraulic valves on the right hand side
of the machine (if seen from the front side) the under die will start to go
up, thus taking also up the upper die and upper block at which the upper
die is fixed.

5. The lower die should be pushed upwards until the two levers of the
pressure transmitter reach a position of two to five degrees before
vertical position.
6. The upper nuts can now be lowered against the upper block and
lightly tightened,thus aligning the upper die against the lower
die.The lower nuts can now also be tightened lightly so the upper die
and block are immobilised.
4.3. Position of the upper die
When the machine will work with material,the upper die will probably
have to be raised in order to reach the same position of the levers (2 to 5
degrees before vertical position).
However, it will now be necessary when raising or lowering the upper die,
to rotate the upper nuts the same amount of (partial) rotations (in the same
direction!)

4.4. Setting of the feeding system
The following steps should be followed and can only be done by a


REMOVED TO SET THE FEEDING SYSTEM.
PUT BACK SAFETY GUARDS AFTER SETTING THE FEEDING SYSTEM.
 The complete feeding system can be adjusted by means of several

screws.
 When loosening the screws XX it is possible to adjust the height of the
feeding system.
 The feeding system should be at a position that it doesn’t touch
neither the lower nor the upper die.The feeding plate also has to push
out the finished cakes which is also important for the exact height of
the feeding system.
 When loosing the screws YY it is possible to move back- or forward the
feeding system.
 The exact position is when the holes of the feeding plate will drop the
material right in the center of the die when the cylinder which is moving
the feeding plate is in its most forward position.
 The hopper can be regulated also. It is done by means of the nuts ZZ.
 It is necessary to have a very small space in between the under side of
the hopper and the surface of the feeding plate in order to prevent the
hopper from damaging the feeding plate.

 By raising the hopper a little bit ,it is possible to put a little bit more
grains in the holes and thus to influence the weight of the cakes a little
bit.
 Of course the space in between the hopper and the feeding plate
has to stay small enough in order to prevent the grains from being
spilled.

4.5. Hydraulic pressure regulation


REMOVED TO REGULATE THE HYDRAULIC PRESSURE.
PUT BACK SAFETY GUARDS AFTER REGULATING THE HYDRAULIC
PRESSURE.
 To regulate the hydraulic pressure from the pump the settingscrew

has to be turned clockwise (raise pressure) or counterclockwise
(lower pressure).
 One of the buttons on the hydraulic valves at the left hand side of the
machine (seen from the front) should be pushed in to see the actual
pressure on the pressure dial.
 The settingscrew has to be turned while pushing in this button so one
can see how much the hydraulic pressure will be.
 Normally it has to be in between 80 and 120 bars.The pressure will
depend a.o.on the weight of the cakes, the grains that are used the
position of the upper die. It will be also decided after the first tests on

site with the appropriate grains.

 Once the pressure is set, the locking nut should be tightened in
order to prevent the setting screw from changing its position.

4.6. Position of reedcontacts on the hydraulic cilinder

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS

SHOULD BE REMOVED TO POSITION THE REEDCONTACTS ON THE
HYDRAULIC CILINDER.
PUT BACK SAFETY GUARDS AFTER REGULATING THE REEDCONTACTS ON
THE HYDRAULIC CILINDER .
 The reedcontacts are numbered 2,3,4 and 5.

 Starting from the front side of the machine they are placed in the
following order:
5,4,2,3
 The several positions of the lower die are determined by the
positions of these reedcontacts.
► Bottom position
■ Contacts nr° 2 and 4 are lit.

■ The lower die falls to this position when the alarmbutton is
switched to the ‘ON’position.
■ These two contacts have to be lit to be able to restart the machine.
■ In case contact nr° 2 is not lit one needs to push in the button
lower button on the hydraulic valve at the right hand side of the
machine.

■ The hydraulic cilinder most towards the back of the machine will
than move out and the contact n°2 will lit up.
■ As soon as this occurs, release the button.
■ It will be possible now to restart the cycle.
■ The alarmbutton is normaly swiched to the ‘ON’ position when
one wants to clean the under die.

► Middle position
■ Contacts nr° 3 and 4 are lit. In this position, th e feed slide is

ejecting the cake and filling in the new load of grain.
► Crushing and baking position
■ The contact nr° 5 will be lit. In this position th e grains are crushed
and baked during a certain time.(Pressure time and baking time)
■ After baking the cake the hydraulic cilinder most towards the
front side of the machine will move from reedcontact nr°5 to
reedcont act nr°4 thus creating an expansion chamber and
allowing the grains to expand.
► Ejecting position
■ Reedcontact nr° 4 and nr° 3 will be lit and the ca ke will be ejected.
■ After ejecting the cakes, the lower die will go down a little bit to
form a cup in which the new load of grains will be dropped and the
cycle will start again.
RESUMED:
■ Reedcontact nr° 5 :will decide how big the expansi on chamber

will be and thus the thickness of the cake (together with the
Thickness Time parameter)
■ Moving it towards the front of the machine=bigger expansion chamber

and thicker cake.
■ Moving it towards the back of the machine=smaller expansion chamber
and thinner cake
■ When moving it too much towards the front of the machine, the
under die will drop too much and will drop out of the ring die and the
grains will escape together with a loud explosion noise.
■ When moving it too much towards the back of the machine, the
expansion chamber which is created will be not enough, and the cake
will explode a second time as soon as the die is opening up.

■ Reedcontact nr°4 : is always placed at the end of the stroke

(completely inwards) of the hydraulic cilinder C.
■ Reedcontact nr°2 : the position the cilinder B wil l move to when the
alarm stop button is switched to’ON’ (Cilinder C will also move to the
most inwards position reedcontact nr°4)
■ Reedcontact nr°3 : the position the cilinder B wil l move to when moving
forward the feeding plate. (Cilinder C will be at the most inward
position). The positioning of this contact should be adjusted so that the
surface of the under die is a little bit higher than the top surface of the
ring die and thus the finished cakes can easily be removed.

■ When it is too much towards the

front of the machine the cakes will
be stuck in the ring die and break
when ejecting them.
■ When it is too much towards the

back of the machine the under die
will be too high and the feeding slide
will hit the under die and the
pneumatic cycle will be interupted
and the machine will stop working
and go into alarm condition.
4.7. Position of reedcontacts on pneumatic cilinders

TAKE CARE OF MOVING PARTS BECAUSE THE SAFETY GUARDS

SHOULD BE REMOVED TO POSITION THE REEDCONTACTS ON THE
PNEUMATIC CILINDERS.
PUT BACK SAFETY GUARDS AFTER REGULATING THE REEDCONTACTS ON
THE PNEUMATIC CILINDERS
■ The reedcontact on the pneumatic cilinder which is moving the

feeding plate forward should be placed on the end of the stroke of
this cilinder (reedcontacts 0 and 1)

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

CHAPTER 5 : WORKING WITH THE MACHINES
5.1. Switching on the machine
 Switch on the air supply of the machine.

 Switch on the electrical switch from the PLC and also on the electrical
control panel at the back of the machine.
 Close the safety guard on the front of the machine.
 Start up the hydraulic motor.
 Check if the under die is in the ring die.
 If not, put the under die in the ring die :
- Switch the ‘alarm stop’ button from ‘OFF’ to ‘ON’ and back to ‘OFF’
- Push the ‘ start ‘ button and the under die will go up and enter in the
ring die.
- Push the ‘stop’ button to stop the cycle as soon as the under die is
inside the ring die.
 Switch the button ‘heating’to ‘ON’ : the machine will start to heat up.

5.2. Individual control panel on the front of the machine
On this control panel there are several buttons
1. START CYCLE:
Starts the cycle if the under die is in the exact position,and all other
cylinders are in the exact starting position.
2. STOP CYCLE:
Stops the cycle IMMEDIATELY if pressed and will put the aircilinders
back in their original start position and will immobilise the hydraulic
cylinder in its current state. It is recommended to stop the machine
when the cakes are ejected and before the new load of grains is
dropped.
3. ALARM STOP:
When switched from ‘OFF’ to ‘ON’ the lower die will drop to its lowest
position, and the ring die will move upwards around the upper die. This
switch is used to put the under die in a position to be able to clean it. It
is also switched from ‘OFF’ to’ON’ and back to do a reset of the machine
to be able to restart it when the machine is not in restart position
(hydraulic cylinders are not in the correct position to be able to restart
the machine)
4. HEATING:
When switched from ‘OFF’ to ‘ON’ the dies will start to heat up untill the
desired temperatures are reached.
5. SAFETY STOP:
will stop the cycle immediately: aircilinders move back to their initial
position and hydraulic cylinders are immobilised.The hydraulic motor is
also stopped and heating is switched off. This safety button is switched
back to ‘OFF’ position by giving it a quart turn.
6. START/STOP HYDRAULIC:
Will start/stop the hydraulic motor.When the motor is running the

indication light will lit up.
7. ALARM FAULT LIGHT:

This light will flash when the machine is in alarm condition or when the
grain level in the hopper has dropped below minimum level.

5.3. Setting the parameters on the display
5.3.1. Individual machine parameters
The individual parameters which can be set on the display are;
► T1 : Temperature upper die (Max:325°C)
► T2 : Temperature bottom die (Max:325°C)
► Baking time : Time during which the grains are heated in

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

between the
Dies (hydraulic pressure applied)
Max:150 in 0.01 sec.
► Thickness Time : After the dies have created an expansion

chamber, there is
the possibility to let the under die rebounce
during a certain time to reduce the thickness of
the cake or to make the surface flatter.The
higher the thickness time, the more the bottom
die will rebounce and the thinner the cake will
be.

Putting the thickness time to 0 will prevent

the bottom die from rebouncing.
Max. 20 in 0.01 sec.
► Cup Time : When the cakes are ejected ,the bottom die will
drop during
a certain time to create a cup in which the
grains will be dropped.The higher the cup time,
the deeper the cup.
Max. 25 in 0.01 sec.

The setting procedure for the parameters is the following:
■ Move the cursor to the parameter you want to set by means of the arrow
buttons.
■ Once the cursor is at the right position, you can give in the value by
means of the numeric buttons.
■ The new value is now entered by pushing the enter button.
5.3.2. Start Up Values
The Start Up values can not be set for each individual machine but are
set for all the machines linked to the same PLC.
The parameters on the screen are the following:
■ Min.Baking Time
■ Min.Pressure Time
■ Number of cycles
■ Numberof cycles cleaning.
The meaning of the first three of these parameters is the following:
When the machine is stopped for a time longer than two minutes, the
surface temperature of the dies will be higher as when the machine is
constantly working. The surface is not anymore cooled by the cold grains
coming into contact with the die surface.
When the machine is restarted, the temperature will be higher and the
cakes will be baked too much.
To overcome this difficulty, the PLC will automatically take a shorter
baking and pressure time and will gradually build up untill the baking time
and pressure time set on the individual machine parameter screen is
reached. It will build up gradually in as much steps as the number of
cycles you have set1. A normal value for this parameter would be five
cycles.
The parameter ‘number of cycles cleaning’ will decide after how much
cycles the cleaning system will clean the die one time.
5.4. Start Up Procedure
 As soon as the machine is switched on properly and heated up

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

5.5. Alarm messages on the screen
Several alarm messages can appear on the screen. They can be cleared
from the screen by pushing the appropriate “acknowledged” button.
The last alarm messages will be stored automatically in the alarm

messages file.
 No grainlevel
Will appear as soon as the grain level in the hopper will drop below
its minimum level. You now have five minutes to fill up the
hopper,otherwise the machine will stop automatically after ejecting
the last cakes.
 Temperature Upper /Lower die too High/Low
The difference between the setpoint temperature and the actual

temperature is too big.
 Interrupt pneumatic cycle
It takes too long for one of the air cilinders to move from one end of its
stroke to the other end.
It could mean that there is a mechanical cause that is blocking the free
movement of one of the air cilinders.
It could also mean that the air pressure has dropped.
 Interrupt hydraulic cycle
It takes too long before one of the reedcontacts is lit up.
This means that for some reason the hydraulic movement is blocked. This
could have either a mechanical cause or the hydraulic group may not be
switched on.
 Hydraulic motor
This means that the thermal overload protection of the hydraulic motor
has switched of. The power supply to the motor should be checked.
The current in all three phases must be the same as the one indicated on
the motor
identification tag.
The setting of the thermal overload protection should be the same as the
current indicated on the motor identification tag.

5.6. Cleaning the dies
TAKE CARE OF MOVING PARTS BECAUSE THE FRONT SAFETY GUARD

HAS TO BE OPENED FOR CLEANING THE DIE. BY SWITCHING THE
‘ALARM STOP’ BUTTON IN THE ‘ON’ POSITION, THE RING DIE WILL GO UP
AND THE UNDER DIE WILL DROP TO ITS LOWEST POINT.
THE WHOLE DIE AND THE AREA AROUND IT IS EXTREMELY
HOT. TAKE CARE WHEN CLEANING AND WEAR HEAT RESISTANT
GLOVES WHEN
WORKING IN THIS AREA OF THE MACHINE.
The dies have to be cleaned as soon as too much dirt has built up in
between the ring die and the lower die. This will prevent the upper
surface of the lowerd die to be higher than the upper surface of the ring
die.
The cakes will break when ejected and the machine will start producing
bad cakes and even stop cycling.
 To remove this dirt, one has to use the hook tool.

 Open the front safety guard and place the’alarm stop button’ in the ‘ON’
position.
 The ring die will go up and the under die will drop to its lowest point.
 The hook tool can now be used to remove the carbonised dirt from

the under die.an air gun can be used to blow away the carbonised
pieces.
 This carbonised dirt also has to be removed from the underside of
the ring die and if necessary from the upper die.

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

 Around it one should wrap a strip of sand paper (P200!!) on which there
are some drops of a water,oil ,lecithine mixture to make the sandpaper
softer. (60% of water,30% of oil,10% of lecithine).
 The surface of the die can be cleaned.
 The sandpaper and wooden piece should be kept FLAT in order not to
round of the edges of the dies or damage the thin layer of coating on the
dies.
 After cleaning the dies ,remove the remaining dirt with a piece of
absorbing paper by means of the same wooden piece.
 After cleaning, close the front safety guard back again and place the
lower die back into the ring die by switching the ‘ Alarm stop ‘button
back to ‘OFF’ and by pushing the ‘Start’ button and ‘Stop’ button .
IMPORTANT REMARK!!!:
The excess building up of too much dirt in between the ring die and
under die can have several causes:
► the moisture level of the grains is too high

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

The building up of a carbonised layer too soon can also have several
causes:
► too high moisture of the grains

► too high temperature of the dies
► too much pressure created on the grains when crushed and baked
► one of the components mixed with the grains is creating a lot of
carbonisation
► there are a lot of sugars within certain grains…
In general, the building up of this carbonisation on the surface of the dies

can be reduced drastically by using a little bit of lecithine in the water the
grains are moisturised with.
The down time of the machine for cleaning will reduce drastically when
using the right moisture, temperature, grains, pressure, mechanical
machine-settings.. and preferably a little bit of lecithine in the water.
5.7. Shut down procedure
Before shutting down the machine, it is necessary to clean the die with
the hook tool and to blow it of with an air gun to remove the carbonised
pieces. If necessary, the die surface should also be cleaned with
sandpaper and the water/oil/lecithine emulsion.
The lower die is placed back into the ring die.
 Put the ‘Heating’ button into the ‘off ‘ position.

 Shut down the hydraulic motor
 Switch off the electric control panel at the back of the machine.
 Switch off the air supply to the machine.
 Switch off the PLC and display
Make sure to remove the remaining grains from out of the hopper. The
grains will dry out and make it very hard to restart the machine the next
day. The grains can be removed by using a vacuumcleaner.
BE AWARE THAT THE DIE OF THE MACHINE AND THE AREA AROUND THE
DIE WILL STAY VERY HOT UNTILL THE MACHINE HAS BEEN SWITCHED
OFF FOR A COUPLE OF HOURS.
5.8. Trouble shooting
1. The machine is not heating up

 Check if the power supply is OK

 Check if the temperature parameters on the screen are set to the
desired temperature
 Check if the PLC is switched on.
 Let an electrician check the fuses in the electrical control box
at the back of the machine.
 Check if the temperature sensor is not broken or detached.The
temperature on the screen will then read ***

2. The hydraulic group can not be switched on
 Check if power supply is OK

 Check if the thermal overload protection is still switched on.
3. The hydraulic cilinder is not moving ,even when the buttons on the
hydraulic valves are pushed in manually and the motor is running
 Check the oil level of the hydraulic group
4. The machine is not starting its cycle when pushing the ‘Start ‘ button
 Check if power from machine and PLC are switched on.

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

feeding plate and goes back without dropping the rice.
 Fill up the hopper with grains
6. The cakes are not strong enough
 Check if the desired temperature is reached for both upper

and under die. If necessary make the temperature higher.
 Check if the hydraulic pressure is OK.
 Check if the position of the upper and under lever is a little bit
before vertical position when crushing the grains.
 Check if the moisture of the grains is OK
7. The cakes have a burnt taste and smell
 Check the temperature and reduce if necessary

 Lower the baking time if necessary.
8. The cakes don’t look the same.
 Check the weight of the individual cakes.If too much difference,it

can mean that the holes in the feeding plate are (partially)
plugged.Check and clean if necessary.

 The alignment of the dies is not correct. Check and adjust

9. The cakes are burnt on one side.
 The grains are not dropped right in the center of the die.Check and
adjust the feeding system.
 The surface of the dies is (partially) dirty.Clean if necessary.
10. The material is squirting out of the die when crushing and baking
 Check the temperature of the dies.Lower if necessary

 Moisture is too high. Lower the moisture of the grains.
 The pressure is too high.Lower hydraulic pressure.
 The two levers are going beyond their optimal position.Lower the
upper die.
11. The grains are dropping out of the cup
 Reduce the ‘cup time’ parameter.The cup is too deep
12. The grains spill on the ring die
 Make the ‘cup time’parameter higher.The cup is not deep enough
13. The cup is deep enough,but the grains spills on the ring die when the
under die and ring die start to go up.
 The speed of the air cilinders making the ring die go up is to slow
compared to the speed of the under die going up. Increase the
speed of the air cilinders moving the ring die up by turning the
adjustable speed regulator.
14. The under die drops out of the ring die when expanding the cakes,
thus generating the loud noise of an explosion.
 The position of reedcontact n°5 is not correct (S ee section

on positioning of reedcontacts on hydraulic and pneumatic
cilinders )
15. The cakes are expanded a second time when the die is opening to eject
the cakes

 The position of the reedcontact n° 5 is not correc t .The cakes have

not enough room to expand and will expand a second time in a very
uneven way when the die is opening to eject the cakes. (See
section on positioning of reedcontacts on hydraulic cilinder )

16. The machine is unable to keep its temperature when it is

producing cakes, the cakes are not baked uniformly
 Ask a skilled electrician to check if all of the heating elements are

still functioning (by means of an ampere-clamp)
17.One of the reedcontacts does not light up anymore.
 Check if the reedcontact is not lighting up anymore even when the

clinder is moving in front of this specific reedcontact.
 Change the reedcontact with a new one and check if it is functioning
well.
5.9. Maintenance
1. The machine has a central greasing system.
 All necessary greasing points are connected to the progressive

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

prevent the dirt or dust to attach to the machine frame, dies, feeding
system etc..at least once every eight hours.

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

if the quality of the oil is still OK. Have the quality checked regularly!!

The hydraulic oil used in our factory is:
UNIL HFO 46
3 microns filtered hydraulic oil.
Check the level in the oil reservoirs regularly!
4. Due to the smoke and vapour created by the baking process and fine
dust inside the grains it is possible that there is building up some
dirt underneath the feeding plate or inside the holes of the feeding
plate.
If this is the case:
 take out the feeding plat

 wash it with some water and soap
 dry the feeding plate
 put it back to its original place.
5. When using dry and clean air it is not necessary to use oil lubrication
on the air supply. it is even not recommended since the air is used to
clean the die, and thus this oil might end up in the finished product !!
6. The air-filters in the ventilation inlest of all electric control boxes

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

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INCOMEC-CEREX GRAIN Operating page n°1

CHAPTER 1 : Technical Data

CHAPTER 2 : Installation of the machine

2.1. Transport of the machine

CHAPTER 3 : Preparation of raw materials

3.1. The different grains

CHAPTER 4: Setting up the machine

4.1. Description of the machines and its parts

CHAPTER 5: Working with the machine

5.1. Switching on the machine

Tel. : +32 55 e-mail : info@incomec- date:

CHAPTER 1 : TECHNICAL DATA

 Identification : Incomec Cerex Grain Processor

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

 Maximum Power consumption :

 Air Consumption : approximately 150 Normal-litre per minute

 Dimensions : Width 535

 Weight : 550 KG or 1210 Lbs.

 Manufacturer : INCOMEC-CEREX N.V.

Tel. : +32 55 e-mail : info@incomec- date:

Tel. : +32 55 e-mail : info@incomec- date:

CHAPTER 2 : INSTALLATION OF THE MACHINE

2.1. Transport of the machine

 The machines are delivered on a EURO-pallet.

2.2. Electrical connection

 The machine needs to be

2.3. Air Connection

 Each machine has to be

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connected to the air supply

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2.4. Fixing the machine to the floor

 The machine has to be bolted to the floor to avoid that the

2.5. Take-away conveyor

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

2.6. Distance between the machines

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

2.7. Air suction hood

 An air suction hood needs to be installed above the line of machines to

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CHAPTER 3 : PREPARATION OF THE RAW MATERIALS

3.1. The different grains

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

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

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3.2. Addition of moisture

 The moisture of the grains should be checked and if necessary water

3.3. Grain specifications and quality

 The INCOMEC CEREX GRAIN PROCESSOR can use a lot of different

 When using wheat,best results are achieved with pearled wheat (4 to 8

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Tel. : +32 55 e-mail : info@incomec- date:

CHAPTER 4 : SETTING UP THE MACHINE

4.1. Description of the machine and its parts

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

Hydraulic cylinder and pressure transmitter

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 Electricity : 3380 or 3220 VAC 50 or 60 Hertz