2000 Series Extruder Manual

Document: 2000-V01R02 Date: 2019-02-27

2100 SE Gateway Drive, Suite 500, Grimes, Iowa50111 USA

Tel: +1-515-254-1260 Fax: +1-515-276-5749
CustomerService@Insta-Pro.com
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Thank you for choosing for your extrusion needs.

For questions regarding:

Installation: General Concerns:

Kinoti Kaburu, Start-up and Service Manager Oz Grimm, Vice President of Engineering
+254-721-366-074 (cell) +1-515-254-1272
kkaburu@insta-pro.com oz@insta-pro.com

Jim Little, Customer Service and Parts Manager

Parts and Service:
+1-515-254-1277
jlittle@insta-pro.com
Jim Little, Customer Service and Parts Manager
+1-515-254-1277
Kinoti Kaburu, Start-up and Service Manager
jlittle@insta-pro.com
+254-721-366-074 (cell)
kkaburu@insta-pro.com

Copyright © 2019 Insta-Pro International.

This document and all information discussed herein remain the sole and exclusive property of Insta-Pro International. No license of any patent, copyright, mask work, trademark,
or any other intellectual property right is granted by one party to the other party under this document by implication, estoppels or otherwise.
Contents 2.2 Control Panel.................................................................................................10

1 Safety ........................................................................................................................... 5 2.2.1 Power Requirements ............................................................10

1.1 Definitions ........................................................................................................ 5 2.2.2 Panel Placement .................................................................................10
1.1.1 Warning ................................................................................................... 5 2.2.3 Thermocouple Installation ............................................................11
1.1.2 Caution ..................................................................................................... 5 2.2.4 Integration to Plant Control System ..........................................11
1.1.3 Note ........................................................................................................... 5 2.3 Product Supply .............................................................................................11
2.4 Meal Discharge .............................................................................................11
1.2 General Safety Instructions ................................................ 5
2.5 Water Supply.................................................................................................12
1.3 Guards................................................................................................................ 5
2.5.1 Usage.......................................................................................................12
1.3.1 Extruder .................................................................................................. 5
2.5.2 Pressure and Flow.............................................................................12
1.3.2 Control Panel ......................................................................................... 6
2.5.3 Water Injection Pump ......................................................................12
1.4 Stability ............................................................................................................. 6
2.5.4 Placement .............................................................................................12
1.5 Ergonomic Requirements .......................................................................... 6
2.6 Steam Removal .............................................................................................12
1.6 Residual Risks .................................................................................... 6 2.6.1 Ventilation Guidelines .....................................................................12
2.7 Start-Up and Training ................................................................................13
1.6.1 Noise ................................................................................. 6
2.7.1 General Start-Up Schedule .............................................................13

1.6.2 Projectiles ......................................................................... 6 2.7.2 Helpful Tools for the Job Site ........................................................15
3 Operation..................................................................................................................18
1.6.3 Hot Surfaces ..................................................................... 6
3.1 Control Panel.................................................................................................18
2 Installation................................................................................................................. 7
3.2 Pre-Start Checklist ......................................................................................19
2.1 Extruder Placement ..................................................................................... 7
3.3 Priming the Extruder .................................................................................19
2.1.1 Working Areas ...................................................................................... 9
3.4 Start-Up ...........................................................................................................20
2.1.2 Anchoring the Extruder to the Floor ......................................... 10
3.5 Extruder Temperature Regulation.......................................................20

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3.6 Shutting Down Extruder .......................................................................... 21 5.8.1 Belt Tension .........................................................................................45

4 Cleaning .................................................................................................................... 22
4.1 Feeder .............................................................................................................. 22
4.2 Extruder Barrel ............................................................................................ 22
4.3 Frame and Bearing Stand ........................................................................ 22
4.4 Drive ................................................................................................................. 22
4.5 Work Areas .................................................................................................... 23
4.6 Disposal of Waste ........................................................................................ 23
5 Maintenance............................................................................................................ 24
5.1 Main Assemblies .......................................................................................... 26
5.2 Top Feeder – 2000-SA701....................................................................... 28
5.2.1 Maintenance ........................................................................................ 30
5.2.2 Auger Replacement .......................................................................... 30
5.3 Side Feeder – 8100RC ............................................................................... 32
5.3.1 Maintenance ........................................................................................ 33
5.3.2 Screw Replacement .......................................................................... 33
5.4 Side Feeder – 8500 ..................................................................................... 34
5.4.1 Maintenance ........................................................................................ 36
5.4.2 Screw Replacement .......................................................................... 36
5.5 Side Feeder Stand – 8100RC-01C ......................................................... 38
5.6 Side Feeder Swing Arm – 8100RC-01D.............................................. 40
5.7 Bearing Stand................................................................................................ 42
5.8 Belt Drive ........................................................................................................ 44
5.8.2 Sheave Removal .................................................................................47
5.8.3 Sheave Installation ............................................................................47
5.9 Motor ................................................................................................................48
5.9.1 Lubrication ...........................................................................................49
5.10 Motor Base .....................................................................................................52
Base, 125 hp .................................................................................................................53
5.11 Bearing Housing ..........................................................................................54
5.11.1 Lubrication ...........................................................................................57
5.11.2 Maintenance ........................................................................................57
5.12 Inner Barrel Components ........................................................................64
5.12.1 Maintenance ........................................................................................65
5.13 Outer Barrel Components ........................................................................66
5.13.1 Wear Sleeve Maintenance ..............................................................67
5.13.2 Thermocouple Replacement .........................................................68
5.14 Control Panel.................................................................................................70
5.15 Preventive Maintenance Schedule .......................................................72
5.16 Troubleshooting ..........................................................................................73
1 Safety 1. The supervisor is responsible for ensuring that all personnel have read and
understand this manual.
2. The operator must verify at the start of each shift that all safety features of the
1.1 Definitions machine are working properly and report malfunctions to the supervisor
immediately.
1.1.1 Warning 3. The supervisor must give clear instructions that the machine must not be
operated with faulty safety devices and that any faulty safety devices must be
Warning is defined as anything that is hazardous to personnel, which could result in
repaired immediately.
death or serious injury.
4. Operators, maintenance, and cleaning personnel are required to follow all
Example:
instructions in the manual completely.
5. The supervisor must only allow operation, maintenance, and cleaning of the
WARNING: Cutter blades are sharp.
machine by trained personnel. Insta-Pro® recommends training reviews for all
1.1.2 Caution personnel annually.

Caution is defined as anything that is hazardous to equipment. 6. Do not alter the original design of the machine. Use only genuine Insta-Pro®
repair parts, and use them only as intended.
Example:
7. This manual must accompany the machine whenever the machine is resold or
relocated.
CAUTION: Refill with oil prior to installation.

1.1.3 Note 1.3 Guards

Note is defined as advisory information, complementary to the procedure described
in the text.
Example:
NOTE: Contact Insta-Pro® for information.
1.2 General Safety Instructions
This manual must be read entirely and followed carefully prior to
installing, operating, cleaning, or maintaining the 2000 Extruder. Failure to
do so can result in improper installation, operation, or use of the 2000
Extruder which could cause equipment problems as well as serious
personal injury. SAFETY WARNINGS MUST BE READ CAREFULLY AND ANY
RECOMMENDED SAFETY PRECAUTIONS MUST BE FOLLOWED STRICTLY.
1.3.1 Extruder
Electrical junction boxes are fully enclosed and require a tool for access to
energized components.
A moveable guard fully encloses the belt drive. The guard requires a tool for access
to moving belts, sheaves, and shafts. A warning label serves as a reminder to
lockout power before adjusting belt tension.
Fixed chambers enclose the extruder screws. Chambers require a tool for removal.
The screws are exposed where product enters and discharges the barrel. This is a
residual risk.
The extruder chambers are hot when the extruder is in operation. A warning label
on the bearing housing stand near the barrel identifies the hazard.

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1.3.2 Control Panel
The control panel houses electrical connections. A moveable cover fully encloses
the panel and requires a tool to access the hazards.
1.4 Stability
Tipping, slipping, or rolling of the machine is prevented.
1. The machine will not tip over when it is oriented up to 10° from vertical in any
direction. (This is a consideration for transportation and installation only. For
proper operation, the extruder must be level when permanently installed.)
2. At installation, the extruder is anchored into the floor and cannot move.
1.5 Ergonomic Requirements
The ergonomic design minimizes the potential for injury.
1. Force required to manipulate any operator control does not exceed 250 N (55 lb).
2. Locate the machine, and all associated containers or conveyors so that stresses
on the operator’s body from bending, lifting, pushing, pulling, and reaching are
minimized.
3. Do not modify the design of the machine without the consent of Insta-Pro®.
1.6 Residual Risks
• Inlets and discharges must be guarded by the customer.
• Never reach into hazard areas with body parts or tools if the machine
is running or energized (potential to start running). Always lock out
the power supply before reaching into these areas.
• The extruder barrel will be pressurized even after the machine has
been stopped and locked out. Use extreme caution when
disassembling. Never stand at the end of the barrel.
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• Do not operate the equipment with parts missing, guards removed, or
safety features disabled.
• Steam and hot water used in the extrusion process cause burns. Do
not contact steam or hot water. Shut-off valves must be located close
to the extruder, easily identified, and easily accessible.
• Make sure the machine is properly grounded to protect from electrical
shock.
• Make sure the working area has sufficient illumination (500 lux
minimum).
• In case of fire, turn the main disconnect off. Keep the panel door
closed to prevent the fire from spreading.
• Wear appropriate personal protective equipment when working on
the electrical system to guard against arc flash hazards.
1.6.1 Noise
Noise levels from the extruder and nearby auxiliary equipment commonly
exceed that of comfort and safety. Hearing protection is required to avoid
hearing damage to people near the extruder.
1.6.2 Projectiles
Moving parts and high pressures in the extruder may result in projectiles.
Eye protection is required for anyone within visual range of the extruder.
1.6.3 Hot Surfaces
The extruder and discharging product are hot and cause burns. Do not
contact hot equipment or product without protective gear.
2 Installation
NOTE: Installation instructions for optional equipment that is not present may
be disregarded.

2.1 Extruder Placement

Before installing the 2000, review the following diagrams.

Figure 2-1: Plan view

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Figure 2-2: Front elevation Figure 2-4: Left elevation

Figure 2-3: Rear elevation Figure 2-5: Right elevation

2.1.1 Working Areas
Prior to anchoring the extruder to the floor, review the diagrams of the working
areas around the extruder. These areas require easy access. Allow enough space for
opening covers and guards, removing service parts, and performing cleaning and
maintenance tasks. Work areas are shown shaded below.

Figure 2-7: Front elevation

Figure 2-6: Plan view

Figure 2-8: Side elevation

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2.1.2 Anchoring the Extruder to the Floor 2.2.2 Panel Placement

Anchor the extruder to the floor prior to start-up. Use the anchor bolts and
vibration isolation pads provided. The following diagram shows the anchor
locations.
The control panel is provided with a stand which allows placement in a location that
is convenient to a specific installation. However, considerations should be made
when placing a control panel:
1. Direct line of sight between the panel and the extruder barrel
This is helpful during start-up and shutdown procedures. The operator must
frequently move back-and-forth between the control panel and the extruder.

Anchor Point

Anchor Point

Figure 2-9: Anchor points

2.2 Control Panel Figure 2-10: Extruder and panel with good line of sight

Electrical diagrams are provided. Only trained and licensed electricians may
perform electrical work. Follow all locally applicable codes and regulations.
2.2.1 Power Requirements
The electrical supply must provide enough power for all of the components. See
nameplates for specifications.
2. Thermocouple cable length and routing
During operation, the control panel monitors temperatures in the extruder barrel.
The cables provided are 10 m (30 ft) long. Please consider this distance when
placing the panel. Do not splice thermocouple cables. If the cables are too short for
your application, contact Insta-Pro®.
 2.2.4 Integration to Plant Control System
Insta-Pro® recommends against control of the 2000 by an automated central
control system. Do not start extruder motors automatically or run them without
product in the machine for the safety of personnel and equipment. Raw materials
and the operator must be ready before starting the extruder.

WARNING: Do not run the extruder without product for more than a
few minutes. Without product, the shaft and barrel can rub and the
resulting friction creates a fire hazard.
Contact Insta-Pro® if you want to integrate your extruder into an automated
system.

2.3 Product Supply

Insta-Pro® recommends the use of a surge bin between the supply conveyor and
the 2000 Extruder. The surge bin helps ensure a steady supply of material is
available to the feeder.
Figure 2-11: Thermocouple cable
CAUTION: Do not attach bins, conveyors, spouting, or other equipment or
structures to the feeder, preconditioner, extruder or other equipment supplied by
Insta-Pro.
2.2.3 Thermocouple Installation
Enclosure of material flow for dust control is permissible as long as the connections
do not transmit any load to the Insta-Pro® equipment. (Flexible or nesting joints
may help facilitate this requirement.)
Any additional covers must be easily removed or include access doors for cleaning
and maintenance access.

Figure 2-12: Thermocouple WARNING: Do not remove, modify, or otherwise interfere with any
guards or other safety features.
Thermocouples are shipped in the spare parts package. The start-up technician will
install them. 2.4 Meal Discharge
Insta-Pro® offers conveyors designed specifically for collecting and conveying the
meal discharged by the 2000 Extruder.

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If a third-party conveyor will be used, the design must accommodate the product(s) 4. Make sure that steam is truly removed and not condensing in the ductwork,
to be handled, the hot and moist environment, and the capacity required plus a which can lead to condensate dripping onto the product. A condensate trap is
safety factor. Contact Insta-Pro® for assistance. recommended.
Table 2-1: Fan Size Guidelines
2.5 Water Supply
2000 Extruder Discharge Conveyor
2.5.1 Usage 4000 m3/hr 2000 m3/hr
(2500 CFM) (1200 CFM)
Water may be used in the Insta-Pro® extrusion process when extruding products
that have high starch content or when shaping with a cutter head. Water is injected
during the initial startup procedure; it can also be used during operation to help
control the temperature of the product within approximately ±2.5°C (±5°F).

2.5.2 Pressure and Flow

During operation, water pressure at the inlet chamber should be 500-700 kPa (75-
100 psi). Water consumption varies depending on product. A flow of 400 L/hr (100
gph) is adequate for most products.

2.5.3 Water Injection Pump

See pump manual for specifications.

2.5.4 Placement
The water system is secured to the preconditioner. The pump may be placed in a
convenient location nearby. Insta-Pro® provides hoses and connectors.

2.6 Steam Removal

2.6.1 Ventilation Guidelines

1. Place vents at the extruder discharge and near the highest point of the
enclosed meal discharge conveyor.
2. Use Table 2-1: Fan Size Guidelines for sizing the ventilation system.
3. Make ventilation hoods and duct work easy to move and disassemble for
cleaning and maintenance.

2.7 Start-Up and Training
Once you have installed the entire processing line, including the 2000 Extruder, you
are ready for start-up and training by an Insta-Pro® technician. The following
guidelines help ensure a proper start-up:
1. Building and installation of the processing line should be complete and clean.
2. Utilities installation is complete and meets all locally applicable codes.
NOTE: The Insta-Pro® technician will only assist in the connection of the
thermocouple wires. All wiring and plumbing are the responsibility of the
customer.
3. Make sure there are enough raw materials on-site to process.
NOTE: Amount depends on extruder capacity for products produced and number of
extruders. Plan to run maximum capacity 8 hr/day while technician is on-site.
4. Make sure you can properly cool and store the volume of product produced.
5. If necessary, provide an interpreter.
6. Arrange for support workers to be on-site in case modifications need to be
made.
a. Often this includes metal fabrication and electrical changes.
b. Experienced electricians and millwrights should be on-site during
start-up until the plant is operational.
c. If you plan to run 24 hr/day, be sure all operators are on-site for
training. Do not plan to operate 24 hr/day until start-up is complete.
7. All estimated expenses must be paid prior to start-up.
8. Start-up Request forms must be filled out, signed, and returned.
9. Pictures must be received from customer prior to travel. If there are changes or
further installations to be made, updated pictures must be received reflecting
the changes prior to travel.
10. All non-Insta-Pro® equipment needed for the process must be tested prior to
travel and its performance verified to be within specifications. (This includes,
but is not limited to, the ability to supply raw materials to the extruder and
remove the processed meal.)
11. Technicians will only travel prior to approval for start-up if customer signs a
Pre-Start-Up Assessment Request Form. This permits the technician to conduct
a pre-start-up assessment on-site to verify the new line is ready for start-up.
There are additional charges for labor and expenses for this service. These
charges must be paid prior to travel.
If you have questions regarding start-up procedures, contact Insta-Pro®.
2.7.1 General Start-Up Schedule
Most start-up and training sessions take 3-5 days. Schedules vary depending on the
amount of equipment and the product(s) produced. The following schedule is a
typical 5-day start-up and training session.
Day 1:
• Insta-Pro® technician is on-site and inspects the plant to determine
readiness. The technician reserves the right to leave and return later at
customer expense if he determines that the plant cannot operate
sufficiently for start-up and training. The technician will discuss any issues
with management and recommend changes.
• After inspection of the plant, the technician prepares the Insta-Pro®
equipment. The extruder compression chambers are removed, the drive
belt tension is checked, and thermocouples are installed.
• Motor rotations are checked on all processing equipment.
• Depending on the amount of time and the product to be run, all the
equipment downstream of the extruder is turned on, flushed out with
approximately 50 kg (100 lb) of raw product and the extruder hopper is
filled for the next morning. The technician teaches the operator(s) to
reassemble the extruder. The plant is readied for operation the following
morning.
Day 2:
• The plant is ready to operate. Initially, the Insta-Pro® technician operates
all equipment Insta-Pro® is commissioning. When the machines stabilize,
on-site training begins. The operators are shown how the equipment
functions and make any necessary adjustments. The technician may
recommend adjustments to optimize production to management.
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Day 3
• This day is a continuation of day 2, with the operators gradually taking
control of the equipment and beginning to operate the plant
independently, but with the supervision of the Insta-Pro® technician.
Day 4:
• This day begins with a brief classroom session where the operators have a
chance to sit down in a quiet setting and digest the information they
learned on the plant floor. They are given a chance to ask questions
regarding:
o Operation
o Maintenance
o Anything else related to the Insta-Pro® equipment or processes.
• The plant operators then start and operate the plant under the supervision
of the Insta-Pro® technician.
Day 5:
• The operators are now able to operate the Insta-Pro® equipment
independently of the technician.
• The technician meets with management to answer questions and concerns
regarding the equipment, start-up, and training.
NOTE: The schedule may change at any point as dictated by factors that are
unforeseen or outside the control of the technician.
NOTE: If at the end of the time allotted the technician determines that proper start-
up and training have not occurred, he may extend his visit to facilitate successful
start-up and training. If this is due to the failure of equipment not supplied by Insta-
Pro® or other reasons outside the control of Insta-Pro, the customer will be
responsible for all additional expenses and be subject to daily Insta-Pro® labor
charges. Travel changes will be made only after consulting with both the customer
and Insta-Pro® management.
2.7.2 Helpful Tools for the Job Site
The items listed below are required or recommended to have on site.
Heat and Oil Resistant Gloves—REQUIRED
Gloves are needed for handling hot extruder parts or meal. Oil resistance is
recommended, since non-oil-resistant gloves absorb water and oil. Heat is then
transferred through the liquid, making the gloves less effective.
Impact Wrench/Ratchet
A 15/16” deep-well socket and ½” drive (minimum) are needed for the compression
chamber clamp bolts. A source of compressed air and an impact wrench are
recommended.
Mallets
Dead-blow mallets are recommended for assembly and disassembly of extruder
shaft components. Since the extruder parts are metal, they can easily be damaged
by metal hammers. (Occasionally, a hammer may be required to effectively
separate badly fouled parts. In this event, protect the part with a scrap of wood in
the area to be struck to help protect it from damage.)
WARNING: Always wear safety glasses, gloves, and protective
clothing when using a mallet or hammer.
CAUTION: Exercise great care when using mallets and hammers. Be aware
of the risk of damaging parts.
Screwdrivers (Standard/Straight Blade)
A variety of large screwdrivers is recommended for separating extruder parts and
for removing large pieces of hardened product from the machine.
Brushes
Wire brushes are recommended for cleaning threads and other intricate areas.
Putty Knives or Scrapers
Putty knives and scrapers are recommended for cleaning. A variety of widths from
25-100 mm (1-4 in) works well to reach most areas.
Brooms and Shovels
An assortment of brooms, brushes, shovels, and waste receptacles are
recommended so operators can keep the area around the extruder clean. Regular
cleaning is important to keep the equipment and work area functional and safe.
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Insta-Pro®
Start Up and Training Request Form
Insta-Pro will NOT schedule start-up until form is completed and returned.
Attention: Kinoti Kaburu / Jim Little
To insure a successful start-up, Insta-Pro has compiled a list of guidelines, which
must be completed prior to the arrival of the service technician.
Company:
Contact:
Address:
City, State:
Country:
Telephone:
Facsimile:
Is electrical installation complete? Yes_______ no _______
If no, anticipated completion date? ____________________
(Includes all Insta-Pro® and non-Insta-Pro® equipment, in place and connected to
utilities.)
Is the balance of the production line operational? yes_____ no_____
If no, anticipated completion date? ____________________
If yes, has equipment upstream from the Insta-Pro® equipment been tested?
Yes ____ No ____ If no, anticipated completion date? ___________
Product(s) to be produced during start-up: ___________________________
_____________________________________________________________
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Are all raw materials needed for processing on site? Yes ______ No ______
If no, anticipated delivery date? ___________________________________
Interpreter needed? Yes ____ No ____ (It is the customer’s responsibility to provide
an interpreter. A competent interpreter helps optimize training.)
Take pictures when installation and utilities are complete:
• All motor electrical connections
• Control panel connections
• Production line
E-mail pictures and questions to one of the following Insta-Pro® representatives:
Kinoti Kaburu (kkaburu@insta-pro.com) or Jim Little (jlittle@insta-pro.com)
No start-ups are scheduled until pictures are reviewed. Insta-Pro® requires two
weeks’ notice to schedule start-up.
By signing this document the customer understands that all additional expenses
incurred by Insta-Pro due to delays resulting from incomplete preparation and
installation will be charged to the customer at Insta-Pro’s current daily service rate,
plus expenses. An average start-up takes 3–5 days, depending upon the amount of
equipment involved. If upon arrival the technician determines start-up services
cannot begin within 5 working days, he is authorized to return home with start-up
scheduled for a later date. All charges for rescheduled start-up will be the
responsibility of customer.
Company: _________________________
Name (printed): _____________________
Title: _____________________________
Signature: _________________________ Date: ____________
Should you have any questions, please contact:
Insta-Pro International Customer Service Department
Phone: 1-800-798-0951 Fax: 515-254-1357
THANK YOU!
 Pre-Start-Up Installation Assessment ❑ Pictures of the following have been sent to Insta-Pro:

Please complete this form and submit it with the Start-Up and Training Request ❑ All Insta-Pro® equipment (Show several views of all machines.)
Form to the Insta-Pro® service department. Include pictures so we may assess plant
readiness. ❑ Extruder

❑ All electrical is complete and all non-Insta-Pro® equipment has been checked ❑ Press
for correct operation, including direction of shaft rotation. ❑ Cooler (Ensure both ends are shown. The inlet must be 50
❑ Check oil in all non-Insta-Pro® equipment mm (2 in) higher than the discharge.)

❑ There is sufficient raw material on-hand. ❑ Transitions between Insta-Pro® equipment and non-Insta-
Pro® equipment.
❑ The plant has been cleaned and all equipment is free of foreign material.
❑ Powered-up control panel
❑ At least one operator has been assigned to the extruder.
❑ General plant layout
❑ The Start-Up Checklist has been completed and returned to Insta-Pro.
❑ Electrical connections
❑ The extruder control panel has been wired by a certified electrician.
❑ Steam connections (if applicable)

❑ Water connections (if applicable)

❑ Proven water supply (if applicable)

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FEEDER START Powers FEEDER KEYPAD

3 Operation
FEEDER STOP Powers down FEEDER KEYPAD (stops feeder motor)
NOTE: Operation instructions for optional equipment that is not present may be
FEEDER SPEED Adjusts feeder motor speed
disregarded.
NOTE: Optional equipment provided by Insta-Pro is provided with a separate FEEDER KEYPAD Starts and stops feeder, changes VFD settings
manual. Read and understand all manuals before operating the Series 2000
Extruder. EMERGENCY STOP Cuts power immediately in case of emergency

DISCONNECT Disconnects panel from power supply

3.1 Control Panel
Additional buttons may be present to control
Series 2000 extruder control panels have pushbutton interfaces and digital displays. Other
additional features, such as solenoid valves.

Table 3-1: Buttons

Table 3-2: Displays

Button Label Function

Button Label Function
CUTTER/ Starts cutter or particlizer motor (powers CUTTER or
PARTICLIZER START PARTICLIZER KEYPAD) EXTRUDER AMP
Displays main extruder motor amps
METER
CUTTER/ Stops cutter or particlizer motor (powers down
PARTICLIZER STOP CUTTER or PARTICLIZER KEYPAD) BARREL TEMP METER Displays temperatures of thermocouples

CUTTER/ HOUR METER Displays hours of operation

Adjusts cutter or particlizer motor speed
PARTICLIZER SPEED
CUTTER/
Displays cutter or particlizer motor speed in RPM
CUTTER/ PARTICLIZER KEYPAD
Changes cutter or particlizer VFD settings
PARTICLIZER KEYPAD
FEEDER KEYPAD Displays feeder motor frequency in Hertz
EXTRUDER START Starts main extruder motor

EXTRUDER STOP Stops main extruder motor

 2. With the system main power locked out, check equipment for foreign objects
and remove. Clean machine according to Cleaning section, page 22.
3. Replace all guards and safety features. Remove lock from main power
disconnect and restore power to the system.

WARNING: Know how to stop the equipment before starting it.

4. Check rotation of extruder and feeder auger(s) by starting them up. Looking at
the discharge end of the extruder shaft, the correct rotation is clockwise.
Looking at the discharge end of a feeder screw, the flighting should push
material towards the observer when rotating correctly. If rotation is incorrect,
contact a qualified electrician to change rotation.
5. Check oil levels (refer to the Maintenance section).
6. If extruder has been in storage for 6 months or more, lubricate motor bearings
(see page 49) and other mounted bearings (see Maintenance section).
7. Test run all support equipment (augers, conveyors, elevators, etc.).
8. Drain all condensate from steam lines and have full steam available at
manifold.

3.3 Priming the Extruder

At the start of production, the extruder must be primed with product to establish
flow through the system. (This is especially important for small orifice dies.) If
equipped, the preconditioner must also be primed. See the preconditioner manual.
1. Disconnect cutter or particlizer and swing it away from the barrel.
Figure 3-1: Control panel 2. Press EXTRUDER START on control panel.
3. Press FEEDER START.
3.2 Pre-Start Checklist 4. Press RUN on FEEDER KEYPAD.
5. Adjust FEEDER SPEED potentiometer to 15 Hz setting.
1. Read and follow all instructions in Safety section, page 5.
6. When product starts to transfer into extruder, turn on water injection pump (if
equipped).
WARNING: Always lock out utilities before removing guards or
7. Turn on inlet water at 50-75 L/hr (13-20 gph)).
disabling safety features.

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8. Run until product discharges steadily from extruder. 12. Turn nose cone in 1/8 turn increments to adjust temperature. Turn the cone
9. Shut down system by stopping feeder and extruder motors in order. toward the nose bullet to raise or away to lower the temperature. Wait for
temperature to stabilize before making additional adjustments.
10. Turn off water to inlet using solenoid valve to preserve flow meter settings.
NOTE: If the desired operating temperature cannot be attained with the nose cone
between 1/8 and 2 turns away from the bullet, the machine must be reconfigured.
3.4 Start-Up Contact Insta-Pro®.

1. Formed products only: Attach cutter or particlizer to barrel.
2. Non-formed products: Install nose cone. Thread into cap until the cone touches
the nose bullet. Make a note of the cone position relative to the nose cap and
thread the cone out 2 full turns. This is the starting position.
13. Once process temperature is reached, increase FEEDER SPEED in 2-5 Hz
increments until EXTRUDER AMP METER peaks near the rated full load Amps.
NOTE: Conditioned product will be wet at first. Increasing FEEDER SPEED will cause
the temperature to increase and the product to become drier.

NOTE: Nose cones are available with left-hand or right-hand threads. Left-hand
threads tighten counter-clockwise and right-hand threads tighten clockwise. WARNING: Steam and condensate cause burns. Wear protective
gear, maintain a safe distance, and be cautious when draining condensate.
WARNING: Make sure all guards are in place and secured. Never 14. Drain condensate from the steam manifold and slowly introduce steam to the
operate cutter or particlizer with guards removed. preconditioner. Start by turning the two valves ¼ open (1/16 of a turn of the
ball valve).
3. Press CUTTER/PARTICLIZER START.
15. Gradually adjust feed rate, water and steam, and cutter or particlizer speed to
4. Press RUN on CUTTER/PARTICLIZER KEYPAD. achieve desired finished product.
5. Press EXTRUDER START. NOTE: Make sure EXTRUDER MOTOR AMPS stays below the nameplate rating.
6. Press PRECONDITIONER DISCHARGE START. NOTE: Make sure recommended process temperature is attained by the final
7. Turn on inlet water. chamber.
8. Press PRECONDITIONER MAIN START. NOTE: Pellet length is determined by CUTTER SPEED and number of knives. Increase
CUTTER SPEED to shorten pellets.
9. Start metered flow to feeder or preconditioner.
NOTE: Particle size is determined by PARTICLIZER SPEED. Increase PARTICLIZER
10. Turn on preconditioner water.
SPEED to decrease particle size.
11. Once flow is established at discharge, run extruder until last chamber
temperature stabilizes. 3.5 Extruder Temperature Regulation
WARNING: Always keep track of the number of turns the nose cone The 2000 should generate a temperature of 100-180°C (200-350°F), depending on
is away from the shaft. Never turn the cone far enough to contact the the material being processed. (Contact Insta-Pro® for recommended temperature
shaft. for specific products.)
There are several ways in which temperature can be regulated:
Steam locks: 5. Press EXTRUDER STOP.
Larger steam locks generate more heat. 6. Press CUTTER/PARTICLIZER STOP*.
*If equipped.
NOTE: When using different size steam locks in combination, install steam locks
from smallest near inlet to largest near discharge.

NOTE: Insta-Pro® recommends NOT increasing steam lock size more than 1
step from inlet to discharge. This creates excessive pressure at the nose bullet.
Screws:
Both single and double flight screws are available. Single flight screws are normally
used in the inlet section. All single or double flight screws are normally used in the
compression chambers. Low-fat/moisture products generate enough heat with
single flights. High-fat/moisture products require double flights to attain process
temperature. Custom-designed screws are also available. Contact Insta-Pro® for
details.
Fat / Moisture / Starch Content:
Temperature changes as the quality of material processed changes. As
temperature varies due to material and process variations, the desired temperature
can be attained by varying the fat/moisture content added. Generally, reducing
fat/moisture increases temperature. This method should be used for temperature
variation of a few degrees only for shaped products— too much fat/moisture
prevents the product from retaining its shape.
Exit Orifices:
The number and size of exit orifices affects temperature. Decreasing orifice size or
quantity increases the temperature.
NOTE: Moisture level should be monitored to ensure product stability.

3.6 Shutting Down Extruder

1. Decrease FEEDER SPEED to 15 Hz.
2. Turn off supply to feeder.
3. Turn nose cone* out to starting position (two full turns from bullet).
4. Allow product discharge from barrel to stop.

21
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4 Cleaning
WARNING: Read and follow instructions in the Safety section, page 5
prior to cleaning the equipment.
WARNING: Turn DISCONNECT off and lockout power before
removing any safety components.
WARNING: Take precautions to protect electrical components from
water and other liquids.
NOTE: Cleaning is easiest immediately following a production run. Waiting to clean
the extruder allows the product to continue cooking from the residual heat in the
shaft and barrel. Over-cooked product becomes hard, making its removal and
disassembly of the shaft and barrel difficult.
4. Remove the nose cap and chamber closest to it. (A slug of material will remain
in the barrel after the extruder has stopped.)
NOTE: If barrel has plugged, all external barrel components must be removed for
cleaning.
5. Carefully clean internal and external barrel components. Whenever possible,
use only tools softer than the components being cleaned. For example, brass or
plastic scrapers and brushes may be used to remove material with reduced risk
of damaging parts.
6. Clean threads on nose cone* and cap. Coat them liberally with anti-seize
compound or grease that is approved for food contact.
7. Remove cleaners before resuming production. Flush contact parts with potable
water. Thoroughly dry parts and apply light coating of edible oil unless
production will be resumed immediately.
8. Reassemble chambers, nose cap, and cone*.
*If equipped.

4.1 Feeder WARNING: Make sure no foreign objects are left inside the extruder.
NOTE: It may be necessary to take all chambers off a new extruder the first few
1. Turn off supply to feeder. times to clean out material that stuck to the new parts. Once all parts become
2. Run feeder until empty. polished, this should not be necessary.
3. Press FEEDER STOP.
4.3 Frame and Bearing Stand
4.2 Extruder Barrel 1. Use compressed air or a broom or brush to remove excess material and dust
from the outside of the frame and bearing stand as needed.
1. Run extruder until empty.
2. Wipe up any oil, water, or other fluids. Fix any leaks as needed.
2. Press EXTRUDER STOP.
4.4 Drive
WARNING: Pressure build-up remains in the barrel after the extruder
has stopped. Make sure the area at the end of the barrel is clear prior to
disassembly. Be careful when removing parts. Never stand in front of WARNING: Never remove or reach through a guard unless the motor
barrel. Take care when handling hot parts. has been locked out from the power supply. Replace all guards before
3. Remove the nose cone*. removing the lock.
1. Stop the machine and lock out power.
2. Remove any material that has accumulated on the motor housing. Material
build-up reduces motor cooling and leads to motor failure.
3. Visually inspect the fan through the guard. The fan must be cleaned if any
material has accumulated.
4. With power locked out, remove the guard and remove all material from the
fan.
5. Visually inspect the drive through the slots in the belt guard. The belt and
sheaves must be cleaned if any dust has accumulated.
6. With power locked out, remove the belt guard. Carefully remove all dust from
the belt and sheaves.
7. Replace all guards.

4.5 Work Areas

After the extrusion equipment has been cleaned, make sure the work areas are also
clean and free of hazards. Raw or processed material, water, oil, tools, and other
objects in the work areas increase the risk of injury.

4.6 Disposal of Waste

Make sure cleaners, tainted product, and wastewater are disposed of properly. Do
not allow contaminants to enter the process flow

23
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5 Maintenance
 WARNING: Read and follow instructions in the Safety section, WARNING: Do not modify equipment. Use only as intended and
page 5 prior to performing maintenance. repair only with Insta-Pro® parts specified.

WARNING: Immediately report any problems to the WARNING: Always turn off the power supply disconnect and
supervisor. lock it before performing any maintenance.

25
 26

5.1 Main Assemblies

6,7,8 1 5

10 4
 Item Part Number Description Qty
1 2000-SA101 Base frame 1
2 2000-SA102 (See Bearing Stand, page 42.) Bearing stand 1
3 2000-SA200 (See Belt Drive, page 44.) Belt drive 1
4 (See Motor Base, page 52.) Motor base 1
5 (See Motor, page 48.) Motor 1
6 (See Bearing Housing, page 54.) Bearing assembly 1
7 (See Inner Barrel Components, page 64.) Inner barrel components 1
8 (See Outer Barrel Components, page 66.) Outer barrel components 1
9 (See Top Feeder, page 28.) Top feeder 1 opt
10 2000R-6600 Downward deflector 1 opt

The Maintenance section has been arranged with the exploded view of an assembly Note: Not all options are shown. For questions regarding machine configurations,
on the top page and the part list and maintenance instructions on the page below. contact Insta-Pro®.
The item numbers on the exploded assembly views correspond to those in the
following parts list and to the numbers in parentheses in the maintenance
instructions.

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 28

5.2 Top Feeder – 2000-SA701

Item Part Number Description Qty
1 2000-SA701-100 Hopper 1
2 2000-SA701-400 Guard 1
3 2000-SA701-300 Guard 1
4 F14-20-12-SFB Serrated flange bolt, ¼”-20 x 1/2” 2
5 8100-84000 Seal plate 1
5 8100-54000 Seal 1
6 F38-16-212 Hex bolt, 3/8”-16 x 2-1/2” 1
7A M2-200/400-50-C-7/8S Motor, 50 Hz 1 Opt
7B M2-230/460-60-C-7/8S Motor, 60 Hz 1 Opt
8 8500-31000 Gearbox 1
9 F38-16-HXNT Hex nut, 3/8”-16 5
10 F12 Flat washer, ½” 4
11 F12-S Lock washer, ½” 4
12 F12-13-GR8 Hex nut, ½”-13 4
13 F12-13-2 Hex bolt, ½”-13 x 2” 4
14 F38-16-1-SFB Serrated flange bolt, 3/8”-16 x 1” 6
15 F14-20-34-SFB Serrated flange bolt, ¼”-20 x ¾” 24
16 2000-SA701-4 Window 1
17 2000-SA701-200 Frame 1
18 F14-20 Hex nut, ¼”-20 24
19 2000-SA703 Auger 1
20 2000-SA702 Inlet adapter 1
21 F38-LW Lock washer, 3/8”

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 30

5.2.1 Maintenance
• Visually inspect daily during operation. Correct all issues immediately.
• Disassemble and inspect all parts every 4000 hours.
• Reducer lubrication: The reducer is filled with synthetic oil and sealed. Do not
adjust the oil level or change the oil unless disassembly of the reducer is
required. Use Klubersynth UH1-6-460 oil. Capacity is approximately 950 ml (1
qt); do not overfill. If recommended gear oil is not available, thoroughly flush
the gearbox with the new oil to remove remnants of the previous oil, then fill.

5.2.2 Auger Replacement

1. Remove the drive guards and bolts between auger shaft and gearbox.
2. Pull the auger from the discharge end. Remove and retain shaft key as it
disengages the gearbox.
3. Replace the auger and assemble in reverse order of disassembly.
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31
 32

5.3 Side Feeder – 8100RC

 Item Part Number Description Qty
1A M2-200/400-50-C-7/8S Motor, 50 Hz 1 Opt
1B M2-230/460-60-C-7/8S Motor, 60 Hz 1 Opt
2 8500-31000 Gearbox 1
3 8100-56000 Bearing 2
4 F516-18-HXNT Hex nut, 5/16”-18 8
5 F516-FW Flat washer, 5/16” 8
6 8100-14A00 Driven sprocket 1
7 Guard 1
8 8100-63000 Chain 3 ft
9 8100-14000 Drive sprocket 1
10 8100-59000 Idler sprocket 1
11 F14-20-58-HHCS Bolt, ¼”-20 x 5/8” 2
12 F516-18-34-HHCS Bolt, 5/16”-18 x ¾” 1
13 Tensioner 1
14 F515-18-112-HHCS Bolt, 5/16”-18 x 1-1/2” 4
15A 8100RC-01A Side feeder, RH 1 Opt
15B 8100RC-01B Side feeder, LH 1 Opt
16 Agitator 1
17A 8100RC-140 Auger, RH 1 Opt
17B 8100RC-150 Auger, LH 1 Opt
18 F516-18-34-CB Carriage bolt, 5/16”-18 x ¾” 6
19 Guard 1

5.3.1 Maintenance 5.3.2 Screw Replacement

• Visually inspect daily during operation. Correct all issues immediately. 1.
• Disassemble and inspect all parts every 4000 hours.
2.
• Reducer lubrication: The reducer is filled with synthetic oil and sealed. Do not
adjust the oil level or change the oil unless disassembly of the reducer is 3.
required. Use Klubersynth UH1-6-460 oil. Capacity is approximately 950 ml (1
qt); do not overfill. If recommended gear oil is not available, thoroughly flush 4.
the gearbox with the new oil to remove remnants of the previous oil, then fill.
Remove the chain guard and mark the position of the sprocket on the main
shaft.
Loosen setscrews in the sprocket and flange bearing.
Pull the screw from the discharge end. Remove and retain shaft keys as they
disengage the gearbox and sprocket.
Replace the screw and assemble in reverse order of disassembly.

33
 34

5.4 Side Feeder – 8500

Item Part Number Description Qty
1A 8100DB-02B Gearmotor, cotton, RH, 50/60 Hz 1 Opt
1B 8100DB-02A Gearmotor, cotton, LH, 50/60 Hz 1 Opt
1C 8500-00155 Gearmotor, wet waste, RH, 50 Hz 1 Opt
1D 8500-00154 Gearmotor, wet waste, LH, 50 Hz 1 Opt
1E 8500-00157 Gearmotor, wet waste, RH, 60 Hz 1 Opt
1F 8500-00156 Gearmotor, wet waste, LH, 60 Hz 1 Opt
2 F38-16-38-HHCS Bolt, 3/8”-16 x 3/8” 6
3 F38-FW Flat washer, 3/8” 6
4 Guard 1
5 F12-13-HXNT Nut, ½”-13 12
6 Drive sprocket 1
7 Driven sprocket 1
8 8100-59000 Idler sprocket 1
9 Tensioner 1
10 Mounting block 1
11A 8500-00150 Side feeder, RH 1 Opt
11B 8500-00151 Side feeder, LH 1 Opt
12A 8500-00161 Auger, RH, cottonseed 1 Opt
12B 8500-00159 Auger, RH, wet waste 1 Opt
12C 8500-00160 Auger, LH, cottonseed 1 Opt
12D 8500-00158 Auger, LH, wet waste 1 Opt
13 Agitator 1
14 Guard 1
15 8500-18000 Seal plate 1
15 9400-03J00 Seal 1
16 9400-03H00 Bearing 1
17 8500-18000 Seal plate 2
17 9400-03J00 Seal 2
18 9400-03I00 Bearing 2
19 8100-63000 Chain 4 ft
20 8500-00153 Stand 1

35
 36

5.4.1 Maintenance
• Visually inspect daily during operation. Correct all issues immediately.
• Disassemble and inspect all parts every 4000 hours.
• Reducer lubrication: The reducer is filled with oil at the factory. Check oil
condition and level the sooner of every 1000 hours or 6 months. Change oil the
sooner of 8000 hours or 2 years. Unless contradicted by the gearbox serial
plate, use Shell S2 G 220 or compatible oil. Capacity is approximately 3.0 l (3.2
qt); do not overfill. If recommended or compatible gear oil is not available,
perform oil change using oil with performance qualities similar to
recommended oil. If substituting alternate lubricant, add a label to the gearbox
with the name and description of the replacement lubricant.

5.4.2 Screw Replacement

1. Loosen setscrews in the gearmotor.
2. Pull the screw from the discharge end. Remove and retain shaft key as it
disengages the gearbox.
3. Replace the screw and assemble in reverse order of disassembly.
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37
 38

5.5 Side Feeder Stand – 8100RC-01C

Item Part Number Description Qty
1 8100RC-01C-01000 Stand 1
2 F38-16-HXNT Nut, 3/8”-16 16
3 F34-10-HXNT Nut, ¾”-10 4
4 8100RC-01C-02000 Foot 4
5 8100RC-01C-00004 Caster 4
6 F38-16-1-SBH Socket Buttonhead Screw, 3/8”-16 x 1” 16
7 F38-FW Flat washer, 3/8” 16

39
 40

5.6 Side Feeder Swing Arm – 8100RC-01D

Item Part Number Description Qty
1 8100RC-01D-03000 Upper arm 1
2 8100RC-01D-02000 Lower arm 1
3 8100RC-01D-00001 Clevis pin 2
4 8100RC-01D-00002 Retaining ring 2
5 (see Barrel Support) Clevis 1
6 Leveling bracket 1
7 F38-16-34-HHCS Bolt, 3/8”-16 x ¾” 4
8 F38-FW Flat washer, 3/8” 4
9 F38-16-HXNT Nut, 3/8”-16 4

41
 42

5.7 Bearing Stand

Item Part Number Description Qty
1 2000-SA102 Bearing stand 1
2 2000-SA102-013 Cover 2
3 F34-10-112 Hex bolt, ¾”-10 x 1-1/2” 6
4 F34-GR8 Flat Washer, ¾” 6
5 F38-16-34-SFB Serrated Flange Bolt, 3/8”-16 x 3/4” 4
6 2000-SA102-1 Latch 8
7 F8-32-12-PHMS Pan Head Machine Screw, #8-32 x ½” 16

43
 44

5.8 Belt Drive

 Item Part Number Description Qty
1 2000-SA200-1-200 Guard, front 1
2 Bolt 3
3 2500-07102 Drive belt 6
4 2500-07101 Sheave, driven 1
5 2500-04000 Bushing, driven 1
6 Bolt 3
7A 2500-07100 Sheave, driver, 50 Hz 1 opt
7B 2500-07103 Sheave, driver, 60 Hz 1 opt
8A 2500-07000 Bushing, driver, 50 Hz 1 opt
8B 2500-07A00 Bushing, driver, 60 Hz 1 opt
9 2000-SA200-1-100 Guard, back 1

5.8.1 Belt Tension
Check tension before initial start-up, after 8 hours of continuous running, after 24
hours, after 100 hours, and every 1000 hours of operation thereafter.
1. Remove front belt guard by removing screws and washers.
2. Check that sheaves are not damaged or excessively worn and that they are
aligned and securely fastened to the shafts. Clean foreign material from shafts,
sheaves, and belts.
3. Place a straight edge across the upper straight segment of one of the belts.
Apply a force to the center of the belt span and measure the distance between
straight edge and belt. At initial installation, 70 N (15 lb) should deflect the belt
20 mm (5/8 in). After 100 hours run-in, 45 N (10 lb) should cause the same
deflection.
4. Loosen motor bolts and shift motor on its base away from extruder shaft to
increase tension and toward shaft to decrease tension.
NOTE: When shifting, make sure motor shaft remains parallel with extruder shaft.
Measure from motor foot to edge of base at front and rear of motor and make sure
distances are the same. Turn shafts by hand and check their alignment.
5. After tension is set, check sheave alignment and secure motor to base. Re-
check tension and adjust if necessary.

45
46
 Item Part Number Description Qty
10 F12-13-1-HHCS Hex bolt, ½”-13 x 3/4” 6
11 F12-FW 6
12 F14-20-CLIP Cage nut, ¼”-20 11
13 F14-FW Flat washer, ¼” 11
14 F14-LW Lock washer, ¼” 11
15 F14-20-12-BHCS Button head screw, ¼”-20 x ½” 11
16 F38-16-HXNT Hex Nut, 3/8”-16 3
17 2000-SA200-3 Adjustable guard 1
18 2000-SA200-1-004 Bracket 1
19 F38-FW Flat washer, 3/8” 1
20 F38-16-234-HHCS Hex bolt, 3/8”-16 x 2-3/4” 1
21 F38-FW Flat washer, 3/8” 1
22 F38-16-1-SFB Serrated flange bolt, 3/8”-16 x 1” 1
23 F38-16-34-SFB Serrated flange bolt, 3/8”-16 x ¾” 2

5.8.2 Sheave Removal 5.8.3 Sheave Installation

1. Remove front belt guard by removing screws and washers. 1. Install bushing onto shaft. Align it with mark made on shaft before bushing was
removed.
2. Loosen motor bolts and shift motor toward extruder shaft to remove tension
from the drive belts and provide clearance between the belts and sheaves. 2. Install sheave onto bushing and move screws and washers to clearance holes in
bushing and threaded holes in sheave.
3. Mark each belt and its corresponding sheave groove with a number if belts will
be re-installed. Remove drive belts. 3. Tighten each screw in an alternating pattern. Make sure bushing does not
4. Make an ink mark or apply adhesive tape to shaft behind bushing to show move relative to mark on shaft as screws are tightened. Torque each screw to
proper location for re-installation. 120 N-m (90 ft-lb).

5. Remove screws and washers from bushing of sheave to be removed and move 4. Install drive belts onto sheaves. (If used belts are being re-installed, return each
them to threaded holes in bushing. belt to the same groove of the sheave as before it was removed.)
5. Shift motor away from extruder shaft to seat belts in grooves of both sheaves.
6. Tighten each screw half a turn in an alternating pattern, repeating until sheave
disengages bushing. 6. Follow instructions for Belt Tension, page 45.

47
 48

5.9 Motor
 Item Part Number Description Qty
1A M125-230/460/380-50/60-RH Motor, 125 hp, 230/380/460 V, 50/60 Hz, right hand 1 opt
1B M125-230/460/380-50/60-LH Motor, 125 hp, 230/380/460 V, 50/60 Hz, left hand 1 opt
1C M100-230/460/380/415-50/60-RH Motor, 100 hp, 230/380/460 V, 50/60 Hz, right hand 1 opt
1D M100-230/460/380/415-50/60-LH Motor, 100 hp, 230/380/460 V, 50/60 Hz, left hand 1 opt
1E M75-230/460/380-50/60-RH Motor, 75 hp, 230/380/460 V, 50/60 Hz, right hand 1 opt
1F M75-230/460/380-50/60-LH Motor, 75 hp, 230/380/460 V, 50/60 Hz, left hand 1 opt
2A F34-GR8 Flat washer, ¾” 4 opt
2B F58-GR8 Flat washer, 5/8” 4 opt
3A F34-10 Hex nut, ¾”-10 4 opt
3B F58-11-HXNT Hex nut, 5/8”-11 4 opt
4 F18-6 BLK STL NIP Pipe nipple, 1/8” NPT x 6” 2
5 F18-MPCB Pipe coupling, 1/8” NPT 2
6 F18-SSGF Grease fitting 2
5.9.1.2 Alternate Lubricants
WARNING: Only qualified electricians may work on the If the recommended lubricant is not available, open the grease outlets and purge
electrical system. the factory grease with one of the following alternate greases:
5.9.1 Lubrication • Exxon Unirex EP 2
NOTE: Each bearing has a grease outlet on the housing below the bearing. It opens • Exxon Polyrex
by removing the screws that attach the cover plate to the motor. To purge old or
• Shell Dolium R
excess grease, run motor with outlets open for 1 hour.
• Texaco Polystar RB 2
CAUTION: Lubricate the motor while running. Afterwards, allow it to run After 100 hours of operation, purge the grease cavities a second time and close the
with the grease outlets open 30 minutes before closing. Do not over-grease the grease outlet covers.
motor bearings. If these lubricants are also not available, select a grease with properties similar to
5.9.1.1 Recommended Lubricant the recommended lubricant. Purge the factory grease as described above.

Unless contradicted by the serial plate, the motor bearings are lubricated with
CAUTION: Do not mix greases of different brands. Mixing greases shortens
Chevron SRI at the factory. This grease should always be used for maintenance.
bearing life.

49
 50

5.9.1.3 Start-up
Motor bearings are greased at the factory. If a motor has been in storage six
months or more, open the grease outlets and lubricate the bearings prior to
starting. Add 7.5-12.5 g (0.25-0.45 oz; 6-10 pumps) of the recommended grease to
125 hp motors and 5.0-6.5 g (0.18-0.22 oz; 4-5 pumps) to 75-100 hp motors using a
standard hand-held grease gun.
NOTE: Low-pressure, hand-held grease guns typically deliver approximately 1.25
grams/pump (0.044 oz/pump).
5.9.1.4 Maintenance
Make sure grease nipples are clean before greasing. Always use grease that is fresh
and contamination-free.
Lubricate extruder motor every 3000 hours. 125 hp motors: 80 g (2.8 oz; 64 pumps)
of grease to drive end; 50 g (1.8 oz; 40 pumps) to fan end. 100 hp motors: 80 g (2.8
oz; 64 pumps) and 30 g (1.1 oz; 24 pumps). 75 hp motors: 50 g (1.8 oz; 40 pumps)
and 30 g (1.1 oz; 24 pumps).
Grease leakage around the shaft could indicate over-packing. Purge excess grease.
It may be necessary to open the grease outlets for cleaning due to hardening of
grease. Scrape out old grease a minimum of every two years.
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51
 52

5.10 Motor Base

Item Part Number Description Qty
1A 2500-02B00 Base, 125 hp 1 opt
1B 2000RC-840 Base, 100 hp 1 opt
1C 2000-84000 Base, 75 hp 1 opt
2 F34-FW Flat washer, ¾” 8
3 F34-10-HXNT Hex nut, ¾”-10 4
4 F34-10-112-HHCS Hex bolt, 3/4”-10 x 1-1/2” 4

53
 54

5.11 Bearing Housing

Item Part Number Description Qty
1 2500-25B00 Seal washer 1
2 F12-20-2-SHCS Socket head capscrew, ½”-20 x 2” 8
3 2500-25000 Front seal 2
4 600R-660-A Dowel pin 2
5 2500R-3800 Front plate 1
6 2500R-1700 O-ring 1
7 2500-25C00 Speedi sleeve 1
8 F34-LW Lock washer, ¾” 8
9 F34-10-2-HHCS Hex bolt, ¾”-10 x 2” 4
10A 2500R-3700 Drive shaft 1 Opt
10B 2500R-3702 Drive shaft, corn 1 Opt
11 2500R-3600 Inner bearing retainer 1
12 2500-24000 Front bearing 1
13 2500R-3400 Bearing spacer 1
14 2500-23000 Thrust bearing 1
15 2500R-3500 Thrust bearing spacer 1
16 2500-16000 Lock washer 1
17 2500-15000 Lock nut 1
18 2500R-3300 Bearing housing 1
19 2500-26000 Rear seal 2
20 2500R-3100 Rear gasket 1
21 2500R-3200 Rear seal plate 1
22 F14-20-34 Hex bolt, ¼”-20 x ¾” 8
23 2500R-1400 Rear bearing 1
24 F34-10-214 Hex bolt, ¾”-10 x 2-1/4” 4

55
56
 Item Part Number Description Qty
25 8000-57000 Plug 4
26 2000R-69B0 Elbow 1
27 2500-27A00 Adapter 2
28 F38-COPPERPIPE Tube 1
29 2000R-69F0 Tee 2
30 2000R-6900 Vent 2
31 F12-13-NYL Lock nut, ½”-13 1
32 F12-13-212-SSSCP Socket Setscrew, ½”-13 x 2-1/2” 1
33 F18-SSGF Grease Fitting, 1/8” NPT 1
34 F18-MPCB Pipe Coupling, 1/8” NPT 1
35 F18-212 BLK PIPE NIP Pipe Nipple, 1/8” NPT x 2-1/2” 1
36 2000R-69D0 Nipple 1
37 2000R-69E0 Elbow 1
38 2000R-69C0 Sight glass 1

5.11.1 Lubrication 5.11.1.2 Recommended Lubricants

Check bearing housing oil level at sight glass after first 50 hours and every 250 Use ISO-VG 220, NSF H1 food grade synthetic oil or equivalent in bearing housing.
hours thereafter. Add oil as needed to maintain level indicated (centerline of shaft) Use lithium complex based, NLGI #2, EP (extreme pressure) grease such as Exxon
through top port on bearing housing by removing the plug. Ronex MP or equivalent in rear bearing.
Grease rear bearing every 400 hours with 50 g (2 oz; 40 pumps) of grease. Do not Do not mix different types of grease or oil.
over-grease.
NOTE: Low-pressure, hand-held grease guns typically deliver approximately 1.25 5.11.2 Maintenance
g/pump (0.05 oz/pump). 5.11.2.1 Rear Bearing Replacement
5.11.1.1 Bearing Housing Oil Change 1. Remove the drive belt, sheaves, and belt guard (see Belt Drive, page 44).
Drain, flush, and replace bearing housing oil after first 500 hours and every 5000 2. Remove rear bearing locking screw and grease extension from bearing housing.
hours thereafter. Place catch pan under bearing housing, remove drain plug from
3. Loosen locknut setscrews on rear bearing cartridge.
bottom of housing, and remove fill plug from top of housing.
4. Prevent shaft from rotating and turn bearing locknut counterclockwise using
soft drift and hammer or chain wrench until assembly becomes completely
CAUTION: Rebuild the entire bearing housing assembly immediately if used
loose.
oil contains metal fragments. Failure to do so will result in additional damage.

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5. Slide bearing cartridge out of housing and off shaft.
6. Clean shaft and housing bore.
NOTE: Do not use oil or grease on shaft or bearing bore to facilitate assembly.
7. Remove factory-supplied grease zerk from new bearing and set aside.
8. Loosen setscrews in locknut of new bearing cartridge and rotate locknut
counterclockwise until one thread remains before sliding bearing on shaft. Do
not remove locknut sleeve assembly from bearing. If this happens, align slot in
sleeve with spline in inner ring bore and reassemble.
9. Align grease port on bearing with grease port in bearing housing and slide
bearing onto shaft and into housing.
10. Align setscrew divot in bearing cartridge with tapped hole. Install and tighten
setscrew to prevent cartridge from moving in housing. When setscrew is tight,
install nylon-insert lock nut onto setscrew and tighten to lock setscrew in place.
11. Tighten adapter assembly. Prevent shaft from rotating. Hand tighten locknut,
then use installation tool or hook-type spanner to bring locknut to snug fit. Figure 5-1: Tightening adapter with opposed spanners.
Snug fit is defined when locknut has been tightened enough to remove
clearance between shaft, adapter sleeve and inner ring. NOTE: If adapter sleeve begins to slip around shaft, retain sleeve using second
hook-type spanner. Engage second spanner into split area of adapter sleeve.
Position wrench in opposing direction of first spanner that is engaged in locknut
(see Figure 5-1). Continue tightening until adapter sleeve no longer slips around
shaft.

Figure 5-2: Marking locknut position
12. Mark position of locknut relative to shaft with grease pencil or dark marker at
top of locknut, sleeve and shaft (see Figure 5-2).
13. Begin to tighten locknut using one of these methods:
• Soft drift pin and hammer
• Chain wrench
14. Tighten locknut clockwise about half a turn. Check visual indicators for any
color change. It is important to check both indicators. If neither indicator shows
any color, continue tightening locknut in 1/8 turn increments while noting
condition of visual indicators.
Figure 5-3: Color change for properly Figure 5-4: Color change for over-
tightened locknut tightened locknut
NOTE: At least one visual indicator should show a color change. It is important to
note that any of the color patterns shown in Figure 5-3 or any patterns in between
are acceptable. The color change in most cases is between the top two pictures.
The indication pattern does not need to be centered and may only show on one
side of the indicator. Only one indicator needs to show color for bearing to be
properly tightened.
15. If both indicators are still clear after tightening one complete turn, continue to
tighten in 1/8-turn increments. Discontinue tightening when at least one
indicator shows a color change or at 1¼ turns.
NOTE: If 1¼ turns is reached and neither indicator shows a color change, dismount
unit. Inspect all parts and clean shaft and housing. Start installation over from
beginning.
16. If the indicator starts to show yellow/red anywhere, mounting has been over-
tightened, see Figure 5-4. To rectify this situation, simply impact locknut
counterclockwise. When adapter assembly becomes completely loose, start
tightening procedure again at step 4.
17. Tighten two setscrews to 20 N-m (15 ft-lb). If a setscrew lines up with slot in
adapter sleeve, tighten locknut clockwise until setscrew clears slot.
59

NOTE: Tightening setscrews in most cases changes eye color and in some cases
removes color. Ignore this change because bearings have been tightened correctly.
18. Align bearing grease port with bearing housing grease port.
5.11.2.2 Front Seal Plate Rebuild
1. Remove all parts from extruder shaft (see Inner Barrel Components page 64
and Outer Barrel Components, page 66).
2. Drain oil from bearing housing (see Lubrication, page 57).
3. Wrap lifting straps around bearing housing and support with a hoist. Do not lift.
WARNING: After the end plate is removed, the shaft will only be supported
by the rear plate and the lifting strap.
4. Detatch front seal plate by removing screws securing it to bearing housing and
screws and washers securing it to bearing housing stand.
5. Remove front plate from bearing housing by using ¾”-10 screws that are at
least 2 inches long and tapped holes in seal plate to push plate away from
bearing housing. In an alternating pattern, turn each screw half a turn. Repeat
until seal plate is disengaged from bearing housing.
CAUTION: Failure to push the seal plate evenly may damage the alignment
pins, the seal plate, and the bearing housing.
6. If alignment pins moved during disassembly, tap them into seal plate until ends
are flush with outside of plate.
7. While front seal plate is off, cover exposed bearing to protect it from dust and
debris.
8. Examine Speedi-Sleeve for wear. Replace if necessary (see Speedi-Sleeve
Replacement, page 62).
9. With raised part of front plate facing up, remove oil seal from seal plate.
10. Remove O-ring from groove in seal plate.
11. Flip front seal plate over and remove second oil seal.
12. Clean plate before installing new seals. A degreasing product may be
necessary.
60
13. Press or gently tap a new seal into front plate, ensuring garter spring side is
facing bearing side of plate. A small amount of grease or oil may be used to
help with installation of seal.
14. After first seal is seated, flip front plate over and install second seal in same
manner. (Both seals should face same direction, with garter springs toward
bearing housing.)
15. Check that garter springs are seated properly in seals.
16. Apply generous amount of grease to new O-ring and install in groove of front
plate.
NOTE: Make sure O-ring is not twisted in groove.
17. Cover key slot with tape to protect new seals from sharp edges.
18. Apply light coating of bearing oil to Speedi-Sleeve and inside of front oil seals.
19. Slide front plate onto shaft and over Speedi-Sleeve.
NOTE: As seal slides onto Speedi-Sleeve, be careful not to roll lip.
20. Apply high-strength (red) thread-locking compound to new screws and attach
seal plate to bearing housing. In an alternating pattern, tighten screws to 180
N-m (132 ft-lb).
21. Re-check seal plate screw torque after 20 minutes.
22. Replace screws and washers that secure seal plate to frame.
23. Refill bearing housing with oil (see Lubrication, page 57).
CAUTION: Refill bearing housing with oil immediately after rebuild.
5.11.2.3 Rear Seal Plate Rebuild
1. Remove extruder drive belt, sheaves, and belt guard (see Belt Drive, page 44).
2. Remove rear bearing locking screw and grease extension from bearing housing.
3. Remove rear bearing (see Rear Bearing Replacement, page 57).
4. Drain oil from bearing housing (see Lubrication, page 57).
5. Remove rear plate screws.
6. Using two rear plate screws, push rear plate out of bearing housing by
alternately turning them into threaded holes on rear plate.
7. Slide rear seal plate off shaft.
8. Clean inside of bearing housing.
9. While rear seal plate is off, make sure to properly cover exposed bearing
housing to protect it from dust and debris.
10. With raised edge of rear seal plate up, remove both oil seals and rear gasket
through the top.
11. Clean rear seal plate.
12. Press or gently tap a new seal into rear plate, ensuring spring side is facing
down. A small amount of grease or oil may be used to help with installation of
seal.
13. After first seal is seated in seal plate, install second seal with spring side facing
up.
14. Install new gasket on rear plate.
NOTE: It is helpful to use spray adhesive to secure gasket during installation.
15. Cover keyway with tape to protect seals from sharp edges.
16. Apply light coating of bearing oil to outside of shaft.
17. Slide rear seal plate onto shaft.
NOTE: As seals slide onto shaft, be careful not to roll lips.
18. Apply high-strength (red) thread locking compound to new screws and attach
seal plate to bearing housing. In an alternating pattern, tighten screws to 180
N-m (132 ft-lb).
19. Install new rear bearing (see Rear Bearing Replacement, page 57).
20. Replace rear bearing locking screw and grease extension on bearing housing.
21. Grease rear bearing (see Lubrication, page 57).
22. Install belt guard, sheaves, and belt (see Belt Drive, page 44).
23. Refill bearing housing with oil (see Lubrication, page 57).
CAUTION: Refill bearing housingwith oil immediately after rebuild.
5.11.2.4 Extruder Shaft Rebuild
Some used shaft components may be reused if they are not damaged or worn.
However, all bolts, bearings, gaskets, O-rings, and oil seals should always be
replaced with new parts whenever the shaft assembly is rebuilt.
1. Support bearing housing and disassemble front seal plate (see Front Seal Plate
Rebuild, page 60).
2. Disassemble rear seal plate (see Rear Seal Plate Rebuild, page 60).
3. Remove all fittings and sight glass from outside of bearing housing.
4. Remove shaft and bearing housing through extruder barrel side of bearing
stand.
5. Press or gently tap shaft out extruder barrel end of bearing housing.
6. Bend tab of lock washer out of notch in lock nut. Remove nut and washer from
shaft.
7. Note orientation of bearings and spacers. Carefully tap or press them off shaft.
8. Clean all parts to be reused with degreaser.
9. Check Speedi-Sleeve condition and replace if needed (see Speedi-Sleeve
Replacement, page 62).
10. Heat bearings in oil to 150°C (300°F) for 20 minutes to expand inner races for
easier assembly onto shaft.
11. Gently slide new bearings and spacers onto shaft, taking care to match
orientation prior to disassembly.
12. Install lock washer and nut. Using spanner, torque lock nut to 375 N-m (275 ft-
lb). Further tighten lock nut until a tang on lock washer aligns with a slot on
lock nut. Bend tang into slot, but do not fold it flat against bottom of slot.
CAUTION: Do not tighten the lock nut using a hammer and punch.
13. Apply light coating of oil to outer races of bearings and gently tap shaft
assembly back into bearing housing.
14. Install shaft and bearing housing assembly into bearing stand.
15. Install sight glass and fittings on bearing housing.
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16. Finish instructions for rear seal plate rebuild (see Rear Seal Plate Rebuild, page 11. Lightly lubricate outside of sleeve with bearing oil.
60). 12. Reinstall the front plate (see Front Seal Plate Rebuild, page 60).
17. Finish instructions for front seal plate rebuild (see Front Seal Plate Rebuild,
page 60).
5.11.2.5 Speedi-Sleeve Replacement
1. Remove front plate from bearing stand (see Front Seal Plate Rebuild, page 60).
2. Mark position of Speedi-Sleeve on shaft.
3. Remove Speedi-Sleeve by applying heat with electric heat blower, which will
expand it enough to let it slide off shaft without causing damage.
NOTE: Alternatively, sleeve can be removed in the following ways, always using
care not to damage shaft surface:
• By relieving press fit tension using small hammer to peen across full width
of sleeve.
• By using cold chisel to cut through sleeve.
• By using pair of wire cutters, starting at or near flange and applying
twisting motion.
4. Clean surface of shaft in area to be sleeved. File down any burrs or rough spots.
5. Shallow wear grooves do not require filling. Optionally, a light layer of Loctite
209 or similar non-hardening sealant can be applied to inside surface of sleeve.
6. If shaft is deeply scored, fill groove with Loctite 66010 or similar powdered
metal epoxy type filler. (Use of adhesive can make future removal of sleeve
more difficult.) Install sleeve before the filler hardens.
7. Place flange end of sleeve onto shaft first.

CAUTION: Use care not to scratch shaft or precision ground sleeve.

8. Use a length of tubing or pipe as an installation tool. Be sure that inside
diameter of pipe is same as that of provided installation tool. Place pipe over
sleeve and gently tap pipe until sleeve is seated on shaft.
9. Remove any sealant or filler from all surfaces outside joint.
10. Remove any burrs from shaft or sleeve.
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5.12 Inner Barrel Components

 Item Part Number Description Qty
1 2000RX-220 Single-flight screw Opt
2 2000R-0200 Screw key 2
3 2000RX-090 Inlet screw 1
4 2000R-0100 Steam lock key Varies
5 2000-07000 Spacer washer Opt
6A 2000-11R00 Steam lock, 5-1/8” Opt
6B 2000-11000 Steam lock, 5-3/8” Opt
6C 2000-06000 Steam lock, 5-1/2” Opt
6D 2000-06X00 Steam lock, 5-9/16” Opt
6E 2000-11RTSP Steam lock, 5-1/8”, TSP Opt
6F 2000-11TSP Steam lock, 5-3/8”, TSP Opt
6G 2000-06TSP Steam lock, 5-1/2”, TSP Opt
7 2000-22000 Double-flight screw Varies
8 (See 6A-6G) Steam lock Opt
9 8000-68000 Retaining key 1
10 2000-62000 Retainer 1
11 2000-63A00 Bullet 1

NOTE: Additional steam locks are available. Sizing varies according to application. Contact Insta-Pro®.

5.12.1 Maintenance
Screws may be reversed (rotated end-for-end), to increase their service life. Screws
of the same design (same part number) may also be shuffled from downstream
(more wear) to upstream (less wear).
NOTE: Insta-Pro recommends reversing and/or shuffling screws every 400-800
hours to obtain maximum useful life of the screws. It is especially important to
rotate the inlet screws, which wear fastest. Exchange screws as follows: among a
group of similarly flighted screws (example: single flight), move the screw furthest
from the inlet end to nearest the inlet end and install it in the reverse orientation.
Move each other screw of that group one position further from the inlet end,
without reversing its orientation. (The screws with the least wear move towards the
discharge end and the worn ends are rotated towards the inlet end.)
NOTE: A screw exhibits wear when the flight edge becomes sharp and the outside
diameter is less than that of a new screw. A screw is worn out when it cannot
maintain the desired operational conditions and produce the desired product any
longer.
NOTE: When using different size steam locks in combination, install steam locks
from smallest diameter near the inlet to largest diameter near the discharge.
NOTE: Single- and double-flight screws are commonly used in combination on the
2000. Other types may be used for special applications.

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5.13 Outer Barrel Components

 Item Part Number Description Qty
1A 2000-10RTT Inlet chamber, top feed 1 Opt
1B 2000-10AR0 Inlet chamber, right side feed 1 Opt
1C 20000-10AL0 Inlet chamber, left side feed 1 Opt
2 8000-57000 Plug 1
3 F516-18-12-SHCS Socket Head Capscrew, 5/16”-18 x ½” Varies
4A 2000-40C00-01 Thermocouple Varies
4B 2000-40D00 Thermocouple cable Varies
5 2000-40C00-02 Adapter Varies
6 2000-21000 Clamp Varies
7 2000-08T00 Compression chamber Varies
8 2000-12000 Wear sleeve Varies
9 F58-11-HXNT Nut, 5/8”-11 Varies
10 F58-FW Flat washer, 5/8” Varies
11 F58-11-4-CB Carriage bolt, 5/8”-11 x 4” Varies
12A 2000-60BLH Nose cone, 5/16” 1 Opt
12B 2000-60LH0 Nose cone, 3/8” 1 Opt
12C 2000-60CLH Nose cone, ½” 1 Opt
12D 2000-60ALH Nose cone, 5/8” 1 Opt
12E 2000-60DLH Nose cone, 15/16” 1 Opt
12F 2000-60ELH Nose cone, 1-1/8” 1 Opt
12G 2000-60TSL Nose cone, TSP 1 Opt
13 2000R-65LH Nose cap 1 Opt
14 F38-16-38-SSSCP Socket Setscrew, 3/8”-16 x 3/8” Varies
15 F58-11-112 Hex Bolt, 5/8”-11 x 1-1/2” 1
16 2000-61000 Lock plug 1 Opt
17 2000-21500 Bolt Assembly Varies

5.13.1 Wear Sleeve Maintenance (more wear) to upstream (less wear). Tighten the setscrews to prevent the sleeves
from rotating.
Worn sleeves may be reversed (rotated end-for-end), if the wear is not centered on
the sleeve, to extend their service life. They may also be shuffled from downstream

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5.13.2 Thermocouple Replacement

Thermocouple
Adapter
Compression chamber

Figure 2-13: Correct installation depth of the thermocouple

5. Hold probe at correct depth and tighten compression nut.

Figure 2-12: Installation of thermocouple in compression chamber

CAUTION: The thermocouple cannot be un-crimped. Make sure the probe is

in the correct position before tightening the compression nut.
1. Remove faulty thermocouple and fitting from compression chamber.
2. Loosen compression nut on new adapter fitting and insert new thermocouple.
Do not tighten nut.
3. Thread adapter into chamber port and tighten.
4. Adjust thermocouple in adapter until probe tip is flush with inside surface of
compression chamber.
 Figure 5-5: Incorrect installation-- tip extends too far into chamber
Figure 5-6: Incorrect installation-- tip does not extend far enough

CAUTION: If the probe extends past the bottom of the chamber groove, it NOTE: If the probe is recessed, product build-up will result in incorrect temperature
will wear prematurely. If it extends past the rifling, the tip will break. readings.

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5.14 Control Panel

 Item Part Number Description Qty
1 (Numerous electrical options available. Contact Insta-Pro®.) Control panel 1
2 2000-SA800-4 Control panel stand 1

NOTE: Electrical schematics and component manuals are located in the control
WARNING: Only qualified electricians may work on the enclosure.
electrical system.

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5.15 Preventive Maintenance Schedule

As needed
As needed

3000h
5000h
3000h
5000h

250h
400h
800h
200h
400h
800h
Check bearing housing oil level Reverse and shuffle extruder worms
Grease rear bearing Replace extruder bearings and seals
Grease feeder bearings Replace feeder screws
Inspect feeder drive, check oil level Build-up chamber wear surfaces
Check drive belt tension Replace wear sleeves
Disassemble and inspect all wetted parts Shift steam locks and spacers
Change feeder gearbox oil Replace extruder worms
Inspect drive belt and sheaves Replace steam locks
Lubricate motor bearings Replace feeder screws
Change bearing housing oil
 Flow surges
Throughput drops

Uneven pellet length

Product does not flow

Discharge temperature is too low

Discharge temperature is too high

Inlet chamber temperature too high

5.16 Troubleshooting

Check condition of ingredients

Increase moinsture / fat content

Decrease moisture / fat content

Check material flow at feeder

Check feed rate

Increase feed rate

Decrease feed rate

Check material flow at preconditioner

Check steam/water supply

Check for extruder drive slip

Check for screw wear

Check for product build-up on screws

Check for steam lock and chamber wear

Increase steam lock diameters

Decrease steam lock diameters

Check for barrel wear

Check for die wear

Check for die blockage

Increase size or quantity of die orifices

Decrease size or quantity of die orifices

Check cutter set-up and blade sharpness

73