TEKNOLINE - Instruction Manual

TEKNOLINE - instruction manual
TEKNOLINE
electronic type
INSTRUCTION MANUAL
to be kept in a safe place for future reference
TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

Tel. +39-02-4886761 R.A. fax +39-02-4882153 P.IVA 10769090159 - E-mail teknoice@teknoice.com
COD. REVISIONE 01 DEL Febbraio 2005
Pag 1
TABLE OF CONTENTS
1 INTRODUCTION pag. 04
1.1 Introduction page 05

1.2 Declaration of conformity page 06
1.3 Warranty page 07
1.4 ID Plate page 08
1.5 Notice form page 09
1.6 Warnings page 10
1.7 Specifications page 11
2 INSTALLATION pag. 12
2.1 Packing and handling pag. 13

2.2 Installation pag. 15
2.3 Electrical Connections pag. 32
2.4 Pneumatic connections pag. 36
2.5 Check points before initial operation pag. 38
3 MACHINE DESCRIPTION pag. 45
3.1 Machine description pag. 46

3.2 Operation pag. 53
3.3 Teknoline 400 controls at operator’s disposal pag. 68
3.4 Surfing trough the touch screene control panel pag. 69

3.5 Main menu pag. 70
3.6 Secondary menus pag. 76
3.7 Setting and timing the station pag. 83
3.8 Teknoline 600 - 800 controls at operator’s disposal pag. 88
3.9 Surfing trough the touch screene control panel pag. 89

3.10 Main menu pag. 90
3.11 Secondary menus pag. 94
3.12 Setting and timing the station pag. 104
4 PRODUCTION pag. 106
4.1 Preliminary Operations pag. 107

4.2 Start up and regulations during production pag. 120
4.3 Production End pag. 129
4.4 Emergency Stop pag. 130

Pag 2
5 CLEANING pag. 131
5.1 CIP Cleaning pag. 132

5.2 Recommended Cleaning Program pag. 137
5.3 Teknoline 400 tray cleaning pag. 138
5.4 Teknoline 600-800 tray cleaning pag. 139
6 MAINTENANCE pag. 141
6.1 Mechanical maintenance pag. 142

6.2 Maintenance of electric system pag. 161
6.3 Maintenance of pneumatic system pag. 162
6.4 Maintenance of refrigeration system pag. 163
7 TROUBLE SHOOTING pag. 164
8 ALARMS / SIGNALLING pag. 168
9 SPARE PARTS pag. 169

Pag 3
1 INTRODUCTION
1.1 INTRODUCTION 05
1.2 DECLARATION OF CONFORMITY 06
1.3 WARRANTY 07
1.4 ID PLATE 08
1.5 NOTICE FORME 09
1.6 WARNINGS 10
1.7 SPECIFICATIONS 11

Pag 4
1.1 Introduction
We thank you for choosing our product.

TEKNOLINE production lines consist of machines designed to provide outstanding performances, built
with first-class materials which are included in the EEC Technical Directives covering food processing
machines. Its production capacity meets the requirements of artisan/industrial ice-cream production.
TEKNO-ICE is committed to the continuous improvement of its products and to conform its production
standards to EEC Machine’s Directive no. 89/392, in order to meet the safety requirements of its
equipment in any duty condition.
TEKNO-ICE wants to keep in close contact with the users of its machinery. Therefore all your questions
or suggestions will be carefully examined and will not remain unanswered.
We are specially interested in the comments of your company’s safety manager and of the representative
of workers’ safety.
TEKNO-ICE will convey the basic information to the operators, during machine commissioning
TEKNO-ICE is also prepared to carry out training courses for the optimum use of its equipments in view
of the European Safety Directives now in force in Italy under Law Decree no. 626/94.
Read attentively the instructions in this booklet before starting the machine.
In case of doubts in understanding these instructions, do not hesitate to contact our representative
before proceeding to operate the equipment. For a proper procedure in handling the information, we
would advise you to use the fax form at page 8.
Your reference for any enquiry is:
TEKNO-ICE srl
via Lazio 37
20090 Buccinasco Milano - Italy
Tel. +39 - 02 - 4886761

Fax +39 - 02 - 4882153
WARNING
Compliance by the user with mentioned ice cream production output, pressure, temperature, and
voltage limits as well as with any other instruction mentioned is indispensable for the proper operation
of the machine and must be complied with by the Customer.
National laws governing the use of electric equipment must be complied with by the installer.
Our company declines any liability for all damages due to improper use of the machine or non-compliance
with the following hazard notices.
NOTES:
1) The machine comes equipped with a kit of emergency spare parts.
2) The data mentioned in this manual may be changed by TEKNO-ICE without notice.
3) The manual includes the instructions covering all the devices fitted on the machine.

Pag 5
1.2 Declaration of Conformity
CE DECLARATION OF CONFORMITY
pursuant Enclosure II,A of CEE Directive 89/392 and subsequent amendments
TEKNO-ICE S.r.l.,
Via Lazio, 37
20090 BUCCINASCO (MI)
herewith declares that
the TEKNOLINE machine ______ serial number _______ subject of this statement
is designed and built in compliance with CEE directive 89/392 and subsequent
amendments (CEE directives 91/368, 93/44, 93/68) and meets the essentials safety
and health requirements of ENCLOSURE I of CEE directive 89/392.(*) Furthermore,
the TEKNOLINE has been manufactured in accordance with the following rules :
CEE 60/204 machinery safety, electric equipment

CEE 89/109 materials expected to come in contact with food
UNI EN 292-1-2 machinery safety, basic design principles, technical specifications
UNI EN 294 safety distance to prevent the access to dangerous areas
UNI EN 349 machinery safety, basic design principles, technical specifictions
D.M. 21/03/73 ministerial decree for materials expected to come in contact with food
DATE
SIGNATURE
____________________ ________________
(*) The regulation enforcing above CEE directives is included in the Decree of the
President of the Republic n.459 of 24th July 1996.

Pag 6
1.3 Warrenty
TEKNO-ICE S.r.l. guarantees the machine:
model: TEKNOLINE _________ Serial No. _______
for a period of twelve months from the shipment date of machine, based on 8 h/day shift.
TEKNO-ICE will replace or repair any part which proves defective during above-mentioned period.
The warranty is limited to the replacement or repair of the defective part, and does not include shipping
nor labour costs.
The warranty for electric components is limited to 6 months from the shipment date of the machine.
The warranty does not cover parts which are normally subject to wear and tear, such as bronze brushes,
ball bearings, gaskets and expendable materials
In case the fault or damage to the machine is due to misuse or tampering of same, or to the intervention
of unauthorized technicians or by the use of non original spare parts, the warranty will not apply.
TEKNO-ICE has no other obligations or liabilities with respect to the foregoing.
For all technical communication with TEKNO-ICE always utilize the notice form at para. 1.5

Pag 7
1.4 ID PLATE
The machine carries an ID plate indicating the basic technical data, such as model, serial number,
voltage, total installed power, frequency, number of phases, type and charge of refrigerant.

Pag 8
1.5 NOTICE FORM
Note: fill in the upper section of this form, then the filled-in form will be used as an original to be
duplicated and utilised for communicating with Tekno-Ice
Messrs. TEKNO-ICE via Lazio 37 - Buccinasco - ITALY FAX +39 - 02 - 4882153
Model: TEKNOLINE _____ Date of supply: __________________
Serial N. __________________ Order N. ______________________
Description of fault :
_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________
______________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
____________________________________________________________________
_____________________________________________________________________
Date of notice : _______________________

Pridution hours accomplished : _________
Signature : ___________________________

Pag 9
1.6 Warnings
1 The personnel operating with the TEKNOLINE production line should be aware of,
and comply with the general safety rules.
2 Non-compliance with said rules may result in injuries and damage to the personnel
and machine.
3 The user must comply with speed, pressure, temperature limits, as well as all the
instructions supplied in this manual in order to keep the machine in proper operating
condition.
4 When installing the machine, the national laws governing the use of machinery
and the environmental conditions should be taken into account.
5 The TEKNOLINE production line is enabled to operate within the following extreme
conditions:
- ambient temperature ranging from 5 °C to 40 °C
- humidity ranging from 20% to 90 %
6 The maintenance must be carried out in compliance with the instructions given in
the relevant chapter of the manual, after disconnecting the machine from the electric
supply. (general switch on OFF) and without compressed air supply (the
compressed air shut-off tap is closed)
7 Any tampering with machine’s safety system shall be at customer’s risk and liability.
8 TEKNO-ICE declines any liability in case above directions are not complied
with.

Pag 10
1.7 Technical specifications
TEKNOLINE unit 400 600 800

Total number of trays *** N° 391 615 781
Hourly output *
Sticks ( 45/50 gr) Pz/h 4000 / 4500 6000 / 6500 7500 / 8000
Ball on cones ( 55/60 gr ) Pz/h 3000 / 3500 4000 / 4500 5000 / 5500
Sandwich ( 45/50 gr ) Pz/h 3000 / 3500 4000 / 4500 5000 / 5500
Log ( 500 gr ) Pz/h 300 / 350 400 / 500 500 / 600
Electric specifications
Standard voltage ** Volt 400 400 400
Standard frequency ** Hz 50 50 50
Total installed power Kw 14.5 15.5 17.5
Main motor Kw 2.2 3 3
Pick-up motor Kw 0.75 0.75 0.75
Dosing trolley motor Kw 1.1 1.1 1.1
Brush motor Kw 0.55 0.55 0.55
Chocolate pump Kw 0.55 0.55 0.55
Chocolate heating elements Kw 3 3 3
Evaporator fans N° 3 3 4
Pneumatic data
Compressed air inlet Pollici 1/2" 1/2" 1/2"
Consumption Nlt/min 1200 1200 1200
Required line pressure Bar 7/8 7/8 7/8
Operatine pressure Bar 6 6 6
NOTE
* The hourly output is based on the standard weight as indicated near the product
** Other voltages and frequencies available upon request
*** Number of trays can vary according to tunnel special version
ATTENTION: This manual applies for the various versions of Teknoline.The purchaser shall refer to
the version he has purchased.

Pag 11
2 INSTALLATION
2.1 PACKING AND HANDLING 13

2.2 INSTALLATION 15
2.3 ELECTRIC CONNECTION 32
2.4 PNEUMATIC CONNECTION 36
2.5 CHECK POINTS BEFORE INITIAL OPERATION 38

Pag 12
2.1 PACKING AND HANDLING
TEKNOLINE production line is packed in several wooden boxes housing the basic machine, work
table, pick-up unit, electric cabinet board, wrapping machine, refrigerating unit, evaporator, trays and
stations. All the boxes can be handled by an ordinary fork lift. The boxes should be opened near the
area where the line will be installed.
Warning: the boxes must be handled by skilled personnel.
First remove the cover and then the side panels. In the box of basic machine you will find a package
containing a kit of standard spare parts, the electric diagram and the instruction manual; store it in a
safe place before continuing to uncrate. Remove the plastic sheet covering the machine and the wood
pieces locking the it to the base of the box. Raise the machine so as to unskid it and locate it in the
expected work place.
Check main components to be intact; in case of damage or of missing components, inform the
insurance company and TEKNO-ICE.
Figure 2.1

Pag 13
Figure 2.2
The boxes can be handled by means of a fork lift: pay attention to the position of the forks which
should be placed as indicated in figure 2.2

Pag 14
2.2 INSTALLATION
First assemble the base in the selected place (the cold room of Tecknoline shall be placed on the
base) locating the components as indicate in figure 2.3. Required screws, nuts and feet are supplied
for assembly. Make sure that a slight slant (3/4 cm) is granted toward the rear part of the base,and
also a slight slant toward the drain water way,to enable the subsequent water drain in the refrigerating
room to be discharged, thus preventing backwater ( figure 2.5A ).
Figure 2.3
Teknoline 400 base
Cross member
Side frame
Adjustable feet
Floor of Teknoline 400 cold room
1 - Drain
2 - Strengthened panels housing the mechanical frame of Teknoline

Pag 15
The base depicted in figure 2.3 is used as a base for the cold room of Teknoline 400 and consists of 5
side frames and three cross members for model 400 and five side frames and four cross members for
model 600 in figure 2.4. The base in figure 2.5 on the contrary serves as a base for the cold room of
Teknoline 800 and consists of 6 side members and eight cross members ( four plus four).
Twenty adjustable feed are to be fixed to the base of model 400; instead for model 600 there are twenty-
five and thirty feed for model 800.
After assembling the base, position the floor panel of the cold room according to the construction
drawing of the cold room itself. Before joining the panels, place the adhesive gaskets along the edges
of the panels, approach one to another at a distance of 1 cm and fill with silicone the gap between the
panels.
Then join the floor panels: by means of a 8 mm Allen wrench tighten the panel hooks following the
correct rotation direction until a locking click can be heard. Complete the operation for all the floor
panels, making sure that panels are perfectly centered with respect to the base below and the drain is
aligned with the line positioning axis. Now remove the silicone in excess from joints.
Teknoline 600 base
Adjustable feet
Cross member
Figure 2.4
Side member

Pag 16
1 - Drain
Teknoline 800 base
Adjustable feet
Cross member
Figure 2.5
Side member

Pag 17
1 - Drain

Pag 18
Figure 2.5A
cold room
± 195 mm
200 mm
base drain
± 197 mm
200 mm
drain

Pag 19
Now position evaporator and mechanic frame on the floor of cold room following the instructions
given in the enclosed drawing, making sure it is aligned with the longitudinal axis.
Figure 2.6 - Teknoline 400

450
1081
1 - Work table
2 - Mechanic frame
3 - Evaporator

Pag 20
450 Figure 2.7 - Teknoline 600
1113
1 - Work table
2 - Mechanic frame
3 - Evaporator
150
743
550 Figure 2.8 - Teknoline 800
1220
1 - Work table
2 - Mechanic frame
3 - Evaporator
953

Pag 21
Figure 2.9
1 - Connection bracket
Once the mechanic frame and evaporator have been positioned, you can complete the assembly of
vertical panels and then ceiling panels. Now assemble steel borders to cover the internal edges of the
floor and plastic borders on the internal edges of ceiling.
Approach the work table of tunnel in front of the cold room following the measures supplied in the
enclosed drawing. Fix the table to the mechanical frame by means of the special connection bracket
(fig. 2.9) and connect the two reduction units inside the tunnel to the angular transmission located
inside the cabinet housing the main motor-drive (fig. 2.10)
The power electric cabinet board should be installed near the cabinet housing the main motor-drive.
The main drive and the electric cabinet board can be installed on the R.H. or L.H. side of the cold room
according to the layout as approved on accepting the order for the machine.
Make sure the Cardan joints are filled with non-freezing grease and then cover them with the special
protection guards.
Join the chain section pertaining the work table to the chain of the mechanic frame by means of the
chain links included in the standard spare part kit, then remove the rod clamping the chain to the
mechanic frame.

Pag 22
1 2 3
Side up
Main motor drive
Figure 2.10
1 Main motor-drive cabinet 6 Support brake for motor-drive

2 Power cabinet board cabinet and electric cabinet
3 Isothermal room 7 Fixing spacer
4 Hole for drive shaft 8 Adjustable foot
5 Bae side memeber 9 Tray flow hole

Pag 23
Figure 2.11
1 2 3 4
1 Main motor-drive cabinet

2 Drive shaft
3 Left side reduction unit inside the cold room
4 Right side reduction unit inside the cold room

Pag 24
Position the cold unit outside (follow the installation instructions on the pertinent manual). It is advisable
to position the refrigerating unit quite close to the cold room to prevent any reduction of the refrigerating
yield through major heat losses or drops in refrigerant flow rae, due to too long piping.
The maximum recommended length for a pining is 15 metres.
Connect the evaporator suction union to evaporator outlet, by means of the copper piping supplied with
the standard kit; also connect the delivery union of refrigerating unit to evaporator inlet ( fig. 2.12).
You should install the expansion valve on the liquid line, near the evaporator. To get the piping inside the
refrigerating room , you shall carry out two holes in the ceiling near evaporator inlet and outlet.
The bulb of expansion valve shall be positioned on an horizontal section of the suction piping, at 1
meter approximately from the exit of the piping itself on the body of the cold room, securely fixed with
the special hose clamps and then insulated together with the suction piping.
You shall also connect the equalizing piping between suction piping and expansion valve; the union on
the suction piping shall be located 15-20 cm after the bulb of the expansion valve.
In Teknoline 400, the piping diameter shall be 22 mm for the delivery line and 67 mm for the suction line,
while in Teknoline 600 piping diameter for the delivery line is 22 mm and 76 mm for the suction line. In
Teknoline 800 the diameter of delivery line is 22 mm and suction line is 89 mm.
Once suction and delivery piping are completed, check for their tightness and then create a hard
vacuum for at least 24 hours. After this you can open the suction valve and the delivery valve of refrigerating
compressor and the liquid line, in order to let the refrigerant contained in the refrigerating unit flow into
the evaporator. Make sure that all the valves are in operating position (open)
Check again for refrigerant leaks in piping and then insulate them properly to prevent any heat loss.
Together with the connections between evaporator and refrigerating unit you should also arrange the
defrost piping (fig. 2.12).
Starting from the union located on the evaporator, install the piping with an upward slant (after making
another hole in the ceiling) to take it out of the cold room, then bend it down to reach a height of 1
meter from the floor. In this position install a 3-way valve, which according to the position, can feed
defrost water to the evaporator, or shut it off and drain at the same time the water left in the vertical
section of piping. Connect the defrost piping to the horizontal union of the 3-way valve, the evaporator
outlet to the top vertical union and the drain to the bottom union.
Also provide a drain for the defrost water coming from the refrigerating room, near the back left-hand
side of the cold unit.

Pag 25
CONNECTION TO FREON PLANT
1 2 3 4 5 6 7 8 9 10 11 12
13
Figure 2.12
1 Cold room
2 Evaporator
3 Defrost water piping
4 Defrost water 3-way valve
5 Expansion valve
6 Expansion valve bulb
7 Equalizing bulb for expansion valve
8 Delivery piping (liquid)
9 Suction piping
10 Refrigerating unit
11 Manual valve for delivery line (liquid)
12 Drain union for defrost water
13 Drain union for defrost water

Pag 26
CONNECTION TO AMMONIA PLANT
In case of an ammonia plant, Tekno-Ice will supply only the evaporator ( pump type ).
For its position inside the cold room refer to instructions at page 18 and 19.
The customer shall provide the required piping for its operation. Here below we give you an example
of actual plant.
We remind that the plant must be a “pump” type
Figure 2.13
1 2 3 4
8 CONNECTIONS TO BE CARRIED OUT BY THE CUSTOMER
SUPPLY FROM TEKNO-ICE
1 Non-return valve
2 Adjustment valve
3 Solenoid valve
4 Tap
5 Return piping (to separator)
6 Feed piping (from pump)
7 Ammonia evaporator
8 Hot gas piping connection

Pag 27
Con tinue the installation of the line by positioning the Pick-up unit on the right-hand side of the work
table according to the drawing. The Pick-up unit can be located in the standard way, “TYPE A”, as in
figure 2.14, in “TYPE B” as in figure 2.15 or in the center, “TYPE C” as depicted in figure 2.16. The
different solution depends on the available room or on the location of other existing lines and is selected
when placing the order of the machine.
Figure 2.14 - Layout "TIPO A" pick-up unit
1 2
1 Work table
2 Pick-up unit ( pick-up area )
3 Pick-up ( product release area)
4 Wrapping machine 5
5 Product take -off belt
3 4
Figure 2.15
Layout "TIPO B" of pick-up unit
1 2
4 3

Pag 28
Figure 2.16 Front layout "TIPO C" of pick-up unit
1 2
3 4 5
1 Work table
2 Pick-up unit ( pick-up area )
3 Pick-up ( product release area)
4 Wrapping machine
5 Product take -off belt

Pag 29
Then place the Pick-up unit in the position as indicated in your solution.
Secure the Pick-up unit to the work table by means of the special fixing bracket.
Now position the product packaging unit, placing it as in Fig. 2.18 near the product release area.
Connect the timing encoders. The products are released directly onto the packaging paper. He wrapping
machine is electronically synchronized with the Pick-up unit and therefore with the main conveyor
chain.
Locate the product take-off belt in front of the Wrapping machine (Fig. 2.14 - 2.15 - 2.16) so that the
packaged products fall on it crosswise, to be then manually picked up and put in cardboard boxes.
Figure 2.17
Pick-up fixing bracket
Clamp on word table

Pag 30
Timing proximity switch
Pick-up unit encoder
Timing proximity switch

Wrapping machine encoder
Figure 2.18
1 Pick-up unit
frame
2 Pick-up pincers
3 Folding box
4 Pick-up unit
frame
5 Wrapping 210
machine

Pag 31
2.3 ELECTRIC CONNECTION
Warning: the electric connection must be

carried out by skilled personnel.
Check that voltage and frequency data on ID plate of

the machines of extrusion line to be the same as
power supply voltage. According to the same data
and the rules in force in the country of installation, 1 Terminals for connection to
work out the cross-section of the supply cable, which mains electric line
in any case can be loaded with a max. of 4 Amperes
per mm2.
Restore the connections between the power cabinet
board X1 and pull boxes, X2 and X3, respectively
located in the raceway located above the work table
and on the cold room ceiling.
After the factory test, all the cables connecting main
electric cabinet to pull boxes, are removed from the
cabinet and folded inside the raceway located above
the work table.
All the wires are numbered to make their connection
in the pull boxes easier.
Take the connection wires from the pull box X3 to
connect the following uses:
evaporator fans
lighting lamps inside the cold room
temperature probe inside the cold room
micro-switch controlling cold room door position
cold room door heating element
In addition it has to be installed on the cold room
roof,the flashing device wich wil go on at every
allarm engaging
Also carry out the connections between the general

cabinet board and the refrigerating unit, both in case
of ammonia plant and freon plant.
Use the wiring diagrams of tunnel and refrigerating Figure 2.19
unit to carry out these connections.
Now connect the electric line to the general cabinet
board X1 and to the cabinet board of the refrigerating
unit.
It is also recommended to install a safety switch near
the above-mentioned cabinet boards in compliance
with the local rules.
From these switches connect the electric wire to the

machines, entering the power electric cabinet boards
through the relevant fair leads. Then connect the three
phases to terminals “R – S – T” (Fig. 2.19) and the
ground wire to the relevant terminals.

Pag 32
1 Cabinet board of Wrapping machine

2 Pick-up Unit
3 Pull box
4 Pull box ( X3 ) ( installed on the top of
cold room )
5 Cabinet board of refrigerating unit board
6 Refrigerating unit
7 Pull box ( X2 )
8 General electric cabinet ( X1)
Figure 2.20

Pag 33
Figure 2.20A
The main motor of the machine is controlled by an
inverter. On the inverter an operator’s panel is fitted,
and inside it the inverter program is stored.
In addition, an instrument for checking the power
supply phases is installed inside the electric cabinet
board. In case in case the supply wires are not
connected as in our factory, the machine will not
run.
The inverter also fulfils the function of checking the

torque exerted by the main motor and therefore of
“safety coupling”. In case, during the operation,
this torque exceeds a preset value for a given
time, it trips by stopping the line. The value is
set in parameter P2174. In case this alarm should
become active, check for a mechanical hindrance
on the line. To make the start easier, after such a
stop, run the line with the jog pushbutton and then
with the start pushbutton.
Do not increase for whatsoever reason the value of

parameter P2174. The factory-set value is 8Nm.
The torque exerted by the motor is displayed on
the advanced operator’s panel (fig. 2.20A pos.3).
This check is also fitted on the inverters controlling
the other work stations.Tampering said
parameter by unauthorized personnel will
1 2 3
cause the forfeiture of any and all warranty
covering the production line. This parameter
can be modified only by a TEKNO-ICE 1 Phase check device
technician or by the customer, with the 2 Main inverter complete with anti-
previous written authorisation by TEKNOICE. jamming filter
The substitution of this part can be done only 3 Advanced operator panel
with an original one. 4 PLC unit
5 Analogical input/out expansion
The production line is fully controlled by a PLC unit. modules
In addition a 56 K modem is installed to enable the 6 Connections of Encoder to work station
Teleservice Maintenance. Therefore when installing 7 Inverter for work station motors
the line also provide a dedicated analogical phone 8 Teleservice communication modem
line for this purpose.

Pag 34
6
7

Pag 35
2.4 PNEUMATIC CONNECTION
Connect the compressed air piping to the inlet union (Fig. 2.21) located on the side of main motor
electric cabinet.
It is recommended to install a manual shut-off valve, on the compressed air line, near the plant.
The line pressure may range from 7 / 8 bar, while the operating pressure is 6 bar; adjust the general
reducer to obtain the above pressure, which can be checked on the pressure-gauge fitted on the
reducer itself.
If the compressed air pressure is less than 4 bar, a safety pressure-switch will shut-off the line.
Figure 2.21
Air inlet union

Pag 36
1 2
1 Air accumulation chamber

2 Air shortage pressure-switch
3 Adjustment of operating pressure
4 Condensation water trap
Figure 2.22
For compressed air consumption and piping size, refer to the specifications given in para.1.7; in any
case the piping size should not be less than the size of air inlet union, nor have restrictions along its
length.
Ensure that the compressed air is free from condensate and oil residuals by using a compressor in
good working order, and providing adequate filtering and condensate drying.

Pag 37
2.5 CHECK POINTS BEFORE INITIAL OPERATION
Before starting the plant it is necessary to check that all the operations can be smoothly performed:
1) Unlock the emergency pushbutton located on the electric cabinet board, by turning it clockwise and
also make sure the emergency systems fitted on the Pick-up unit and Wrapping machine are unlocked.
2) Turn to ‘ON’ main switch of the electric cabinet board.
3) Feed the plant with compressed air by opening the relevant shut-off valve. Check for leaks of
compressed air, and If required, remove them.
4) Check rotation direction of chain by actuating the tray-chain motor with the jog push-button. It
should be as indicated in figure 2.20.
The line is factory-tested, therefore if the tray-chain motor turns correctly also the other motors do
(brush motor, product take-off belt motor and chocolate tank pump).
Make sure that in any case the rotation of above-mentioned motors is as indicated by the arrows
located on them.
Also check the rotation direction of all the evaporator fans to be clockwise, looking at the evaporator
from the front.
Also check the rotation direction of the Wrapping machine, (refer to the relevant manual for installation
and commissioning).
Start the tunnel tray-chain at minimum speed, checking that the chain turns smoothly, then put in
place all the trays on the tray-chain after removing the plastic sheet covering them.
The Pick-up unit pincers are positioned above the trays, therefore pay attention to their height, which
should not collide with the trays.

Pag 38
Flat tray for production of : ice-cream

on stick, truffle, bon-bon and cakes
200-250
Holes for pins of conveyor chain
300
Tray with holes for production of: ball-on-
200-250
cone, ice-cream on stick (possible or not
according to ice-cream product size), russian
type cups filled waffles.
Holes for accommodating waffles
300
Tray with print : for sandwich and half-

sandwich type ice-creams products , ice-
200-250
cream on stick (possible or not

according to the size of the ice-cream
products)
Prints for accommodating waffles
300
Tray with holes and edges:

hardening of comes /cups coming from
200-250
filling machines or ice-creams

wrapped in paper with a max. height
of 100 mm
Conteinement edge
Air holes
Conteinement edge 300

Pag 39
The pneumatically actuated functions, such as stick feeder and hammer, are controlled by the PLC
unit through the data as set in the proper window of the touch screen panel. The encoder located on the
tray-chain drive motor, shows the position of the chain at any time in angular values. The latter also is
a reference for the other work station.
Figure 2.23
1
1 Main motor
2 Encoder connector
3 Main motor encoder
4 Timing proximity switch
5 Datum mark cam

Pag 40
Refer to section “Controls at operator’s disposal” to

Parameter setting menu
get access to this page
By pressing the key concerning a station you move

into the control of same. From it, it is possible to adjust
the start of the operation of the station (cam on) and the
work duration (amplitude)ATTENTION: the operation of
the “electronic cam” controlling the operation time of the
station is different from the generally used methods. In
general we have a start and an end angular position.
Thus, if we should vary the start angular position we
would be forced to vary also the final position to keep
the same work duration.
In this case, on the contrary, once the
start angular position has been set, it
is necessary to input in the ‘amplitude’
box the duration time of the operation.
Thus by varying the start angular
position we will vary he final position
of the operation.
Station parameter menu

90°
AMPLITUDE
START
180° 0°

Pag 41
The movable dispenser slide is electronically synchronized with the tray movement through an encoder
and a timing proximity switch.The dispensing unit for time-dispensed products and the extruder for
horizontally extruded products are secured on the top plate of slide.

Pag 42
The machine requires a “zero point” to start the monitoring of the operation of tray-chain:
1 By means of the jog pushbutton stop the chain with two trays (figure 2.25 pos. 1 and 2) at the
inlet and outlet of the front end of work table aligned and with the trays 3 and 4 as shown in figure
2.25)
2 In the page of “maintenance menu” you should read in the “chain angular position” box an
angular value close to 0 (figure 2.26 pos.1)
3 In main motor drive cabinet the timing proximity switch should start to read the datum mark . If
this should not occur, adjust the adjustment dowel.
4 The proximity switch ( figure 2.28 pos.2 ) which is located in the bottom section of the gear in
front of the work table ( figure 2.28 pos.3 ) should start to read one of the three datum marks of
the cam ( figure 2.28 pos.1 )
Figure 2.26
4 1
3 2
Figure 2.25
Figure 2.27 Figure 2.28
1 2 3

Pag 43
BLANK PAGE

Pag 44
3 MACHINE DESCRIPTION
3.1 MACHINE DESCRIPTION 46

3.2 OPERATION 53
3.3 TEKNOLINE 400 CONTORLS AT OPERATOR' DISPOSAL 68
3.4 SURFING TROUGH THE TOUCH SCREENE CONTROL PANEL 69

3.5 MAIN MENU 70
3.6 SECONDARY MENUS 76
3.7 SETTING AND TIMING THE STATION 83
3.8 TEKNOLINE 600 - 800 CONTROLS AT OPERATOR’S DISPOSAL 88
3.9 SURFING TROUGH THE TOUCH SCREENE CONTROL PANEL 89

3.10 MAIN MENU 90
3.11 SECONDARY MENUS 94
3.12 SETTING AND TIMING THE STATION 104

Pag 45
3.1 MACHINE DESCRIPTION
Teknoline is a line for the production of extruded ice-cream products, supplied complete
with all the essential units, installed on the basic machine, connected one to another
and tested at manufacturer’s factory.
The main units of Teknoline production line are:
- cold room
- mechanic frame with tray-chain, reduction units, tension sliding shoes
- work table with operating stations
- pick-up unit with tub and enrobing chocolate vat
- refrigerating unit
- evaporator with fans
- electric cabinet board
- “touch screen” control panel
- packaging unit with product take-off belt
Figura 3.1
1 Cold room 7 Electric cabinet board

2 Mechanic frame 8 Continuous freezers (optional)
3 Work table 9 Chocolate vat with pump and enrobing tank
4 Pick-up unit 10 Packaging unit
5 Refrigerating unit 11 Conveyor belt for packaged products
6 Evaporator 12 Touch screen control panel

Pag 46
Figure 3.1
12
4 8
10
11

Pag 47
Cold room
It consists of 120 mm thick insulating panels, which is assembled on site following the assembly
instructions. It features a back door for maintenance purpose and two front windows for the entry and
exit of tray-chain.
Mechanic frame
This is the frame supporting the tray-chain and trays, chain tension and drive members, such as
tension sliding shoes and internal reduction units (Figure 3.2 and 3.3)
Figure 3.2
1
3
4
5
6
1 Journal box with ball-bearings

2 Pinion
3 Cardan joint
4 Internal bi-projecting reduction unit
5 Connection shaft
6 Internal reduction unit
Figure 3.3
1 Chain guide
2 Chain tension sliding

shoes
3 Chain

Pag 48
Work table
This is the tunnel section outside the cold room, where the products are dispensed, extruded and
decorated, as well as detached from the trays with the subsequent withdrawal by means of the Pick-
up unit pincers.
In the bottom section of the work table are housed:

- cam and unit for the movement of dispensing slides and horizontal extruder slides
- lubricating unit complete with tray-chain lubricator
- monitoring system for tray-chain wear
In the top section of work table (connection raceway) are housed

- pull box for electric connections
Figure 3.4
- pneumatic valves
1 Set of pneumatic valves

2 Lubricator
3 Chain lubricating nozzle

Pag 49
Pick-up unit
This serves basically to transfer the products from tunnel trays to the Wrapping machine, with
possible enrobing.
The movement of the Pick-up unit is electronically synchronized with the tray-chain by means of an
encoder ad and timing proximity switch.
The main components of the Pick-up unit are: motor and reduction unit, pincer-chain, pick-up
pincers, adjustment unit of pincer pick-up height, chocolate tank and chocolate vat, cam system for
opening and closing the pick-up pincers (Figure 3.6 and Figure 3.6A)
1 Adjustment knob for product

1 pick-up pincers height
2 Pincers height adjustment
cam
3 Pick-up main motor
4 Reduction unit
5 Encoder
2 6 Timing proximity switch
7 Pincers opening cam
Pick-up unit
3 4 5 6
Figure 3.6
Area upriver of products pick-up

Pag 50
Product release area on wrapping machine
Pos. A 1 Pos .B 2 3 4

2 Product release centring cam
3 Pneumatic cylinder
4 Pneumatic cylinder adjustment
5 Pincers opening by-pass cylinder
Gruppo di prelievo
Product by-pass area
Figure 3.6A

Pag 51
When actuating the Pick-up unit (when the wrapping machine is stopped) you will note that the pincers
opening cam of the release area is in position A (Figure 3.6A). The by-pass cam will be in a pincers
opening position. When the wrapping machine will be running and synchronized with the production
line, the release area cam will move automatically to position B (Figure 3.6A) and the by-pass cam will
move upward, thus letting pass the closed pincers. Each time you stop the wrapping machine, the by-
pass cam will start to operate thus preventing products from getting onto the wrapping machine. The
pincers opening cam of the release area will move automatically from position B to position A. Thus the
products still on the pick-up unit between the by-pass area and the wrapping machine will not get on
the wrapping machine itself. The cam in figure 3.6 serves instead to open completely the pincers when
producing ball-on-cones.
Refrigerating unit
It serves to circulate the refrigerant in evaporator, to obtain low temperatures inside the cold room. It
consists basically of an electric motor actuating the compressor, a condenser and an electric cabinet
board with operator panel.
Refer to the enclosed refrigerating unit manual.
Evaporator
It serves to circulate and cool the air inside the cold room.
Il consists of a finned pack of tubes where the refrigerant flows and by a set of fans that cool it, by
circulating air through the evaporator.
A water-cooled defrosting system (upon request) is provided to defrost of evaporator, at the end of
production run.
Electric cabinet board

It includes all the electric equipment, required for line operation.
Touch screen control panel

It includes all controls,required for line operation
Packaging unit
It receives the finished products from the pick-up pincers and wraps them.

Pag 52
3.2 OPERATION
The main function of Teknoline consists of dosing or shaping and then freezing, on special trays, the
ice-cream coming from the continuous freezers to obtain enrobed products on stick, funny faces, ball-
on-cones, and others. These products, after a short time inside the tunnel, will be picked up by the
pincers, in some case enrobed with chocolate and then packaged in a fully automatic way.
The low temperature inside the cold room is kept by means of the refrigerating unit, which feeds the
evaporator. The latter, thanks to the built-in fans, cools the air down to a low temperature and continuously
circulates it, by blowing it on the products to freeze them.
The Teknoline production line enables to obtain several products, which basically can be divided in four
different productions:
- products obtained by vertical extrusion, horizontal cut and stick inserting ( Sticky ice-cream chocolate
covered)
- products obtained by vertical extrusion, horizontal cut and combined with a biscuit (sandwich and
maxibon type half sandwich)
- products obtained by horizontal extrusion and vertical cut (Logs)
- products obtained by time-controlled dispensing (Ball-on-cones)
You can obtain also special products (such as decorated cakes) using 2 or more devices systems.

Pag 53
Production of vertically extruded ice-cream products (enrobed ice-cream on stick, funny faces,
miniatures, sandwich). Besides the basic line components (Figure 3.1) it requires the following devices:
- set of plain trays
- ice-cream cutting drive unit (Figure 3.2) electronically synchronized with tray movement.
- extruder support, fixed above cutting unit
- extruder slide, adjustable in all directions
- extruder complete with device for ice-cream flow adjustment to the various sections of extruder (optional)
- cutting wire bows, electrically heated; the standard cutting system features two wires
- pneumatic stick-dispenser to insert the stick into ice-cream slices; the operation of stick-dispenser
is synchronized with the ice-cream cutting system by means of electronic cams
- pneumatic hammer to detach the products at the cold room exit
- product pick-up pincers with special arms replaceable for picking up different products.
Figure 3.2 1 2 3 4
5 6 7 8
1 Extruder slide 5 Pneumatic hammer

2 Extruder support 6 Cutting drive unit
3 Extruder 7 Ice-cream cutting wire
4 Stick magazine 8 Stick-dispenser

Pag 54
PRODUCTS WITH STICK (enrobed ice-cream on stick /funny faces - 3 pieces per tray)
- products obtained by vertical extrusion, vertical cutting and stick insertion
The ice-cream coming from continuous freezers is sent to the extruder. It flows out of it after taking
shape and dimension from it; the stick is inserted into the ice-cream at the extruder outlet and immediately
after the ice-cream portion is cut, which then falls onto the tray.
With its movement the tray-chain carries the slices inside the cold room where they remain about 15
minutes to freeze. At the cold room exit, the ice-cream is completely frozen, and therefore a slight blow
on the tray will be enough to detach the ice-cream portions. In fact after the pick-up pincers have
seized the product stick, the pneumatic hammer hits the tray thus causing the product to get detached.
The portions seized by the pincers are then lifted from the trays, and if included in the production cycle,
are dipped into the enrobing tank chocolate. Afterwards the products cover a suitable course to enable
the chocolate coating to dry and then are released directly on the packaging paper.
The movements of ice-cream cutting and product pick-up are electronically synchronized. The stick
insertion and the hammer blows are pneumatically actuated and synchronized with other functions by
means of electronic cams.
It is possible to vary the product thickness in two ways: by changing the production speed of the line
or modifying the hourly output of freezers. To reduce the portion thickness you shall therefore increase
the speed of tray-chain or decrease freezers’ speed. Vice-versa, to increase the product thickness you
should reduce the speed of tray-chain or increase freezers’ output.
It is possible to modify the position for stick insertion, by lifting or lowering the Stick-dispenser. Also the
position where the hammer hits can be modified both acting on the stick timing cam and on the
hammer itself.
10
200 / 250
60
34
Figure 3.3

Pag 55
Production of vertically extruded products (sandwich, half-sandwich)

Besides the basic line components, (Figure 3.1) it requires the following equipment:
- set of trays with print
- biscuit dispensing magazine
- biscuit-layer unit
- ice cream cutting unit drive (Fig. 3.3A), electronically synchronized with tray movement
- extruder support, located on top of the cutting unit
- complete extruder.
- cutting wire bows, electrically heated; the standard cutting system has 2 wires
- pneumatic hammer for detaching ice-cream portions at the exit of cold room
- product pick-up pincers with special arms which can be replaced according to various products
Figure 3.3A
1 2 3 4 5 6 7 8 9 10
1 First biscuit dispensing magazine 6 Extruder support

2 Hammer 7 Extruder
3 Biscuit layer drive unit 8 Ice cream cutting wire
4 Cutting drive unit 9 Biscuit layer drive unit
5 Extruder slide 10 Second biscuit dispensing
magazine

Pag 56
PRODUCTS WITHOUT STICK (bricket / sandwich – 3 pieces per tray)

– products obtained by vertical extrusion and horizontal cutting without stick insertion.
The ice-cream coming from the continuous freezers is sent to the extruder, and it will flow out of it after
taking shape and dimensions from it; at the extruder outlet the ice-cream portion is cut. Then, after
cutting, it will fall onto the tray below.
The tray-chain with its movement carries the portions inside the cold room where they will remain about
15 minutes to freeze. At the cold room exit, the ice-cream is completely frozen, and therefore a slight
blow on the tray will be enough to detach the ice-cream portions. In fact, after the pick-up pincers have
seized the product, the pneumatic hammer hits the tray, thus causing the product to get detached. The
portions seized by the pincers are then lifted from the trays, and after a short course are released
directly on the packaging paper.
The biscuits are joined to the ice-cream slice (to obtain a sandwich) on the work table in a fully
automatic way.
Ice-cream cutting Is electronically synchronized, the hammer blows are pneumatically actuated and
synchronized with the other functions thanks to the eletronic cam
Il is possible to modify the product thickness in two ways: by modifying the line production speed or
freezers’ hourly output.
To reduce the thickness of portions you should therefore increase the speed of tray-chain or decrease
freezers’ output. Vice-versa to increase product thickness you shall reduce tray-chain speed of or
increase freezers’ output
200 / 250
Figure 3.3B

Pag 57
Production of horizontally extruded products (Logs, 1 piece per tray)

Besides the basic line components, (Figure 3.1) it requires the following equipment:
- movable extruder slide, electronically synchronized with tray movement
- mechanical cam suitable for the product to be produced (Fig. 2.24)
- extruder with ice-cream decoration device and flow regulating device to the various sections of extruder.
- ice-cream vertical cutting, pneumatically actuated. Its single wire is electrically heated
- hazelnut crumbs dispenser
- pneumatic hammer for detaching ice-cream portions at exit of cold room
Figure 3.4
1 extruder slide
2 pneumatic motor for
decoration pipes
3 extruder for logs
4 decoration pipes
5 vertical cutting wire
2 3

Pag 58
LOGS (one piece per tray)

- products obtained with horizontal extrusion and vertical cutting
The ice-cream coming from the continuous freezers is sent to the extruder. It flows out of it after taking
shape and dimension from it. The slide on which the extruder is installed does not remain still, but
moves rapidly flowing the trays in the same direction. When the slide has completed the forward
movement, the vertical cutting unit and the slide return movement are simultaneously actuated. This
way the cutting of ice-cream portions is clean and the extruder can restart a new cycle on the following
tray.The logs, once they have been cut, lay on the trays below. The log decoration device is housed
above the extruder, and it consists of two properly shaped pipes that are actuated by a pneumatic
motor. Immediately after the log cutting, the hazelnut crumbs dispenser will add on the top an adjustable
hazelnut decoration.
With its movement the tray-chain carries the portions inside the cold room where they stay about 60
minutes to freeze. When it comes out of the cold room, the ice-cream completely frozen, and therefore
a slight blow is enough to get the log detached from the tray. The ice cream portion should to be picked
up by hand, in case it is expected in the production procedure, and taken to the wrapping machine and
then put in boxes.The movement of the extruder slide is electronically synchronized, while the vertical
cutting, hazelnut crumbs dispenser and hammer are pneumatically actuated and synchronized with
the other functions thanks to electronic cams.
Decoration
50 / 60
200 / 250
Hazelnut crumbs
Figure 3.4A
Pag 59
Production of ice-cream products with time-controlled dispensing ( ball-on-cones / truffles ,3

pieces per tray )
Besides the basic line units (Figure 3.1) the following equipment is required:
- set of trays with holes (ball-on-cones)
- movable dispenser slide, electronically synchronized with tray movement
- wafer cone manual loader
- chocolate tank and pump (ball-on-cones)
- two chocolate sprayer ( ball-on-cones)
- ice-cream by-pass valve
- ice-cream dispenser
- product pick-up pincers with special arms (ball-on-cones)
Figure 3.5
1 Ice-cream doser 3 Chocolate sprayers

2 Chocolate tank with pump 4 Trays with holes for
housing wafer
5 Ice-cream by-pass valve

Pag 60
Jam dispenser ( opzional )
1 Jam entry union

2 Station support
2
4 Dispensing valve
5 Injection syringe

Pag 61
BALL-ON-CONES (three pieces per tray with holes)

- products obtained with time-controlled dispensing
the first operation consists of inserting manually the wafer cones into the holes of tray, then the wafer
cones are impermeabilized with chocolate by means of the special sprayers. The chocolate is kept a
constant temperature, usually 36°C, in the special tank and an adjustable quantity of it is sent from
there to the sprayers by a pneumatic pump. Immediately after the impermeabilizing process the ice-
cream is dispensed into the wafer cones. The chocolate sprayers and ice-cream dispensers do not
keep still during the filling, they lower and approach the wafer cones and move, following the movement
of the wafer cones housed in the trays; once the dispensing is completed, the sprayers and dispensers
are lifted back to the start position to carry out a new dispensing cycle. Two sprayers and two dispensers
are usually used to fill two wafer cones at the same time.
After the ball-on-cones are shaped, they enter the cold room to freeze; at the cold room exit they are
picked up by the Pick-up unit pincers and, subsequently, only the portion of ice-cream protruding from
the wafer cone is enrobed. Then the products follow a pre-fixed course to enable the chocolate to dry
and are then released onto the packaging paper.
All the movements, of dispenser slide, products pick-up and release, are electronically synchronized.
While sprayers and dispensers are pneumatically actuated and synchronized with the other functions
thanks to electronic cams.
It is possible to modify the size of ice cream ball on the cone by varying the line production speed or
freezers’ hourly output. To obtain smaller ball-on-cones you should therefore increase the speed of
tray-chain, or reduce freezers’ output. Vice-versa, to increase the size you should reduce the speed of
tray-chain or increase freezers’ output.
10
200 / 250
34
Figure 3.6

Pag 62
TRUFFLES (three pieces per flat tray)

The ice-cream dispensers do not keep still: during the dispensing stage, they lower, approaching the
trays and move, following its movement ; once the dispensing is completed, they are lifted again to the
start position to start a new cycle. Two dispensers, placed horizontally, are used for truffles.
After the products are shaped, they enter the cold room to freeze; at the cold room exit the ice-cream
is completely frozen, therefore a slight blow on the tray of the hammer is enough to get the truffles
detached .Subsequently the product take-off belt will divert the products from the trays and send them
to a connection conveyor belt to the enrobing, if provided, and to packaging area.
The movement of the extruder slide is electronically synchronized: While dispenser opening closing
and lifting, and the pneumatic hammer are pneumatically actuated and synchronized with the other
function thanks to electronic cams.
It is possible to modify the size of products by varying the line production speed or freezers’ hourly
output. To reduce the size of portions you should therefore increase the speed of tray-chain, or reduce
freezers’ output. Vice-versa, to increase the size you should reduce the speed of tray-chain or increase
freezers’ output.
200 / 250

Pag 63
BON BON (nine pieces per flat tray)

The ice-cream dispensers do not keep still: during the dispensing stage, they lower, approaching the
trays and move, following its movement; once the dispensing is completed, they are lifted again to the
start position to start a new cycle. Three dispensers, placed crosswise with respect to trays, are used
for truffles.
After the products are shaped, they enter the cold room to freeze; at the cold room exit the ice-cream
is completely frozen, therefore a slight blow on the tray of the hammer is enough to get the bon bon
detached .Subsequently the product take-off belt will divert the products from the trays and send them
to a connection conveyor belt to the enrobing, if provided, and to packing area.
The movement of the extruder slide is electronically synchronized: While dispenser opening closing
and lifting, and the pneumatic hammer are pneumatically actuated and synchronized with the other
function thanks to electronic cams.
It is possible to modify the size of products by varying the line production speed or freezers’ hourly
output. To reduce the size of portions you should therefore increase the speed of tray-chain, or reduce
freezers’ output. Vice-versa, to increase the size you should reduce the speed of tray-chain or increase
freezers’ output.
200 / 250

Pag 64
Production of ice-cream products with vertical extrusion plus time-controlled dispensing (cakes, 3
pieces per tray)
Besides the basic line units (Figure 3.1) it requires the following equipment:
- ice-cream cutting unit drive, electronically synchronised with tray movement
- support for extruder, fixed on top of cutting unit
- extruder complete with ice-cream flow adjustment device to the various sectors of extruder
- cutting wire bows, electrically heated; the standard cutting unit has two wires
- dispenser slide, mechanically synchronized with tray movement
- jam tank and pump
- ice-cream by-pass valve
- ice-cream dispenser
- pencil filler
- product pick-up unit with special arms

Pag 65
CAKES (3 pieces per flat tray)

- products obtained by vertical extrusion, horizontal cutting plus time-controlled dispensing.
The ice-cream coming from the continuous freezers is sent to the extruder. It flows out of it after taking
shape and dimension from it; at the outlet of the extruder the ice-cream portion is cut. Then it falls on
the tray below. Then the portions are decorated with ice cream dispensed on top. Immediately after ice-
cream decoration, we have jam dispensed in the center of decoration. The ice-cream decoration is
done by means of a time-controlled dispenser, while jam dispensing is carried out with a special
device, called Pencil filler, fed by a pneumatic pump housed in jam tank. The Pencil filler and ice-cream
dispenser do not keep still: during the dispensing, they lower and approach the ice-cream slices, and
move following the movement of the portions positioned on the trays; once the dispensing process is
completed, the Pencil filler and dispenser are lifted again and cover a stretch backward to start a new
cycle.
With its movement the tray-chain carries the ice-cream portions inside the cold room where they stay
about 20 minutes to freeze. When it comes out of the cold room the ice-cream is completely frozen,
and therefore a slight blow of the hammer is enough to detach them. Then, the conveyor belt will divert
the cakes from the trays toward a connection conveyor belt to be put manually in cardboard boxes. The
ice-cream cutting and dispenser slide movement are electronically synchronized. Opening, closing
and lifting of dispenser, jam dispensing and hammer blow are pneumatically actuated and synchronized
with the other functions thanks to electronic cams.
It is possible to modify the portion size by changing line production speed or freezers’ hourly output. To
reduce the size of cakes you should therefore increase the speed of tray-chain, or reduce freezers’
output. Vice-versa, to increase the size you should reduce the speed of the tray-chain or increase the
freezers’ output.
Decoration
First layer
200 / 250

Pag 66
BLANK PAGE

Pag 67
3.3 CONTROLS AT OPERATOR’S DISPOSAL
CONTROL PANEL OF TEKNOLINE 400
5
1
7
2
8
3
9
4
1 Touch screen control panel 5 Machine stop push button

single colored type 6 Jog
2 Machine start push button 7 Power on lamp
3 Reset push button 8 Production/Cleaning selecto
4 Signal lamp for cold room door open 9 Emergency stop push button
It is possible to choose the lenguage before arriving to the "Main menu"

Pag 68
3.4 SURFING THROUGH THE TOUCH SCREEN CONTROL PANEL
Recipe menu Recipe menu Recipe menu
First page of Second page of Third page of

main menu main menu main menu
Parameter Parameter Parameter

setting setting setting
menu menu menu
Maintenance Maintenance Maintenance

menu menu menu
Configuration Configuration Configuration

menu menu menu
Password Password Password

menu menu menu

Pag 69
3.5 MAIN MENU'
On turning on the control pan you can

choose the language. After selecting it by
pressing an area of the operation panel,
you have access to the main menu
consisting of 3 pages. The window is divided
is two sections: one for display (production
speed, products per tray, current recipe,
temperature inside the cold room and
percentage of use of refrigerating
compressor), one for control (by pressing
one key we turn on the relevant station, if
enabled) and one for operating additional
windows (parameter setting, maintenance,
second page of main menu).
First page of main menu

Pag 70
1 2 3 4
10 9 8
The main menu consists of three screens including the main controls:
In the first page there are the controls concerning the stations required for the production of vertically
extruded ice-cream products with stick and vertical cutting.
In the box marked with 1 the name of the current recipe is displayed. By pressing in it you have access
to the recipe page. In box 2 the production speed is displayed and by pressing in it, it is possible to set
production speed expressed in pieces /hour. In box 3 we have the number of pieces per tray. In box 4
the produced pieces are indicated. In box 5 the temperature inside the cold room is displayed in
centigrade degrees and by pressing in it you can set the required operating temperature. In box 6 the
percentage of use of refrigerating compressor is displayed.
All the keys bearing a station name (such as box 7) , if pressed, turn on the relevant station.
Attention: if the key is shaded, it means that it cannot be actuated because it was not activated in the
current recipe. To activate it, follow the instructions at page 75.
If keys 8 – 9 – 10 are instead pressed, you have access to the relevant menu pages

Pag 71
By pressing “MAIN2” of main menu you have

access to the second page of same. Here again
we have a fixed display section (the same as
main menu), one for control (by pressing one key
you turn on the relevant station, if enabled) and
the same section for operating additional
windows.
(parameter setting, maintenance, third page of
main menu)
Second page of main menu

Pag 72
In the second page you find the controls pertaining the stations required for the production of ice-cream
products obtained by time-controlled dispensing.
Attention: if the key is shaded, it means that it cannot be actuated because it was not activated in the
current recipe. To activate it follow the instructions at page 79.

Pag 73
By pressing “MAIN 3” of main menu you have

access to the third page of same. Here again we
have a fixed display section (the same as main
menu), one for control (by pressing one key you
turn on the relevant station, if enabled) and the
same section for operating additional windows.
(parameter setting, maintenance, first page of
main menu)
Third page of main menu

Pag 74
Third page of main menu
In the third page you find the control pertaining the stations required for the production of ice-cream
products on stick by means of the retractable belt and the controls concerning the nitrogen tanks
(required for the production of ice-cream products enrobed with jam, “solero” type.
Attention: if the key is shaded it means that it cannot be actuated because it was not activated in the
current recipe. To activate it follow the instructions at page 75.

Pag 75
3.6 SECONDARY MENUS
Main menu
By pressing in the box near the product name

where the name of the current recipe is
mentioned (f.i. ball-on-cone) you have access
to the recipe operating window
Recipe menu
Pag 76
Recipe menu
1 2
9
4
6 5
Through this menu it is possible to create and transfer recipes. A recipe is the whole of data setting
and the stations required for producing a certain type of product. In box number 2 the name of
the current recipe is displayed. By clicking on box 3 you have access to the list of stored recipes. From
them we can choose the recipe we want to work with and transfer it, i.e. we make it operative. If we
select a recipe but without transferring it, we will note that the data in column 4 and 9 are blinking.
Press key "TEKNO-ICE" it is possible to get back to main menu
Attention: the recipe can be transferred only when the machine is stopped
To create a new recipe click on pushbutton 8 and input the name of the new recipe.
To remove a recipe just select it and then click on push button 9

Pag 77
Main menu
Maintenance menu
From main menu by pressing key

1, “MAINTENANCE” you have
access to the relevant menu, Then
from here, by pressing “CONFIG”,
you go to configuration menu.
Configuration menu

Pag 78
Configuration menu
Through this menu it is possible to enable the stations required for the current recipe. To enable it, it
is necessary just to click on key 1 corresponding to the required station. Thus in the screen of the main
menu, the corresponding station will turn out to be usable and not shaded.Press key "TEKNO-ICE" it
is possible to get back to main menu.

Pag 79
Main menu
From main menu by pressing

“MAINTENANCE” key you have access to
maintenance menu.
Maintenance menu

Pag 80
Maintenance menu
6 5
Through this menu you can set the speed of the machine during cleaning operation and the speed for
jog operation.In addition, by pressing push button 1 you can enable the cleaning brush and tray lubrication.
Each time you carry out the line cleaning operation it is necessary to have access to this menu.
In position 4 the wear percentage of tray-chain is shown.
Tekno-Ice has developed this exclusive method of monitoring the condition of tray-chain.Press key
"TEKNO-ICE" it is possible to get back to main menu.

Pag 81
Configuration menu
By pressing the key "PASSWORD" is

possible to get into menu "PASSWORD"
Five level of users are already set :
level 1 standard user
level 2 working shift in charge
level 3 factory person in charge
The other two level are only for inside use
of TEKNO-ICE.The passwords of level 1 and
2 wil be given during commissioning and
line erecting.
Press key "TEKNO-ICE" it is possible to
get back to main menu.
Menu' password
Password menu

Pag 82
3.7 SETTING AND TIMING THE STATIONS
Main menu
From the main menu by pressing “SET
PARAMETERS” key you have access to the
relevant menu though which you can adjust the
intervention time of the various work stations.

Pag 83
By pressing the key pertaining a

certain station you enter in the control
area of same. From there it is possible
to adjust the start of station
intervention (cam on) and its work
duration (amplitude).
ATTENTION: The operation of the
“electronic cam” controlling the
operation time of the station is different
from the generally used methods. In
general we have a start and an end
angular position. This way, if you
should vary the start angular position
you would be forced to vary also the
final position in order not to modify the
work duration.
In this case, on the contrary, once the
start (beginning) angular position has
been set it is necessary to input in
the “amplitude” box, the duration time
of operation. Thus, by varying the start
angular position you will vary
automatically the final position of the
operation.
90° Station parameter menu

AMPLITUDE
START
180° 0°

Pag 84
By pressing the key pertaining a certain station you enter Parameter setting menu
the control area of same. There are work stations that
instead of an intermittent pneumatic action operate by
tracking in a constant phase the tray-chain: They are:
cutting with horizontal wire, pick-up unit and dispensing
slide.
This means that when varying tray-chain speed, these
stations will automatically adapt their operating speed.
To do this the stations are equipped with an encoder and
a timing proximity switch.
At their start they carry out some revolutions, which are
required to search their position with respect to the tray-
chain (phase search), and then they start to work at the
correct speed.
Moreover, with the dispensing and horizontal wire cutting
slide, their movement is the one of the mechanical cams
installed on above-mentioned stations.
For this reason it is necessary to fit on the dispensing
slide the cam suitable to the production you want to obtain.
Thus, in order to obtain products with time-controlled
dispensing (f.i. ball-on-cone) you shall fit a cam with a
profile different from the one you use to obtain horizontally
extruded products (logs).

Pag 85
TAP VALVE
3
2
7
8
The on examining, for instance, the pick-up page we see:

keys 2 and 3 describe the condition of synchronization of station,
key 4 shows a setting wich the value is a matematic costant to optimjze the sincronizeing work of
machine
key 5 allows to correct the station position in rispect of the trays holding chain,
key 6 is set a value which allows to get a more or less hard correction during the following-up of
station in rispect of the trays holding chain ( level 2 password ),
data shown in keys 7 and 8 are "for reading only" and show the station encoder number of pulses

Pag 86
BLANK PAGE

Pag 87
3.8 CONTROLS AT OPERATOR’S DISPOSAL
CONTROL PANEL OF TEKNOLINE 600-800
2 8
4 5 6 7
1 Touch screen control panel 5 Reset push button

2 Machine start push button 6 Production / cleaning
3 Machine stop push button selector switch
4 Jog 7 Emergency push button
8 Power on lamp

Pag 88
3.9 SURFING TROUGH THE TOUCH SCREEN CONTROL PANEL
Recipe menù Parameter setting menù
Main menù
Configuration menù Inverters menù
Maintenance menù Password menù

Pag 89
3.10 MAIN MENU
The choice of user language is given at the Control panel switching on.Once selected, by touching
the relevant pad on the operator panel, it is possible to get into the main menu.
The various menus are no more monochromatic but are now coloured.The main menu is divided in 5
parts:
the sides ones ( number 1 and 4) houses the controls to manage the working stations
the middle one ( number 2) vary according to the operation which is being carried out
the number 5 houses the touch pads to get into sub-menus
the number 3 is only for visualizing

Pag 90
Main menù
1 2 3 4

Pag 91
1 Evaporator fun ON / Evaporator fun OFF

2 Refrigeration unit ON / Refrigeration unit OFF
3 Pick-up system ON / Pick-up system OFF
4 Pick-up chocolate pump ON / pick-up chocolate pump OFF
5 Pick-up chocolate tank heater ON / pick-up chocolate tank heater OFF
6 Horizontal wire cutting ON / horizontal wire cutting OFF
7 Stick dispencer ON / stick dispencer OFF
8 Product detouching hammer ON / Product detouching hammer OFF
9 Vertical wire cutting ON / vertical wire cutting OFF
10 Nuts dosing unit ON / nuts dosing unit OFF
11 Configuration menù
12 ON = pick-up chocolate pump working OFF=not working
13 Maintenance menù
14 ON = jam pump working OFF=not working
15 Password menù
16 Cutting wire heating percentage
17 Chocolate pick-up tank temperature
18 Jam tank heater working
19 Inverter menù
20 Wire cutting heating ON
21 Chocolate pick-up heater ON
22 Total production
23 Nytrogen tank ON / nytrogen tank OFF
24 Type "twister" estruder ON / OFF
25 Type "viennetta"/"twister" belt conveyor ON / OFF
26 "viennetta" / "twister" belt cycle ON / OFF
27 Chocolate spryer tank ON / OFF
28 Pencil filler dosing station ON / OFF
29 Ice cream dosers ON / OFF
30 Chocolate spray ON / OFF
31 Wafer loading station ON / OF
32 Dosing holder trolley vertical moving ON / OF
33 Dosing holder trolley ON / OF
34 Refrigerating compressor working percentage
35 Product per tray
36 Increases working speed according to value set in box 38
37 Inner cold room temperature
38 Working speed increase – decrease value
39 Working speed
40 Receipt being treated
41 Decreases working speed according to value set in box 38
42 Working station phasing/running data setting access to

Pag 92
Main menù
42 41 40 39 38 37 36 35 34
1
33
2 32
3 31
4 30
5 29
6 28
27
7
26
8
25
9 24
10 23
11 12 13 14 15 16 17 18 19 20 21 22

Pag 93
3.11 SECONDARY MENUS
Main menù
By pressing in the box near the product (pos.
1)name where the name of the current recipe 1
is mentioned (f.i. ball-on-cone) you have
access to the recipe operating window
Recipe menù

Pag 94
Recipe menù
8
1
2
6
3
5
Through this menu it is possible to create and transfer recipes. A recipe is the whole of data setting
and the stations required for producing a certain type of product. In box number 9 the name of
the current recipe is displayed. By clicking on box 8 you have access to the list of stored recipes. From
them we can choose the recipe we want to work with and transfer it, i.e. we make it operative. If we
select a recipe but without transferring it, we will note that the data in column 1 and 2 are blinking.
To transfer the recipe press box 6.Press key "TEKNO-ICE" it is possible to get back to main menu
Attention: the recipe can be transferred only when the machine is stopped
To create a new recipe click on pushbutton 3 and input the name of the new recipe.
To remove a recipe just select it and then click on push button 5
Box 4 shows the correct connection between touch screen panel and PLC unit.The blinking of this box
shows the correct talking between the two device.

Pag 95
Main menù
From main menu,by pressing box 1
"CONFIGURATION MENU" ,it is possible
to get into the relevant menu.
Configuration menù

Pag 96
Configuration menù
6
1 2 3
From this menu it is possible to enable the stations necessary to the recipe being used.To enable them
it is only required to click on the relevant box number 5.In this way on the screen of main menu there will
be shown the relevant station wich can be used and not blank.It also possible to change the working
language by simple pressing on box number 4.By acting on box number 3 it is possible to set day and
hour.
Into box number 2 there will be the name of the installed software.It is possible also to match togheter
one recipe and one product drawing with all its relevant data by pressing box number 1.
By pressing on writing "TEKNO-ICE" it is possible to get back to main menu.

Pag 97
Main menù
"MAINTENANCE MENU" ,it is possible to
get into the relevant menu.
Maintenance menù

Pag 98
Maintenance menù
18 17 16 15
14
13
12
11
1 10
2 9
8
3 7
6
4 5
From this menu it is possible to set the machine speed during washing cycle and the jogging speed.
In addition by pressing boxes 13 and 14,will be enabled the washing brush and chain lubrication devices
In box number 16 is set the value of the temperature underneath wich is not possible carry out the
washing cycle ( password level 2 )
In box 18 is shown the percentage of wearing out of the tray holding chain.
TEKNO-ICE have developped this esclusive system to monitorize the condition of tray holding chain.
There are also shown the controls of lights,heaters and cold room door by-pass.
By pressing on writing "TEKNO-ICE" it is possible to get back to main menu.

Pag 99
Main menù
"INVERTERS MENU" ,it is possible to
Inverters menù

Pag 100
Inverters menù
16 15 14 13 12
3
4
5
6
11
10
7
9
Only skilled operators are allowed to get into this page, from where it is possible to manage all the
line’s inverters:
12 “Viennetta” and “twister” conveyor belt
13 “twister” extruder
14 horizontal cutting device
15 pick-up
16 main chain
Into fields 1-2-3-4-5-6 there are shown indicative parameters showing the functioning mode of inverter
themselves.
To change one parameter act as follows.
1 select the inverter in the field n° 11
2 write into the field n° 7 the new parameter ( i.e. 2174)
3 select into the field n° 8 the type of parameter (i.e. FLOT for parameter 2174) Please refer to
the inverter manual for better and more information)
4 write into the field n° 9 the new value of parameter
5 pres touch pad n° 10 to set the new parameter.

Pag 101
Main menù
"PASSWORD MENU" ,it is possible to
Password menù

Pag 102
Password menù
By pressing the key "PASSWORD" is possible to get into menu "PASSWORD"

Five level of users are already set :
level 1 standard user
level 2 working shift in charge
level 3 factory person in charge
The other two level are only for inside use of TEKNO-ICE.The passwords of level 1 and 2 wil be given
during commissioning and line erecting.
It also shown boxes releting to the touch panel contrast adjustment ( boxes 2 and 3 ) and one box to
calibrate the pressure on box pressing ( box 4 ).By pressing box 1 it is possible to clean the panel itself
without interacting with the various settings.
Press key "TEKNO-ICE" it is possible to get back to main menu.

Pag 103
3.12 SETTINGS AND TIMING STATIONS
By pressing the key "SET" pertaining a certain station you enter in the control area of same. From
there it is possible to adjust the start of station intervention (cam on) and its work duration (amplitude).
ATTENTION: The operation of the “electronic cam” controlling the operation time of the station is
different from the generally used methods. In general we have a start and an end angular position. This
way, if you should vary the start angular position you would be forced to vary also the final position in
order not to modify the work duration.
In this case, on the contrary, once the start (beginning) angular position has been set it is necessary
to input in the “amplitude” box, the duration time of operation. Thus, by varying the start angular
position you will vary automatically the final position of the operation.
1 2
90°
AMPLITUDE
START
180° 0°
270°

Pag 104
By pressing the key pertaining a certain station you enter the control area of same. There are work
stations that instead of an intermittent pneumatic action operate by tracking in a constant phase the
tray-chain.They are: cutting with horizontal wire, pick-up unit and dispensing slide.
This means that when varying tray-chain speed, these stations will automatically adapt their operating
speed. To do this the stations are equipped with an encoder and a timing proximity switch.
At their start they carry out some revolutions, which are required to search their position with respect
to the tray-chain (phase search), and then they start to work at the correct speed.
Moreover, with the dispensing and horizontal wire cutting slide, their movement is the one of the
mechanical cams installed on above-mentioned stations.
For this reason it is necessary to fit on the dispensing slide the cam suitable to the production you
want to obtain. Thus, in order to obtain products with time-controlled dispensing (f.i. ball-on-cone) you
shall fit a cam with a profile different from the one you use to obtain horizontally extruded products
(logs).
Pick-up menù
2
3
4
5
6
Taking as example the pick-up page, we have then:
Pos. 1 shows the mathematic constant which optimises the machine synchronisms
Pos. 2 shows the value which allows to adjust the working station position in respect of the
tray holding chain
Pos. 3 shows the setting of a value which allows to get a more or less drastic correction during
the following up station working in respect of the tray holding chain (level 2 password)
Pos. 4 only reading – shows station encoder pulses
Pos. 5 only reading – shows station encoder pulses
Pos. 6 shows the synchronism state of station

Pag 105
4 PRODUCTION
4.1 PRELIMINARY OPERATIONS 107

4.2 START UP AND REGULATIONS DURING PRODUCTION 120
4.3 PRODUCTION END 129
4.4 EMERGENCY STOP 130

Pag 106
4.1 PRELIMINARY OPERATIONS
Make sure that the trays and all the devices expected to come in contact with the ice-cream have been
thoroughly washed and dried; this applies also to the tray-chain, which even if not directly in contact
with the products, must be cleaned, lubricated and dried (automatically), each time the evaporator is
defrosted.
Make sure that all the connections between the continuous freezers and dispensing / extruding stations,
have been properly carried out, with all the necessary gaskets and unions duly tightened.
In case products have to be enrobed, prepare an adequate quantity of chocolate and start in advance to
heat chocolate vat, so as to have chocolate available at the correct temperature. Connect pump delivery
to the enrobing tank, while the chocolate return takes place by gravity, from the tank to the vat.
Warning: the chocolate vat is suitable just for keeping the chocolate temperature; therefore it should
be fed with chocolate already liquid at the correct temperature.
Turn to “ON” the main switch of the refrigerating unit at least 5 hours before starting the unit itself (it
is advisable to leave the switch always in work position) so that the heating element inside the
compressor sump, can slightly heat up the oil. Make sure that water shut-off valves are in work position.
Make sure that the main switch of Teknoline cabinet board is in ON position, that all emergency
pushbuttons or cables are unlocked, that the power-ON signal lamp is on and that the manual compressed
air shut-off valve is in work position.
Prepare the Wrapping machine for the product you intend to package, turn the main switch to ON
position and turn on the heating of rollers and sealing jaws, (only if the wrapping paper is a hot-seal
type).
Refer anyway to the relevant instructions manual .
Set the correct recipe ( refer page 76 or 104 )
- Vertically extruded products with stick (Enrobed ice-cream on stick - Funny faces ) page 108
- Vertically extruded products without stick ( Sandwich – half-sandwich ) page 112
- Horizontally extruded products (Logs) page 115
- Products obtained by time-controlled dispensing ( Ball-on-cone) page 116
- Products obtained by time-controlled dispensing (Truffles ) page 117
- Products obtained by time-controlled dispensing (Bon-bon ) page 118
- Vertically extruded products with subsequent time-controlled dispensing (Cakes) page 119

Pag 107
Vertically extruded products on stick (Enrobed ice-cream on stick – Funny Faces)

Prepare the line with:
- suitable trays
- extruder for the required production
- suitable stick magazine
- pick-up pincers with arms for sticks
- enrobing tank with chocolate vat (if enrobing is expected)
- folding box of Wrapping machine adjusted for the current product
Enable the ice-cream cutting unit, then start the tray-chain, by means of jog pushbutton and stop with
cutting bows in closed position. Adjust the extruder slide so as to have the cutting wires exactly in the
center of extruder, with a distance between bottom edge and cutting wires equal to 30 mm approx. Also
make sure that the extruder front edge is 60 mm inside the trays (Fig. 4.1)
Still with motionless chain and cutting bows closed, approach the stick-dispenser to the extruder and
adjust the stick-dispenser so that the stick is inserted in the special window machined in the extruder
at a distance of 40 mm (Figure 4.1)
Warning: the cutting bows shall not absolutely hit the stick-dispenser; the latter shall be higher than
the cutting position.
Lock the datum bolt (Figure 4.3), so as to have at all times the same position as the stick-dispenser;
even when changing extruder, height and position of the stick-dispenser shall not be modified, but only
the position of the new extruder shall possibly change, to conform to the stick-dispenser.
Start the tray-chain at minimum speed with the cutting unit turned on and notice the time when the
bows close for the first time on each tray: to get the ice-cream portions fall correctly on the trays
below, the bows should close just after the tray beginning (Figure 4.2)
If the cutting process should not be as above-described, you have to anticipate or delay it, until the
above-mentioned condition is obtained; to change its position, operate in the corresponding configuration
page (Figure 4.5 pos.2).
Figure 4.1
Figure 4.2
10
3
1 2 4
139.5
200 5
40
60 1 Trays
2 L.H. ice-cream cutting bow
3 Extruder
4 R.H. ice-cream cutting bow
5 Tray beginning

Pag 108
After adjusting the cutting position it is advisable to time also the pick-up pincers so that their position
matches the position of products (Figure 4.1); to time the pincers, operate in the corresponding parameter
setting page (Figure 4.5 pos. 1), by anticipating or delaying the pincers.
Position the pneumatic hammer, so that the first blow on each tray takes place only when all the three
pincers, pertaining the same tray, are already closed. Since, otherwise, the products not yet seized by
the pincers, on getting detached from the tray, could move and it would be then impossible for the
pincers to seize a stick that is out of position.
The product release shall occur exactly in the centre of packaging paper .
Check that sealing and cutting of packaged products occurs without hitting the product inside. Otherwise,
i.e, in case the jaws cut the ice-cream or the stick, refer to the manual of the wrapping machine to
modify the position of product inside the paper (advance or delay the paper with respect to product
release)
Figure 4.3
1 Stick-dispenser lock knob
2 Set screw
7 Proximity switch for stick-

dispenser position
Figure 4.4
3 Height- adjusting top ring nut
4 Set knob
5 Set screw
6 Height-adjusting bottom ring

nut

Pag 109
Pick-up unit menu
Figure 4.5
1 Set the correction value

Horizzontal cutting menu

Pag 110
Pick-up menu
Main menu
Horizontal wire cutting menu


Pag 111
Vertically extruded products without sticks ( Sandwich and half-sandwich)

- suitable trays
- biscuit-layer drive unit
- magazines suitable to the required production
- pick-up pincers with arms for products without stick
- folding box of Wrapping machine suitable to the current product
Assemble the first and the second drive unit

by tightening it to its own reduction unit by
means of screw (figure 4.6 pos.3)
1
Figure 4.6
1 Main drive shaft

2 Set screw
3 Reduction unit
2 3

Pag 112
Once it is assembled, the drive unit should be timed with

trays movement and centred with the print on the tray for
biscuit positioning. In addition the biscuit-holding wheels
should be adjusted according to the width of the biscuit to
be produced.
To carry out the timing with respect to the trays, operate
in the corresponding menu page.
To adjust the biscuit-holding wheels according to the width
of same act on the set screw Figure 4.6 A pos.1.
In order to centre the unit on the tray print act on knob in
Figure 4.6A pos.3.
Finally adjust the height of biscuit release by acting on
knob in Fig. 4.6 pos.2
Install the suitable magazines.
1 5
Figure 4.6A
1 Width adjusting block

2 Unit height adjusting knob
3 Unit longitudinal adjusting
knob
4 Set screw of longitudinal
position
5 Biscuit-holding wheel

Pag 113
Enable the ice-cream cutting unit, then start the tray-chain, by means of the jog pushbutton and stop
with the cutting bows in closed position. Adjust the extruder slide so as to have the cutting wires
exactly in the centre of extruder, with a distance between the bottom edge and cutting wires equal to
30 mm approx. Also make sure that the extruder mouth is centred with the print on the trays for biscuit
positioning.
Start the tray-chain at minimum speed with the cutting unit turned on and notice the time when the
bows close for the first time on each tray: to get the ice-cream portions fall correctly on the trays below
the bows should close just after the tray beginning (Figure 4.2)
If the cutting process should not be as above described, you have to anticipate or delay it, until the
above-mentioned condition is met; to change its position, act as depicted in Figure 4.5
Make sure that the drive units for biscuit loading and trays are timed one with another.
It is also advisable to time the pick-up pincers so that their position matches the position of products;
to time the pincers, act as depicted in figure 4.5, by anticipating or delaying the pincers.
Position the pneumatic hammer, so that the first blow on each tray takes place only when all the three
pincers, pertaining the same tray, are already closed. Since, otherwise, the products not yet seized by
the pincers, on getting detached from the tray could move and it would be then impossible for the
pincers to seize a product that is out of position.
The product release shall occur exactly in the centre of packaging paper.

Pag 114
Horizontally extruded products (Logs)

- suitable trays
- hazelnut crumbs dispenser
- product take-off belt
Assemble the extruder on the relevant slide and lock it in place; start the tray-chain at minimum speed
and turn on the horizontal extruder slide. The slide will cover a stretch in the same direction of trays,
then it will rapidly move backward to resume the movement in the same direction of trays. Make sure
that the slide movement, in the direction of trays, starts at the beginning of tray and stops and the end
of tray; otherwise, operate in the corresponding configuration page so that the above-mentioned condition
are obtained.
Using the jog pushbutton, with the extruder slide turned on, stop the tray-chain when the slide is about
to move backward; position the vertical cutting, sliding it along its way near the mouth of the extruder.
Lock the cutting unit and make sure that the cutting bow does not hit against the extruder during the
cutting process.
After adjusting the cutting position it is advisable to position correctly the hazelnut crumbs dispenser,
which should be centred with respect to the extruder; also make sure that hazelnut dispensing starts
and ends at the beginning and at the end of tray.
Then position the hammer.

Pag 115
Products obtained by time-controlled dispensing (Ball-on-cones)

- trays with holes
- sprayers, chocolate tank and pump
- ice-cream dispenser and by-pass valve
- pick-up pincers with arms for cones
- product guides on Pick-up unit
- enrobing tank with chocolate vat
- folding box for Wrapping machine suitable to the current product
Assemble on the work table the chocolate tank with the pneumatic pump, the sprayers and the ice-
cream dispensers with the by-pass valves.
Turn on the tray-chain and start to place manually the wafer cones into the special trays.
Still with the tray-chain at minimum speed, turn on the extruders-holder/lifting slide. The slide lowers,
approaching the trays and covers a stretch in the same direction of trays, then it lifts and moves
backward to start a new cycle. Make sure that the slide movement, in the direction of trays, starts
when the dispensers and sprayers match the tray holes; otherwise, operate in the corresponding
configuration page. Make sure that, when the dispensing process is turned on, the ice-cream dispensers
open when they start moving down and close when lifting.
After this, it is advisable to time also the pick-up pincers so that their position matches the position of
products; to time the pincers, operate in the corresponding configuration page .
For the production of ball-on-cones the pneumatic hammer is not required, since the ice-cream is
contained in wafer cones and is not in contact with the trays. You should fix and then check the proper
working order of the product guides on the Pick-up unit: these are used to keep the ball-on-cones in a
straight position during the pick-up operation and to reverse them and keep them in an upside-down
position during enrobing and the time required for chocolate to dry.
The cones should be released exactly in the centre of the packaging paper.

Pag 116
Products obtained with time-controlled dispensing (Truffles)

- suitable trays
- ice-cream dispensers and by-pass valves
- products take-off coveyor belt
Assemble the ice-cream dispensers on the dispenser slide and the by-pass valves.
Start the tray-chain at minimum speed, then turn on the dispenser-holder/lifting slide; the slide lowers,
approaching the trays and covers a stretch in the same direction of trays, then it lifts and moves
backward to start a new cycle.
To have Truffles correctly dispensed and in the required position, the dispenser should cover a stretch
in the direction of trays at their same speed; this movement should also coincide, every three cycles,
with the center-line of tray; otherwise, operate in the corresponding configuration page.
Also make sure that, when the dispensing process is turned on, the ice-cream dispensers open when
their downward movement is finished and close during the upward movement.
Then position the hammer, so that it hits before the product take-off belt, with the latter positioned to
convey Truffles onto a second connection belt.

Pag 117
Products obtained with time-controlled dispensing (Bon bon)

- suitable trays
- products conveyor belt
Assemble the ice-cream dispensers on the dispenser slide and the by-pass valves.
approaching the trays and covers a stretch in the same direction of the trays, then it lifts and moves
To have Bon-bon correctly dispensed and in the required position, the dispensers should cover a
stretch in the direction of trays at their same speed; this movement should also coincide, every three
cycles, with the center-line of tray; otherwise, operate in the corresponding configuration page.
Also make sure that, when the dispensing process is turned on, the ice-cream dispensers open when
their downward movement is finished and close during the upward movement.
convey the Bon-bon onto a second connection belt.

Pag 118
Vertically extruded products with subsequent time-controlled dispensing (Cakes)

- suitable trays
- jam tank and pump
- pencil filler
- product take-off belt
Enable the ice-cream cutting unit, then start the tray-chain, by means of the jog pushbutton and stop
with cutting bows in closed position. Adjust the extruder slide so as to have the cutting wires exactly
in the center of extruder, with a distance between its bottom edge and the cutting wires equal to 30 mm
approximately. Also make sure that the center line of the extruder matches the center of time-controlled
dispenser, since the latter shall dispense ice-cream on top of the previously extruded and cut slice and
therefore if the center lines do not coincide, the decoration will not be centered with the ice-cream
slice.
Start the tray-chain at minimum speed with the cutting unit turned on and note the time when the bows
close for the first time on each tray: to get the ice-cream portions fall correctly on the trays below, the
bows should close just after the tray beginning (Figure 4.2).
If cutting should not occur as described, you have to advance or delay it, until the above condition is
met; to modify the position , operate in the corresponding configuration page.
Install the ice-cream dispensers and the pencil-filler, on the dispenser-slide and the by-pass valve.
approaching the trays and covers a stretch in the same direction of the trays, then it lifts and moves
To have Cakes correctly decorated and in the required position, the dispenser should cover a stretch in
the direction of trays at their same speed; this movement should also coincide, every three cycles,
with the center-line of tray; otherwise, operate in the corresponding configuration page. Also check the
height of dispenser and pencil filler, whose nozzles should be at 25 mm approx. from trays
Also check that, when the dispensing is turned on, the ice-cream dispenser and the pencil-filler, open
when the downward motion is over and close during the upward movement.
convey Cakes, onto a second connection belt

Pag 119
4.2 START-UP AND REGULATIONS DURING PRODUCTION
Start the tray-chain, evaporator fans and freezing units; to prevent the ice from building up in the
evaporator it is not possible to start the refrigerating units unless the fans are operating. Similarly
it is not possible to start the refrigerating units unless the tray-chain is running; this is done to
prevent the chain from stiffening which might result in a defective operation of same at the start-up.
Make sure that the temperature set on the temperature thermo-regulator of the cold room is the expected
one (usually about - 38/ -40°C), then wait for the set value to be attained.
As already mentioned to start the refrigerating unit you should first start the tray-chain, fans and enable
the start-up of unit
Once the temperature according to the first set value (-38c°) has been attained, you can start the
production run.
Bring the production speed visualized on the touch screen panel at the required value writing it into the
relevant box ( fig.4.7 and fig.4.8 pos.1 ).
Follow the start-up instructions, concerning the various types of production, as mentioned below:
- Vertically extruded products with stick (Enrobed products on stick - Funny faces)- page 121
- Vertically extruded products without stick (Sandwich and half-sandwich) - page 124
- Horizontally extruded products (Logs) - page 125
- Products obtained by time-controlled dispensing ( Ball-on-cone) page 126
- Products obtained by time-controlled dispensing (Truffles , Bon-bon ) page 127
- Vertically extruded product with subsequent time-controlled dispensing (Cakes) page 128
Warning : don’t stop the chain while the tunnel is cooling down, since the same would stop when
restarting. As an exception, only when the temperature is at –30°C you can stop the chain a few
seconds.
TEKNOLINE 400 Main menu TEKNOLINE 600-800 main menu
Figura 4.7 Figura 4.8

Pag 120
- Vertically extruded products with stick (Enrobed ice-cream products – Funny faces)
Once the temperature, that has been set in tunnel cold room, has been attained:
- loosen the knob locking extruder slide and shift the extruder so that it is outside the tray area
- prepare, below the extruder, a container to receive the first batch of ice-cream, coming from the
continuous freezers and flowing from the extruder
- start the continuous freezers and let the ice-cream flow until it has attained the required shape and
hardness
- enable the horizontal ice-cream cutting, wire heating and stick-dispenser by pressing the relevant
push button; wire heating, even if enabled, will be active only when the extruder, in operating position,
excites the relevant sensor. A second sensor starts up the stick-dispenser, only when the latter is in
work position.
- move the extruder back to its work position and lock it with the relevant knob: automatically wire
heating is started up
- adjust the speed of the tray-chain and/ or freezers’ speed, to obtain an ice-cream slice with the
desired size
- adjust the temperature of cutting wire.
- rotate the stick-dispenser, moving it to the work position and lock it with the relevant knob: automatically
the stick-dispenser starts to operate inserting the stick into the ice-cream slice.
- check the stick to be inserted in the centre of the ice-cream portion, otherwise modify the height of
stick-dispenser (Fig. 4.10)
- check the weight of ice-cream portion; if not correct modify the overrun percentage of continuous
freezers
- if the products need to be enrobed, start the pump of chocolate tank
after about 15 – 20 minutes, according to production speed, the first products will come out
- start the pneumatic hammer to detach the products from trays

- check the pincers to seize correctly the sticks, otherwise modify their height and / or position until the
pincers properly seize all the sticks (Figure 4.4 and 4.1)
- in case of product enrobing, adjust tank height, so that the full ice-cream section is enrobed
- when the pincers holding the first products are near the release area, start the Wrapping machine in
automatic mode, start the paper centring system as well (if the machine features this option and the
paper has datum marks)
- once the products are packaged, they are released onto the conveyor belt to be then put manually in
cardboard boxes.
Check during production that the temperature in the cold room is kept at –38° / -40° C; if on the
contrary it tends to rise, for instance up to –35 / -36°C, you might have problems in detaching the
products from trays.
The causes of temperature rise might be:
- output higher than line capacity: decrease production speed
- ice cream of portions with little overrun: increase the overrun percentage in continuous freezers
- iced evaporator: stop the production and defrost
- improper operation of refrigerating unit: see the “refrigerating unit maintenance” section.

Pag 121
Figure 4.10
Top ring nut for height adjustment
Fixing bolt
Set screw
Bottom ring nut for height adjustment
Lock knob for stick-

dispenser
Set screw
Proximity switch for

stick-dispenser position

Pag 122
Figure 4.11
1 Knob for adjusting pincers height in release area

2 Pincer height adjustment cam

Pag 123
Vertically extruded products without stick (Sandwich – half-sandwich - Miniatures)
once the temperature, that has been set in the tunnel cold room, has been attained:
-loosen the knob locking extruder slide and shift the extruder so that it is outside the tray area
continuous freezers and flowing from the extruder
hardness
- enable the horizontal ice-cream cutting and wire heating by means of the relevant push buttons; wire
heating, even if enabled, will be active only when the extruder, in its work position, excites the relevant
sensor.
- enable the first biscuit magazine
- move the extruder back to its work position and lock it with the relevant knob: automatically the wire
heating is started up.
- enable the second biscuit magazine
- adjust the speed of tray-chain and/ or freezer speed, to obtain the ice-cream slice with the desired
size
- adjust the temperature of cutting wire
- check the weight of the portion, if it is not correct then modify the overrun percentage in continuous
freezers.

- check the pincers to seize correctly the sticks, otherwise modify their height and / or position until the
pincers properly seize all the portions (Figure 4.4 and 4.1)- in the case of miniatures, which are not
expected to be seized by the pincers, check the take-off belt to be properly adjusted in height (miniatures
should not pass below it) and to convey properly the products to the connection belt for enrobing and
then put manually in cardboard boxes.
- when the pincers holding the first products are near the release area, start the Wrapping machine in
cardboard boxes.
Check during production that the temperature in the cold room is kept at –38° / -40° C; if on the
The causes of the temperature rise might be:
- ice cream of portions with little overrun: increase the overrun percentage of continuous freezers

Pag 124
Horizontally extruded products ( Logs)
Once the temperature, that has been set in the tunnel cold room, has been attained:
- loosen the knob that locks extruder slide and turn the extruder so that it is outside the tray area
continuous freezers and flowing from extruder
hardness
- enable the horizontal ice-cream cutting, and ice-cream cutting wire heating
- move the extruder back to its work position and lock it with the relevant knob:
- adjust cutting wires temperature to obtain a clean cut
- adjust the speed of tray-chain and/ or freezers’ speed, to obtain the ice-cream slice with the desired
size
- adjust the rotation speed of pneumatic motor in order to obtain the desired decoration
- adjust the pneumatic reduction unit of hazelnut crumbs dispenser in order to obtain the required
dispensed quantity
- check the ice-cream portion weight; if it is not correct modify the overrun percentage in the freezer
continuous
after about 50 – 60 minutes, according to production speed, you will obtain the first products

- check the take-off belt to be properly adjusted in height and to convey correctly the products on the
connection conveyor to be then put manually in cardboard boxes.
Check during production that the temperature inside the cold room is kept at -38° / -40° C; if on the

Pag 125
Products obtained with time-controlled dispensing (Ball-on-cones)
- prepare, below the by-pass-valves, a container to receive the first batch of ice-cream, coming from
the continuous freezers
- start the continuous freezers and let the ice-cream flow until it has attained the required hardness
- enable the dispenser slide, dispenser lifting device and ice-cream dispensing by means of the relevant
push buttons; let the ice-cream flow from the dispensers until it has attained the required hardness
- then start chocolate pump and sprayers
- adjust the speed of tray-chain and / or freezers’ speed, to obtain a cone ball of the required size
- check the weight of portion, if its not correct modify the overrun percentage of continuous freezers.
- adjust pump and sprayers output, to obtain a complete impermeabilization of wafer cones
- if the products are expected to be enrobed, start chocolate vat pump.
- check the pincers to seize correctly the cones (the pincer needles should seize the wafer cones just
below the ball) otherwise modify their height and / or position until the pincers properly seize all the
cones (Figure 4.4 and 4.1)
- in case of product enrobing, adjust tank height, so that the whole ice-cream section is covered
- when the pincers with the first products are near the release area, start the Wrapping machine in
cardboard boxes.
Check, during production, that the temperature inside the cold room is kept between at -38° / -40° C;
if on the contrary it tends to rise, for instance up to –36 / -37°C, you might have problems in detaching
the products from trays.
- improper operation of refrigerating unit: see the “refrigerating unit maintenance” section

Pag 126
Products obtained with time-controlled dispensing (Truffles – Bon-bons)
Once the temperature, that has been set in the cold room, has been attained:
- prepare, below the by-pass-valves, a container to receive the first batch of ice-cream, coming from
the continuous freezers.
- start the continuous freezers and let the ice-cream flow from by-pass valves until it has attained the
required hardness
- enable the dispenser slide, dispenser lifting device and ice-cream dispensing by means of the relevant
box
- remove from trays the first ice-cream batch which is still soft with a plastic spatule
.- adjust the speed of tray-chain and / or freezers’ speed, to obtain products with the required size
- check the portion weight, if it is not correct modify the overrun percentage of continuous freezers.
after about 20 minutes, according to production speed, the first products will come out

- check the take-off belt to be properly adjusted in height (the Bon-bons should not pass below it) and
to convey correctly the products onto the connection conveyor to be enrobed and then put manually in
cardboard boxes.
Check during production that the temperature in the cold room is kept between –38° / -40° C; if on the
contrary, it tends to rise, for instance up to –36 / -37°C, you might have problems in detaching the

Pag 127
Vertically extruded products with subsequent time-controlled dispensing (Cakes)
- loosen the knob locking the extruder slide and shift the extruder so that it is outside the tray area
continuous freezers and flowing from extruder
- prepare, below the by-pass valve, a second container to receive the ice-cream, coming from the
continuous freezers
- start the continuous freezers and let the ice-cream flow from extruder and by-pass valve, until it has
attained the required shape and hardness
- enable the horizontal ice-cream cutting, wire heating by means of the relevant push buttons; the wire
heating, even if enabled, will be active only when the extruder, in operating position, excites the relevant
sensor.
- move the extruder back to its work condition and lock it with the relevant knob: automatically wire
heating is started up
- adjust the speed of tray-chain and/ or freezers’ speed, to obtain an ice-cream slice with the desired
size
- adjust the temperature of cutting wire in order to obtain a clean cut
- enable the dispenser slide, dispensing lifting device and ice-cream dispensing by means of relevant
box on the touch screen; let the ice-cream flow from dispensers until it attains the required hardness
and remove with a plastic spatule from trays the first ice-cream portions which are not properly decorated
due to the still soft ice-cream.
- adjust the speed of the freezer feeding the dispenser to obtain the required decoration
- start the jam pump and pencil filler to obtain the jam dispensed in cake centre; adjust pump output to
obtain the required amount of jam
- check the weight of portion, if not correct, modify the overrun percentage of continuous freezers.
after about 15 - 20 minutes according to production speed, the first products will come out

- check the conveyor belt to be properly adjusted in height and convey correctly the products onto the
connection conveyor to be enrobed, if required, and then put manually in cardboard boxes.
Check during production that the temperature in the cold room is kept between –38° / -40° C; if on the

Pag 128
4.2 END OF PRODUCTION RUN
Vertical extrusion production

To end the production run, first turn off the continuous freezers, immediately after remove the extruder,
turn off the ice-cream cutting device and stick-dispenser; wait for all the products to be out of the cold
room and seized by the pincers or unloaded from the product take-off belt.
Turn off the chocolate pump (if the product is enrobed), pneumatic hammer, refrigerating unit and open
the old room door:
Set tray-chain speed at about 1800 pieces /hour and wait for the temperature inside the cold room to
reach a positive temperature, before carrying out the washing operations.
Horizontal extrusion production

To end the production run, first turn off the continuous freezers, immediately after rotate the extruder so
that it is outside the tray area, then turn off ice-cream cutting device and hazelnut dispenser; wait for
all the products to be out of the cold room and unloaded from the product take-off belt.
Turn off the pneumatic hammer, refrigerating unit and open cold room door:
Increase the tray-chain speed to about 1800 pieces /hour and wait for the temperature inside the cold
room to reach a positive temperature, before carrying out the washing operations.
Time-controlled production
To end the production run. first turn off the continuous freezers, immediately after turn off in sequence:
wafer cones loader, chocolate pump and sprayers, ice-cream-dispenser, ice cream dispenser slide and
lifting device, and, in case it has been used, also the pencil filler; wait for all the products to be out of
the cold room and seized by the pincers or unloaded from the product conveyor belt.
Then turn off the chocolate pump (if the product is enrobed), pneumatic hammer (if used), refrigerating
unit and open the cold room door:
Increase the tray-chain speed to about 60 pieces /minutes and wait for the temperature inside the cold
room to reach a positive temperature, before carrying out the washing operations.

Pag 129
4.5 EMERGENCY STOP
If, for any reason, the immediate stop of a function, a motor or a pneumatic movement were required,
actuate the emergency systems which is closest to you. The emergency pushbuttons are located on
main electric cabinet board, on touch screen control panel and on Pick-up unit.
By actuating the emergencies you immediately stop the electric and pneumatic supply to the whole
line.
Actuating one of the above-mentioned emergency devices, besides stopping the production line, also
the refrigerating unit is turned off; on the contrary by pressing the emergency stop located on the
refrigerating unit, you just turn off the latter, without modifying the operation of other Teknoline units.
To resume the regular operation:
1 reset the actuate the emergency device

2 press the reset key touch screen panel
restart all the functions, as explained in the preliminary operations and start-up section

Pag 130
5 WASHING
5.1 WASHING THE PRODUCTION STATIONS 132

5.2 WASHING TABLE 137
5.3 TEKNOLINE 400 WASHING TRAYS CLEANING 138
5.4 TEKNOLINE 600-800 WASHING TRAYS CLEANING 139

Pag 131
5.1 WASHING THE PRODUCTION STATIONS
Vertical extruder: unlock the extruder by loosening the relevant knob, then pull it out so that it is
outside the tray area; connect the CIP washing system to the freezers and then to the extruder, by
using the same piping used for production. Start the washing plant and prepare the freezers for CIP
washing: the rinsing water and the soda and acid solution, coming from the tub, will be sent to the
freezers and by means of the ice-cream piping, to the extruder, thus washing both of them. The washing
cycle usually includes several steps, which are listed in “Washing Table” section.
Once the CIP washing cycle is completed, it is advisable to circulate a disinfecting solution both in
freezers and in the extruder. Rinse abundantly with water before starting a new production run.
Stick-dispenser: once the production is finished you should empty the stick magazine, rotate the
stick-dispenser to have it outside the tray area and with the tray-chain running, turn on the station.
Wash with lukewarm water to remove the residuals of wood and ice-cream; then dry with compressed
air.
Figure 5.1 – Washing the freezers / piping / vertical extruder
2
1 Washing tub piping
3 2 Extruder
3 CIP washing tub
4 4 Connection piping between
1 freezers and extruder
4 5 Continuous freezers (optio
nal)
5 5

Pag 132
Horizontal extruder: unlock the extruder by loosening the relevant knob, then rotate it so as to place it
outside the tray area; connect the CIP washing system to the freezers and then to the extruder, using
the same piping used for the production. Start the washing plant and prepare the freezers for CIP
washing: the rinsing water and the soda and acid solutions, coming from the tub, will be sent to
freezers and by means of the ice-cream piping, to extruder, thus washing both of them. The washing
cycle usually includes several steps, which are listed in “Washing Table” section.
Once the CIP washing cycle is completed, it is advisable to circulate a disinfecting solution both in
freezers and extruder. Rinse abundantly with water before starting a new production run.
Figure 5.2 - Washing the freezer / piping / horizontal extruder

3
4
2
1
5
1
6 6
1 Piping connecting freezers to extruder

2 Horizontal extruder
3 Knob locking extruder in position
4 CIP washing tub
5 Washing tub
6 Continuous freezers

Pag 133
Horizontal extruder: unlock the extruder by loosening the relevant knob, then rotate it so as to place it
outside the tray area; connect the CIP washing system to the freezers and then to the extruder, using
the same piping used for the production. Start the washing plant and prepare the freezers for CIP
washing: the rinsing water and the soda and acid solutions, coming from the tub, will be sent to
freezers and by means of the ice-cream piping, to extruder, thus washing both of them. The washing
cycle usually includes several steps, which are listed in “Washing Table” section.Once the CIP washing
cycle is completed, it is advisable to circulate a disinfecting solution both in freezers and extruder.
Rinse abundantly with water before starting a new production run.
Figure 5.3 - Ice-cream dispenser
1 - Pneumatic cylinder
2 - Gasket
3 - Shutoff stem guide
4 - Hose-clamp
5 - Gasket
6 - Dispenser body
7 - Shutoff stem
8 - Gasket
9 - Hose-clamp
10 - Gasket
11 - Nozzle
Figure 5.4 - Chocolate sprayer

1 - Sprayer plug
2 - Metal gasket
3 - Shutoff stem spring
4 - Shutoff stem
5 - Shutoff stem guide nut
6 - Chocolate flow regulating valve

7 - Sprayer body
8 - Hollow washer
9 - Air-chocolate mixer
10 - Nozzle
11 - Nozzle ring nut

Pag 134
Tank, pump and chocolate sprayers: drain the chocolate left in the tank, wash the latter manually, then
fill it with lukewarm water and detergent; start the tray-chain with pump and chocolate sprayers in
operation, so as to effect a pre-washing of both components. Then disassemble the above components
for their manual washing. After reassembling pump and chocolate sprayers, fill the tank with a disinfectant
solution and start again the tray-chain with pump and sprayers in operation so as to disinfect them.
Rinse abundantly with water before starting a new production run.
Pencil Filler: remove the jam contained in the tank, wash manually the latter, then fill it with lukewarm
water and detergent; start the tray-chain with pump and Pencil Filler in operation, so as to effect a pre-
washing of both components. Then disassemble the above components for their manual washing. After
reassembling pump and Pencil Filler, fill the tank with a disinfectant solution and start again the tray-
chain with pump and Pencil Filler in operation so as to disinfect them. Rinse abundantly with water
before starting a new production run.
Figure 5.5 - Chocolate pump
2 - Chocolate outlet hose connector
3 - Gasket
4 - Non return valve (delivery)
5 - Pump body
6 - Non return valve (suction)
7 - Gasket
8 - Suction valve seat

Pag 135
Chocolate vat: by turning off the chocolate vat pump, all the chocolate existing in the enrobing tank
returns to the vat by gravity; close the chocolate outlet valve and remove the piping connecting pump
and enrobing tank. Disconnect also the piping connecting the vat and pump and wash manually pump
and piping, cover the vat with its cover and let the chocolate heating turned on, so that the chocolate
left in the vat for the following production run, is kept at the operating temperature, without solidifying.
If, on the contrary, you do not intend to use within short the chocolate vat, empty it and wash it
manually.
Pick-up unit: adjust the tray-chain speed at minimum, and with the help of a soft brush, a warm water
jet (not at high pressure) and non-foamy detergent, wash manually all the pick-up pincers. Then rinse,
and dry with a jet of compressed air.
Wrapping machine: with the tray-chain in operation at minimum speed, also start the wrapping machine
(automatic mode): with the help of a soft brush, a warm water jet (not at high-pressure) and non-foamy
detergent, wash manually all the pockets of pocket-conveyor, overhead chain, lug chain, product
guides and folding box . Then rinse and dry with compressed air.
By means of the jog pushbutton move the seal jaws to a position suitable for cleaning.
Then press wrapping machine emergency pushbutton and turn relevant main switch to “OFF”;
then clean seal jaws by means of a steel brush, so as to remove any paper or stick residual from
the jaws.

Pag 136
5.2 WASHING TABLE
Cleaning steps Min. Temp. °C
1 Pre-cleaning with throw-away water 3/5 15/20
2 Detergent cleaning: 0.5% caustic soda solution

with polyphosphate additives, circulating the solution 10/15 65/70
3 Rinsing with throw-away water 3/5 15/20
4 *Descaling cleaning: solution with citric or acetic

acid with Ph = 3.5 / 4.5. Circulate the solution 5/10 65/70
5 *Final rinsing with throw-away water 3/5 15/20
6 *** Disinfecting solution *** 15/20
* While the first three steps must be carried out each time a production run is completed, the fourth and
the fifth step can be carried out just once in a week.
*** At the end of the cleaning cycle, a disinfecting solution can circulate in freezers and stations. The
solution should be drained and the whole equipment rinsed with clean water, before the following
production run takes place.
The above-mentioned times are approximate and the program is effective from the bacteriological point
of view.
Warning
- Do not use acid or chlorine detergents other than those recommended in the relevant table
- The hydrochloric acid attacks stainless steel and chrome, causing micro-porosities
- Do not utilise temperatures above 90°C
- After sterilising, do not dismantle any part of the machine, to avoid any contamination.
- Weekly dismantle and manually clean the machine and inspect all the parts to prevent any mechanical
and corrosion problem.
- Much attention should be paid in choosing detergents and disinfecting solutions; to concentrations,
temperatures and to the time they remain in contact with the materials the freezer is made of.
- Comply with the directions for use as recommended by the manufacturers of solutions.

Pag 137
5.1 TEKNOLINE 400 TRAYS CLEANING
Once the stations have been washed, the temperature in the cold room has reached positive values
that enable to wash trays and tray-chain. Through the maintenance menu page set tray-chain speed at
1,800 pieces/hour, position the washing station in its operating position (bottom) and fill the tray washing
station hopper with water and non-foamy detergent. Also connect warm water to the station and adjust
its flow so as to wash properly the trays without undesired splashing. Start (again through the maintenance
menu page) the washing brush and the washing and lubricating system of the tray-chain and perform a
complete revolution of chain. After all the trays have been washed, stop the warm water flow and fill the
hopper with a solution of water and disinfectant; perform another complete revolution of tray-chain in
this condition, then turn off washing brush and chain lubrication and move back the washing station to
the rest position (top)
Before starting the following production run, rinse trays with water and then dry them with the relevant
device.
Warning:
- always turn on the chain washing and lubrication device when washing the trays so as to remove the
washing solution or water from the chain
- make sure that the lubricant bowl is not empty and that an oil drop is fed into the compressed air
every 3-5 seconds for chain lubrication.
1 Tray-chain start push button

2 Chain lubrication start
3 Washing brush start
4 Washing speed setting
5 Production/Washing selector switch

Pag 138
5.2 TEKNOLINE 600-800 TRAYS CLEANING
Once the stations washing is carried out, the temperature into the cold room will have positive values
ant it allows the trays and tray holding chain washing.
1 Get into “Maintenance” menu and select the holding chain speed at more / less 1800 p. p. h. .
2 Start the line by pressing the push button n° 1
3 Set the washing station in its working position (lower) and fill in the washing station hopper
with not foamy detergent. In addition connect to the same station hot water and adjust the
flow so that the trays are well washed and undesired drops are spread around.
4 From the same “Maintenance” menu start the rotating brush, the cleaning system and the
chain lubrication system and let the chain turn for a complete revolution.
5 Once all the trays have been cleaned, stop the hot water flowing and fill in the hopper with
water and disinfectant solution let the chain turn for a complete revolution also in this
condition.
6 Stop the rotating brush and lubrication system devices and re-set the washing station in its
rest position (upper)
7 Before starting the next production, rinse the trays with new water and then dry them with the
relevant drying device.
WARNING: the cleaning and lubrication devices must always be “ON” even when the trays are being
washed, in order to take off any possible residual of cleaning detergent or water into the
chain moving parts.check the oil container of the lubricating group is always filled in with
oil and that the lubrication dropping frequency is one drop of oil added to compressed air
every 3-5 seconds,to lubricate the chain.
6 7 8
3 4 5
1 Chain holding trays start push button

2 Production / washing selector
3 Washing speed setting
4 Number of cleaned trays indicator
1 2
5 Number of complete revolution indicator

Pag 139
1
1 Lubrication oil adjustment
2 Lubrication bowl
3 Lubricator window
Figure 5.9
Figure 5.8 - Washing station
Rest position Washing position
1 - Hopper
2 - Warm water inlet

hose connector
3 - Tray drying device

Pag 140
5 MAINTENANCE
6.1 MECHANIC MAINTENANCE 142

6.2 MAINTENANCE OF ELECTRIC SYSTEM 161
6.3 MAINTENANCE OF PNEUMATIC SYSTEM 162
6.4 MAINTENANCE OF REFRIGERATING SYSTEM 163

Pag 141
5.1 MECHANIC MAINTENANCE
Warning: In order to avoid serious hazards to persons and to the machine, we strongly recommend that
maintenance be carried out by qualified personnel only. Before removing the side panels or starting
maintenance operations, press the emergency pushbuttons and cut off the voltage from the machine
by means of the main switch.
For the maintenance of the Wrapping machine refer to the relevant manual.
Basic Machine
Frequency Operation Figure Part Notes
Clean and lubricate tray-chain 6.1 1
200h Clean cold room inside/chain/pinions/chain guides 6.2 1, 2, 3 2
400h Check tray-chain tension 6.3 1,2,3,4,5 3
400h Check oil level in reduction units 6.4 1,2 4
400h Lubricate sliding shoes and journal boxes 6.5 1,2 5
800h Lubrication of Cardan joints 6.4 - 6.6 2-1 7
3000h Replace ball-bearings/ gaskets in sliding shoes 6.9 8
3000h Replace ball-bearings/ gaskets in journal boxes 6.10 8
4000h Replace ball-bearings and oil in reduction units 6.4 4
Notes
1 It must be performed each time trays are washed
2 Do not use high-pressure water-cleaners
3 The distance between sliding shoe rod and spring-guide pad should be 3/4 mm approx. If
bigger, this means that chain is slack and therefore it must be stretched by screwing the
relevant bolts until the above condition is obtained. If on the contrary the distance
between sliding shoe rod and guide-spring pad is less than 2 mm, this means that the
chain is overstretched and therefore it must loosened by unscrewing the relevant bolts.
Then lock the latter by means of relevant nuts after the adjustment is completed.
4 In inside reduction units use oil : Kluber Oil 4 UH1 68 –Mobil SHC 626 – Total SFG0
In the external reduction unit use oil: Kluber /Syntheso D220EP – Esso / Glycolube
Range 220 Fina /Gira S320 – Shell / Tivela oil SC 320
5 Use non-freezing oil only: SKF LGLT2 – 50°C
6 Use only Kluber Oil 4 UH1 68
7 For couplings inside the cold room, use non-freezing grease: SKF LGLT2 – 50°C
8 Lubricate ball-bearings with non-freezing grease before assembling them
* Use non-freezing oil ( SUNISO 3G oil is recommended )
Warning: Non-lubrication of tray-chain will result in an irregular wear of same. In case this defect is
assessed to be due to user’s negligence, then the automatic termination of the warranty for
the whole line will ensue

Pag 142
Figure 6.1A 3/4 mm *
Sliding shoe rod Spring-guide pad
* During the start up please check carefully this distance that must be 3/4 mm.Check again after 15
days of work.

Pag 143
Figure 6.1
1 - Tray-chain lubrication nozzle
Figure 6.2
1 - Tray-chain guide
2 - Chain drive pinion
3 - Tray-chain
Figure 6.3
1 Sliding shoe stretching

bolt
2 Lock nut
3 Spring-guide pad
4 Sliding shoe rod
5 Sliding shoe spring

Pag 144
Figure 6.4
2 - Cardan joints 1 - Lubrificant level window
Figure 6.5
1 - Ball-bearings journal box grease nipples
2 - Sliding shoe grease

nipples

Pag 145
Horizontal ice-cream cutting unit

Replace bow wires 6.12 5 1
200 h Check bow position 6.12 4 2
1000 h Check tension / lubricate chain 6.12 3 3
1000 h Check bow tim ing 6.12 1,2,4,6 4
4000 h Replace bow wheels and guides 6.11 3,4,5,6,7,8 5
4000 h Replace followers / drive cam s 6.11 1,2
Notes
1 It m ust be perform ed when the cutting wires are worn out or anyway in case they are
broken
2 They should close at the centre of extruder without hitting one against the other
3 Rem ove the bolts fixing cutting unit to work table, lift it by tilting backward. Thus you can
check tray tension and if necessary m odify it as well as lubricate it with com m on grease
4 Operation to be perform ed on a cabinet bench: disconnect the proxim ity switch which
enables cutting wires heating and cutting wires, dism antle the cutting unit and lay it on the
bench. Move the cutting coupling until you get the bows perfectly horizontal; the bows
should be closed and centred. Otherwise loosen the two bolts fitted on the cam s and
without m oving the arm s any longer, m ove the bows to a closed position: then lock again
the cut tim ing bolts. The tim ing coupling between the two bows serves to obtain a
perfectly identical m ovem ent of the two bows
5 Operation to be perform ed on a cabinet bench: disconnect the proxim ity switch which
enables the cutting heating and cutting wires, dism antle the cutting unit and lay it on a
bench. Replace followers and cam s, then reassem ble the cutting unit
Figure 6.11 - Ice-cream cutting unit

3 4 4 5
6
1 2
7
1 - Bow drive cam follower

2 - Bow drive cam
3 - Adjustable wheels for vertical slide
4 - Vertical slide guides
5 - Fixed wheels for vertical slide
6 - Fixed wheels for horizontal slides
7 - Guides for horizontal slides
8 - Fixed wheels for horizontal slides

Pag 146
Figure 6.12 - Ice-cream cutting unit
1 2 3 4 5 6 78
1 - Timing coupling for the two bows

2 - Bolts for cutting timing
3 - Chain stretcher
4 - Cutting bows
5 - Ice-cream cutting wire
6 - Cam / bow connection arms
7 - Bow drive cam
8 - Top section of cutting coupling

Pag 147
To obtain a correct ice-cream slice cutting, the bows, thanks to the shape and position of their actuating
cams, should move to the position of their maximum height in a full open condition; then they start the
cutting process involving a descent equal to ice-cream’s from extruder and their simultaneous closing.
The cutting process ends with bows completely closed and rapidly lowering, to get off from the ice-
cream which keeps flowing down from the extruder and then they begin the upstroke with the
simultaneous opening, which brings them back to the initial condition, now ready to repeat another
cutting sequence.
The adjustments of cutting process, which can be obtained by loosening the bolts fixing the bow drive
cams, is crucial to obtain clean cut ice-cream portions without a central crest.

Pag 148
Stick-dispenser
Frequency Operation Figure Part Note
Remove wood dust 6.14 **
2000 h Clean silencers 6.14 1
4000 h Replace silencers 6.14 1
4000 h Replace pneumatic cylinder
Notes
** Operation to be performed at the end of each production cycle
1
Figure 6.14
1 - Pneumatic valve silencers

Pag 149
Pneumatic hammer
4000 h Replace hammer striker 6.15 2 1
4000 h Replace pneumatic cylinder 6.15 1 1
Notes
1 The pneumatic hammer height must be so adjusted that the striker hits the tray just by
inertia. Therefore when the piston is at stroke end, the striker should just rest on the
tray below, without forcing it
Regulator of hammer upward movement speed

Figure 6.15 1
Regulator of hammer downward movement speed
2 Striker

Pag 150
Horizontal extruder / dispenser slides

1000 h Lubricate slide supports 6.17 1 1, 2
1000 h Lubricate bearings of slide supports 6.17 3 1
1000 h Check chain tension and lubrication 6.16 1 1
1000 h Lubricate followers 6.16 2,3 1
6000 h Replace followers 6.16 2,3
6000 h Replace bearings of slide supports 6.17 1,3
Notes
1 Use common grease
2 By means of grease nipples of figure 6.17 part 2

Pag 151
Vertical ice-cram cutting unit

Replace ice-cream cutting wire 6.18 1 1
2000 h Replace wheels for ice-cream cutting wire 6.18 2
6000 h Replace drive followers / cams 6.18 3, 4
Notes:
1 It must be performed when the cutting wire is broken or worn out

Pag 152
Chocolate pump
2000 h Replace gaskets 6.19 4, 7
4000 h Replace ball valves 6.19 5, 6
Figure 6.19
2 - Pump body
3 - Hose connector
4 - O-Ring 2081
5 - 5/8" non return valve
6 - 5/8" non return valve
7 - O-ring 3100
8 - Valve seat

Pag 153
Chocolate sprayers
4000 h Replace shutoff stem spring 6.20 3
4000 h Replace shutoff stem 6.20 4
Figure 6.20
1 - Sprayer plug
2 - Metal gasket
3 - Shutoff stem spring
4 - Shutoff stem
5 - Shutoff guide nut
6 - Chocolate flow adjusting valve
7 - Sprayer body
8 - Hollow washer
9 - Air-chocolate mixer
10 - Nozzle
11 - Nozzle ring nut

Pag 154
Ice-cream dispensers
2000 h Replace gaskets 6.21 2, 5, 8, 10
Figure 6.21
2 - O-ring 3081
3 - Shutoff stem guide
4 - Clamp
5 - O-ring 3118
6 - Dispenser body
7 - Shutoff stem
8 - O-ring 119
9 - Clamp
10 - O-ring 3156
11 - Nozzle

Pag 155
Pencil Filler
4000 h Replace diaphragm of solenoid valve 6.22 1

Pag 156
Product take-off belt

500 h Check belt tension 6.23 1
1000 h Replace belt 6.23 1

Pag 157
Pick-up unit
400 h Wash pincers as detailed at para. 5.1 6.25
400 h Lubricate pincers chain 6.24 1
1000 h Check tension of pincers chain 6.24 1
1000 h Grease Cardan joints 6.24
Notes
1 Use common grease
1 Chain
stretcher
Figure 6.24

Pag 158
Figure 6.25
Stick pick-up arms

Cone pick-up arms
Sandwich pick-up
arms

Pag 159
Chocolate vat
400 h Check water level in jacket 6.26
2000 h Replace chocolate pump rotary packing 6.26
2000 h Replace gaskets 6.27

Pag 160
6.2 MAINTENANCE OF ELECTRIC SYSTEM
The electric system has been designed and built to ensure the best protection to machine components.
The illuminated green pushbutton (Fig.6.33 – part 19) is used to start the tray-chain drive motor, while
the red pushbutton (Fig. 6.33 – part 26) serves to stop said motor. A yellow pushbutton is also installed
(Fig. 6.19 – part 27) for jog running of tray-chain drive motor.
.
Warning: turning on the wire heating is connected to the extruder, it turns on automatically when it is
in work position ( if the relevant selector switch had been previously turned on).
Warning: turning on the stick-dispenser is connected to its position, it turns on automatically when it
is in work position (if the relevant selector switch had been previously turned on).
WARNING:should there be the necessity to reset the PLC,it is imperative to call TEKNO-ICE
before.
6.21 HOW TO REPLACE THE MMC MEMORY CARD INTO CPU SIEMENS
1 Cut the mains feeding at the electrical board by turning the main switch
2 On PLC CPU (first card to left) there is a small push button marked “PUSH”; press it and the
card will come out about 1/8"
3 Take it off and insert the new one in the same way as the ole has come out (the bevel corner in
down position) and then the small push button marked “PUSH” will come out.
4 Turn the main switch “ON”; the system will start automatically the procedure to re-load the
program. At the end there will be “ON” the 2 led marked DC5V and RUN.
6.22 RESET OF PLANNING ON CF-card for TOUCH SCREEN PANEL MODEL TP170
(TEKNOLINE 400) AND MODEL TP270 (TEKNOLINE 600 AND 800)
1 Cut the mains feeding to the touch screen panel

2 Insert the “Memory CF-Card” into its relevant slot of touch screen panel
3 Turn the switch to give mains to the panel
4 For some seconds the system starts an inside auto test; before starting the project routine, it
will appear on screen a window with some key having the following writings:
TRANSFERT
START
CONTROL PANEL
TASK-BAR (only for TP270)
5 Clicking on key “CONTROL PANEL” it automatically activates the sub screen panel in Windows
mode of panel itself.
6 Click 2 times on imagine Backup/Restore (shown by a floppy disc)
7 Click on key Restore and follow / wait the directions shown on video
At the end of this job, even tough the panel allows to take off the “CF-Card”, leave the card itself into
the panel, since it is used also to store the receipts.

Pag 161
6.3 MAINTENANCE OF PENUMATIC SYSTEM
Pneumatic system
1000 h Clean inside the water trap 1
1000 h Check pressure regulator setting 2
1000 h Clean silencers
4000 h Replace silencers
Notes
1 Do not use alcohol or solvents
2 Operating pressure regulator – 6 bar

Pag 162
6.4 MAINTENANCE OF REFRIGERATING SYSTEM
The evaporator of TEKNOLINE line does not require any maintenance, except the defrost operations
to be performed at the end of each production run. Always strictly comply with the routine
maintenance of compressor, as indicated on the relevant manual.

Pag 163
7 TROUBLE SHOOTING
Problem Possible Cause Solution

Power lamp is off defective lamp replace
main switch is OFF turn to ON
emergency device active cut off
Power failure check
Chain drive motor does Lack of compressed air check
not start or stops Tunnel door is open close
Maintenance selectors are on turn off
Thermal relay tripped reset
Inverter alarm is active check for mechanic
problems
It is not possible to Chain drive motor stopped start

change chain drive motor Thermal relay tripped reset
speed check
Tray cleaning brush does Chain drive motor stopped start
not start or stops Thermal relay tripped reset
One or more evaporator Thermal relay tripped reset
fans do not start or stops Emergency device is active turn off
Chocolate pump does Thermal relay tripped reset
not start or stops Emergency device is active turn off
Power cord to chocolate vat not connect
connected
Chocolate heating Thermal relay tripped reset
elements do not start or Emergency device active turn off
stop Power cord to chocolate vat not connect
connected
Refrigerating unit does Chain drive motor stopped start
not start or stops Evaporator fans stopped start
Refrigerating unit selector is not ON turn ON
Main switch of Refrigerating unit is OFF Turn ON
Push button for refrigerating unit start is Turn ON
not ON reset
Refrig. Unit thermal relay tripped check /consult manual of
Refrig. Unit protection tripped Refr. Unit
Tunnel temperature is Refrigerating unit turned OFF start

not correct Refrigerating unit is not regularly check / consult refrig. Unit
operating manual
Wrapping machine does Main motor is stopped start

not start or stops (In For any other possible cause refer to the
automatic mode) relevant manual
Horizontal ice-cream Main motor stopped start

cutting wire does not Extruder not in work position check
heat up Heating element protection tripped reset
Transformer protection tripped reset

Pag 164
Problem Probable Cause Solution

Horizontal ice-cream Main motor stopped start
cutting wire does not Heating element protection tripped reset
heat up Transformer protection tripped reset
Chocolate / jam tank Emergency device active turn off
does not heat up Transformer protection tripped reset
Lack of water in jacket check
Heating element defective replace
Internal lighting does not Lamps burnt-out replace
work Micro-sw. wrong positioned / defective check
Lamp protection tripped reset
Transformer protection tripped reset
Stick-dispenser does not Drive motor stopped start
work Air Shut-off valve closed open
Selector not active turn on
Stick-dispenser not in work position check
Pneumatic valve defective replace
Pneumatic cylinder defective replace
Horizontal ice-cream wire Drive motor stopped start
cutting does not work Selector not active turn on
Chain lubrication does Drive motor stopped start
not work Pneumatic valve defective replace
Lack of oil in bowl check
Regulators set wrong check
Pneumatic hammer does Drive motor stopped start
not work Selector not active turn on
Extruder slide does not programmer signal missing check
work pneumatic valve defective replace
Vertical ice-cream cutting pneumatic valve defective replace
does not work pneumatic cylinder defective replace
Hazelnut dispenser does Drive motor stopped start
not work Pressure regulator set wrong / defective check
Pneumatic actuator defective replace
Products are not properly cutting timing not correct check
arranged on trays cutting wires not heated up check
Cutting bows not properly aligned check
Chocolate sprayer does Drive motor stopped start
not work Selector turned off turn on
Pneumatic regulator set wrong adjust
Dispensers slide does Drive motor does not work Start
not work Pneumatic valve defective Replace
Pneumatic cylinders defective Replace

Pag 165
Problem Probable Cause Solution

Dispensers do not work Drive motor stopped start
Pneumatic cylinders defective replace
Chocolate / jam pump Drive motor stopped start
does not work Pneumatic valve defective replace
Pneumatic regulators set wrong adjust
Pencil filler does not Drive motor stopped start
work Pneumatic valve defective replace
Jam valve dirty / defective clean /replace
Products are not Cutting timing not correct check
properly arranged on Cutting wires not heated up check
trays Cutting bows not aligned check
Products are not seized Pincers not fit for product Check
up by pick up unit Pincers height not adequate Adjust
Products are not frozen, do not detach Adjust tunnel temperature
from trays /production speed
Hammers strike is not correct check
Enrobing with excessive Chocolate too hot/ too cold Adjust temperature
/ little chocolate Chocolate too thick / too liquid Change chocolate
Product is not Chocolate tank too low Adjust
completely enrobed Chocolate level too low Check pump, valve and
chocolate quantity inside the
vat
Chocolate pump works Wrong direction of rotation Check
but the chocolate flow is Low level of chocolate in vat Restore
poor or nil Shut-off valve is closed Open

Pag 166

Pag 167
8 ALARM SIGNAL

Pag 168
9 SPARE PARTS
9.1 STANDARD SPARE PARTS
The machine comes equipped with a kit of standard spare parts. They can be useful for installation,
normal operation of the line or to cope with minor troubles that may occur during the start-up.
The list of spare parts included here below is subject to modifications owing to the constant efforts of
Tekno-Ice to improve their machinery. Therefore it may happen that a discrepancy is found between the
description below and the material actually received.
Kindly note this remark and thanking you for the kind cooperation,
We remain,
Yours faithfully,
Tekno-Ice

Pag 169

Pag 170

Pag 171

Pag 172

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TEKNOLINE - instruction manual

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

1.1 Introduction page 05

2.1 Packing and handling pag. 13

3 MACHINE DESCRIPTION pag. 45

3.1 Machine description pag. 46

3.3 Teknoline 400 controls at operator’s disposal pag. 68

3.4 Surfing trough the touch screene control panel pag. 69

3.8 Teknoline 600 - 800 controls at operator’s disposal pag. 88

3.9 Surfing trough the touch screene control panel pag. 89

4 PRODUCTION pag. 106

4.1 Preliminary Operations pag. 107

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

5 CLEANING pag. 131

5.1 CIP Cleaning pag. 132

6 MAINTENANCE pag. 141

6.1 Mechanical maintenance pag. 142

7 TROUBLE SHOOTING pag. 164

8 ALARMS / SIGNALLING pag. 168

9 SPARE PARTS pag. 169

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

We thank you for choosing our product.

Your reference for any enquiry is:

Tel. +39 - 02 - 4886761

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

1.2 Declaration of Conformity

herewith declares that

CEE 60/204 machinery safety, electric equipment

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

TEKNO-ICE S.r.l. guarantees the machine:

model: TEKNOLINE _________ Serial No. _______

TEKNO-ICE has no other obligations or liabilities with respect to the foregoing.

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

1.5 NOTICE FORM

Messrs. TEKNO-ICE via Lazio 37 - Buccinasco - ITALY FAX +39 - 02 - 4882153

Model: TEKNOLINE _____ Date of supply: __________________

Serial N. __________________ Order N. ______________________

Date of notice : _______________________

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

1.7 Technical specifications

TEKNOLINE unit 400 600 800

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

2.1 PACKING AND HANDLING 13

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

2.1 PACKING AND HANDLING

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

Teknoline 400 base

Floor of Teknoline 400 cold room

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

Teknoline 600 base

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

Floor of Teknoline 600 cold room

Teknoline 800 base

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

Floor of Teknoline 800 cold room

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

Figure 2.6 - Teknoline 400

TEKNO-ICE srl via Lazio n.37 - 20090 Buccinasco Milano - Italy

model: TEKNOLINE ___ Serial No. _

Model: TEKNOLINE _ Date of supply: ______________

Serial N. Order N. ____