XZL Series Simplex Refining Plodder User Manual

XZL Series
Simplex Refining Plodder
User
Manual
Nantong Tongji Co., Ltd
www.tongji-china.com
User Manual – XZL Series Simplex Refining Plodder
0. INTRODUCTION
0.1 SINCERE THANKS
Sincerely thanks for using our machine.

In order to use the machine at its best efficiency and protect the safety of the
machine operators, we suggest you read this machine user manual carefully,
because it will not only enable you to have a better understanding of the machine, but
also guide you to install, test, use and maintain the machine in the correct way, so that
the machine can give the best efficiency, and benefit your company most.
If you have any opinions and suggestions to this machine or you need our service,
please feel free to contact us.
Please communicate with us through following ways:

Add: No 19 Dasheng road, Gangzha District, Nantong Jiangsu, China
Phone: 0086-513-85059019, 0086-513-85059027; Fax: 0086-513-85656922
E-mail: sales@tongji-china.com
0.2 CUSTOMER AND MACHINE INFORMATION
Your information has been registered to our customer information system, as well
as the machine information. Whenever you need help, please provide us with the
following information:
Customer
Machine
Model Number:
Date of Manufacture:
Serial Number:
Power: V Hz Phase Wire
0.3 AIM OF THE USER’S MANUAL
This manual is provided to the customer together with the machine and is aimed
to provide the user with all the information required to:
Help the customer and operators understand the machine.
Inform the machine operator of all the safety precautions to be taken.
Handle the packed and unpacked machine safely.
Nantong Tongji Co., Ltd www.tongji-china.com 2 / 41

Install the machine correctly.

Inform the operator of the machine characteristics and how it works.
Operate the machine safely.
Perform the change-over procedures and maintenance properly and safely.
Know some common knowledge of trouble shooting.
Put the machine out of service safely and in compliance with current
regulations as regards the operators’ health and safety, as well as the
environmental protection.
The customer and the factory manager have the responsibility to carefully read
and understand the instructions contained in this manual as recommended by current
safety regulations. Besides, the machine operators and maintenance people should
also read and understand the parts of this manual dealing with the jobs they have to
perform, and get trained and qualified by the customer before they operate/maintain
this machine.
This manual assumes that current safety rules and sanitary regulations are
observed in the plant where the machine is to be installed. And reading and
understanding this manual will guarantee trouble-free operation and safe working
conditions.
The instructions, illustrations and technical documentation contained here are
the property of Nantong Universal Machinery Co., Ltd and can’t be reproduced or
transmitted in any form.
Furthermore, the customer should be certain that only copies of this manual that
have been updated by the supplier are given to the machine operators.
0.4 HOW TO USE THIS USER’S MANUAL
All pages in this manual are numbered and the page number is indicated at the
right below part of each page. When referring the manual, the user should first review
the TABLE OF CONTENTS to find the related chapter and its start page number, and
then the user can go the page and start to review the detailed information.
If the user can not find the satisfying information or find something wrong, please
communicate with the supplier for clarification before any actions that may cause
danger.
0.5 HOW TO KEEP THIS USER’S MANUAL
One electronic copy and one hard copy of the manual will be provided to the
customer with the machine. The manual should be kept with the utmost care and
accompany the machine wherever and whenever, even when the machine is sold.
The electronic copy of the manual should be kept in the customer computer or a
CD/DVD. The hard copy of the manual should be prevented from any damage or
contamination, such as fire, moisture, oil, etc, and the user should take care of it and
don’t touch it with dirty hands or put it in dirty environment.
Do not change anything of the manual.

TABLE OF CONTENT
0. INTRODUCTION ............................................................................................................................................. 2
0.1 SINCERE THANKS .................................................................................................................................... 2

0.2 CUSTOMER AND MACHINE INFORMATION ....................................................................................... 2
0.3 AIM OF THE USER’S MANUAL............................................................................................................... 2
0.4 HOW TO USE THIS USER’S MANUAL ................................................................................................... 3
0.5 HOW TO KEEP THIS USER’S MANUAL ................................................................................................. 3
1. GENERAL INFORMATION ........................................................................................................................... 6
1.1 MACHINE IDENTIFICATION ................................................................................................................... 6

1.2 AFTER SALES SERVICE ........................................................................................................................... 6
1.3 SAFETY RULES ......................................................................................................................................... 7
1.4 MACHINE SAFETY MEASURES ............................................................................................................. 8
1.5 LABELS ON MACHINE............................................................................................................................. 9
1.6 WARNING OVER RESPONSIBILITY....................................................................................................... 9
2. TRANSPORTATION AND STORAGE ....................................................................................................... 10
2.1 MACHINE DISASSEMBLY BEFORE PACKING ................................................................................... 10

2.2 MACHINE DOWNLOADING .................................................................................................................. 10
2.3 MACHINE STORAGE .............................................................................................................................. 10
2.4 MACHINE UNPACKING ......................................................................................................................... 11
2.5 CHECKING AFTER UNPACKING .......................................................................................................... 11
3. TECHNICAL SPECIFICATION ................................................................................................................... 12
3.1 MACHINE FUNCTION ............................................................................................................................ 12

3.2 MODLE SELECTON ................................................................................................................................ 12
3.3 PRODUCTS ............................................................................................................................................... 13
3.4 MACHINE CHARACTERISTICS ............................................................................................................ 13
3.5 TECHNICAL PARAMETERS ................................................................................................................... 13
3.6 MACHINE MAIN PARTS INTRODUCTION .......................................................................................... 13
3.7 SPECIAL CONFIGURATION ................................................................................................................... 18
4. INSTALLATION ............................................................................................................................................. 20
4.1 MECHANICAL INSTALLATION ............................................................................................................ 20

4.2 ELECTRICAL INSTALLATION............................................................................................................... 21
4.3 OIL AND LUBRICANT ............................................................................................................................ 22
4.4 CHILING WATER CONNECTION........................................................................................................... 22
4.5 CHECKLIST AFTER INSTALLATION.................................................................................................... 22
5 CONTROL AND OPERATON ...................................................................................................................... 23
5.1 POWER ON AND OFF.............................................................................................................................. 23

5.2 CHILLING WATER ................................................................................................................................... 23
5.3 CONTROL BUTTONS .............................................................................................................................. 23
5.4 SPEED ADJUSTMENT ............................................................................................................................. 24

5.5 ELECTRICAL DRAWING ........................................................................................................................ 24
6 MACHINE START UP ................................................................................................................................... 25
6.1 CHECK THE INFEED CONVEYOR AND RECYLE CONVEYOR ....................................................... 25

6.2 CLEANING................................................................................................................................................ 25
6.3 PREPARATION ......................................................................................................................................... 25
6.4 MACHINE SETTING ................................................................................................................................ 25
6.5 CHILLING WATER ON ............................................................................................................................ 25
6.6 POWER ON ............................................................................................................................................... 26
6.7 JOG RUN AND FUNCTION CHECK ...................................................................................................... 26
6.8 DRY RUN .................................................................................................................................................. 27
6.9 PRODUCT RUN ........................................................................................................................................ 27
7 CHANGE-OVER AND TROUBLE SHOOTING ......................................................................................... 29
7.1 LINE CHANGE-OVER ............................................................................................................................. 29

7.2 PULL OUT THE WORM ........................................................................................................................... 29
7.3 MACHINE STOP FOR THE NIGHT ........................................................................................................ 29
7.4 TROUBLE SHOOTING ............................................................................................................................ 29
7.6 ISSUES AND SOLUTION ........................................................................................................................ 30
7.7 BIG ISSUE AND SOLUTION ................................................................................................................... 31
8 MAINTENANCE ............................................................................................................................................. 32
8.1 SAFETY RULES DURING MAINTENANCE ......................................................................................... 32

8.2 MAINTENANCE TOOLS LIST ................................................................................................................ 32
8.3 CLEANING................................................................................................................................................ 34
8.4 CHECK ...................................................................................................................................................... 34
8.5 LUBRICATION ......................................................................................................................................... 36
9 ANNEX ............................................................................................................................................................. 37
9.1 NOISE LEVEL........................................................................................................................................... 37

9.2 OPERATING LIFE AND ABANDONMENT ANNOUNCEMENT ......................................................... 37
9.3 FREE TOOLS AND SPARE PARTS ......................................................................................................... 38
9.4 HOW TO ORDER SPARE PARTS ............................................................................................................ 38
10 OPERATION SOP ........................................................................................................................................ 40

1. GENERAL INFORMATION
1.1 MACHINE IDENTIFICATION
There is one nameplate located on the machine, as per the indication below:
Machine name and model
Machine size
Machine weight
Power supply
Serial number and date of manufacture
Company name and address
1.2 AFTER SALES SERVICE
After the machine has passed the acceptance test in our company, it will be
transported to the customer’s specified place.
Our company will appoint technical support engineers to the customer’s factory
for machine test work. The test time will be negotiated and decided by the customer’s
needs.
The customer will be in charge of all of the fee of transportation, hotels, 3 meals
per day, as well as the technical support fee.
The machine guarantee period is 1 year. Within the guarantee period, it the
machine has any quality problem, our company will replace the broken parts with new
ones for free. If the machine has big problem and our engineers are needed for site
support, the customer will be in charge transportation, hotels, 3 meals per day,
without any technical support fee.
After the guarantee period, it the machine has any quality problem, our company
will replace the broken parts with new ones with only cost price. If the machine has
big problem and our engineers are needed for site support, the customer will be in
charge of all of the fee of transportation, hotels, 3 meals per day, as well as the
technical support fee.
Our company guarantees the machine for its life time. In case of failure, the
following details need to be supplied:
1) Failure details
2) Diagnostic report
3) How was the failure handled and results
4) Machine manufacture date and serial number
After sales service contact information:

Phone: 0086-513-85059019, 0086-513-85059027; Fax: 0086-513-85656922

！
1.3 SAFETY RULES
When this machine is being used in the bar soap finishing line in the customer’s
workshop, machine operators must operate the machine in compliance with all of the
following safety rules and operation rules, and must fully understand and keep in
mind of all of the possible safety problems that may happen, as well as all of the
safety devices installed on the machine and the protective measures of the machine.
Do not attempt to operate until you have read thoroughly and understand
completely all instructions, rules, etc, which are contained in this manual. Failure to
comply can result in accidents involving fire, electric shock, or serious personal injury.
Keep owners manual and review frequently for continuous safe operation.
1) Know your machine
For your own safety, read the owner’s manual carefully. Learn its application and
limitations as well as specific potential hazards pertinent to this machine.
2) Keep work area clean
Disorder area and working table will cause accident.
3) Do not use in dangerous environment
Do not use power tools in damp or wet locations, or expose them to rain. Keeps
work area well illuminated.
4) Keep non-professional people away
All visitors should be kept at a safe distance from work area, and psycho and
non-operation people must NOT come near the machine.
5) Do not force the machine
It will do the job better and be safer at the rate for which it was designed.
6) Use the right tools
Do not force the machine or attachments to do a job for which they were not
designed.
7) Wear proper apparel
Avoid loose clothing, gloves ,neckties, rings, bracelets, or jewelry, which could be
caught in moving parts. Non-slip footwear is recommended. Wear protective covering
to contain long hair.
8) No alcohol
No one is allowed to enter the operation are after drinking alcohol, and no one is
allowed to drink alcohol in the working area.
9) Don’t maintain the machine in running states
The machine should be maintained such as lubrication, proper adjustment.
10) Before maintenance, accessory changing or assembling and reassembling
motor, be sure to cut off the power from the power resource
11) Keep the machine from irrelevant parts
Don’t place tools, mechanical parts or other non-operation relevant parts on the
machine or inside the machine.
12) Use E-stop to stop emergent problem

Push the E-Stop immediately to stop the machine if some emergent problem
happens during the running,
13) Install and fix the protective board and safety cover
Do examine the machine carefully after the maintenance and repair work is done,
and make sure that the protective board and the safety cover are installed and fixed
firmly before starting the machine.
14) Follow operation manual when moving or lifting the machine
Go through in detail to refer to the instructions before any action is taken, and
move or lift the machine according to the operation manual.
15) Follow operation manual for lubrication work
Follow all of the lubrication rules and requirements and safety requirements when
filling oil in the machine. If not, it will cause injury to human body and also damage the
machine components.
16) Keep the control cabinets in safe and good environment
Find the most suitable position and do necessary to keep the cabinets from the
dusty, the electromagnetic radioactive, the vibration and the shocking environment.
17) Don’t change the safety system
Don’t close the safety swift or disable it.
Don’t change the machine safety system by any reason. It will be the user’s 100%
responsibility for any damage caused by the change of the machine safety system by
the user.
18) Use recommended accessories
Consult the owner’s manual for recommended accessories.
19) Never leave the machine running unattached
1.4 MACHINE SAFETY MEASURES
Several safety devices and guards are installed on the machine, including:
1 Fixed guards
The fixed guards are not equipped with safety switches, but they can only be
removed by using tools or keys. Only when the machine is OFF and locked, and by
the authorized professionals, can the guards be allowed removed for maintenance.
And as soon as the maintenance work is done, the guards must be fixed.
2 Emergency Stop button
The E-stop is used only for emergency to stop the machine immediately.
For the normal operations, use the Stop button.
3 Earth connection of machine and motor
Reliable earth connection can prevent electrical damage to operator and machine
in case of electricity leakage. The customer must do the earth connection according
to local regulations
4 Warning and Danger Label
Please follow the warning and danger labels on the machine. It will cause
damage even death if not strictly following the instructions. Please keep these labels
intact and clear to read for people, otherwise, change to new and same labels.
1.5 LABELS ON MACHINE
This table shows labels that are stuck on the machine.

Picture Description Qty Position
Electrical injury
may happen
1 Panel
when
approaching
Fill oil into gear

box before 2~3 Gear box
power on
1.6 WARNING OVER RESPONSIBILITY
Our Company will not be responsible for problems, damages and accidents due
to not following this manual, nor for problems resulting from modifications,
reconstruction or wrong installation of the machine.
Our Company will not be responsible for damages due to natural calamity, wrong
operation, lack of maintenance, short circuit caused by electrical failure.
Our Company will not be responsible for the use of packing materials and filling
products differing from soaps for which the machine has been designed. It is
specifically prohibited to use the machine for acid, corrosive or flammable
substances.
Our Company will not be responsible in case of parts replaced by parts not
supplied by us. To prevent accidents it is important the parts are replaced before the
end of their lifetime.

2. TRANSPORTATION AND STORAGE

2.1 MACHINE DISASSEMBLY BEFORE PACKING
After customer test, because of the space constraint and damage prevention, the
machine will be disassembly before packing.
1. Wires and cables between the machine and its control panel will be dismantled
2. Hopper is dismantled;
2.2 MACHINE DOWNLOADING
The machine is particularly heavy. Please take care of handling the wood cases
properly. Packed machines transported on trucks or in containers are to be
unloaded by a fort lift truck, an overhead traveling crane or a crane.
Fort Lift Truck Overhead Traveling Crane Crane

Attention:
1. The lifting equipment hoisting capacity must be bigger than the cargo;
2. Pay attention to the cargo gravity center before hoisting
Before any downloading work, please find the case dimensions and weight
information in the packing list and then find the suitable crane. When using the crane,
the wooden cases must not be inclined more than 10°. When downloading these
heavy wooden cases, it is recommended to use proper tools and professional
personnel to perform the work.
If the customer has no crane, forklift can be used to lift the wooden bottom frame
of the machine.
2.3 MACHINE STORAGE
If the machine is to be stored for a long period of time before use, open the crates
to verify the machine has not suffered from the transportation.
Keep the machine in a dry storage environment with the temperature between
-10°C and + 50°C, and the relative humidity between 10% and 80%. Keep the
machine in the horizontal position and do not load the machine with other machine on
top of it. Take all precautions necessary to prevent humidity to alter the components
of the machine. Grease or oil all parts subject to corrosion.

2.4 MACHINE UNPACKING
The machine is very heavy, so that wooden bottom is used. When the customer
receives the cargo, please dismantle the wooden bottom per below picture
instruction:
Total 4 screws need to be dismantled
The control panel is packed in a wooden case, and please follow below
instructions to unpack it:
1
2
3
6
5 4
1: the lid, 2&4: the side walls, 3&5: the end walls, 6: the bottom
Attention: When dismantling all the nails on the lid, side walls and end walls of the
wooden case, operators should wear safety gloves in order to avoid any wounds or
abrasions caused by wood splinters.
2.5 CHECKING AFTER UNPACKING
When the machine has been unpacked, a check should be made by the customer
to see if there are some parts that have been damaged during the transportation or
some parts are missing/not delivered with the machine. In case of any parts damage
or parts missing, the customer should immediately take pictures and contact our
company.

3. TECHNICAL SPECIFICATION
XZL series simplex refining plodder is a new model which our company has
developed especially for toilet soap and laundry soap production.
According to different line capacity and soap formula, we have several models of
different structure, worm size, worm material.
3.1 MACHINE FUNCTION
The mixed soap from the mixer or amalgamator goes into the top hopper and
then to the first plodder. Through the driving force of the worm, the soap chips are
compressed. When the soap goes through the refining plate/mesh and the fixed
drilled plate, the soap is refined and discharged out as soap pallets. In the process,
the soap is compressed hard and refined to make the soap material even and feels
soft.
Soap pallets or chips
Soap pallets
3.2 MODLE SELECTON
The machine capacity is the total weight of the soap pallets the machine can
make in an hour. For example, XZL300 means this model of machine can produce
300kg soap pallets in an hour.
Normally, the machine can be selected by below table:
Model Production Line Capacity Actual Capacity
XZL300 300 kg/hour 300-400 kg/hour

3.3 PRODUCTS
Toilet soap and laundry soap.
3.4 MACHINE CHARACTERISTICS
The material contacting with the soap is made of high quality SUS304 (except
the aluminum worm) to prevent foreign damage to the soap and guarantee the
product quality. The barrel inner body is made of high quality seamless stainless steel,
without any water leakage. The clearance between the barrel and the worm is very
small, so that the pushing force is big and no material will go backwards.
The speed can be adjusted to meet different capacity and formula request.
3.5 TECHNICAL PARAMETERS
Parameter XZL300 XZL500 XZL1000 XZL2000 XZL3000

Capacity (kg/h) 300 500 1000 2000 3000
Worm Diameter(mm) φ160 φ200 φ250 φ300 φ350
Speed(r/m) 22 23 21 16 20
Power(kW) 7.5 15 22 30 45
Dimension L 2100 2665 3200 3645 3413
(mm) W 1200 1500 1700 1500 1900
Without hopper H 1274 1300 1370 1545 1613
Weight(ton) 1.5 3 4 5 6
Water flow(m3/h) 1 2 3 4 5
Water temperature(℃) Pressure: 0.3--0.5Mpa; Inlet water temperature: <15℃
Worm Material SUS304 or Alunimum (based on contract)
Speed Adjustment:
XZL300 XZL500 XZL1000 XZL2000 XZL3000
Speed adjustment YES YES YES YES YES
PLC:
PLC NO NO NO NO NO
Water Solenoid Valve:
Solenoid Valve NO NO NO NO NO
Water Temperature Auto Control:
Auto Control NO NO NO NO NO
3.6 MACHINE MAIN PARTS INTRODUCTION
The machine mainly consists of main frame, driving transmission, chilling circuit,
control panel, etc.

1) Main Frame
It is welded part by steel pipe and plates. The machine is covered by doors and
protective covers, the stairway is cover by anti-slippery aluminum plates.
2) Motion Transmission
For XZL300 and XZL500 refining plodders, the machine use integrated motor
and gear box, no need of pulley and v-belts, so that the machine size is smaller and
the transmission efficiency is higher.
The motion transmission is as below: motor drives the gear box, the main shaft,
the 2-jaw coupling, then the worm and the scraper.

motor XZL300, XZL500
Gear box
Main shaft
2-jaw coupling
worm
scraper
For XZL1000, XZL2000 and XZL3000 refining plodders, because the motor
power is very big, so we keep the design of pulley and V-belt to prevent motor
overload and the absorb the vibration.
The motion transmission is as below: motor drives the gear box, the main shaft,
the 2-jaw coupling, then the worm and the scraper.
The gear box we use is of famous brand in China, hardened cylindrical gear
reducer, with coupling to connect with the main shaft.
The gear box has heavy duty thrust roller bearing and cylindrical roller bearing,
because when the worm is pushing the soaps, there is big shaft force and the force is
born by the thrust roller bearing.
Special reminding: there should be sufficient lubricating for the bears, otherwise,
the life time of the bearing will be shortened. Please check it regularly.

motor XZL100, XZL2000 and XZL3000
Small pulley
Big pulley
Gear box
Main shaft
coupling
2-jaw coupling
Worm
scraper
3) Worm
The worm is made of SUS304 or cast aluminum alloy, through precision
machining and polishing.
The comparison of worm material and characteristic is as below:

Material Aluminum Alloy SUS304
Light, not easily wear the worm
shaft sleeve;
Hardness is small, so that the Anti-corrosion is good, suitable to
Advantage
clearance between the worm and different soap noodle formula
the barrel can be maintained within
0.5-0.6mm
Anti-corrosion is not good, can be Hardness is high, and can easily
Disadvanta
rusted to some special noodle wear the worm shaft sleeve, so
ge
formula that the clearance between the

worm and the barrel can be

maintained within 0.8-1.0mm;
Need to change the shaft sleeve
more often
4) Chilling Water Circuit
The machine barrels are chilled by water. There is a water inlet at the front and
an water outlet at the end because when working, the front part of the barrel has a
higher temperature than the end.
For small capacity plodders, the need of chilling water is not big, so that the first
plodder water outlet is connected with the second plodder water inlet. The water
enters the first plodder and then into the second plodder. The customer only needs to
connect 1 inlet and 1 outlet to the machine.
出水
进水
5) Control panel and operation box

There is an independent control panel and operation box for this machine.
For machine control, please refer to below chapters in the user manual.

The image shown here is indicative only. The actual product may differ.
3.7 SPECIAL CONFIGURATION
1) Refining plate and refining mesh

For some special soap, some customers use refining plate and refining mesh to
achieve below function:
1. To filter the foreign particles inside the soap, such as metal chips, plastic linear,
etc;
2. Refining
There is different sizes and meshes, which is normally measured by US Mesh
Number. It is to the holes diameter and the opening rate. Normally, the Number is
bigger means the holes small and the refining is better, meanwhile, more power
consumption. We do not suggest any Number bigger than 50
Number Refining Capacity Power Consumption
20 Poor Big Small
30 OK OK OK
50 Good Small Big
This is optional and needs to be confirmed before order.

2)Rotating Plate
For some special formula, such as the laundry soap in China, to increase the
transparency, there is a rotating plate installed at the end of the worm which is
rotating along with the worm.
The holes are bigger than the fixed plate because if small hole, difficult to output
and lower capacity.
For toilet soap customer and other laundry soap customers, they do not choose
this function because of higher power consumption.
This is optional and needs to be confirmed before order.
Rotating plate

4. INSTALLATION
ATTENTION:
For the following installation work, only qualified professional engineers can do and must
follow tightly this installation instruction.
The machine must be installed and operated in the closed environment with the
temperature between -10°C and + 50°C, and the relative humidity between 10% and 80%.
4.1 MECHANICAL INSTALLATION
According to our drawing, dig 4 holes on the floor and put in the foundation bolt,
then fill in cement to fix the machine.

Attention: if some customer does not want to make the foundation, they can put the machine just
on top of the floor. They need to confirm:
The floor capacity is OK;
The floor is flat. If not flat, needs to add pad below the machine to adjust level
If the floor is inclined, the machine must be fixed to prevent any movement during working.
Step 1: Put the machine in position

Make sure of the floor is capable before installation.
Step 2: Adjust the machine level and fix
Adjust the machine level to prevent any gap between machine and the floor.
Fix the machine by setscrews or foundation hangers.
For some special case, use anti-vibracation pads at the machine bottom.
Step 3: Assembly the big hopper
Set the hopper on top of the first plodder
Step 4: Install the infeed conveyor and the recycle conveyor
Put the conveyors in position and install the conveyor hopper.
4.2 ELECTRICAL INSTALLATION
According to our electrical drawings and documentation, the electrical installation

work must be done by qualified professional engineers. The work scope is as below:
1. Put the control panel in position to our drawings;
2. Wire the machine with the panel to our drawings;
3. Install the power supply from the workshop to the machine, and the wire earth
grounding;
4. Check all wires according to drawings.
5. Check all wire earth grounding.
ATTENTION: the electrical installation is of great importance and please take care.
Modle Power(kW) Power Supply
XZL300 7.5 3P+PE，6 mm2 wires

XZL500 15 3P+PE，10 mm2 wires
4.3 OIL AND LUBRICANT
Please make sure to add oil inside the gear box, oil type N220 and N320;
Check and there is no oil leakage.
4.4 CHILING WATER CONNECTION
Connect the chilling water to the machine
Machine XZL300 XZL500 XZL1000 XZL2000 XZL3000

Qty of inlet 1 1 2 2 2
Qty of outlet 1 1 2 2 2
Inlet diameter(inch) 1 1 1 1 1.5
Outlet diameter(inch) 1 1 1 1 1.5
Inlet temperature(°C) 10-15 10-15 10-15 10-15 10-15
Water flow(m3/h) 1 2 3 4 5
4.5 CHECKLIST AFTER INSTALLATION
1) Check if the machine and the panel are in position to the drawings;
2) Check if the machine are fixed tight onto the platform;
3) Check if earth grounding is done for the machine and the panel.
4) Check all wires are installed to the drawings.
5) Check if there is oil inside the gear box;

5 CONTROL AND OPERATON

5.1 POWER ON AND OFF
On front door of the control panel, there is a main power switch. Clockwise to switch it
to 1 for power ON and counter-clockwise it to 0 for power OFF.
1 Power ON 0 Power OFF
5.2 CHILLING WATER
Open the side door of the machine, turn on the manual valve to check if the
chilling water is flowing and if there is any water leakage.
5.3 CONTROL BUTTONS
Buttons Type Color Function
启动 button green Start the machine

Start
停止 Button Red Stop the machine

Stop
急停 Button Red Stop the machine immediately

E-Stop

5.4 SPEED ADJUSTMENT
Button Function
调速 Rotate the switch to adjust the machine running speed

Speed Adjustment
Delta Brand VFD ABB Brand VFD Schneider Brand VFD
380V/50Hz, the rated power and the rated current is as below:

Rated Power(kW) 4 5.5 7.5 11
Rated Current(A) 8 11 15 22
Rated Power(kW) 18.5 22 30 37
Rated Power(kW) 45 55 75 90
For other power supply with different voltage and frequency,
please refer to the nameplate of the motor.
5.5 ELECTRICAL DRAWING
The machine drawings are inside the machine control panel.

6 MACHINE START UP
The biggest issue for the machine is metal
falling into the worms and causing damage to
the worm and the plate and the scraper.
6.1 CHECK THE INFEED CONVEYOR AND RECYLE CONVEYOR
1) Check the infeed conveyor and recycle conveyor to see if there is any foreign
particles, such as screw and metal chips.
2) Check the screws on side of the conveyor to see if any missing or loose;
3) Power on the conveyor to see if anything abnormal.
6.2 CLEANING
1) There is no foreign items or screws on top of platform and the stairs;

2) There is no foreign items or screws inside the top hopper;
3) There is no foreign items or screws inside the barrel;
4) There is no foreign items or screws inside the panel.
6.3 PREPARATION
1) Power is on and the voltage is stable.

2) Chilling water on, temperature is between 10-20 degrees
3) Protective cover is full and installed, functional.
4) No non-relative people are around the machine;
5) The machine is power OFF.
6.4 MACHINE SETTING
1) Set the machine speed to 5Hz.
6.5 CHILLING WATER ON
1) Open the chiller or chilling towel or the tap water;

2) Open the valve to see if water flowing in and out;
3) Observe if there is any water leakage;
4) Use the hand to feel the chilling pipe and the barrel to see if the temperature
drops.

6.6 POWER ON
1) Power on to the workshop.

2) Power on to the machine control panel.
3) Check if there is any abnormal noise.
4) Check if there is any static electricity or electricity leakage.
6.7 JOG RUN AND FUNCTION CHECK
Step Action Check

The worm is not crashing the barrel inner surface,
there is no abnormal noise;
1 Press down ”Start”
No abnormal noise for gears.
No abnormal noise for motor.
2 Press down “Stop” The machine can stop immediately, no abnormal noise
Press down
“E-stop” while the
3 Then press down ”Start”, no movement
machine is in stop
status
Press down “Start”,
The machine stops immediately and if the “E-stop” is
4 then press down
not reset, then other buttons will not function.
“E-stop”
ATTENTION: THE WORM ROTATON IS AS BELOW:
Ventilation Fan
There is ventilation fan for the control panel and the machine.
When the machine power is ON, check the fan rotation to see if the air is OUT.
If the air is IN because of the wrong wiring and fan rotation, the machine will burn up.

6.8 DRY RUN
Start the machine and dry run for 8 hours

Every 1 hour, check if there any abnormal noise or other problems
- Abnormal noise
- Motor temperature rises quickly (normally the temperature remains below
50 degrees)
- Gear box temperature rises quickly (normally the temperature remains
below 50 degrees)
- Conveyor belt miss-placement
- Oil leakage, air leakage
- Machine vibration
Time Observation
1st hour
2nd hour
3rd hour
4th hour
5th hour
6th hour
7th hour
8th hour
6.9 PRODUCT RUN
1) Conditions for product run

Only after 8-hour dry run, can start the product run.
Can try dry run the machine several times to observe the machine functions and
the make the operator familiar with the machine
2) Speed Setting
Set the speed at 20Hz or less and then can increase the speed slowly.
3) Chilling water setting
The inlet water is set 10-15 degrees
4)Machine start sequence
a) Start the mixer or amalgamator to discharge the noodles into the hopper
b) Start the chilling water
c) Start the downstream conveyor

d) Start the machine
5) Checklist
- The motor electricity current not exceeding the rated value
- The motor temperature is below 60℃
- The gear box temperature is below 60℃
- The screws are fixed, no vibration, not loose
- The machine not shaking
Attention:
 During dry run and product run, the operator needs to stands besides the
machine and can fast push the E-stop if emergency happens.
 Only qualified professional operator can operate the machine
 In the first 8 hours of product test, pay attention to abnormalities, such as
noise, vibration, temperature increase.
 During running, if any hard particles enter the barrel, such as screw, nut,
scraper, it cause serious damage to the worm and to the barrel. So, must pay
attention that no foreign particles can go inside the noodles and the machine.
 The machine has been cleaned before packing and shipment. But the
customer must do a complete cleaning of the machine before use, especially
the hopper, the barrel. There might be things fall down for the first time use.
We recommend the customer to use new soap noodles and test longer time
before formal production.

7 CHANGE-OVER AND TROUBLE

SHOOTING
7.1 LINE CHANGE-OVER
Before changeover, make sure that there are no product inside the machine and
conveyor. The changeover procedure is as below:
1) Stop the line
2) Cut off the electricity
3) Lock and tag
4) Clean
5) Check
Cleaning
Check the hopper, clean out the chips completely.
Clean the scraper, the frill plate, the refining mesh.
Pull out the worms to clean the worms
7.2 PULL OUT THE WORM
1. Disassemble the scraper;

2. Disassemble the drilled plate;
3. Set the motor speed at 3Hz, jog start the first plodder until it reaches out by
about 10cm;
4. Stop and pull the worm manually.
7.3 MACHINE STOP FOR THE NIGHT
If machine will stop for the night, follow the above steps to clean the hopper, the
worms.
If not clean the machine completely, there is be material inside the barrel. After
the night, the material will become hard.
1. The next day when start the machine, the motor current will be very high to
cause damage to the motor;
2. The material inside the barrel is hard. When the next day soap bar comes out,
there will be hard material blocks.
7.4 TROUBLE SHOOTING
Following information are as reference to help customers to identify the problems

earlier and faster, and solve the problems more quickly in the right way.
Whenever any problem arises, it’s suggested that a thorough check of the
following list before taking any remedy actions which may prove to be unnecessary or

even cause machine damage.

No Part Failure and Solution
Failure: motor not start
Possible reasons and solutions:
1 Circuit breaker overload: close the break to see if any electricity leakage or
circuit shortage;
1 Motor
2 Contactor faulty: replace it
3 VFD faulty: check fault code and solution
4 Switch off: manual switch on
5 E-stop pressed: reset the E-stop
Failure: high temperature too high
1 motor bearing wore out or damaged: replacement
2 overload: check if too much material or the material is too sticky to exceed
the machine capacity
2 Motor 3 Machine damage: check if the scraper is OK and if any metal inside the
worm
4 Block of the refining plate and the drilled plate: check if the material output
is OK and even, if not, disassemble the refining plate and the drilled plate to
clean.
5 Motor fan damage: check if motor fan is running and if the fan is damaged
Failure: temperature too high
3 Gear box 1 Too much or too little oil: adjust the oil to the normal level
2 Gear box bearing wore out or damaged: replacement
3 Gear box gear wore our or damaged: replacement
Failure: oil leakage
4 Gear box Possible reasons and solutions:
1 sealing ring damaged: replacement
7.6 ISSUES AND SOLUTION
Below information is for customer reference in case of similar situation:

1)Motor not start, motor burned, high motor electricity current
If the first time to start the machine of this day, might because that there is
material inside the barrel and it becomes very hard to cause high starting current.
Also, check if there is foreign particles inside the barrel, such as scraper, screw
driver, screw, nut, etc.
Set the speed at 5Hz, slowly start the motor to see if anything.
If not, then get the worm out to see if there is serious damage.
2) Dark dots inside the soap
Sometimes in China, our customer meets this problem because
1. They use a lot of French chalk/silicate, and the French chalk gets darkened
when friction with the worm and barrel, so that it will cause dark material at the

position of the worm sleeve.

2. The worm sleeve breaks and the soap goes inside the sleeve to get dark.
3. The worm sleeve wears out and the soap goes inside the sleeve to get dark.
4. Pull out the worm and clean the worm. If aluminum worm, check if there is a
layer of corrosion, which can fall off. Use polishing machine to polish the worm
completely. If SUS304 worm, check if there is any corrosion points around the screw
corner. Use polishing machine to polish the worm completely.
7.7 BIG ISSUE AND SOLUTION
If facing below big issues, please contact us immediately.

1)Metal particles inside the worm and damaged the worm
Take a photo and contact us.
2)Worm wears out and the clearance is too big >2mm (more than 3 years)
Contact us to order spare parts.
This issue can cause lower capacity.
3)Gear box damage
Take a photo and contact us.

8 MAINTENANCE
The operation, maintenance, and repair of the machine can only be performed by
those who are qualified.
Do not wear rings, watches, chains, bracelets, etc. during maintenance.
Always wear individual protection devices (safety gloves, safety glasses and
safety shoes).
Do not use free flames, pointed elements or pins to clean the machine.
Do not smoke and drink during machine maintenance.
Do not do the machine maintenance after drinking alcohol.
Before any maintenance, the power and the

air must be cut off, lock and tag, and
prevent any other people near the machine
and prevent any miss-operation.
8.1 SAFETY RULES DURING MAINTENANCE
Warning
1) Turn OFF the machine.
2) Turn off and lock the power and air.
3) Working on the machine must be carried out by authorized professionals only.
Protective and Safety Devices
1) Do not override any protective and safety devices.
2) After having terminated maintenance work, close the guard doors and refit the
protective grates and covers.
During the Maintenance Process
1) Keep electrical and electronic components/assemblies dry.
2) Electrical lines, control cabinets, and plastic parts must not come into contact
with acid and caustic solutions.
3) Only when there are two professionals at the same time, can they start to solve
the electrical fault or error on site and take notes.
Welding and spark-producing work
1) Disconnect all electrical components before doing this type of work.
2) Protect the machine from any spark splashing and damage.
3) Protect the gear box oil from any fire.
8.2 MAINTENANCE TOOLS LIST
To carry our following maintenance work, following tools are needed and the

customer should prepare them and always keep them available.

No. Picture Name Type Qty.
1 Trowel Small size 2 pieces
Double open end

2 SS 1 set
spanner
Inner hexagon
3 SS 1 set
spanner
4 Slotted screwdriver Magnet head 1 set
5 Phillips screwdriver Magnet head 1 set
6 Cotton, soft cloth Cotton, soft, dry Some
7 Air gun Small 1 piece
8 Digital multi-meter Safe and reliable 1 piece
9 Water bucket Plastic or metal 1 piece
10 Thermal gun Infrared, no touch 1 piece
Grease cup:
11 Grease gun M10x1 1 piece
(GB1152-89)
Note:
Too pictures above are just for demonstration, not real configuration or color. The

customer should prepare these tools according to local market availability and
operators’ operation habits.
8.3 CLEANING
Pay attention to below things:

1) Cut off the power, lock and tag, so that the machine will not run accidentally;
2) Do not use any toxic and flammable cleaning liquid;
3) Only use non-toxic, odorless, and safety qualified cleaning detengent;
4) When use water to clear, air dry out the water after the cleaning;
5) When use the air gun, wear eye protection glass to prevent eye damage;
6) No liquid should be in contact with electricity;
7) Clean the hopper, the worms, the barrel, the scraper, the plate;
8.4 CHECK
1) Every Shift (every 8 working hours)

A Check before run
1) Check if the oil height is within the requested range of the gear box;
2) Check if the protective cover is in position and functional;
3) Check if the power supply is OK;
4) Check if there is blockage of the drilled plate;
5) Check if the scraper is fixed tight;
B Check when the machine is running
1) Check if the output is steady;
2) Check if there is any abnormal noise;
3) Check if the chilling water is working well;
4) Check if the ventilation fan is working OK;
5) Check every 4 hours if the temperature of the motor, the gear box is OK;
6) Check if the electricity current is OK within the range and no big difference;
2) Every Week (every 40 working hours)
1) Check if the machine bottom bolts are loose and the machine displacement;
2) The new machine will need to change the gear box oil for the first 500 hours;
3) Check if the v-belts wear out and tighten the motor;
4) Check if the chilling water runs OK, no blockage;
5) Check if there is any collision between the worm and the barrel;
6) Check if the refining plate, refining mesh and the drilled plate is OK
3) Every Month (every 200 working hours)
1) Pull out the worms to check if there is damage of the worm and the barrel;
2) Check the drilled plate;
3) Check the worm support sleeve;
4) Fasten all fasteners;
5) Check the sealing of the bearing, the gear box, if there is any leakage. If
leakage, then there will be sealing replacement;
4) Every Half Year (every 1200 working hours)

1) Check if the worms are running well, no shaking. If abnormal, contact us;
2) Check the sealing of the gear box.
5) Every Year (every 2400 working hours)
1) The machine will need a major maintenance every year;
2) Polish the worms
3) Change the V-belt
4) Check if the bearings are wore out and fill in the grease.
Check Points
Picture Check Points
If any loose screws of the infeed conveyor, the recycle
conveyor, the hopper;
If the screw goes into the worm, will cause serious
damage
Gear box if enough oil, if oil leakage, if broken

If the gear box breaks, it’s big issue
V-belts wear out

If worn out, the transmission efficiency will be low
If little worn out, only needs to tighten the motor
If much worn out, need to change new V-belts
Check if the scraper is loose

Normally the scraper nut is loose or the shaft
sleeve/shaft breaks
Check if the shaft sleeve is worn out

If worn out, the worm will fall down to contact the barrel
which will cause damage to the worm and the barrel

Check if the bearing box screws are loose. If loose, the

sealing will be a problem, and the noodles will get out
from the worm back.
8.5 LUBRICATION
For a better preventative maintenance, the proper lubrication helps to keep

machine in good conditions. Regular lubrication need to apply the whole life of the
machine.
Before lubrication operation,
- Do not, by any means, mix mineral oils with synthetic oils.
- Do not, by any means, mix different types of saponified grease.
- Under extreme climatic conditions, it might be necessary to use grease with a
different viscosity (e.g., use thin-bodied oils at extremely low temperatures)
The machine should not be operated at its maximum speed during the 50
operating hours after it has been completed commissioning.
Do the lubrication work according to below table:
No. Position Picture Lubricant Cycle
First plodder Gear N220 gear oil

1 6 months
box N320 gear oil
First plodder bearing

2 Grease 3 months
box

9 ANNEX
9.1 NOISE LEVEL
When used under normal production conditions, the machine has a noise level of
85 dB. It’s essential to keep the machine in the following state to measure the noise
level:
All parts have the right setting
All lubrication points are lubricated
No over worn parts
No abnormal noise
No loud environmental noise
Measure method: When the machine is in full running mode, measure the noise
level at four sides with 1 meter distance from the machine and 1 meter high from the
ground.
1m
1m Machine 1m
1m
9.2 OPERATING LIFE AND ABANDONMENT ANNOUNCEMENT
The operating life of the machine is 15 years. After the operating life, the machine
should be abandoned and processed by relevant regulations and should not pollute
the environment.
The machine will be disassembly and the relevant parts will be processed by the
local laws and regulations.
1) Commercial parts
Recycle the commercial parts which are still in the operation life, like the motors,
transformers, bearings, pneumatic parts, etc.
2) Mechanical parts
Hand them to the junk dealing company for steel recycling.
3) Plastic
The plastic should be recycled, especially those polycarbonate protective door
plastic.
4) Oil and grease
Put them into steel containers and hand them to the junk dealing company.
Do not pour the oil or grease into the sewers or on the ground to pollute the
environment.
5) Others
Hand them to the junk dealing company for suitable process.
9.3 FREE TOOLS AND SPARE PARTS
Model Part Spec/Drawing Number Qty Position

Drilled plate sleeve XCT300-05-18 1 Barrel
XZL300 Refining plate Hole diameter 1mm 2 Barrel
Wrench 1 Big nuts
Scraper sleeve XCT500-03-26A 2 Barrel
Support sleeve XCT500-03-08B 2 Barrel
XZL500
Refining plate Hole diameter 1mm 2 Barrel
Wrench 1 Big nuts
Scraper sleeve XCT1000-03-07 2 Barrel
Support sleeve XCT1000-03-04 2 Barrel
XZL1000
Wrench 1 Big nuts
Drilled plate sleeve XZL2000-00-06 2 Barrel
XCT2000
Wrench 1 Big nuts
Hanging rod XCT1200-00-01 4 Frame
Drilled plate sleeve XCT3000-02-11A 2 Barrel
XCT3000
Wrench 1 Big nuts
Hanging rod XCT1200-00-01 4 Frame
9.4 HOW TO ORDER SPARE PARTS
When ordering spare parts, please provide follow information:
Spare Parts Ordering List

Customer information:
Machine name and model:
Machine serial number:
No. No. No. No. No.

Please first send Fax or e-mail to us and then make a call to confirm.

Phone: 0086-513-85059019, 0086-513-85059027; Fax: 0086-513-85656922

10 OPERATION SOP
Refining Plodder Operation SOP

Step 1: Start the machine
Front of the control panel, power on;
Inside the machine, open the water valve;
Set the speed at 5Hz;
Step 2: Check
No foreign particles inside the infeed conveyor, machine and recycle conveyor;
Oil inside the gear box;
Step 3: Start in sequence

Start the infeed conveyor to transfer the soap chips into the hopper
Start the chilling water
Start the downstream conveyor
Start the machine
Step 5: Stop
When there is no material in the hopper, stop the infeed conveyor When there is
When there is no material in the barrel, stop the machine;
Stop the chilling;
Power off the machine on the control panel

Toilet Soap
and
Laundry Soap
Machine Supplier

XZL Series Simplex Refining Plodder User Manual

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XZL Series Simplex Refining Plodder User Manual

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XZL Series

Simplex Refining Plodder

Nantong Tongji Co., Ltd

Sincerely thanks for using our machine.

Nantong Tongji Co., Ltd

0.2 CUSTOMER AND MACHINE INFORMATION

0.3 AIM OF THE USER’S MANUAL

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Install the machine correctly.

0.4 HOW TO USE THIS USER’S MANUAL

0.5 HOW TO KEEP THIS USER’S MANUAL

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0.1 SINCERE THANKS .................................................................................................................................... 2

1. GENERAL INFORMATION ........................................................................................................................... 6

1.1 MACHINE IDENTIFICATION ................................................................................................................... 6

2. TRANSPORTATION AND STORAGE ....................................................................................................... 10

2.1 MACHINE DISASSEMBLY BEFORE PACKING ................................................................................... 10

3. TECHNICAL SPECIFICATION ................................................................................................................... 12

3.1 MACHINE FUNCTION ............................................................................................................................ 12

4.1 MECHANICAL INSTALLATION ............................................................................................................ 20

5 CONTROL AND OPERATON ...................................................................................................................... 23

5.1 POWER ON AND OFF.............................................................................................................................. 23

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5.5 ELECTRICAL DRAWING ........................................................................................................................ 24

6 MACHINE START UP ................................................................................................................................... 25

6.1 CHECK THE INFEED CONVEYOR AND RECYLE CONVEYOR ....................................................... 25

7 CHANGE-OVER AND TROUBLE SHOOTING ......................................................................................... 29

7.1 LINE CHANGE-OVER ............................................................................................................................. 29

8.1 SAFETY RULES DURING MAINTENANCE ......................................................................................... 32

9.1 NOISE LEVEL........................................................................................................................................... 37

10 OPERATION SOP ........................................................................................................................................ 40

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1.2 AFTER SALES SERVICE

Nantong Tongji Co., Ltd

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12) Use E-stop to stop emergent problem

1.4 MACHINE SAFETY MEASURES

1.5 LABELS ON MACHINE

This table shows labels that are stuck on the machine.

Fill oil into gear

1.6 WARNING OVER RESPONSIBILITY

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2. TRANSPORTATION AND STORAGE

2.2 MACHINE DOWNLOADING

Fort Lift Truck Overhead Traveling Crane Crane

2.3 MACHINE STORAGE

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2.4 MACHINE UNPACKING

Total 4 screws need to be dismantled

2.5 CHECKING AFTER UNPACKING

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3.1 MACHINE FUNCTION

Soap pallets or chips

3.2 MODLE SELECTON

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Toilet soap and laundry soap.

3.4 MACHINE CHARACTERISTICS

3.5 TECHNICAL PARAMETERS

Parameter XZL300 XZL500 XZL1000 XZL2000 XZL3000

3.6 MACHINE MAIN PARTS INTRODUCTION

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motor XZL300, XZL500

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