VERSATILE MOULDER Safe Operating Procedures TRAINING MANUAL Current 22 May 2003 Contains 24 pages
V E R S AT I L E M O U L D E R CONTENTS • • • • • • • • • • • • • • • • About this Instruction Manual User Liability Safety Precautions Before You Start Name of Parts Hazard Risk Analysis Safe Operating Procedures Standard Operations Checklist Operations Checklist Operations Overview Product Guide Daily Cleaning Procedure Operations Competency Cleaning Competency Trouble Shooting Risk Assessment Moffat's policy is one of continual improvement and development.
V E R S AT I L E M O U L D E R About this Instruction Manual This manual contains all the necessary information for the use, cleaning and maintenance of the machine. The purpose of this booklet is to allow the user to take all measures and set up all the human and material resources needed for safe and long-lasting use of the machine. This manual should be available for all staff and maintenance personnel authorised to use the machine.
V E R S AT I L E M O U L D E R User Liability Working Safety The machine must be used only by personnel suitably trained for the purpose and who have been trained in the contents of this publication. To ensure safe work, comply with the following instructions: • Install the machine in compliance with workplace safe work requirements. • Install the machine in an area away from personnel not authorised to operate it and especially out of the reach of minors.
V E R S AT I L E M O U L D E R Safety Precautions To ensure maximum safety and optimum performance from this machine it is essential that you or any other operator of the machine read and understand the contents of this manual before the machine is started. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by these symbols. CAUTION Serious injury possible These safety alert symbols mean CAUTION, WARNING or STOP/DANGER - a personal safety instruction.
V E R S AT I L E M O U L D E R Before you start the VERSATILE M O U L D E R Before starting, undertake a General Safety check • Area clean and free from obstructions, e.g. nothing placed on top of the machine such as a dough knife, etc. • Operator not wearing loose fitting clothing. WARNING: Make sure the machine is switched off during cleaning, maintenance and lubrication When using the machine, never place hands near working areas.
V E R S AT I L E M O U L D E R Names of Parts Emergency Stop Specialty Tube for shell or laminated rolls Attachment Raise/Lower Handle Guide Width Adjustment Handle (Loaf Guides) Attachment Mounting Frame Belt Guards Start Button Stop Button Rear Belts Adjustment Handle Safety Mouth Assembly Counter Weight Roll Chutes Emergency Stop Button Stop Bar Sheeting Roller Adjustment Handle Splitter Handle Catchment Tray Front Panel Locking Knobs Fixed Castors Lockable Swivel Castors © M O F F AT 2 2 M AY
V E R S AT I L E M O U L D E R Hazard Risk Analysis Machine in use WARNING: Set up the machine on a flat even surface. 3 Electrical isolation switch should be fully accessible to the operator. 1.5 metres above the floor is a recommended height. 3 1 Cleaning of machine should only be carried out with a damp cloth. Buckets of water or a hose should not be used. 1 ✓ ✗ 2 Do not remove or tamper with Micro Key Switch on Safety Mouth Assembly. Do not over–ride the microswitch during cleaning.
V E R S AT I L E M O U L D E R 1 Check that the machine is clear of all objects and that all switches are off. 4 Test red Emergency Stop Button operation by pushing the mushroom button in. (See below) 6 Mould dough according to work-place procedures. Keep fingers clear of the Mouth Guard. WARNING: The operator should never tamper with or make repairs to this machine. All maintenance other than approved cleaning operations to be carried out by trained technicians only.
V E R S AT I L E M O U L D E R MOFFAT SUGGESTS— Use this form to train staff, copy and laminate for your workplace Standard Operations Checklist ✓ OPERATION INSTRUCTIONS Set sheeting, roller gap to required product setting. Option for sandwich breads using splitter. Set rear belt to required product setting. Lower the loaf Guide Width Attachment between the belts. Pull out catch tray. Engage the Splitter. Press Start Button.
V E R S AT I L E M O U L D E R Standard Operations Checklist OPERATION INSTRUCTIONS MOFFAT SUGGESTS— Use this form to train staff, copy and laminate for your workplace ✓ Feed dough into the Safety Mouth Assembly. Follow recommended work–place procedures for the desired product. Observe action of dough pieces under curling chain. Dough should curl upwards and not deviate to the sides. Check finished product against work–place standards for shape, size and consistency. Repeat process.
V E R S AT I L E M O U L D E R Operations Checklist FRENCH STICK 300g — 450g 4 PIECE SANDWICH BREAD 680g 1 Set Sheeting Roller gap to required product setting. 1 Set Sheeting Roller gap to required product setting. 2 Set Rear Belt Adjuster to required product setting. 2 Set Rear Belt Adjuster to required product setting. Arrow indicates the correct setting for 650g dough pieces. 3 Do not lower Guide Width Attachment. 4 Do not engage 4 piece Splitter. 5 Pull out Catch Tray. 6 Press Start Button.
V E R S AT I L E M O U L D E R Operations Checklist HI–TOP 450g — 680g VIENNA 450g — 680g TANK LOAF 450g — 680g HOT DOG/KNOT ROLLS 85g — 120g 1 Set Sheeting Roller gap to required product setting. 11 Press Stop Button when finished. 2 Set Rear Belt Adjuster to required product setting. Arrow indicates the correct setting for 680g dough pieces. 450g dough pieces 120g dough pieces 3 Lower the Guide Width Attachment into the machine. Set on central placement. 4 Do not Engage the 4 piece Splitter.
V E R S AT I L E M O U L D E R Operations Overview 1 Set sheeting, roller gap to required product setting. 1 If splitter option is required: The Guide Width Attachment must be lowered into the machine. The Guide Width Attachment keeps the dough pieces centred during the moulding process. D Adjusting the width of the Guide Attachment to suit the type of product. D A Un–clip handle from the bracket which holds the Guide Width Attachment in the up position. A E Engage splitter.
V E R S AT I L E M O U L D E R Operations Overview 3 Pull out Catchment Tray. 6 3 11 Check finished product against work–place standards for shape, size and consistency. 11 4 Press Start Button. 4 7 For rolls, feed dough pieces into Roll Chutes. 7 12 Repeat the process. 13 Press Stop Button when finished. 5 Place dough onto the Safety Mouth Assembly. Swing down to feed the dough into the moulder. 8 Making Paninni or Shell Rolls. 5 8 NOTE: Use the Emergency Stop only in an emergency.
V E R S AT I L E M O U L D E R Product Guide SHEETING ROLLER ADJUSTMENT REAR BELT ADJUSTMENT GUIDE WIDTH ADJUSTMENT 4-6 8 — LONG ROLLS 4 4 or 5 — SHORT ROLLS 6 6 — 60 GRAM SHELL ROLLS 4 4 — SECOND ROLLING 4-5 26 — 450 G SLIPPER VIENNA 6-7 ON ARROW — 450 G TRAYED VIENNA 6-7 13 — 680 GRAM SANDWICH 8 ON ARROW 4 PIECED SANDWICH ENGAGE 4 PIECE SPLITTER PRODUCT 450 GRAM.
V E R S AT I L E M O U L D E R MOFFAT SUGGESTS— Use this form to train staff, copy and laminate for your workplace Daily Cleaning Procedure WARNING Electrically isolate Dough Moulder. 1 Brush off all external surfaces. Use a bannister brush and work from top to bottom. Use bannister brush outside of machine; clean mouth assembly with damp cloth. 3 Open sheeting rollers to maximum (15) and wipe down with damp cloth. 3 1 4 To remove curling chain, undo Locking Knob and lift out the Chain Assembly.
V E R S AT I L E M O U L D E R Daily Cleaning Procedure 9 Reassemble machine, turn on power and check for correct operation. MOFFAT SUGGESTS— Use this form to train staff, copy and laminate for your workplace 6 Inspect the curling chain before re-assembly. 6 7 Check rear belts for signs of old dough. Clean with plastic scraper if necessary and brush lightly. Note: Never use a metal scraper. 7 8 Clean attachment arms and rollers with a plastic scraper and damp cloth.
V E R S AT I L E M O U L D E R GUIDE SHEETS for Staff Training Pages in the following section of this manual should be copied and used when training staff to operate the VERSATILE M O U L D E R MOFFAT recommends that competency assessment check lists be completed signed and a copy kept in the personnel files for future reference.
V E R S AT I L E M O U L D E R Operations Competency Checklist MOFFAT SUGGESTS— Use this form to train staff, and place a copy in personnel file. Element ✓ Implement safe work procedures.
V E R S AT I L E M O U L D E R Cleaning Competency Checklist ✓ Implement essential hygiene and sanitation procedures. MOFFAT SUGGESTS— Use this form to train staff, and place a copy in personnel file.
V E R S AT I L E M O U L D E R Trouble Shooting Problem The VERSATILE MOULDER does not operate/start. Remedy Possible cause Not plugged in to socket at main switch. Plug in and switch on. The main switch is “off”. Turn on. Fuse overload at the power board Contact supervisor. The moulder overload has been activated. Resets automatically (10 min). Stop button still locked in down position. Release by rotating and pulling. Start Button not pressed. Press Start Button.
V E R S AT I L E M O U L D E R Trouble Shooting Problem Possible cause Remedy Skinning of dough pieces. Dough pieces not covered during resting. Cover dough pieces. A fine mist of water can be sprayed on the product prior to moulding. Dough sticking to belt. Excess water in dough formulation. Redo batch. Add flour externally on dough pieces. Dough piece tearing. Insufficient water in dough mix. Redo batch. Settings too tight. Loosen settings. Moulder not cleaned as per cleaning instructions.
V E R S AT I L E M O U L D E R Risk Assessment The following risk assessment covers the reasonably foreseeable hazards to health and safety arising from the VERSATILE MOULDER and from systems of work associated with this machine.
V E R S AT I L E M O U L D E R Risk Assessment The following risk assessment covers the reasonably foreseeable hazards to health and safety arising from the VERSATILE MOULDER and from systems of work associated with this machine. Hazard identified Friction burns from inserting hand between the Belts at top rear of machine. Existing controls Area inaccessible from the front operating position. Warnings in manual and warnings about sole operator use.
