Automatic Protein Bar Production Line
Technical User & Operation Manual
Introduction
This manual provides operating instructions, technical description, and maintenance guidelines for the Automatic Protein Bar Production Line. The system is designed to produce protein bars using a PLC-controlled automation platform with synchronized conveyors and cutting mechanisms.
The machine allows automatic parameter adjustment through recipe selection, reducing operator intervention and ensuring consistent product dimensions.
System Configuration
Main Control Components
| Component | Manufacturer |
|---|---|
| PLC | Schneider Electric |
| Expansion Module | Schneider Electric |
| Expansion Module | Schneider Electric |
| HMI | Inovance |
| VFD Drives | Delta |
Production Line Layout
The production process flows through the following sections:
- Extruder Section
- Dough Feed Conveyor
- Cutting Table
- Cutters
- Guillotine Cutter
- Distance Conveyor
- Retraction Section
- Split Conveyor
- Delivery Conveyor
Machine Description
Extruder Section
The extruder forms the dough into a uniform sheet before cutting.
Main Features
- Servo-driven roller gap adjustment
- Thickness control through PLC recipe parameters
- Adjustable roller speeds through VFD control
Operator Parameters
| Parameter | Description |
|---|---|
| Set Thickness | Desired sheet thickness |
| Actual Thickness | Measured thickness |
| Roller Speed | Controls extrusion rate |
Operation
- Load dough into hopper.
- Select product recipe.
- Servo automatically adjusts roller gap.
- Dough sheet exits onto feed conveyor.
Dough Feed Conveyor
The dough feed conveyor transports the extruded sheet to the cutting table.
Control
- Speed controlled by Delta MS300 VFD
- Speed measured in Hz
Typical Function
Maintains synchronization between extrusion rate and cutting speed.
Cutting Table
The cutting table aligns the dough sheet before entering the cutter.
Features
- Encoder synchronization
- Adjustable conveyor speed
- Product positioning stabilization
Cutter 1 – Primary Cutter
The first cutter performs the initial shaping or strip cutting of the product sheet.
Function
- Receives the dough sheet from the feed conveyor
- Cuts the sheet into product strips according to the configured width
Main Components
- Cutter motor with VFD control
- Cutting blade assembly
- Conveyor synchronization system
Adjustable Parameters
| Parameter | Description |
|---|---|
| Cutter Speed | Blade rotation speed |
| Conveyor Speed | Synchronization with product flow |
| Strip Width | Determines width of protein bar strips |
Operation
- Dough sheet enters from the extruder section.
- Cutter 1 performs the initial cutting operation.
- Product strips continue moving to the second cutter.
Cutter 2 – Final Cutter
The second cutter performs the final sizing of the protein bars.
Function
- Cuts the strips produced by Cutter 1 into final bar lengths.
Main Components
- Motor-driven cutter assembly
- Encoder synchronization
- PLC timing control
Adjustable Parameters
| Parameter | Description |
|---|---|
| Bar Length | Final product length |
| Cutter Speed | Motor frequency |
| Synchronization Timing | Matching product flow speed |
Operation
- Strips from Cutter 1 move along the conveyor.
- The PLC synchronizes cutter timing using encoder feedback.
- Cutter 2 divides the strips into final bar pieces.
Important Operational Note
For consistent product dimensions:
- Cutter speeds must match conveyor speed.
- Improper synchronization may cause:
- uneven bar lengths
- product deformation
- conveyor blockage.
All synchronization is controlled automatically by the PLC and encoder feedback system.
Retraction Section
Configuration
The retraction unit contains:
- Autopanning Machine 1 with Bottom Conveyor
- Autopanning Machine 2 with Bottom Conveyor
Both machines operate sequentially to control product spacing and ensure sm ooth transfer to the next section.
Autopanning Machine 1
Function
- Receives bars from the distance conveyor
- Stabilizes product movement
- Maintains uniform spacing between bars
Components
- Bottom conveyor
- Gear motor with VFD control
- Product guide system
Adjustable Parameters
| Parameter | Description |
|---|---|
| Conveyor Speed | Controlled through VFD frequency |
| Product Spacing | Controlled through PLC timing |
| Conveyor Direction | Forward/Reverse control |
Autopanning Machine 2
Function
- Receives product from Autopanning Machine 1
- Further regulates spacing
- Transfers product to the split conveyor
Components
- Bottom conveyor
- Motor with VFD control
- Product transfer guides
Adjustable Parameters
| Parameter | Description |
|---|---|
| Conveyor Speed | VFD frequency control |
| Product Transfer Speed | Synchronization with upstream conveyors |
| Product Spacing | Controlled through PLC logic |
Operational Note
Both autopanning conveyors must remain synchronized with upstream conveyors and cutters.
Incorrect speed settings may cause:
- Product stacking
- Irregular spacing
- Product deformation
Speed synchronization is maintained through PLC control and VFD frequency adjustments.
Guillotine Cutter
The guillotine cutter divides the sheet into bars.
Control Method
- Encoder-based synchronization
- PLC-controlled cutting cycle
Adjustable Parameters
| Parameter | Description |
|---|---|
| Cutting Length | Product bar length |
| Cutter Frequency | Motor speed |
| Cutter Delay | Timing adjustment |
Distance Conveyor
The distance conveyor creates separation between bars after cutting.
Function
- Prevents product overlap
- Maintains proper spacing before retraction
Control
Speed adjusted through VFD frequency.
Split Conveyor
The split conveyor transports products toward the final output.
Functions
- Product alignment
- Maintaining spacing
- Continuous transfer to delivery conveyor
Delivery Conveyor
The delivery conveyor is the final stage where finished protein bars exit the system for:
- Further processing
Recipe Management
The system supports multiple programmable recipes.
Example:
| Recipe | Product Thickness |
|---|---|
| Recipe 1 | 3 mm |
| Recipe 2 | 10 mm |
Loading a Recipe
- Open Recipe Selection screen.
- Select required recipe.
- Press LOAD.
- PLC automatically updates machine parameters.
Parameters automatically adjusted:
- Extruder gap
- Conveyor speeds
- Cutter timing
- Retraction speeds
HMI Interface Description
Main Screens
Line Overview
Displays:
- Machine sections
- Conveyor operation
- Machine status
Settings Screen
Adjustable parameters include:
- Retractor reverse delay
- Retractor forward delay
- Tray sensor delay
- Conveyor bypass options
Recipe Screen
Used for loading and managing production recipes.
Section Screens
Separate screens allow monitoring of each machine section:
- Extruder
- Cutting Section
- Retraction Section
- Split Conveyor
These screens display:
- Motor frequencies
- Operational status
- Parameter values
PLC I/O Monitoring
The HMI provides real-time monitoring of PLC signals.
Input Signals
Examples:
- Cutter encoder
- Product sensor
- Emergency stop
- Start push button
- Retraction home sensor
- Tray sensor
- Safety guard switches
Output Signals
Examples:
- Conveyor motors
- Cutter motor
- Retraction actuator
- Alarm buzzer
- Indicator lamps
Machine Start Procedure
Follow this sequence to start production.
Step 1
Check that:
Emergency stop buttons are released Safety guards are closed Power supply is available
Step 2
Turn ON the control panel.
Step 3
Allow PLC and HMI to initialize.
Step 4
Load required product recipe.
Step 5
Verify all sensors and I/O signals.
Step 6
Start conveyors.
Step 7
Start extruder.
Step 8
Start cutter.
Step 9
Begin feeding dough into hopper.
Machine Stop Procedure
- Stop dough feeding.
- Stop extruder motor.
- Stop cutter operation.
- Stop all conveyors.
- Turn OFF control panel if necessary.
Safety Instructions
Strictly follow safety procedures.
- Do not operate machine with open guards.
- Keep hands away from moving parts.
- Use emergency stop in case of malfunction.
- Perform maintenance only after power isolation.
Preventive Maintenance
Daily
- Clean conveyors
- Inspect sensors
- Check product buildup
Weekly
- Inspect belts and couplings
- Verify VFD operation
- Check encoder signal stability
Monthly
- Tighten electrical connections
- Inspect servo mechanism
- Check PLC cabinet ventilation
Troubleshooting Guide
| Problem | Possible Cause | Solution |
|---|---|---|
| Uneven bar thickness | Extruder gap incorrect | Adjust servo setting |
| Incorrect bar length | Encoder misalignment | Inspect encoder |
| Conveyor not running | VFD fault | Reset drive |
| Cutter not operating | Safety guard open | Close guard |
Technical Specifications
| Parameter | Value |
|---|---|
| Product Thickness | 3 mm / 10 mm |
| Line Length | 7m |
| Control Voltage | 24 V DC |
| PLC Platform | Schneider Modicon |
| Drive Type | Delta MS300 VFD |
System Advantages
- Automatic recipe changeover
- Precise thickness control using servo mechanism
- Encoder synchronized cutting
- PLC based automation
- Flexible production speeds
Recommended Operating Practice
For stable production:
- Maintain constant dough consistency
- Ensure conveyors are synchronized
- Avoid excessive feed rate at extruder
- Regularly inspect sensors and encoders
Electrical layout:
