Doug Trovinger

Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 1 of 67 PROHIBITED It is unacceptable to begin operation of the line without verifying that all equipment is safety installed and is in location prior to starting up. No food or drink should be near workstation machinery or equipment which has raw or cooked product being produced. Due to the nature of some equipment, pinch or cut hazards may result in serious or debilitating injuries. Additionally, cellular phones are not recommended to be on the production floor to prevent product contamination. ATTENTION Caution is recommended around workstations within the Sun Chips production area due to following hazards: open flames, hot surfaces, product falling from conveyor belts, slip and pinch hazards, and high voltage panels. ACTIONS IN EMERGENCY SITUATIONS In the event of an emergency or a need to shut down equipment immediately, locate the nearest Emergency Stop button for the equipment that is the result. This also includes Emergency Spill Kits, Eye Wash Stations, and First Aid Stations. Notify Facility Leadership or a Production Supervisor Immediately of any accident. Additionally, it is a requirement to report all accidents immediately after they occur. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 2 of 67 THE FOLLOWING PPE MUST BE WORN Shirts with no Buttons or Zippers, Steel-Toed Footwear, Safety Glasses, Hair, and Beard Nets (when necessary), CutResistant Gloves, and Ear Protection at a Minimum. Masks are not required but are recommended in select areas of the production line. Refer to the Good Manufacturing Practices (GMPs) for additional information and restrictions. CLEANING AND SANITATION POLICIES Refer to SSOP ##-### for Cleaning and Sanitation Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 3 of 67 Equipment Pre-Start Checks for Procedures 1. Check that all parts of the system are clean and free from damage. This includes the following: - Face of the Reading Extruder and all elements of the equipment Excessive lubricant Chippings and worn spirals Ensure that all equipment is unplugged prior to inspection. Caution! If any damage is observed, promptly report it to a Team Leader or a Line Manager Right away. Note: If any piece of equipment inspected is dirty and/or has excess product, it must be cleaned before continuing with the Setup process. Caution! If any damage is observed, submit a work order. If it is not in working condition, report it to Maintenance. Note: If any piece of equipment inspected is dirty and/or has excess product, it must be cleaned before continuing with the Setup process. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 4 of 67 2. Verify that all Emergency Stop (E-Stop buttons) have been disengaged. If they have been, continue to Step 3 of the process. Note: If any Emergency Stop buttons are engaged or pushed in, equipment will not run until they are pulled and disengaged. 3. Ensure all wheel locks are firmly in place before starting any equipment. Shifting of equipment may result in significant product waste, components coming undone while production occurs, personal injuries, and/or equipment damage. 4. Make sure all bolts and tools are available to complete the assembly of the Extruder and delay the Startup of the production line. If any items are missing, notify a Line Supervisor or Manager promptly. 5. Inspect the Extruder Drives and see if any residue is left over from cleaning and sanitation. If there is, a second wash through may be required. Once cleared, press the GREEN button to close the Extruder (the RED button opens it). Note: Make sure no tools are in the enclosure area of the Extruder when closing. Also stay away from it when closing as significant injuries including amputation may occur. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 5 of 67 Tool Requirements for Procedures Listed 6. The following tools are needed to safely setup the equipment: - 10mm and 3/16” Allen Wrenches 24mm and 5/8” Socket Wrenches 1/2" Ratchet Wrench with Extension Cart with a Small Scale to Complete Catch Tests Site-Approved Heat Resistant Gloves Site-Approved Squeegee (to remove excess water into drain), Broom and a Dustpan Stopwatch SETUP Initial Setup for Extruder Equipment 7. To start, install the Extruder Square Plate. Then, align and put the screen back into the plate. Note: Depending on the cleaning process before, this may already be Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 6 of 67 installed except for the bolts as described in the step 9. 8. Lube all eight (8) larger screw holes and the three (3) smaller holes on the Extruder Square Plate with a Food Grade NSF H1 Anti-Seize and Lubricant. 9. Use the following tools to screw in the eight (8) large screw holes and four (4) smaller ones on the Plate: a. Large Screws: 24mm Socket Wrench with a 1/2" Ratchet with Extension b. Small Screws: 10mm Allen Wrench The smaller bolts should be screwed in the front part of the Extruder (away from you) and the larger ones in the back (closer to you). Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 7 of 67 10. There are times where the Die Extruder Unit will need to be cleaned and cleared before starting the Extruder. If necessary, begin by unscrewing the TOP two (2) bolts on the side. Use a 5/8” Socket Wrench with a 1/2” Ratchet with Extension. Clean and reinstall. Note: If the Die Extruder Unit is in acceptable condition and does not require a reclean, skip to Step 11 of the process. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Document Number Reviewed by Approved by (EHS) Need Document No. Approved by (QFS) Version Number Release Date Page 1 8 of 67 11. Next, the Die Face Plate will need installed. You will need to install a total of 13 3/16” bolts on the top row and 14 on the bottom row. Make sure the gasket is inserted in the faceplate. Utilize the pattern below to correctly install the screws: ------------------------------------------------------------------(Left Side) >>>>>>>>> END <<<<<<<<< (Right Side) A C E G I K A C E G I K M M M L J H F D B L J H F D B (Diagram of the Die Face Plate) ------------------------------------------------------------------- Note: To ensure there is equal tightening on the Plate, start with the ends (A and B) and work your way towards the middle part of the Plate (M). This ensures the tightening is consistent on both sides and is not stronger on one side versus the other. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 9 of 67 12. Next, install the Extruder End Plate with the Temperature Gauge at the end of the Extruder as shown. The gauge should be pointing up vertically. Once in place, bring the front end of the Extruder together with this part as shown on the right. 13. Add a step to hook up the 2 black hydraulic hoses on the screen pack by the side where the operator will be standing. (Click pictures for this) 12. 13. Insert a pair of BLACK hydraulic hoses on the Extruder. These are installed by the side where the Operator stands. Hand tighten in place so they are tightly installed on the Extruder. Caution! Placing the hydraulic hoses loosely on the Extruder will result in fluid spilling onto the equipment and popping off during production. Thus, equipment damage and personal injuries may result. Insert a pair of BLACK hydraulic hoses on the Extruder. These are installed by the side where the Operator stands. Hand tighten in place so they are tightly installed on the Extruder. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 10 of 67 Caution! Placing the hydraulic hoses loosely on the Extruder will result in fluid spilling onto the equipment and popping off during production. Thus, equipment damage and personal injuries may result. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 11 of 67 14. Continue by plugging in the Red Power Cord and two (2) Thermal Couples. The longer one (without tape) takes the temperature of the Extruder whereas the shorter one (with tape around it) takes temperature readings for the Die Plate. 15. Go to the Extruder OIT screen. Check the temperatures of the two (2) probes. If they are put on backwards, they will provide a false reading and high temperature. They will then need to be reinstalled in the correct order. Correctly Installed Incorrectly Installed (Backwards) (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 12 of 67 16. Insert the Extruder Screen and Filter Puck into the Screen Pack. Note that on average each screen can be used for about 60-90 minutes at a time while production take place and the Extruder Die Plate temperature is above 175o Fahrenheit. 17. After the screen is put in, hook up the two (2) YELLOW Hydraulic Hoses to circulate fluid hot water fromwater from the Mokon Water Heater through the Screen Pack assembly. One will feed fluid in and the other will circulate it out. 18. Next, install the two (2) Continental hoses so that hot water from the Mokon Water Heater can flow in and out of the Die Plate. Make sure these are tightly installed. Warning! Hoses that are improperly installed on the Die Plate will result in equipment damage, scalding hot water spewing out of the connections, and a tripping hazard due to wet floors. Tightly check connections before continuing to the next step. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 13 of 67 Initial Setup for Mokon Water Heater 19. Start by checking that there is no leftover water or residue on the equipment or hoses. Note: Hoses should be fully drained prior to operation to prevent residue or possible contaminants flowing between pieces of equipment. 20. Insert the Infeed and Outgoing Water hoses to the Mokon Water Heater if not already done so. Then, turn the Incoming Water Hose Valve to the ON position before turning the Mokon on. Wait 30 MINUTES before continuing to the next step to prevent the motor from burning up and water is in the heating vessel unit. 21. Once the Heater is up to temperature, hook the hoses into the back of the Mokon that will distribute water to the Die Plate of the Extruder. Also, turn on the Water Valve. Set the clear hose into the drain as shown in the bottom picture. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 14 of 67 Initial Setup After Mokon Water Heater is Ready 22. Go to the Extruder OIT Screen to heat the cylinder. Start by clicking on the GREY Barrel Temps button in the middle of the screen. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 15 of 67 23. Set the temperature points based on the Test Plan or recipe being executed. Always start with the DIE TEMP first (last set of buttons on the right). a. Enter the value for the Heater Band (Zone 6) on the keypad that displays on the right side. Press OK. b. A confirmation box will pop up showing the existing temperature and updated temperature. To confirm press the YES, I’m Sure button. c. Repeat the process starting with Zone 5 and go backwards to Zone 2. Do not change values for Zones 1, 7, 8, or 9. Note: In most cases, the following temperatures will apply to Zones 5 through 2: - Zone 5: 325oF Zone 4: 320oF Zone 3: 200oF Zone 2: 150oF Always check the Test Plan or recipe for actual values used as they may vary from this. 24. Press the HEAT SYSTEM button (currently as a RED box) located towards the top and central part of the OIT screen. Press the AUTO button. Confirm the action by clicking OK and then EXIT. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 16 of 67 25. Confirm the Barrel and Heating Band are heating up. See the flashing ORANGE block on the screen. 26. Press the HEAT SYSTEM button (currently as a RED box) located towards the top and central part of the OIT screen. Press the AUTO button. Confirm the action by clicking OK and then EXIT. 27. Confirm the Barrel and Heating Band are heating up. See the flashing ORANGE block on the screen. Cutter Conveyor and Auxiliary Drive System Setup for Extruder Workstation (change this whole Cutter procedure and pictures Steps 28 to 42) 26. Move the Cutter Conveyor into position and centrally locate it between the two open sides of the cage as shown(Step)Place the Cutter Conveyor in position so that it product exits out of the Extruder and onto the belt. At least TWO (2) Team Members will need to be available to move the equipment into place as it is long and heavy.. Note: Make sure that the conveyor on the other end has enough clearance to drop product into the Fryer. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 17 of 67 28. 27. Ensure that the Wheel Locks are fully engaged so that the conveyor will not rock back and forth when product transfers from the Extruder to the Fryer. 28. Insert the BLUE plug into the EXIT CONVEYOR DC DRIVE plug. Then, plug in a pair of 110V plugs for the Infeed Conveyor and Cutter. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 18 of 67 29. Next, insert the ORANGE Air Hose and plug it into its designated opening. Make sure that it is tightly fitted so it does not pop out during production. 30. Proceed to the Fryer OIT screen to engage the Cutter Belt. Press the Extruder Tab located at the bottom of the screen. Then, press the GREY ‘To Extruder’ button located in the middle. Once the next screen pops up, click on the Cutter Conveyor Motor button on the right (the icon next to where you see 28 FPM). In the pop-up box, press the START button, then OK, and EXIT. This will activate the conveyor in Manual Mode and turn it GREEN as seen in the last picture of this step. Note: If you need to change the speed of any component, click on the black boxes with YELLOW text. Here, you can (a) manually enter in the speed, (b) use the buttons to incrementally move it up or down, or (c) use the dials and adjust it as you see fit. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 19 of 67 31. Walk over to the Wood’s Control Panel and move the switch up to the START position. Adjust the speed of the cutter as needed. Rarely will the torque need adjusted and should only be done if the Test Plan or recipe requires it. Note: If the product is too small, adjust the Cutter by reducing the speed. Otherwise, if product is too big, increase the cutter speed so it moves more quickly. 32. Finally, go to the E-Trol Control Panel and move the power switch to the RUN position (left). Adjust the speed of the Infeed Conveyor if needed by moving the dial in the center of the unit. The default speed is 40 feet per minute (FPM). Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 20 of 67 29. Attach the Cutter to the Cutter Hub. Use a 9/16” wrench to tighten the bolts. ( Warning! Be extra careful when screwing in the bolts. Watch out for hot parts behind the Cutter Hub. Burn injuries may result if the equipment is touched. Cutter Cutter Hub Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 21 of 67 30. Close the Cutter Cage by pushing both sides inward until the Cutter is enclosed on both sides. Make sure the red clamp is tight holding both sides of the Cage closed. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 22 of 67 31. Plug the Cutter into its designated Power Outlet. Also connect the rectangular RED Safety Switch into the Cutter Conveyor. Make sure the two contacts touch each other. 32. Next, plug a set of two (2) plugs from the Cutter Conveyor into the Extruder. The Conveyor (M36) will be the TOP plug and the Cutter (M35) will be the bottom plug. These plugs are on the side of the machine below a RED Emergency Stop button. Note: Verify the right plugs are inserted into their correct outlet. If they are inserted in an opposite direction, the equipment will not be recognized by the Extruder OIT screen. 33. Place the two (2) Cutter Guards on the front and back of the Cutter System. This aids in preventing excessive product being spilled onto the floor. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 23 of 67 34. Go to the Extruder OIT Screen. Do an equipment run test of the Cutter Conveyor Belt and Cutter System. a. Click on the RED EXT AUTO SYSTEM button in the upper right-hand corner of the screen. Press the HAND button. When it prompts you confirming the choice, press YES. Press EXIT once the Prompt turns MAGENTA (PURPLE). b. Next, click on the MAIN CUTTER (M35) ICON. Within the popup menu, press the START button. This prompt, like the last will turn a MAGENTA color as shown. c. Finally, to turn on the AUXILLARY DRIVE (or Cutter Conveyor; M36), click on the icon and turn on the machine (as explained in the previous step). d. Observe the cutter conveyor and cutter operating. If there are any abnormalities, reinstall and work through Steps 48 through 54 before doing a second test. Otherwise, continue. e. To complete the test, repeat same process as denoted with sub-steps a through c above except pressing the STOP button in each of the three locations. (Step 36a) Caution! While completing the test, DO NOT touch any of the components while in operation. Additionally, DO NOT open the safety cage either. Equipment damage and personal injury (including possible amputation of limbs) may result. (Step 36b) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 24 of 67 (Step 36c) (Step 36d) (Step 36e) 35. Once all equipment is stopped, the Extruder will go into a cool-down phase. Zones that complete this cycle will have the box on the OIT screen turn from ORANGE to TURQUOISE and flash. 36. After the test has been completed, use two (2) Team Members to strategically move the Cutter Exit Conveyor to the end of the Cutter Conveyor Belt already in position. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 25 of 67 Cutter Exit Conveyor Setup at the Extruder Workstation 37. Move the Cutter Conveyor into position and centrally locate it between the two open sides of the cage as shown. Insert the Curtain Flaps underneath the chute and dangle straight down. Note: If the curtain flaps are tangled or inconsistently hung, product will exit unevenly onto the belt and possibly onto the floor. 38. Plug in the equipment and turn on the power to the Belt. 39. Click on the BLUE MAINT button in the lower left-hand corner. When the keypad comes up, enter 4040 as the password and then the Enter Key. Press the MAIN button in the lower left-hand corner. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 26 of 67 40. Within the Maintenance menu, click the MODE button in the lower left-hand corner. Press the YELLOW STAND-ALONE button and then the BLUE MAINT button, and then the BLUE MAIN button (see top picture) in the upper left-hand corner of the screen. 41. Press the BLUE RESET button several times (usually four (4) to five (5)) until the icons LOCAL READY and MOTOR READY turn GREEN as shown. (Prior to Reset) (After Successful Reset) (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 27 of 67 42. Press the FREQ UP button until the CMH HZ value reaches 20.00. After the value has been set, press the GREEN START button to complete the Extruder Workstation setup process. STARTUP Recipe and Extruder Setpoints 1. Begin with accessing the Extruder OIT screen. Press the ACTIVE RECIPE button on the bottom of the screen. 2. Using information furnished from the Test Plan or recipe, click on all buttons to input values for the Extruder Setpoints, Startup, and Shutdown. Only enter in values for the Half-Rate column if (a) emergency issues or (b) equipment malfunctions and needs troubleshot/repaired. Once complete, click on the Extruder tab on the bottom of the screen. 3. Next, confirm there is water at the Die Plate Place the Extruder system into AUTO mode so product can be extruded. Click YES when the prompt comes on the screen. The BLUE text transitions from “STANDBY – CONFIRMATION” to “RAMP UP” and finally “PRODUCTION.” Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 28 of 67 4. Go to the Mixer and confirm product is mixing properly and to the point it can begin to be worked through the Extruder. 5. Once product has been observed going into the Extruder, go to the OIT screen and turn on the Die Cutter Motor and Auxiliary Cutter When turned on, these will both be highlighted in MAGENTA on the screen. 6. Observe product working through the equipment as production begins and the Startup sequence completes. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 29 of 67 STARTUP Recipe and Extruder Setpoints 1. Begin with accessing the Extruder OIT screen. Press the ACTIVE RECIPE button on the bottom of the screen. 2. Using information furnished from the Test Plan or recipe, click on all buttons to input values for the Extruder Setpoints, Startup, and Shutdown. Only enter in values for the Half-Rate column if (a) emergency issues or (b) equipment malfunctions and needs troubleshot/repaired. Once complete, click on the Extruder tab on the bottom of the screen. 3. Next, confirm there is water at the Die Plate Place the Extruder system into AUTO mode so product can be extruded. Click YES when the prompt comes on the screen. The BLUE text transitions from “STANDBY – CONFIRMATION” to “RAMP UP” and finally “PRODUCTION.” Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 30 of 67 4. Go to the Mixer and confirm product is mixing properly and to the point it can begin to be worked through the Extruder. 5. Once product has been observed going into the Extruder, go to the OIT screen and turn on the Die Cutter Motor and Auxiliary Cutter When turned on, these will both be highlighted in MAGENTA on the screen. 6. Observe product working through the equipment as production begins and the Startup sequence completes. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 31 of 67 OPERATION Equipment Operation Pre-Start Checks 1. Confirm there is enough product consistently working through the Mixer and Wheat Product workstation to minimize gaps and production delays. Refill as needed. 2. Periodically observe product as it works through the different pieces of equipment notating any significant changes in temperature, speed, and other variables against Test Plan or recipe requirements. 3. Perform a three (3) Catch Tests to ensure proper operation of the Extruder. One is dedicated to Wheat whereas another is for Dry Mixes, and the third is for Water going through the Extruder. Have a GRAY cart with a small scale and table available to complete tests. This should be done with TWO (2) Team Members – one being a timekeeper and the other performing the require actions. Catch Test #1 – Wheat Product 4. To complete a Catch Test, place paper towel around the Discharge end of the Extruder. Place a larger Catch Container below the hole. 5. Begin this catch test by going to the Wood’s E-Trol to get the correct speed based on the number of pounds per hour the Test Plan calls for. 6. Using a Stopwatch, complete a Catch Test to determine how much product is produced in a one-minute timeframe. The Team Member keeping time should announce when there is 5, 4, 3, 2, and 1 second left in the test. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 32 of 67 (Procedure Continues on the Next Page) 7. Using the cart with the small scale, tare the scale (with the empty bucket) so it has a zero reading before putting the container on it (upper picture). Once the container is taken off, it should have a negative value as shown in the lower picture of this step. 7.8. Use the following formula below top determine the number of pounds per hour the Extruder is producing. See the graphic to the right for an example of the formula and the weight used to get the value: 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = Weight Collected (g) × 60 Minutes 454  Sample Calculation For 237.0g Weight  𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = 237.0g × 60 Minutes 454 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = Version Number Release Date Page 1 33 of 67 14,220 454 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = 31.32 8.9. Compare the weight from the Catch Test to the Test Plan or recipe for weight targets. If there is a significant variance, apply the following actions below: a. If the weight is LOWER, move the Auger % up in two (2) percent intervals b. If the weight is HIGHER, move the Auger % down in two (2) percent intervals Repeat the catch test until it is within +/- three (3) pounds of the weight targets on the Test Plan or recipe Catch Test #2 – Water Catch Test 9.10. Start by going to the going to the Extruder OIT screen. Press the EXTRUDER menu button tab on the bottom. Then, press the Water Pump icon on the left side of the screen. Once the pop-up box comes up, press the ON button. (Procedure Continues on the Next Page) 10.11. Start by taking the small clear house out of the Extruder. Then, set the stopwatch for one (1) minute and repeat the process as provided in Step 6. 11.12. Go back to the Extruder OIT screen and turn off the water pump. Press the Water Pump icon and then the OFF button in the pop-up box. Then, press Exit. This will shut down the water pump post-test. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 34 of 67 12.13. Use the following formula below top determine the number of pounds per hour the Extruder is using in terms of water content. See the graphic to the right for an example of the formula and the weight used to get the value: 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = Weight Collected (g) × 60 Minutes 454  Sample Calculation For 488.8g Weight  𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = 488.8g × 60 Minutes 454 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = 29,328 454 𝑂𝑢𝑡𝑝𝑢𝑡 𝑃𝑒𝑟 𝐻𝑜𝑢𝑟 (𝑙𝑏𝑠. ) = 64.60 13.14. Perform at least one ADDITIONAL Catch test to get closer to the targeted value as outlined in the Test Plan or recipe. Adjust the water flow if the variances are significantly off high or low comparable to the target amount. Catch Test #3 – Dry Mix Catch Test 15. To begin this final Catch Test, confirm the K-Tron is in Gravity Mode. If it is already in Gravity Mode, skip to Step 20 of the process. Otherwise, continue with turning on the equipment and calibrating the machine for this mode. 16. Using the cart with the small scale, tare the scale (with the empty bucket) so it has a zero reading before putting the container on it. 17. Press the HOME key on the panel and wait about two (2) to three (3) seconds before doing the catch test. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 35 of 67 18. To complete the Catch Test, press, the GREEN RUN button. Complete the same process as mentioned in Step 6 of this part of the procedure to do an accurate test. After the minute, press the RED STOP button on the Keypad. The results will display on the Control Panel Screen. 19. If the results are significantly higher or lower than the stated values provided with the Test Plan, make necessary adjustments and complete additional Catch Tests. Otherwise, continue with the procedure. 20. Once the Catch Tests have been completed and are within acceptable limits as outlined in the Test Plan, product production can begin. (Procedure Continues on the Next Page) Catch Test #3 – Dry Mix Catch Test 14. To begin this final Catch Test, confirm the K-Tron is in Gravity Mode. If it is already in Gravity Mode, skip to Step 20 of the process. Otherwise, continue with turning on the equipment and calibrating the machine for this mode. 15. Using the cart with the small scale, tare the scale (with the empty bucket) so it has a zero reading before putting the container on it. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 36 of 67 Press the HOME key on the panel and wait about two (2) to three (3) seconds before doing the catch test. To complete the Catch Test, press, the GREEN RUN button. Complete the same process as mentioned in Step 6 of this part of the procedure to do an accurate test. After the minute, press the RED STOP button on the Keypad. The results will display on the Control Panel Screen. If the results are significantly higher or lower than the stated values provided with the Test Plan, make necessary adjustments and complete additional Catch Tests. Otherwise, continue with the procedure. Once the Catch Tests have been completed and are within acceptable limits as outlined in the Test Plan, product production can begin. If the K-Tron is OFF, start by pressing the MENU button on the Control Panel Screen. Scroll down to the CALIBRATION option and press ENTER. 16. Replace steps 16 – 20 and pictures with new steps to tare scale. 17. Within the CALIBRATION menu, scroll down using the NEXT key. Choose the FEEDFACTOR option and press ENTER. Make sure the REFILL ARRAY option is set to ON. If it is OFF, press the ENTER key to change. Once this is completed, press the MENU key to get back to the main screen of the K-Tron Control Panel. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Approved by (QFS) Need Document No. Version Number Release Date Page 1 37 of 67 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 38 of 67 18. To start preparing for the test, press the MENU button on the K-Tron Control Panel. Then, scroll to the CALIBRATION option and press the ENTER key. 19. Once you’re in the CALIBRATION screen, press the CALIBRATION choice again. Then, choose the AUTO CALIB FF option (third one on the screen) and press ENTER. It will then prompt you to execute an automatic calibration (AUTO FF CALIB). Press the ENTER key to acknowledge the request. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 39 of 67 20. Press the GREEN RUN button to start the warm period prior to doing a catch test. Wait 10-15 seconds to do the test so there is consistent product flow. This will ensure the K-Tron is ready to complete a test accurately. Note: Failure to complete the warmup period will result in in correct results from the Catch Test sample. Do not skip this step to get accurate results. 21. Press the HOME key on the panel and wait about two (2) to three (3) seconds before doing the catch test. 22. To complete the Catch Test, press, the GREEN RUN button. Complete the same process as mentioned in Step 6 of this part of the procedure to do an accurate test. After the minute, press the RED STOP button on the Keypad. The results will display on the Control Panel Screen. 23. If the results are significantly higher or lower than the stated values provided with the Test Plan, make necessary adjustments and complete additional Catch Tests. Otherwise, continue with the procedure. 24. Once the Catch Tests have been completed and are within acceptable limits as outlined in the Test Plan, product production can begin. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 40 of 67 Operating the Extruder 21. (Step).To operate the Extruder, begin by going to the OIT Control Panel and then press the EXTRUDER tab located at the bottom of the screen. 22. Check to confirm that the funnel is installed properly because it has a sensor inside or it will not engage equipment. 23. Back at the OIT screen, press on the Barrel Temp button located in the upper left part of the screen. Once the pop-up comes on the screen, press the AUTO button (which will turn YELLOW), and then Exit. The icons showing different parts of the barrel will either flash RED (signifying it is heating up) or GREEN (which denotes it being too hot and cooling down). 24. Next, you will need to setup the Extruder Ramp system. This button is on the upper left-hand corner of the screen. Start by clicking on the Extruder Drives button located in the middle of the screen. Press the START button and then EXIT. Repeat the same process for the Extruder Ramp System. These will both turn YELLOW as illustrated in the bottom picture. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 41 of 67 25. Ramp up the system for 60 seconds. Once the Water Stable status changes to a GREEN dot, proceed with turning on the Dry Mix and Wheat. Operating the K-Tron by The Extruder 26. Begin by going to the K-Tron Control Panel. Press the MENU button and scroll down until you get to the SCALE option. Press the ENTER key. 27. Next, choose the GENERAL OPTION and press ENTER. Continue by choosing the AUTO TARE option and then pressing the ENTER key. Finally, it will prompt you to confirm a new tare needs to be initiated. Press the ENTER key one additional time and it will complete the tare. 28. Operate the K-Tron as needed throughout the production run. When completed with its use, press the RED STOP button (located next to the 6 key). Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Approved by (QFS) Need Document No. Version Number Release Date Page 1 42 of 67 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 43 of 67 SHUTDOWN Extruded Product Exhaustion (Replace with steps and pics for Sun Chips Extruder Shutdown) 1. Make sure that all product has been exhausted and gone through the Extruder workstation. Note: Do not begin the Shutdown process while product is in transit through the workstation and transitions from the Cutter Exit Conveyor. Significant product waste will result if the equipment is shut down prematurely. System Shutdown on OIT Screen and Switch Turnoffs 2. Begin by going to the Extruder OIT screen. On the MAIN screen, press the RED AUTO SHUTDOWN button located in the upper right-hand corner. When the pop-up message comes up to acknowledge the decision, press the CONFIRM button and then EXIT.Begin by changing the temperatures of the Extruder and Mix Temperature on the OIT screen. Adjust the water temperature setpoint in each one of the five (5) zones to approximately 90o. For the mix setpoint, it can be between 100o and 150o Fahrenheit. Complete this step for about one minute (or 60 seconds). Note: When shutting down the Extruder, the wetter the dough, the better it will be to clean. 3. Next, press the EXTRUDER tab again on the bottom of the screen. Press the Barrel Temp button and then the OFF key. Touch the Exit button once complete. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 44 of 67 3.4. Product will complete through the workstation from near the Hapman Hopper onwards. It will take approximately one (1) minute for product to exhaust from the Extruder to the Cutter Exit Conveyor.While on that screen, manually turn on cold water for each zone starting with Zone 1 and then working your way to the right to Zone 5. Mokon Water Heater Shutdown 5. To start, verify that the CLEAR plastic tube is in the drain so that the vessel empties properly and not onto the floor. Note: Make sure the hose is fully in the drain so that hot water flows directly into it. Spillage onto the floor results in a tripping hazard and potential burn injuries from splashing that occurs if someone falls into the hot liquid. 6. Walk over to the Mokon Water Heater. Press the BLACK Auto Cool Shutdown button. Reset the temperature of the equipment to 80o degrees Fahrenheit. Note: As cool water enters the Extruder, sweat and condensation will be visible on the equipment. This is a positive sign that it is cooling down. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Approved by (QFS) Need Document No. Version Number Release Date Page 1 45 of 67 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 46 of 67 7. Once the temperature reaches the range above, press the RED STOP button. This will shut off the Mokon Water Heater. This is in the top row of buttons as seen to the right. Unplug the YELLOW hoses from the Die Screen Plate and store away by the Support Post off the floor. Hang down so that excess liquid can drain onto the floor and into the drain. Keep the BLACK hydraulic hoses in place. 8. Go back to the OIT screen and close all water valves in each of the Extruder zones. Then, press the Auto System button on the screen, then Extruder Drives. When the pop-up comes on the screen, press the STOP button and then exit. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 47 of 67 4.9. Next, press the EXT AUTO SYSTEM button. When the pop-up comes onto the screen, press the OFF button, CONFIRM, and then EXIT. 5. Next, press the EXT AUTO SYSTEM button. When the pop-up comes onto the screen, press the OFF button, CONFIRM, and then EXIT. [END NEW MATERIAL FOR EXTRUDER SHUTDOWN] 10. Use a Site-Approved Squeegee to mop up any excess water or liquids that have deposited onto the floor into a drain to prevent slips and falls. Mokon Water Heater Shutdown 6. To start, place verify that the CLEAR plastic tube is in into the drain so that the vessel empties properly and not onto the floor. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 48 of 67 Note: Make sure the hose is fully in the drain so that hot water flows directly into it. Spillage onto the floor results in a tripping hazard and potential burn injuries from splashing that occurs if someone falls into the hot liquid. Cutter Conveyor System Shutdown 11. Begin by going to the Fryer OIT screen to start the shutdown process of the equipment. Click on the Cutter Conveyor motor (the icon next to where you see 28 FPM). Press the STOP button which is below the GREEN highlighted square in the pop-up box. This will shut down the equipment as seen in the third picture. Repeat this process for the Cutter Belt and Infeed Conveyor. 12. Once all product has moved through the conveyors and into the Fryer, unplug the Cutter Conveyor, Cutter Belt, and Infeed Conveyor. Then unhook the ORANGE Air Pressure Hose and set aside. (Procedure Continues on the Next Page) (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Approved by (QFS) Need Document No. Version Number Release Date Page 1 49 of 67 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 50 of 67 TEARDOWN Teardown of Extruder 1. To begin, unhook the two (2) YELLOW Hydraulic Water Hoses that circulate fluid throughout the Screen Pack Assembly. Caution! Due to the weight of select pieces of equipment that require to be uninstalled, it is recommended to have TWO (2) Team Members available to complete the tasks. 2. Next, take out the Extruder Screen and Filter Puck that was last used before production was finished in the Extruder workstation. Depending on the temperature, it is recommended to use Heat-Proof Gloves to perform this task. Place on a cart so that parts removed from the Extruder are in a single location. 3. Remove the BLACK Hydraulic Hoses from the Extruder. Place them on the cart or designated area other equipment is positioned when removed from it. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 51 of 67 (Procedure Continues on the Next Page) Remove the BLACK Hydraulic Hoses from the Extruder. Place them on the cart or designated area other equipment is positioned when removed from it. Remove the black Hydraulic hoses. 3. Unplug the Red Power Cord and two (2) Thermal Couple links. Place the links off to the side but in a location that can be easily accessed postclean and sanitation. 4. Unplug the RED Power Cord and pair of Thermal Couple links. Place the links off to the side but in a location that can be accessed post-clean and sanitation. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 52 of 67 4.5. Separate the Extruder End Plate with the Temperature Gauge at the End of the Extruder. Depending on how tight it is, it may require an additional Team Member and/or a tool like a crowbar to separate. Use caution as parts may still be hot. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Document Number Reviewed by Approved by (EHS) Need Document No. Approved by (QFS) Version Number Release Date Page 1 53 of 67 6. Next, remove the Die Face Plate will need installed. You will need to take out a total of 13 3/16” bolts on the top row and 14 on the bottom row. Utilize the pattern below to correctly install the screws: ------------------------------------------------------------------(Left Side) >>>>>>>>> END <<<<<<<<< (Right Side) A C E G I K A C E G I K M M M L J H F D B L J H F D B (Diagram of the Die Face Plate) ------------------------------------------------------------------- Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 54 of 67 5. Next, remove the Die Face Plate will need installed. You will need to take out a total of 13 3/16” bolts on the top row and 14 on the bottom row. Utilize the pattern below to correctly install the screws: ------------------------------------------------------------------(Left Side) >>>>>>>>> END <<<<<<<<< (Right Side) A C E G I K A C E G I K M M M L J H F D B L J H F D B (Diagram of the Die Face Plate) ------------------------------------------------------------------- 7. Carefully remove the BLACK gasket from the Die Plate after the bolts have been removed. 8. Take out the black gasket from the faceplate for sanitation. (get pic) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 55 of 67 Unscrewing the TOP two (2) bolts on the side. Use a 5/8” Socket Wrench with a 1/2” Ratchet with Extension. Place this piece on the cart. 9. Use the following tools to remove the eight (8) large screw holes and four (4) smaller ones on the Plate: a. Large Screws: 24mm Socket Wrench with a 1/2" Ratchet with Extension b. Small Screws: 10mm Allen Wrench The smaller bolts should be screwed in the front part of the Extruder (away from you) and the larger ones in the back (closer to you). Place all bolts onto the car separating them so they can be easily obtained after cleaning. 10. Next, uninstall the Extruder Square Plate. Once uninstalled, carefully place on the cart so that does it is not damaged. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 56 of 67 11. Finally, open the Extruder Drives. Press the RED button to open the Drives so they are exposed on the side Control Panel of the Extruder. (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 57 of 67 Use the following tools to remove the eight (8) large screw holes and four (4) smaller ones on the Plate: Large Screws: 24mm Socket Wrench with a 1/2" Ratchet with Extension Small Screws: 10mm Allen Wrench The smaller bolts should be screwed in the front part of the Extruder (away from you) and the larger ones in the back (closer to you). Place all bolts onto the car separating them so they can be easily obtained after cleaning. Next, uninstall the Extruder Square Plate. Once uninstalled, carefully place on the cart so that does it is not damaged. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 58 of 67 12. Finally, open the Extruder Drives. Press the RED button to open the Drives so they are exposed on the side Control Panel of the Extruder. 13. Clean any visible residue or moisture on the Extruder and surrounding area. Squeegee any excess liquid into nearby drains to prevent accidental falls. Discard any product waste into a WHITE Site-Approved Food Waste Bin. 14. Execute a Lock Out/Tag Out on the equipment. a. This is to inform the Cleaning and Sanitation Team that the equipment is ready to be cleaned and sanitized. b. Always use the BLUE LOTO lock and tags for Line Operator LOTOs. Note: Use the correct LOTO-colored lock to designate the equipment is ready for cleaning and sanitation. Using the wrong lock color may result in unnecessary time spent on maintenance or other repairs when the equipment is operable. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Approved by (QFS) Need Document No. Version Number Release Date Page 1 59 of 67 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 60 of 67 (Procedure Continues on the Next Page) (Procedure Continues on the Next Page) Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 61 of 67 Finally, open the Extruder Drives. Press the RED button to open the Drives so they are exposed on the side Control Panel of the Extruder. Clean any visible residue or moisture on the Extruder and surrounding area. Squeegee any excess liquid into nearby drains to prevent accidental falls. Discard any product waste into a WHITE Site-Approved Food Waste Bin. Execute a Lock Out/Tag Out on the equipment. This is to inform the Cleaning and Sanitation Team that the equipment is ready to be cleaned and sanitized. Always use the BLUE LOTO lock and tags for Line Operator LOTOs. Note: Use the correct LOTO-colored lock to designate the equipment is ready for cleaning and sanitation. Using the wrong lock color may result in unnecessary time spent on maintenance or other repairs when the equipment is operable. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 62 of 67 6. Finally, open the Extruder Drives. Press the RED button to open the Drives so they are exposed on the side Control Panel of the Extruder. 7. Clean any visible residue or moisture on the Extruder and surrounding area. Squeegee any excess liquid into nearby drains to prevent accidental falls. Discard any product waste into a WHITE Site-Approved Food Waste Bin. 8. Execute a Lock Out/Tag Out on the equipment. a. This is to inform the Cleaning and Sanitation Team that the equipment is ready to be cleaned and sanitized. b. Always use the BLUE LOTO lock and tags for Line Operator LOTOs. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 63 of 67 Note: Use the correct LOTO-colored lock to designate the equipment is ready for cleaning and sanitation. Using the wrong lock color may result in unnecessary time spent on maintenance or other repairs when the equipment is operable. Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 64 of 67 Test Questions & Sign Off Question Answer - The trainee must be able to demonstrate the safe operation of the equipment before sign off. Once this document has been trained to the operator alongside the sanitation document (if any), the documents should be signed by both the trainee & the trainer, then scanned and sent to the EHS Department. Trainee signature: Print name: Date: Trainer signature: Print name: Date: Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 65 of 67 Revision History t Questions & Sign Off Version Date Revised by Sections Modified Details of amendment Test Questions & Sign Off Question Answer - The trainee must be able to demonstrate the safe operation of the equipment before sign off. Once this document has been trained to the operator alongside the sanitation document (if any), the documents should be signed by both the trainee & the trainer, then scanned and sent to the EHS Department. Trainee signature: Print name: Date: Trainer signature: Print name: Date: Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Reviewed by Approved by (EHS) Doug Trovinger Document Number Approved by (QFS) Need Document No. Version Number Release Date Page 1 66 of 67 Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years. Dallas TPC Standard Operating Procedure Sun Chips Extruder Developed by Doug Trovinger Reviewed by Approved by (EHS) Document Number Need Document No. Approved by (QFS) Version Number Release Date Page 1 67 of 67 Revision History t Questions & Sign Off Version Date Revised by Sections Modified Details of amendment Printed copies of this document are for informational purposes only. Current up to date & controlled copy is located on a secure SharePoint site owned by the EHS Department. Archived documents to be kept for a minimum of five years.