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Operating Instruction CTC Triad Rolling Cutting Machine 1. Profile CTC Triad Rolling Cutting Machine is one set of machine combination for rolling cutting and pelleting fresh tea leaf in the CTC black pelleted tea production line, which shall be mainly used for three times continuously rolling cutting and pelleting to satisfy the CTC black pelleted tea specifications and facilitate the following fermentation and drying. The rolling cut and pelleted size can be controlled by adjusting the spacing between each couple of gear roller to satisfy the different black pelleted tea specifications.
2. Major Technical Specifications 1.Production capacity: standard fresh tea leaf 1200㎏/h； 2.Working gear roller face width：914mm； 3.Working gear roller diameter：210mm； 4.Fast roller revolving speed：720r/min； Slow roller revolving speed：72r/min； 5.Supportive power for single set gear roller：the first set 22kw, the second set 18.5kw, the third set 18.5kw； 6.Profile dimension：12000x2200x1900mm.
3. Major Structure and Principle of Operation CTC Triad Rolling Cutting Machine is mainly consisted of three sets of rolling cutters. These three sets of rolling cutters are linked as one combination by conveying belts and can rolling cut and pellet fresh tea leaf after kneaded and cutting to satisfy the black pelleted tea specifications. Each set of rolling cutting machine is independent relatively and shares the same principle of structure. The single set of rolling cutting machine is mainly consisted of one couple of stainless steel gear roller, frame work parts, transmission parts of electric motor reducer, feeding conveyor parts and electrical control cabinet. The first set of machine shall be rough rolling cutting machine combination, the second and the third sets of machines shall be refining rolling cutting machine combination. There are fast roller and slow roller in each couple of gear roller. The tea leaf shall be kneaded, pelleted while feeding to the gear rollers by the conveyor for rolling cutting. The size of rolling cutting and pelleting can be controlled by adjusting the spacing between two rollers. The sketch 1.1 shows the machine structure as follows:
1- feeding conveyor parts；2- gear roller and frame work parts；3- Transmission parts of electric motor reducer
4. Installation, Adjustment, Commissioning and Operation 4.1. Installation, Adjustment and Commissioning （1）This machine is packed and transported according to machine combination such as steel gear roller and frame work parts, transmission parts of electric motor reducer and feeding conveyor parts. The machine combination information such as machine name and number is inside the packing case. These three parts shall be assembled as a rolling cutting machine combination according to the number. （2）The foundation bolts shall be fixed at the place which the machine shall be installed according to the technical specifications supplied with the machine. The installation shall comply with the installation drawings. （3）The steel gear roller and frame work parts shall be assembled at first for each set of machine, the feeding conveyor parts shall be linked with the frame work after the assembly of frame work is completed, finally the transmission parts of electric motor reducer shall be fixed. After completion of assembly of these three major parts, turning each transmission part manually to ensure such transmission reliable and normal, then switching on the power for idling commissioning of each single set of machine. After each single set of machine is tested and operated and confirmed to be satisfied and normal, the idling commissioning for three sets of machines can be started to ensure no problem in such joint commission and running is normal.
4.2. Operation （1）Before switch on the machine, check machine appearance, linkage system and lubrication. The space between the fast and slow rollers shall be adjusted to satisfaction, in general, the space for the first set of machine shall be 0.32～0.68㎜, the space for the second set of machine shall be 0.20～0.38㎜, and the space for the third set of machine shall be 0.16～0.32㎜.The abovementioned spaces can be adjusted flexibly to meet the required product requirement in accordance with the tea variety, aging. （2）The electric motor shall be started by the electrical control device, the first electric driving motor, the second electric driving motor and the third electric driving motor shall be started separately in sequence. Switch on the gear clutch to run the conveyor; Pull down the detaching handle for fast and slow rollers to run such fast and slow rollers. Feeding can be done after the machine combination run idling to normal state. （3）The tea leaf which has been withered – cleaned – kneaded and cut shall be fed on the conveyor belt evenly and entered into the gear rollers for twist mincing. The mincing at each grade shall be observed whether can satisfy the product requirement. In case of failure to meet the requirement, the space between two gear rollers needs to be adjusted to guarantee satisfactory product. The machine shall be stopped before adjusting the space, the power for machine combination shall be switched off, and the space of each group of gear roller shall be adjusted separately. The normal quantity production can be started after the machine can produce the required qualified product is confirmed. （4）Since the space of gear roller to rolling cut the fresh tea leaf is quiet narrow, the pureness of fed tea leaf required high, the fresh tea leaf shall be free of foreign materials such as small gravel, tea branches, metal etc. Otherwise the gear rollers may be damaged to produce unexpected product. The user shall be pay great attention to this problem. （5）Before switch off the machine, check whether all tea leaves in the rolling cutting machine is completed for process, then in sequence of the first, the second and the third, the conveyor shall be switched off at first, then the rolling cutting machine shall be switched off, finally the conveyor connected into the third set of machine shall be switched off.
5. Machine Service and Maintenance It is the necessary condition to guarantee safety in production and prolong the machine service life and ensure normal operation of the machine the machine service and maintenance regulations shall be executed strictly and the safety operation specifications shall be abided by strictly. Therefore, the operator shall know the machine structure, performance and operation instructions well, and shall pay attention to service and maintenance as follows during operation: 5.1. Before switch on the machine, the operator shall check whether there are foreign materials such as gravel, branch, steel wire and other metal foreign materials in the tea leaves to be processed, in case that any of these foreign materials is found, it shall be removed before machine starts. 5.2. During operation, pay attention to the running smoothness and coordination of parts such as gear rollers, conveyor belts and transmission, and whether heating of the electric motor and bearings are normal. In case that running is not smooth, abnormal impact, over-heating of machine parts and over noise, the machine shall be switched off immediately for check; such trouble shall be shot before switch on. 5.3. The lubricating points shall be greased periodically to ensure normal running of each part. 5.4. Pay great attention to adjusting the space between gear rollers and the parallelism between rollers. The tea cut by both sides shall be ensured even and no gear bump is allowed since gear ring may be damaged. After the adjustment is completed, each positioning bearing shall be fixed to ensure no loose and displacement during running. Such space adjustment shall be done by special professional only; other staff is not allowed to adjust at his own wish. 5.5. The wear and abrasion may be incurred after 80～100 continuous running for each couple of gear roller (depending on tea variety and aging), thus the tea processing quality will be influenced, such gear roller needs to be repaired by grinding. Stop the machine then remove the worn gear rollers, the spare gear rollers shall be fixed before production. The worn gear rollers shall be sent to the machine repair workshop and shall be repaired and grinded by the gear repairing grinder. The original tooth profile shall be formed by grinding. The repaired gear rollers shall be stored for change next time. 5.6. After the machine switched off by each working shift, these places of the machine where there are tea juices and tea residue shall be cleaned by wet cloth. Such simple machine service can make the next working shift running normally. 5.7. The machine service and maintenance system shall be abided by strictly. The machine shall be checked and serviced as per schedule. After each process season, the machine needs to be checked and serviced once. When service, parts shall be cleaned, the wear and abrasion of each wearing part shall be determined whether repair or change. 6. Delivery Scope of Machine Combination 6.1. One set of CTC Triad Rolling Cutting Machine； 6.2. One set of electrical control cabinet； 6.3. 6 spare gear rollers； 6.4. One copy of Operating Instruction； 6.5. Quality Certificate, packing list.
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