1: What is the cleaning / changeover procedure?
- Remove the melt head onto the wash down trolley.
- The tank and stirrer can be scraped down to remove bulk build up product. There's an option for quick access stirrer seal removal.
- Use a high pressured hot water hose down inside all product contact areas.
- If the seal is removed the stirrer can be turned by hand.
- The melt head can be hosed in the wash room.
- After removing all product, carry out any sanitizing procedures.
- The machine will dry faster if the heating is turned back on, this can be done after assembling.
2: What is the maximum allowable temperature to melt and maintain the product at?
It can melt product at any temperature up to 80C (175F). Melted product in the hold tank below can also be maintained at temperatures of up to 60C (140F).
3: What is the time delay from machine start-up to production, i.e. time for the system to heat up ready for use?
It takes approximately 40 minutes to heat up. The product can be used as soon as the tank volume is above the pump suction outlet, and there is enough to fill the process system melted.
4: Can I connect the melter to an existing product pipeline in our factory?
Yes, the product outlet has a triclover (or preferred connection) that connects to existing process equipment. The melter also includes a triclover connection at the rear of the tank for product return to the melter if required.
5: Do you offer any downstream process equipment to connect to this, e.g. product pipeline, process pump?
Yes, we offer several types of product delivery systems from the melter to your existing equipment. These include product filters and magnets, pumps, jacketed pipelines, sieve systems, etc.
Contact us for a free consultation to discuss your requirements.
6: How long will it take to train new factory employees to use the melter?
The operation and changeover tasks on the melter are simple and intuitive, which allows factory workers to operate the machine after a short training session. PTL provide detailed instructions on the melter functions, and we also provide on-going support for your machine when needed.
7: How many workers are needed to operate and/or clean this machine?
For normal operation, only one worker is needed to load product onto the grid and / or adjust the machine settings. We recommend having two workers available during changeover of the melt-grid and removal of the stirrer.
8: Are there any difficult-to-reach areas, or laminate faces, that prevent the machine being fully allergen cleaned?
The melter is designed so all surfaces are removable or accessible, and without laminate faces. It has removable components to improve cleanability and enable customers to meet strict allergen requirements. The slide-out melt head and removable stirrer allow access to all areas of the tank and grid during cleaning processes.
9: Can I customise the size and shape of the machine to suit my factory requirements?
We offer three standard sizes of the melter V20 (S1, S3 and D3), but if your requirements are outside of these standard sizes, please get in touch and we can discuss custom options for your system.
10: What is the tank volume?
11: Are the tank and melt grid separate heating controls?
Yes, they are independent control zones.
12: What over-temperature protection is in place?
The water heating has a safety cut out temperature setting for both zones.
13: What feed/loading options are available?
- Bulk bag gantry for gravity feed of wafers from super sacks
- Bulk tote dumping stations and feeding conveyors for wafers from totes or bulk drums
- Bag dump stations and feeding conveyors for wafers from boxes and bags
- Manual loading
14: What is the advantage of a PTL melter over a kettle?
In short - foot-print, power, fast priming and availability of molten product, flexibility, cleaning, ability to locate next to use point and portability.
15: Will the holding tank overflow if it’s already full and there is product still on the melt grid?
No. The tank high level sensor will shut down the melt grid heating at the selected height.
16: Is the electric water heating system included as standard?
Yes. We can also use other heat sources if preferred, such as gas, plant hot water, and steam.
17: What products can we melt in the V20?
The melter is specifically designed for chocolate and compound chips/wafer/buttons and small blocks.
However you can also melt cocoa liquor, cocoa butter, shortening and other fats in small and large block (up to 1 ton block) form. We would use the V20 or a block melter depending on the application.