Lesson 1Sensors and controls: encoders, VFDs, pressure switches, flow meters, basic PLC I/O mappingDescribes key sensors and control devices on food lines, including encoders, VFDs, pressure and flow instruments. Explains basic PLC I/O mapping, signal types, and how maintenance staff verify correct field wiring.
Encoder types and mounting practicesVFD parameters and protection featuresPressure switches and transmittersFlow meters used in food processesDiscrete versus analog PLC signalsI/O mapping, tags, and loop checksLesson 2Pumps and compressors: common types in food plants, typical flow/pressure ranges, NPSH, duty cyclesOutlines common pump and compressor types in food plants and their roles. Explains typical flow and pressure ranges, NPSH concepts, and duty cycles, highlighting cavitation risks, overheating, and efficiency impacts.
Centrifugal and positive displacement pumpsFood-grade compressor types and usesTypical flow and discharge pressure rangesNPSH available versus NPSH requiredCavitation causes, signs, and preventionDuty cycles, starts per hour, and limitsLesson 3Conveyor systems: types, components, typical motor sizes (0.5–7.5 kW), belt speeds, tensioning methodsReviews conveyor types and main components used in food plants. Covers typical motor sizes, belt speeds, and tensioning methods. Links loading, friction, and tracking to wear, product damage, and unplanned downtime.
Belt, modular, and roller conveyor typesKey conveyor components and supportsTypical conveyor motor sizes and polesBelt speed selection and adjustmentsTensioning and tracking methodsCommon conveyor failure symptomsLesson 4Electric motors: IEC frame, power ratings, service factors, typical failure modes, bearing specsIntroduces IEC motor frame sizes, power ratings, and service factors. Reviews insulation classes, bearings, and cooling. Describes common failure modes, vibration and temperature warning signs, and basic inspection practices.
IEC frame sizes and mounting codesPower ratings, duty types, and service factorInsulation classes and temperature riseBearing types, lubrication, and lifeTypical electrical and mechanical failuresMotor inspection and test routinesLesson 5Compressed air network: typical supply pressures (6–8 bar), receiver sizing, dryers, filters, condensate trapsExplains compressed air supply pressures, receiver sizing rules, and layout. Details dryers, filters, and condensate traps, with focus on food safety, energy efficiency, and preventing water, oil, and particle carryover to equipment.
Typical main and branch line pressuresReceiver sizing rules and placementDryer types and dew point targetsFilter grades for particles and oilCondensate traps and drain maintenanceLeak checks and pressure drop controlLesson 6Electrical panels and motor control: MCC layout, starters, contactors, overloads, circuit breaker types and settingsExplains electrical panel and MCC layout, segregation, and labelling. Details starters, contactors, overloads, and breakers, including trip settings, coordination, and safe isolation practices for maintenance activities.
MCC structure, buckets, and bus systemsControl versus power compartment layoutDirect-on-line and soft startersContactors, overload relays, and relaysCircuit breaker types and trip settingsLockout, tagging, and verification stepsLesson 7Typical instrument ranges and example values for a medium-sized food line (motor kW, belt tension N, air pressure bar)Defines typical ranges for motors, belts, and air pressure on a medium food line. Links nameplate data, torque, belt tension, and pneumatic settings to performance, energy use, and early detection of abnormal operating conditions.
Reading motor nameplates and kW ratingsEstimating torque from kW and speedTypical belt tensions and measurement toolsStandard plant air pressure setpointsEffect of pressure on actuator forceRecognizing abnormal value deviationsLesson 8Sanitation-compatible equipment considerations and food-grade lubricant requirementsCovers hygienic design features, cleanable materials, and sealing methods for food equipment. Explains food-grade lubricant types, approvals, application methods, and contamination control to meet sanitation and audit requirements.
Hygienic design principles for food machineryMaterials and surface finish for cleanabilitySeals, gaskets, and dead-leg avoidanceFood-grade lubricant types and approvalsLubrication points, intervals, and recordsContamination risks and mitigation steps
