🔁 OVERVIEW
A successful pulping session =
✅ Right machine start-up
✅ Steady fruit feed
✅ No clogging
✅ Smooth pulp flow
✅ QC checks
✅ Clean & safe shutdown
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⚙️ 8.1 Machine Start-Up (मशीन चालू करने की SOP)
| Step | Action | Notes |
| 1️⃣ | Visual check of machine exterior | Oil leakage? Loose wires? |
| 2️⃣ | Check power connection | MCB ON, voltage stable (5–7 kW) |
| 3️⃣ | Turn ON control panel | Green light = live power |
| 4️⃣ | Run dry cycle for 1 minute | Without fruit – to detect sound/vibration issues |
| 5️⃣ | Check blades, mesh, outlet | No obstruction, secure fit |
| 6️⃣ | Test water inlet & pressure | For cleaning, safety |
📍 Real Case: Bihar site skipped dry cycle – blade slipped → jam → 3 hrs delay. Always run DRY TEST!
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🍎 8.2 Fruit Feeding (फल डालने की सही प्रक्रिया)
| Rule | Detail |
| A | Wash fruits with clean water + remove dirt/leaves |
| B | Check ripeness – avoid under-ripe or fermented |
| C | Remove fruits with fungal spots, cuts |
| D | Feed fruit slowly – don’t overload chute |
| E | Maintain uniform feed rate – 10–15 kg per minute |
| F | Keep helper with glove + stick to adjust flow (no hands inside!) |
🔍 Tip: Use a graded crate system – green (pass), yellow (overripe), red (reject)
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🧃 8.3 Pulp Extraction Process (पल्प निकलने की प्रक्रिया)
| Step | Action |
| 1️⃣ | Once fruit enters drum, blades crush and pulp flows out |
| 2️⃣ | Mesh filters fibre, seeds, peel (varies by fruit) |
| 3️⃣ | Pulp is directed to collection trough or drum |
| 4️⃣ | Use sieve if needed for extra filtration |
| 5️⃣ | Fill in pre-cleaned, labelled containers |
| 6️⃣ | Maintain flow rate – don’t let pulp stagnate |
🧰 Operational Norm:
1 operator per 1 machine
1 helper for adjusting flow & packing
📦 Pack Tip: Use double-check lid seal after pulp is cooled
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🔍 8.4 In-Process Quality Check (चलती प्रक्रिया में क्वालिटी चेक कैसे करें?)
| Parameter | Frequency | How to Check |
| Pulp thickness | Every 30 mins | Stick test / flow test |
| Colour & shine | Every hour | Compare with ref sample |
| Foreign matter | Continuous | Visual check during flow |
| Brix/sweetness (optional) | Mid-shift | Hand refractometer |
| Pack leak check | Every batch | Push + shake drum |
📷 QC SOP: Click photos of 1 open pack every 3 hours – share to HO QA
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🧼 8.5 Cleaning, Shift Changeover, Shutdown
A. Mid-Shift Clean (4+ hour ops)
• Use water spray, wipe outer body
• Clean pulp collection tray
• Check and clean mesh – fruit fibre often clogs it
B. End-of-Day Shutdown
| Step | Action |
| 1️⃣ | Switch off panel |
| 2️⃣ | Drain water & pulp residue |
| 3️⃣ | Clean inside drum with brush |
| 4️⃣ | Remove mesh & wash separately |
| 5️⃣ | Wipe control panel with dry cloth |
| 6️⃣ | Log machine end status (clean? power off?) |
| 7️⃣ | Lock tool box & store spares |
📍 Staff Practice: Create a "Clean & Click" protocol – take photo of cleaned machine every evening
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🧯 8.6 Downtime Handling (ब्रेकडाउन, जाम और रुकावट को कैसे संभालें?)
| Issue | Likely Reason | Action |
| Machine vibration | Unbalanced blade | Stop – call engineer |
| Pulp not flowing | Mesh choked | Pause – remove + clean |
| Excess motor noise | Gearbox issue | Shut down – escalate to HO |
| Fruit jam at entry | Overload or sticky fruit | Reduce feed + manually adjust |
| Electric trip | Surge or wet wiring | Dry panel + retry – else call HO support |
📦 Case Tip: Maintain downtime logbook – with start/end time, issue, action taken
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⚠️ 8.7 If Not Done Properly… This Happens:
| If Skipped | Consequence |
| No dry run | Jammed blade, delay |
| Bad fruit fed | Rotten pulp, bad smell, batch rejection |
| Mesh not cleaned | Low yield, motor strain |
| No QC | Customer complaints, rep loss |
| No clean shutdown | Foul smell, pest risk |
| No downtime log | HO can't support |
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✅ Final Thought:
"Pulp निकलता है मशीन से — पर मुनाफा निकलता है SOP से."
एक अच्छी पल्पिंग का मतलब है:
• मशीन steady
• टीम steady
• प्रॉसेस steady
Because in this business, it’s not about how many fruits you process. It’s about how cleanly and consistently you do it. 🍍⚙️🧼
