HAND-OPERATED OIL PRESS MANUAL

“KAPMOND 30”

Hand-Operated Oil press “KAPMOND 30” Designed by Roger GAMOND Manufactured at Katutura Artisans’ Project (KAP) Corner A. Mogalie & A. Potgieter St Katutura, Windhoek Tel: +264 61 216 308

Hand-Operated Oil press “KAPMOND 30” Manual Windhoek, June 2005. Document prepared by Julien GALLARDO, With financial support from the French Co-operation. CRIAA SA-DC 22 Johann Albrecht St Windhoek PO Box 23778 Tel: +264 61 220 117 Fax: +264 61 232 293 E mail : [email protected]

Disclaimer: This manual deals with processing, including those activities which can be dangerous. Special care needs to be taken when operating machinery. The authors and publisher take no responsibility for any loss or injury sustained as a result of these or any other activity.

MAIN PARTS

Hand Wheel

Screw

Upper Piston Frame Oil Cage Gauge Stainless Steel Tray Table Hydraulic Jack

Lever Plates Stand

DESCRIPTION AND SPECIFICATIONS

The “Kapmond 30” hand-operated hydraulic 30-tonne press is suitable for the cold pressing of local oilseeds and kernels, especially soft ones (low fiber content and oil-rich materials) such as Marula and Manketti kernels. The “Kapmond 30” is a simple, heavy-duty, low-maintenance press that is suitable for small-scale operations, especially where there is no electricity. It is a valuable example of appropriate technology that enables small enterprises, including producer groups and cooperatives, to add value to indigenous resources. Size: length: 0,7 m width: 0,6 m height: 1,6 m

Weight: with 1 cage and 6 plates: ±250 kg Jack force: 30 tons

Pressure: In the hydraulic circuit at 30-tonne: ±720 bars (1 bar = ±1 kg/cm2) Gauge: Only use the gauge model supplied with the press, as other models might not be able to withstand the force of the jack. The gauge is calibrated in both tons (red scale) and in kg/cm2, or bars (blue scale). The maximum force (30 tons) corresponds to 720 bars. Hydraulic piston stroke: ±150 mm. Note that the threaded piston nose (or extension) allows for an extra 70-mm stroke. This is useful when there is only a small amount of material at the bottom of the cage to be pressed. Hydraulic fluid: Any high quality grade 32 hydraulic oil can be used. Never use engine oil or break fluid. Hydraulic pump hand lever: This lever has been designed to be as light as possible. The joint end is made of spring steel, which makes extended use possible. Cage: Its capacity varies from 7 kg to 9 kg of materials depending on the nature of the oil bearing material.

HOW TO OPERATE THE PRESS (1) FILLING THE CAGE Do not contaminate the oil and oilcake with unclean hands. Operators must wash their hands with soap and water as frequently as required.

Plate

Cage

1- Put the cage on a clean bag on a flat and hard surface (wood board for instance).

2- Put a plate inside the cage.

4- Place a plate on the kernels. It has to be horizontal. Then, pound on the plate to pack the kernels.

5- Add a second, third, fourth and fifth layer of packed kernels separated by plates to fill the cage.

3- Pour ±2L of kernels in the cage.

6- Place the cage on the tray and centre it on the upper piston.

HOW TO OPERATE THE PRESS (2) PRESS OPERATING

7- Screw the upper piston firmly down with the hand wheel.

9- Place a bucket under the tray outlet to collect the oil. Add a fine stainless steel mesh on top.

11- Progressively increase the pressure until it reaches the 30tonne mark on the gauge. When the gauge reading stays at or above the 25-tonne mark, the first pressing process is finished.

8- Lock the jack’s valve.

10- Start pressing the kernels slowly.

HOW TO OPERATE THE PRESS (3) CAGE EMPTYING

12- Clean the cage (you can use a clean piece of leather). Push all the oil in the tray trough the outlet to the bucket.

14- Unscrew the upper piston with the hand wheel.

16- Place the cage up side down. Use the pestle to push the plates and the cake out.

13- Open the release valve of the jack. The table lowers.

15- Empty the cage on a clean bag. Use a screw driver to remove the first layer.

17- Crumble the pressed kernels (cake) and fill the cage the same way as the first time for a second pressing.

MAINTENANCE OF THE PRESS (1)

EVERY DAY:

A thorough cleaning must be done, especially the tray, cage, plates, mesh and buckets.

EVERY WEEK: A thorough cleaning of the entire press and the accessories must be done. Also check for any crack in the welding beams (particularly the frame), loose nuts and hydraulic fluid leak.

Cleaning of the cage with brush, water and soap

Let the parts to dry entirely before pressing oil again !

MAINTENANCE OF THE PRESS (2)

EVERY MONTH:

1- Check the oil level in the jack's tank and top it up if low. 2- Remove the piston from the lower end of the screw using a 19mm socket, remove the old grease, clean with a soft brush and petrol, dry it and add some new grease. 3- Remove the screw, clean the same way and add some new grease. Removing the piston Removing the screw

Do not lose the spacer !

EVERY SIX MONTHS: Remove the hand lever from the press head. Replace the bolts and the locknuts. DO NOT remove the small plunger (see next page).

EVERY YEAR: Remove the jack from the table and take it to KAP or a professional for servicing. All the seals and the fluid must be replaced. Also replace any damaged part (lever, rod and joint bolts).

HOW TO REMOVE THE LEVER FROM THE JACK

Plunger

1- Remove the 2 bolts.

2- Remove the lever.

HOW TO FIT THE LEVER ON THE JACK

1- Replace the lever in the front guide.

2- Replace the bolts fitted with new locknuts.

HOW TO REMOVE THE JACK

1- Remove the lever (as explained before).

2- Tilt and remove the table with the jack.

3- Place the table and the jack up side down. Remove the two nuts holding the jack.

4- Pull the jack up.

HOW TO FIT A NEW JACK

1- Put the table up side down and put back the jack.

2- Fit the two nuts and fasten the jack.

3- Fit back the table and the jack on to the press. Then do not forget to fit the lever back.

HOW TO FILL THE JACK’S OIL TANK UP

1- If the jack doesn’t lift fully any more, this could be due to a lack of oil in the jack.

2- To refill the jack, carefully take off the rubber cap on the side of the jack using a screw driver.

3- Fill the jack with grade 32 hydraulic oil until the oil in the jack reaches the hole.

Never use engine oil or brake fluid !

4- Close the hole with the cap, using a screw driver.

Be careful to avoid hydraulic oil contamination of processed oil !