How to Make a 4-Way Solenoid work as a 3-Way
There are several different types of solenoid valves used for hot melt application equipment. We are specifically referencing gun applicator solenoids in this article. The gun solenoid is what is used to fire the gun and apply the glue onto boxes in a packaging line. The two most common types of solenoids used to fire automatic pneumatic glue guns are 4-way and 3-way. The difference between the two is simple: a 4-way solenoid is used when you have an air open/air closed gun and a 3-way is used for an air open/spring closed gun. Essentially, a 4-way solenoid utilizes pneumatic pressure to open the piston, initiating glue flow, and close the piston to shut off glue flow. Whereas a 3-way solenoid utilizes pneumatic pressure to open the piston and when the air shuts off an internal spring closes the piston, shutting off glue flow.
Now let us say your packaging facility has multiple glue lines, and some are air open/air close applicator systems and some are air open/spring close applicator systems. You can standardize your inventory by purchasing only 4-way solenoids and converting them to 3-way on an as needed basis. However, please note that you cannot run a 3-way as a 4-way.
Below are the steps to change a 4-way solenoid valve into a 3-way solenoid valve:
- Remove air line #2 from solenoid
- Plug air line #2 on solenoid with a ¼ NPT flush plug
It’s that easy!
For any further questions about solenoids, give a sales rep at Universal Systems a call at 561-272-5442 or email us at sales@ussefl.com.
Independent Air vs. Common Air Glue Guns
Hot melt applicators are used in high-speed packaging to apply melted hot glue onto the sub-straights of boxes. There are several different styles of applicators that Universal Systems manufactures, both single module and multi-module. If you are running a multi-module pneumatic applicator, you can run the air to the module either independently or at the same time, otherwise known as independent air versus common air.
If you are running your system where your modules all fire at the same time, common air applicators are what you want. They are easy to use and only require one solenoid to fire all the modules on that gun. They are by far the most machined and used applicator gun in the industry.
If you are running your system where your multi-module gun fires the modules at different times, then you will need an independent air applicator. An independent air applicator requires each module to have its own airline and solenoid to fire independently of the other modules on the manifold. It allows for more versatility, but is more expensive to operate due to the need for multiple solenoids.
If you are running a multiple module applicator and don’t know if you need a common air or independent air operation, call your sales rep at Universal Systems. We will help you identify the positives and negatives of each set up and understand which is the best for your line. An added value of using a Universal Systems ProBilt applicator gun, is that our manifolds are machined with our unique design to allow you the versatility to go from common air to independent air with just the addition of one of our patented plates. This way, if you decide to change your setup after purchasing a manifold, they can be easily converted between common air and independent air.
For more information, call us at (561) 272-5442 or email a sales representative at sales@ussefl.com.
How to Properly Mount Your Hot Glue Gun
When setting up your cartoner or tray former, you need to think through placement of hot melt equipment for maximum glue hold and minimal glue usage. That includes both determining the ideal length of hoses needed, as well as the placement of the glue applicator. There are a few things that you really need to take into consideration for both, but this article will focus on properly mounting your glue gun.
- Make sure that wherever you are placing the applicator guns, the module and nozzle are positioned approximately an inch to an inch and a half away from the sub-straight. That will lessen stringing and popping. The shorter the distance the glue must travel in the air to hit the sub-straight, the less likely it is to cool and cause stringing and poor adhesion.
- Fit and position the module so that you can easily hit the sub-straight with either a straight or right-angled nozzle. If you are tight on space, consider using a slim-line or mini applicator so that you have more maneuverability of the manifold. You want to set it up so that both the module and nozzle are easy to access for replacement and or troubleshooting.
- Placement of an in-line filter assembly is also key for maximum long-term efficiency. You need to be able to get the filter body positioned in a way where you can easily access and replace the filter. Take into consideration utilizing a right angle or 45 degree fitting to make it easier to access.
- Try to mount the gun so that the in-line filter assembly can go directly into the hose without kinking the hose. The more secure the hose is, the longer it will last you.
If you are struggling with the logistics on how to set up your glue system within your packaging line, reach out to a Universal Systems technician, who will be able to get your hose and gun mounted in the best possible way.
Keep it Simple for the Next Generation of Workers
Overcomplicating machinery has never been our goal at Universal Systems. Our focus for over the last 40 years has been to manufacture reliable, easy to use, tough equipment that will last decades. The only way we know how to do that is to keep our systems as easy to operate as possible.
Our AccuScan Control Panels are the same on every ProBilt tank we manufacture. They are easy to understand and easy to replace. We specifically manufacture our products to allow our customers to standardize their inventory and minimize their spending. Making all of our products uniform in design, allows for line operators to be trained on the equipment only once. Additionally, it allows the line operators to understand how to program the machines and troubleshoot any error codes that occur since our codes never change. Even our error codes are easy to understand. For example, rtdH means your RTD is reading high, while HtrL means your heater is low.
We know how important it is to train operators on the equipment they are managing. All of our systems come with an intricate manual that includes installation instructions, parts schematics and troubleshooting guidelines. We also provide a preventative maintenance recommendation schedule that lists what items should be kept in your inventory and how often items should be proactively replaced. Here at Universal Systems, we want to make hot melt application as easy as possible for the future generation of operators. For more information or to get our preventative maintenance recommendations sent to you, contact USSE at sales@ussefl.com.
Why Glue is Better Than Tape to Seal Boxes
Having been in business for over 40 years, here at Universal Systems we are a little biased regarding why glue is better than tape, however there are some key differences that all packaging facilities should take into consideration before buying a case sealing system.
Are you looking for a case sealing system that is durable, reliable, easy to maintain and affordable long term? If so, then you should definitely look into hot melt systems. Universal Systems’ ProBilt melters are stainless steel and come with a 10-year heater warranty. We offer full time customer service and can easily walk you through setup and maintenance. Tape sealers can be more difficult to set up and run for high-speed packaging. Tape is also not as forgiving as glue, and more expensive per box. It can get jammed more easily and needs to be replaced more often, increasing your long-term budget.
If you are running a high-speed packaging line, sealing a lot of boxes, then you should probably use hot glue versus tape. Tape machines have a much slower run time than hot glue application systems. While it does take time for the glue to melt and allow it to set, once hot glue is applied, it will be on there forever. Glue is also more durable through all different types of weather conditions. Tape tends to unstick in heat and in cold. The strength of adhesion you get with hot glue is much stronger than tape. So, if you are sealing boxes that are heavy, such as bottles, then hot glue is the way to go.
The application process is also very different with hot glue than tape. With hot glue, you have the versatility to use it for several different types of applications including larger or smaller boxes, filters, non-wovens, etc. Additionally, through nozzle size and air pressure, you can regulate how much glue you apply to each box. With tape, it is a set feature that you cannot change.
For all of those reasons and more, if you are evaluating case sealers make sure you take a look at every aspect of your business now and in the future. If you are running a large packaging facility and need versatility and longevity, go with hot glue. If you are smaller and have a set box sealing system in place that will not change much over time, go with tape.
If you have any other questions about hot glue case sealing systems, please call (561) 272-5442 or email sales@ussefl.com.
It is Usually Always a Clog
The most common reason for your hot glue system acting up is because of a clog. Clogs are common because you are working with glue, which is sticky and chars over time. Below are some of the most common technical calls we receive, with the solution…and you guessed it, it’s usually always a clog.
Pump is not pumping
There are several reasons as to why your pump can stop up. Honestly, it is usually dirty oily air in your shifter. However, when it is not your shifter it is usually a clog. If your shifter is running fine, but it sucked something up into the hydraulics of the pump, the pump shifter will be stopped in the top position, unable to shift down. That is because you probably have some char or debris in your hot glue reservoir and while pumping, you sucked something up into the ball check valve. You have now clogged up your pump and need to send it in for a flush and clean. Another potential issue could arise if your pump is running but sluggish. If your pump is running mush slower than it used to, it is probably because you haven’t changed out your tank filter and it is clogged. The tank filter is located on the side of the tank and filters all glue before it runs into the hoses. If that filter is not regularly changed (every 500 – 1500 hours depending on how clean your glue is) then that clog can cause pressure to back up into the tank and not allow your pump to run at full capacity.
Gun is not firing
If your gun is not firing at all, it is probably your solenoid valve. However, if your gun is firing every other time or randomly, it is probably due to a clog in your in-line filters. The in-line filters filter the glue from your hoses into your gun. These filters are there to help filter our char or debris that was missed by the tank filter or that has built up in the heated hose. If the filter screens are not changed regularly, they will get clogged up and not allow for your gun to fire properly. For example, if you need to increase air pressure in order for your gun to fire, it is probably the in-line filter clogged up. Another clog can happen in the gun manifold itself. Typically, this is only in multi-module guns. If you have a multi-module gun and the last module in the line is not firing, there is probably a clog in the manifold.
Module Drips
If your module is constantly dripping glue, then you have a clog in your module. This is most common in air open, spring close modules. A piece of char will get stuck in the seat and not allow the piston to seal tightly, causing the glue to drip out. A clogged module will need to be replaced with a new module.
Nozzle keeps clogging
This one is fairly straight-forward. If your nozzles keep clogging there are a few solutions. First, you can change out your in-line gun filters. They are probably not clean and not filtering the glue through the gun. You can also increase your nozzle diameter. If you are running small hole nozzles such as .010 or .012 diameter, try a .014 or .016 and you will start to see less clogging. However, that will lay down a little more glue, so keep that in mind when reviewing your glue usage.
The best way overall to reduce the number of clogs in your hot melt systems is to do preventative maintenance. That means cleaning your tank every month or every quarter, depending on how many shifts your tanks are running. Universal Systems makes Purge Plus tank cleaner and we sell them in a 5-gallon pail so that you are set for at least 2 – 3 cleanings. Additionally, change out your tank filters and in-line filters. These 3 tips are the most inexpensive way to keep your hot melt system running smoothly.
The Lost Art of Troubleshooting
Troubleshooting is most definitely a lost art. In today’s throwaway society, we have lost touch with our ability to fix things ourselves. That is true in all aspects of business and most definitely prevalent in the packaging world.
For us, in the hot melt application industry, we have seen it get progressively worse over the last few years. Ever since the pandemic, it seems that most hot melt manufacturers no longer stand behind their equipment and help with troubleshooting. Industry giants, like Nordson, want you to buy new machines, they don’t want you to fix what you already have. Here at Universal Systems, that is the exact opposite of our company culture. We are here to help, we believe in our equipment, and that the art of troubleshooting isn’t something that should be lost forever.
That being said, troubleshooting a pump not running doesn’t mean hitting it with a wrench until it moves. There is an art to it. Using deductive thinking to pinpoint the cause of the issue versus just replacing each piece until it starts working again. For example, your line is running a multi-module gun, and the last module on the line isn’t getting glue. In order to figure out where the real issue lies you first need to make sure all of your key points are met. First, is your glue heated to the correct temperature? What is the consistency of the glue out of the first module in the gun versus the second, etc.? If the gun isn’t heated to temperature, your glue’s viscosity may not be correct to run through the manifold to all modules. Second, have you checked your in-line filters? There could be a clog in the filter not allowing enough glue to flow into the gun to get to all modules. There could also be a clog in manifold itself. Once you eliminate all potential variables, you will be able to deduct what your actual problem may be.
Training on equipment is also very important in practicing the art of troubleshooting. If you have line operators that understand how your equipment works, they will be better equipped to troubleshoot potential issues. If your line operators or floor managers are not fully versed with your equipment, you should be able to call the equipment manufacturer to go through troubleshooting steps with you. At Universal Systems, we pride ourselves in our customer service and ability to walk any customer through troubleshooting. If you have a manufacturer, like Nordson, that will not take that time with you, maybe it’s time for a change to USSE.
How Dirty Air Impacts Your Pneumatic Systems
Pneumatic hot melt systems are run by air in both the pump and the applicator guns. One of the most important ways to ensure the longest run time out of any pneumatic system is to make sure that the air is clean and dry. That can be easier said than done. Most all packaging facilities have oil, water, or debris in their air. That is just the way it is. Some factories will install air cleaning systems and then add lubricators to lines to ensure that other equipment that requires oil runs smoothly. But even with the most expensive and elaborate air filtration system, there will always be some type of substance that gets by and can lead to issues in the pneumatic pumps of hot melt units. The simplest solution is to install an oil removal filter regulator to the air line running to the pump.
Oily air is our most commonly found issue inside facilities that have pumps stop up. The reason is because the shifters are manufactured with very specific tolerance clearance between the shifter spool and sleeve. This design is a necessity in order to get the pump to shift. Too much clearance and the air will just blow by the spool, never building up enough air pressure to pump. Too little clearance and the shifter will jam. That being said, if you have oily air or dirty air being run through the shifter, over time, that will cause a film to build up inside the shifter and cause a jam. Depending on the amount of oil or dirt in your air, and the number of hours the systems is run for, will determine how long this will take to happen. However, if you feel like your facility air is questionable, we suggest that you use the oil-removal filter regulator to prevent any shifter stop ups.
Another pump issue that can be caused by dirty or oily air is that it can get into the air motor and damage the rulon seals. The seals need to be tight to snuggly move up and down the air motor and if they get damaged by oil or dirt, that can lead to your pump not efficiently pumping. These seals can be replaced over time and should be checked every 2,000 hours.
Universal Systems offers pump rebuild kits for the seals, as well as sells the shifter valves in case you ever run into a pump issue caused by dirty, oily air. For more information on our pump rebuilding services, or for any technical support you might need, please call (561) 272-5542 or email sales@ussefl.com.
How Melter Sustainability Lowers the Impact on Your Budget
Budgeting is nothing new, it is one of the toughest parts of business. When you are running a packaging plant and need equipment, but the budget does not allow for it, what happens then? There is an answer to that dilemma…buy reliable melters and do preventative maintenance from the start.
Reliability is what we focus on at Universal Systems. We know that being up and running is the most important part of high-speed packaging. Not only do we offer full time customer service and an unparalleled heater warranty, our melters and components are easy to install, easy to operate and the most affordable on the market. All of our ProBilt melters come with a 4-hose max capacity and 10 year heater warranty. They also all run the same pump and same AccuScan Control Panel, no matter what size tank capacity, allowing you to stock less overall inventory since there is such versatility. This key feature helps you in lowering your overall budget spending.
When calculating budget, you also need to take into consideration personnel and training of personnel. The Universal Systems ProBilt melters are easy to install and operate, proud of the fact that we are plug and play. With just the press of a button, you can set the temperature on your tank and all your hoses and guns. With our seamless set back feature, you can leave the tank heated to 165 degrees if you are not using it for a shift, then heat back to regular set temperature within minutes to run at full capacity again.
Another key fact in lowering your overall spend is preventative maintenance. At Universal Systems, we really push our customers to maintain their equipment and keep it clean and filtered. Be as good to your equipment as you want it to be to you. Spending only hundreds of dollars monthly on preventative maintenance items such as filters and cleaning kits will save you thousands of dollars per year trying to fix what you could have prevented. We put together a suggested preventative maintenance schedule. For more information call one of our sales reps today at (561) 272-5442 or email sales@ussefl.com.
Tried and True: How Reliability and Innovation Don’t Always Go Hand in Hand
Innovation is important in any industry, including packaging. However, the latest and greatest isn’t always the best for your operation. There are several reasons as to why it is better to stick with the old tried and true systems.
Reliability
If it ain’t broke don’t fix it. I am sure you have heard that saying before. There is a reason. If you have a system that has run great for you in the past, stick with it. Getting something new is not for everyone. With new equipment comes more complications such as line operator training, all new inventory, potential downtime due to the learning curve, etc. In addition, most all new equipment comes with new technology that, while it is probably meant to be helpful and less time consuming, becomes over complicated and more time consuming. Universal Systems ProBilt has kept its reliable technology for decades. And while that sounds like we are not innovating, that is not true. We are sticking with what we know works. We have found the secret sauce, why over complicate it?
Ease of Use
With every innovation, comes new challenges. Learning new ways to do things is not easy for everyone and can slow most people down. That is true in our everyday lives, just like it is in packaging. It’s called high-speed packaging for a reason, and every new technology feature opens the door to potentially slowing people down. If your network connection is slow, or the on-board computer screen doesn’t want to keep up with the operation. All these new luxuries can cause slowdowns. Our Universal Systems ProBilt tanks and components are easy to operate with our plug and play style. The board’s simplicity is our greatest asset. It lowers the number of faults and tells you the exact problem if there is a fault. With our ProBilt AccuScan Control Panel, you don’t need a book of faults to reference, the screen tells you what the issue it. Keeping it simple for all operations on the line.
Knowledge is Power
If you have a ProBilt melter, then your line operators know how to set it up, how to use it and the maintenance required to keep it running for decades. As we see other companies in the industry switching out their systems and discontinuing product lines, we have decided to keep with what we know. Inherently allowing our customers to keep with what they have been running for as long as they have worked with us. At Universal Systems, we don’t have any planned obsolescence. You will never not be able to get help with any of our equipment because we no longer support it. We make sure that we support everything we have ever made and will stay that way.