As we head into the New Year and the weather gets colder, you may be experiencing inconsistencies with the adhesives on your packaging lines. What most line operators and maintenance managers do not realize is that the location of your packaging line in the plant can play a large role in the dependability of your adhesive.
This time of year, we receive several troubleshooting calls regarding hot melt consistency, heated hose and gun temperature consistency and glue stringing. It is important to take the external environment into consideration when attempting the first step in troubleshooting some of these problems. One of the first questions to ask is: where is your packaging line located? For example, if it is at the end of the packaging process, which it most likely is, then it might be on the exterior wall of your plant. Or it might be near an external door or window. If it is on the outskirts of the plant facility, and you are located in a part of the United States that is cold in the winter, then the outside temperature could be impacting not only the viscosity of your glue, but the heating time of your glue and its adhesion ability.
Every time your line operator opens the fill door on the hot melt tank, the external air hits the existing glue and cools it off. Even if the lid on your tank is only open for a few minutes, that could impact not only the current glue in the tank reservoir, but the glue you are adding to the tank. Especially if you are adding in cold glue. If your glue pellets are colder than normal, it will take a longer amount of time to heat them. A solution to this issue would be to invest in an auto-fill hot melt application system. Universal Systems SE manufactures the ProBilt™ Phoenix Auto-Fill Application System. Not only will this system help in the winter months, it helps all year long by drastically reducing the number of times your line operator needs to add glue pellets.
Another important task would be to inspect your system setup for any cold joints. A cold joint would be any unnecessary extensions that you have added throughout the adhesive application process. Most cold joints are found on older machines that used larger sized extensions and filter housings. For example, the older gun filter assemblies had larger filter housings and longer extension joints, that are unnecessary and can inhibit the consistency of hot melt flow. The more cold joints on the system, the more inconsistent the glue will heat and stay heated throughout the entire application process.
If your main problem is glue stringing in the colder months, an easy solution would be to shorten the distance from the nozzle tip to the top of the box. Limiting the amount of time the glue has to travel in the air will help to lessen the problem of stringing, which can cause a weakened seal on the box.
For any further information on the ProBilt™ Phoenix Auto-Fill Application System, or to speak to a technician about any troubleshooting of your adhesive application system, please call Universal Systems SE at (800) 848-5018 or email email@example.com.
There are a few brands to consider when shopping for a hot melt system for your packaging line. Universal Systems SE’s ProBilt™ product line has been around for over 40 years and has several key features that can help influence purchasing agents, as well as line operators, on why it is the best in the industry.
4 Hose / 4 Gun Standard Capability
Unlike any other hot melt tank option on the market, the ProBilt™ line of melters all come equipped with 4 hose and 4 gun capability. This is a standard option that is usually an add on from other manufacturers, like Nordson®. Nordson® has both the 2 hose/ 2 gun and 4 hose/ 4 gun melters, each differing in price. The ProBilt™ melters all come with 4 hose/ 4 gun capability at a lower price point than any Nordson®. This allows our customers versatility and the option to grow.
Easy to Program Control Board
One of the many benefits to owning a ProBilt™ system is the easy to operate, AccuScan™ Control Board. If you are plugging in a brand new tank, the board will be programmed to our factory settings. The line operator, can scan through the hose, gun and tank settings and set them to the temperatures needed. There are also a few fail safes installed in the machine. For example, if it is a cold start set up, the hoses and tank will heat first, then the guns will start to heat once the hose and tank are within 35 degrees of the set point. The reason for this is so that the gun doesn’t char, since the gun heats up faster than the hose and tank. Once temperature is reached, the “Heat On” light will blink and you are ready to use. The control board also comes equipped with alarm settings and a set back functionality, our next two key features.
Set Back Functionality
The set back functionality is one of the most important features that comes standard on all ProBilt™ tanks. Essentially, when the shift is over and you no longer need to run your packaging line, you push the set back button. This will “set back” the temperature of the tank, hoses and guns to 165 degrees. Allowing the glue already in the system to sit overnight without charring. When the morning comes, or the next shift starts, simply hit the set back button again, and all previous temperature settings will re-engage. This will decrease the start up time on the hot melt system significantly and allow your lines to be fully operational within minutes.
Another key feature to the AccuScan™ Control Board are the alarm options it provides. The first alarm option allows for the panel to tie to an alarm light in your facility. In case anything happens that stops the system from running effectively, an alarm light can go off, alerting the line operator immediately. Another feature is the ability to tie it to the packaging line itself, called PMI or Parent Machine Interface. Parent Machine Interface will signal the packaging line when the glue is at full temperature thus preventing the line to start up until it receives the signal.
Please watch our video on how to set the ProBilt™ melter temperatures. For more information on our ProBilt™ systems please call today (561) 272-5442 or email firstname.lastname@example.org
Over the years, large CPG companies moved away from manufacturing and packaging their products in the USA. There are is one obvious reason for that, cutting costs. The cost of materials and the cost of labor are both cheaper overseas. But cheaper isn’t always better. Yes, it increases overall profitability, which is essential for a company’s success, but cutting costs can also equate to lower quality products, poor customer service and lack of reliability.
Well, times are changing! With impending tariffs worldwide, it might not be the best option for you to work with a company that manufactures overseas.
Here at Universal Systems SE, we are proud to stamp “Made in the USA” on all of our components. Whether you are buying a nozzle or ProBilt™ tank, you can rest assured that they were 100% made here in the USA. We source all of our raw materials from US companies, and try to keep them “in the family” of small business owners. Not only do we believe in keeping everything home grown, we support small businesses, the true bread and butter of this great nation.
There is also the advantage of immediate customer service, when dealing with a US company like Universal Systems SE. We are here when you need us, to troubleshoot any questions or if you need products overnight. Since our manufacturing facility is in Delray Beach, FL, we operate on EST, so even companies on the west coast can catch us in the morning or early afternoon.
For more information on the products that we manufacture here in the USA, please email email@example.com or call us at (800) 848-5018.
The most common type of hot melt system used on packaging lines is a manual fill system. With manual fill systems, there are several roadblocks that can occur with safety and productivity that many companies are experiencing. Universal Systems SE took those concerns into consideration when designing our ProBilt™ Phoenix auto-fill system.
It is first important to understand how a hot melt system works. Hot melt adhesive application systems house a Teflon® coated interior tank, where the glue pellets are added and melted. The glue is then pumped out, travelling through a heated hose, into an applicator gun, through a module and nozzle, finally landing the glue at its final destination.
Universal Systems SE has ProBilt™ tanks that range from an 8 lb (4L) capacity, up to a 20 lb (10 L) capacity. Depending on how many hours per day the packaging line is operated, and the size of the glue tank needed, line operators are in charge of making sure that there are always glue pellets in the melter. Running low on glue inside the melter tank can cause a plethora of issues with the system. One of the most common issues is running the pump dry. If a line operator lets the tank run dry and the pump “shotguns”, the pump or shifter can fail. Honestly, that is the most common cause for pump rebuilds that we see in our shop. The easy solution to this is making sure that the tank is always full with pellets.
However, consistent tank filling can increase the risk of other potential issues. The first, is that it increases the risk to employees. Since the tank runs anywhere between 200 – 400 degrees, it is HOT. If a line operator is in a rush or makes one careless move, they can easily be burned by the pot. Another issue is that when you open the tank lid to refill with pellets, cold air flows into the tank and cools down the internal temperature. If the glue is continuously getting hot and cold, it could negatively impact its bonding ability.
These potential issues prompted Universal Systems to develop and release our ProBilt™ Phoenix auto-fill system in 2018. Unlike with manual filling, the automatic filling process does not require the line operator to fill glue pellets directly into the hot tank. Operators fill the free-standing container, which is separate from the tank. The glue pellets are then deposited into the internal pot via the vacuum and wand system when the internal tank glue level is low. The Phoenix is available in two tank capacities, the 15 lb and 20 lb units. Each glue container has maximum and minimum fill lines so that line operators know how much or how little to fill the pellets. Since the containers can hold much more glue than a standard heated pot, line operators no longer need to worry about checking the melters as often as with a manual system. This will also ensure that line operators will not get burned and that the glue inside the pot will stay consistently heated, creating maximum bonding ability.
The scenario is usually the same, a packaging line melter goes out in the middle of the busiest time of year. Most commonly, maintenance directors and buyers simply replace the current OEM melter with the latest model. That is not always necessary. Universal Systems SE ProBilt™ melters have the same footprint as most all Nordson® systems and can easily fit into where the original tank is positioned. Just because your current packaging line has a Nordson® melter does not mean you have to replace it with another expensive Nordson®. Plus, all of our ProBilt™ melters are in stock and can ship same day!
There are several key points to take into consideration when choosing a hot melt system for your packaging line. The most important are: Melt Rate, Durability, & Cost-Effectiveness.
The melt rate is the rate at which the tank will melt the adhesive you put into the reservoir. This is where the tank capacity comes into play. Before moving forward with any hot melt adhesive system, first you need to understand how many pounds you need to melt per hour. The melt rate is dependent on how many hoses and gun applicators you are running and how many boxes are sealed per minute on your packaging line. The most common tank capacity is the 20 lb. (10 Liter) ProBilt™ 20, with a melt rate of 23 lbs. per hour. If you are only running one line with one hose and gun applicator, then you may only need the 15 lb. (7 Liter) ProBilt™ 15 which melts 18 lbs. per hour.
Depending on how many shifts you are running, you need a melter that will work consistently and effectively. All ProBilt™ melters come with a 10-year heater warranty, which is the highest in the industry. In addition, all melters come standard with 4 hose / 4 gun capability and a set-back functionality that allows for easy start up and shut down. ProBilt™ melters are constructed out of 316 stainless steel, not only for its sleek look that will seamlessly blend with your packaging line, but also for its durability and sustainability through the tough elements a packaging line ensures.
The economy has become a roller-coaster in the last year. With that, large CPGs are cutting back not only in personnel but in spending budgets for packaging. These tighter budgets won’t always allow for a buyer to simply purchase the latest Nordson® melter. Here at Universal Systems SE, we have seen more and more companies trying to repair older melters and plug any current issues with band-aids to stretch their fixed budgets as far as they can. Since we manufacture parts that are compatible with old Nordson® tanks, we have been able to help a lot of companies cost effectively navigate the times. In addition to our parts business, all of our ProBilt™ series melters are cost effective replacements for any Nordson®.
To learn more about Universal Systems SE’s ProBilt™ series of melters and components, please reach out to a customer service representative at firstname.lastname@example.org or call (561) 272-5442.
If you follow the packaging industry, whether through news articles, industry periodicals or first hand through direct buyers at CPG companies, one of the largest drivers in packaging is the stress on workforce demands. This can include how difficult it is to find reliable workers that are dedicated to the success of the company. It can also be in the aspect that most of the line operators working the packaging line equipment are not trained properly on that piece of equipment and all of its capabilities.
As the packaging industry tries to modernize technology, not all of their workforce can keep up. As a hot melt equipment manufacturer, one of our core competencies is our knowledgeable technical support. If you have any Universal Systems SE equipment or ProBilt™ machines on your packaging lines, you can rest assured that you will get speedy, knowledgeable sales and technical support. However, in many instances, line operators do not have that type of experience or knowledge base. That can lead to “on the fly” fixes, which usually equates to weakened product and voided warranties. At Universal Systems SE we understand that knowledge is power, and we want to make line operators jobs easier, not harder. With that in mind, we have kept all of the ProBilt™ hot melt application systems uniform and easy to operate. We also try to make our clients smarter when they call with issues, asking questions to help them learn or giving them some simple troubleshooting tips to follow for the future.
In addition to being able to help line operators with questions and knowledge, we also make sure to include in every shipment all of the pertinent manuals and information guidelines needed. For example, if your company is ordering ClearFlow™ heated hoses (Universal Systems SE’s proprietary line of heated hot melt hoses), each shipment will include installation and care instructions. The same goes for our ProBilt™ applicator guns. With the purchase of any ProBilt™ application gun, we include a list of maintenance recommendations on the gun, modules and nozzles.
So, as CPGs continue to have concerns with their workforce, we here at Universal Systems SE we will continue to do everything in our power to ensure that we keep them knowledgeable on our equipment.
As we continue through 2019, it is clear that big brand CPG budgets are getting tighter when it comes to packaging. Larger companies are no longer bleeding money on big brands that offer not much more than a brand name and pretty blue logo. We have often asked ourselves how companies like Nordson® can get away with charging so much for the same quality product that Universal Systems SE manufactures. Especially since those big brands are not even manufacturing in the USA. That trend is starting to change.
As the American economy continues to change, it is clear that companies need an alternative to the brand name big price tags. It all comes down to shopping around for quality manufacturing that can be done in a more cost-effective way. And yes…it can be done. Cost-effective manufacturing should be the main focus of all companies when it comes to packaging their products. Americans no longer care about a name, they care about performance, quality and cost. Just because it is the most expensive thing on the market, doesn’t make it the best or most reliable. And that rings true for packaging manufacturers as well.
Many CPGs are losing the battle for shelf space and margin growth, which is increasing the pressure on suppliers such as packaging manufacturers to decrease costs. With more brands on the shelf and less market share, big CPGs need to start thinking smartly about their packaging solutions. It might not be the best idea to bring in a company like Nordson® to customize a hot melt solution that will cost you an exorbitant amount of money and take 6 months to get, when you can go with a company like Universal Systems SE who has engineers with over 40 years of experience that actually understand what you need because they have pretty much seen it all.
Not only is cost-effective manufacturing a pull in the marketplace, but knowledgeable customer service and support. If your packaging line goes down, it could cost you thousands of dollars a minute. A large brand with an untrained rep isn’t going to be able to get you up and running with a phone call. Universal Systems SE will! Think about that the next time you place an order for a new hot melt system or components.
Whatever you might need for your hot melt machines, we manufacture it at our Florida facility. Whether it is heated hoses, applicators, filters, modules, nozzles, etc. We also can walk you through troubleshooting any issues or help you with customized set ups. Call Universal Systems SE today at (561) 272-5442.
RTD Sensors (resistance temperature detectors) are used in hot melt packaging systems because of their precision in sensing and proportioning temperature. They consistently maintain a temperature control stability of +/- 1-degree Fahrenheit. With the ever-increasing price of adhesive, it is important that RTD sensors are used in all of Universal Systems’ hot melt hoses and glue applicators for steady adhesive application. When combined with USSE’s patented AccuScan™ solid-state control system, RTD sensors provide precise bead uniformity for all of our ProBilt™ applicators.
Since RTD sensors are so key to the adhesive application process, it is important to check them first whenever you notice glue inconsistencies. If you see that your glue bead is not sticking properly or getting clogged, it could be caused by inconsistent glue temperature. There are several causes of inconsistent glue temperature. For example, if your tank operators are opening the cover to add glue, that will cause a temperature change. RTDs control that process, by notifying the heater to turn on and run longer when those situations occur. If your RTD is weak, then the heater will not be able to maintain steady temperature. It is the easiest, most overlooked and one of the least expensive components in your application process, but is worth it’s weight in glue!
When it comes to understanding the components that make up your adhesive application system, we believe that knowledge is power. So, if you have any questions, or think that you may be having issues with your RTD sensor, do not hesitate to call Universal Systems at (800) 848-5018 to speak with one of our technicians. We can walk your line operator through testing RTD sensors and how to switch them out correctly and safely.
Universal Systems SE manufactures high quality hot melt application manifolds that will work with most all hot melt application systems. We understand the importance of durability, consistency and effectiveness in packaging manufacturing, which is why we use 6061T aluminum when making all of our manifolds.
What is a Manifold?
When evaluating what you need for your hot melt application system, it is important to understand each item that makes up the application gun. The manifold is the aluminum gun body, that houses the heater & sensor, and is where the modules mount.
Why do we use Aluminum?
Aluminum is used on all of our hot melt applicator manifolds because it is an excellent conductor of heat and dissipates heat very efficiently. Aluminum also has a very high strength to weight ratio, meaning that although it is light-weight, it is extremely strong. Its strength is what allows for peak performance during the rigorous packaging process. It is also non-toxic, cannot burn and is easily recyclable.
Why do we use 6061T Aluminum?
All of Universal System’s ProBilt™ manifolds are manufactured using 6061T aluminum. 6061T aluminum is aviation aluminum and used for the building of all jet aircrafts. This will extend the lifespan and durability of the manifold and increase it’s on the floor performance.
For more information on how to buy a hot melt gun applicator or manifold, please reach out to email@example.com or call (561) 272-5442 today!
There are several different set ups available for your hot melt application. That’s because not all industries use glue application for the same reason. The most common form of hot glue application is standard case packers for mass production high speed packaging. Typically, those lines use standard H200 modules. However, glue application is used to seal other, more specific products. For example, swirl pattern modules are used for glue application on feminine hygiene products, diapers and also for sealing air filters. This blog is going to specifically explain zero cavity modules and what industries use them and why.
Zero cavity modules have a very specific look, with a nozzle head attachment rather than a screw on nozzle. They also come with an E-Z Micro Adjust attachment to manage precision glue application. This nozzle & micro-adjust feature is custom manufactured for precise glue placement on smaller boxes, such as crayon boxes or pharmaceutical products. This unique technology allows for line operators to place a small amount of glue on a small, predetermined location without creating any stringing. Typically, because of this precise requirement, most zero cavity modules are made with either a .008 or a .012 diameter orifice, so that there can never be too much glue applied.
Because zero cavities have a matched piston needle and seat, when they finally wear out, most manufacturers require customers to replace the entire module. Universal Systems does not. We manufacture a rebuild kit specifically for zero cavity modules for a fraction of the price of replacing an entire module. Check out our rebuild kits here: https://www.ussefl.com/products/hot-melt-modules/module-rebuild-kits/.
Not many hot melt application manufacturers offer zero-cavity modules. Luckily, here at Universal Systems we have been manufacturing this specific module for over 25 years. If you would like to learn more about zero cavity modules or get a price quote, please reach out to firstname.lastname@example.org or call (561) 272-5442.