The best way to keep your packaging line up and running as efficiently as possible is to do preventative maintenance. Here at Universal Systems SE, we have advocated for regular packaging line maintenance, including all of your glue melter equipment and components. However, it is not only important to know when to do maintenance, it is also important to know how to do that maintenance. There are more mistakes made in the switching out of glue equipment and components than you may think. Whether you are changing out a filter or switching a pump, there are steps to take in order to ensure a smooth transition, with the least amount of downtime. Here are a few tips on switching some of our ProBilt hot melt equipment products.
First and foremost, it is important to know the model of your tank. Even though that sounds like standard knowledge, there are many tanks that look similar but have different tank capacities, pump types and filters. Once you know the tank model, you can look up if you need to replace the entire tank filter or if you can replace just the screen. On USSE’s ProBilt tanks, for example, you have the option to change only the tank screen. This allows you to save some money long term, while still maintaining your tank. It is recommended that you make the change while the tank is in setback and to wear Kevlar gloves so that you don’t burn yourself. The tank filter is located on the side of the tank. It can be removed with a flat head screw driver. Once the complete filter assembly is removed, there is a long screw that secures the screen to the assembly. Simply remove that screw, switch the screen, and replace the filter assembly. If you are changing out the tank screen, make sure that you do not damage the filter bung or o-rings when making the switch. Also, be careful, the glue inside the filter is HOT.
These are the easiest of filters on your glue line to change out. In most cases, the filters can be reordered in packs of 5. Locate where the filter is on the filter assembly body and use a wrench to loosen and remove. Kevlar gloves should be worn, as the outside of the filter will be hot and there will be glue on the filter you are removing. Simply put the new filter in place and tighten.
Usually modules are switched out because they are dripping or leaking. This is typically caused by either char or end of life of seat and piston. Switching out a module is fairly simple. Before taking off the old module and replacing with the new, make sure that the system is not running. Each replacement module comes with 2 o-rings and 2 screws. Place the o-rings on the back of the module and secure it on the gun applicator with the new screws.
If you are running an H200, zero cavity or reduced cavity module, there are rebuild kits available.
Switching out a glue pump is the least common practice on a packaging line. However, this is also simpler than you would think. Most technicians think that in order to change out a pump, you need to turn the tank off and let the glue cool. That is not always the case. If you are running a ProBilt tank and have an experience technician, he can switch out the pump while the system is still on. First, make sure you are wearing Kevlar gloves because the system will be hot. Turn off the air running to the system, this will limit any injuries. Remove the 3 bolts holding in the pump, use needle-nose pliers and do this carefully. Put the old pump on a large piece of cardboard where the glue can drain, cool and harden. Carefully put the new pump in, secure it with the 3 bolts and turn back on the air.
For any other questions about tank maintenance, please contact one of Universal Systems’ experienced technicians at (561) 272-5442 or email email@example.com
This is most definitely a new reality that we are all facing. Never before have so many companies had to shut down several, if not all, of their packaging lines because of a global pandemic. However, it was a scary and necessary measure taken to prevent further outbreaks of COVID-19. Now, as we slowly start to reopen as a nation, so does our packaging facilities. State by state, Governors are rolling out the reopening phases that each company, both essential and non-essential must follow.
With the reopening happening, that may mean you are going to run into a few speed bumps. As we all know, machines that typically run seven days a week, don’t like being shut down for three months. Especially if they are not shut down and cleaned out properly before they sat around idle. So, when you switch the power button back to “ON”, everything might not turn green.
In an effort to help with troubleshooting, we have put together a quick list of potential fixes.
1. CLEAN YOUR TANK. We cannot stress this enough. Even if your team drained the glue in the tank reservoir before shut down, there will still be old residue that will impact your restart. Cleaning your tank is fairly simple. First, make sure to detach all guns from the hoses before running the cleaner through. Utilizing our Purge Plus cleaner, fill the tank reservoir and heat. Place the end of the hose inside a bucket and flush the cleaner through the tank and out through the hose.
2. CHANGE ALL FILTERS. This includes both the tank filter and in-line gun filter. Starting with new fresh filters is the smart way to go.
3. NOZZLES MIGHT GET CLOGGED UPON INITIAL RESTART. Nozzles have small orifices that dispense the glue onto packages. If there is any left-over char in the tank from restart, the nozzles could get clogged up first. Try switching the nozzle to see if that fixes the issue.
4. REBUILD KITS. There are a few items that can be rebuilt on your adhesive melter system. For example, your pump. If you think that your seals have dried up from sitting idle through the down time, and you have a skilled mechanic trained to work on the equipment, try ordering a rebuild kit. This will save you money on purchasing a new pump.
If you experience any other issues during your restart, please call us directly at (561) 272-5442 and a technician will walk you through troubleshooting any issue. Stay Safe!
Have you ever purchased a case of soda or carton of coffee cups and can’t get the box open? Of course, we all have. In the packaging industry, especially for hot melt machine manufacturers, that is a red flag. Whenever we get a box that has too much hot glue on it means that the packaging line is not set up properly or not being cleaned regularly.
If you are wondering why too much glue means that the line is not set up properly or not being cleaned regularly it is because one of two issues is occurring (or sometimes even both). The first issue is most likely that the line operators and/or maintenance managers are not cleaning the tank regularly and the lines are clogging up with char, which will subsequently clog nozzles. Instead of cleaning the tanks and hoses, and replacing the tank filter and in-line gun filters, most operations just buy bigger nozzles. If the diameter of the nozzle orifice is larger, then it will allow through more bits of char and not clog up as easily. Unfortunately, this is not a long-term solution. Putting down more hot glue will drive up the amount that facilities spend on adhesive pellets, and ultimately the annoyance will trickle down to the consumer when they can’t get their box open. The solution is simple…utilize Purge Plus to clean your tank every 1,000 hours. For some facilities that could mean cleaning every quarter and for others that could be twice a year, it all depends on the facility. In addition to cleaning the tank and hoses with Purge Plus, make sure that the tank filters are changed every 500 hours. The in-line gun filters should be changed every 150 hours to ensure that no char travels into the gun applicator, through the module and nozzle and onto the box.
The second issue that could cause too much glue on boxes, is that the line was not set up correctly from initial purchase. A lot of cartoners have standard hoses, guns, modules and nozzles that will work for most case packers, but not for all. Make sure to take into consideration the temperature of your packaging facility (which can impact the adhesion and viscosity of the glue as it travels through the application process), the distance that the guns are to the box upon application, and the surface area of the box you are covering. The longer the bead of glue you place, the less likely you are to need a larger diameter nozzle. The shorter the range you are covering, you might need more glue to make sure that maximum adhesion occurs, which means you need a larger diameter nozzle.
If you think you are putting down too much glue on your packaging line and need help, call one of Universal Systems’ technicians at (561) 272-5442. We have the most knowledgeable technicians in the business that can help you with almost any question.
There are a couple different types of filters that you need to change out regularly on your adhesive melter system. One is a tank filter, which we describe in a previous article: The Importance of Tank Filters. The second, is the in-line gun filter. This is the filter that goes between the hot melt gun applicator and heated hose. This is the last line of defense against char being transferred through the module and potentially clogging the nozzle.
There are a three different in-line filter assemblies that are available for your hot melt system: Straight, 45 Degree & 90 Degree. The first is a filter assembly with a straight connector from the gun to the hose. This straight fitting is used when guns line up directly with hoses, typically applying the glue straight out to onto the boxes. The other two filter assemblies offer a 45 degree and 90 degree fitting that allows you to connect the hose to the gun at an angle. These filter assemblies are mostly used on setups where the applicator guns are either above or below the packaging line.
Each filter assembly is available with 50 mesh, 100 mesh and 200 mesh filters. The replacement filters are sold separately in packs of 5 for easy installation so that you do not need to switch out the entire assembly. The filter is easily screwed into the top of the filter body as seen below. Please make sure that you lubricate the o-rings before installation to help you for future filter changes.
For more information on which in-line filter assembly is best for you, please call (561) 272-5442 or email firstname.lastname@example.org.