Maximum Efficiency, Minimal Downtime
One of the most important tasks that any packaging facility or high-speed packaging line can accomplish is to run at maximum efficiency with minimal downtime. While that may seem near impossible to do, there are some key points below that will help any plant manager achieve that goal.
Preventative Maintenance
Completing routine preventative maintenance tasks is essential to stay up and running. While it may seem unnecessary to do preventative maintenance, especially since your lines are running normally, it is the only way to ensure your production lines stay continue running normally. The worst thing that can happen is for the line to go down and you lose a day or even a week’s worth of productivity. Maybe you do not know why the line is down, maybe you do not keep the spare parts needed, whatever it may be, it could have been prevented by some simple maintenance. That is why, at Universal Systems, we recommend changing your hot melt tank filters every month and clean the tank every quarter. In addition, also change out your in-line glue filters every month to ensure that you do not have any char clogging up your guns, modules or nozzles.
Keep Your Product Manual
It is all too common that we receive technical calls because the maintenance manager or line operator does not have the product manual and understand how their equipment should work. With every ProBilt tank system, we include the product manual which lists error codes, troubleshooting and replacement part numbers. We also have our product manuals available online. Another important step is to read through the setup manual if you are experiencing problems. Maybe something was set up incorrectly or not reset when an item was replaced.
Use Product Stickers on Machines for Easy Restock
Whenever USSE sends out modules or nozzles, we include a sticker that can be used on either the machine or the order wall of the Buyer. It is an easy and efficient way to know what parts you have running on each line and what you need to have in stock for a quick replacement.
Make Sure your Equipment Manufacturer is a USA Manufacturer
As a country, the US has gotten away from relying on US based manufacturing. Mainly, because of our obsession with cheap goods. But cheap goods do not have a long lifespan and while we may be saving money upfront, it costs us in the long run. That is no different in the packaging world. The best part about working with Universal Systems is that we have kept our products at a reasonable price for over 40 years and we stock every part you might need. So, if your hot melt equipment ever does go down, we can ship replacement parts same day.
USA Made Products
We have been in business for over 40 years here in the United States. While many of our competitors took advantage of cost cutting opportunities and shipped their manufacturing jobs overseas, we have stay tried and true here, first in New Jersey and now located in South Florida.
While we believe that Made in the USA has always meant something special, it is now more important than ever. With new tariffs being implemented, large corporations who have moved their manufacturing overseas, are now struggling to keep pricing the same and get their products to their US customers. Since the backbone of our business are US based packaging facilities, making sure that our products are in stock is very important. And since we focus on making sure that all our raw material suppliers are located here in the US, we can guarantee that our pricing will not increase due to tariffs.
We are a proud US business that wants to take advantage of the patriotism and boom that the US manufacturing industry is going to see over the next decade. If you are running high speed packaging lines and need hot melt application equipment, you can feel confident that working with Universal Systems is the right choice. We offer technical and sales support for anything you might need, whether it is Nordson replacement parts or custom heated hoses or manifolds. Just reach out to us at (561) 272-5442 or sales@ussefl.com and we are certain we can help keep your facility up and running. Let’s support our fellow Americans and keep our manufacturers and packaging plants here in the USA.
Hands On Hot Melt Machinery vs. Remote Access Equipment
The hot melt industry has been changing over the years and most recently has made a push for remote access machinery, or even Bluetooth enabled equipment. At Universal Systems, we believe in the old school “hands on” approach to high speed packaging. Having a human component to troubleshoot and catch issues before they even start, in our opinion, is the only way to effectively manage your manufacturing systems. However, some of our competitors are moving toward human-less systems, where one person can manage the line from afar. With the equipment telling the person what they need and when they need it. There are pros and cons to each.
Here are the reasons why we feel like the “hands on” approach to line operators is still important.
Experience
Real time on the spot decision making based on experience will always be irreplaceable.
Troubleshooting
If something were to happen on the line, a line operator can real-time troubleshoot and fix the issue faster and more efficiently than a computer.
Eyes on the Problem
Putting your eyes on the actual problem helps you to better understand what the issue is and how to fix it. Reading an error code or getting an alert that you then must spend time researching is not always the best solution. If you can see why the line is down, then you have a better chance of getting it fixed and back up and running quickly.
Makeshift Fixes
Not that we are a proponent of makeshift fixes, sometimes it is necessary. With someone on the line, they can quickly switch out a filter or unclog a nozzle without there being much downtime. If you are working remotely, you would then have to call down to someone on the floor to make the switch, which could take more time than your operation can afford.
Overall, while computers and technology can be helpful and advance the industry, nothing can effectively replace a valuable line operator with experience and the ability to think on their feet. The same goes for technical support. It is invaluable to be able to work with a company who can offer you real-time technical support. At Universal Systems, you can always speak to someone who can help. We don’t send you through teleprompts or force you to send an email that may or may not get answered in a timely manner. We pride ourselves in our response times and helping our customers who are on the floor and putting in the work to get their equipment running at maximum capacity. For any technical support or customer services give us a call at (561) 272-5442 or email sales@ussefl.com.
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.
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.