Knowing your strengths and the value add that you provide are important keys to success for any business. Universal Systems SE’s strength is the in-house manufacturing, QA process and customer service that we provide to our customers all year. The value add is the high-quality material and product that we put to market at a more affordable rate than most of our competitors.
Every day we have maintenance managers or co-packers calling in to find out if we can support their old Nordson® tank. The simple answer is yes. We can support old melters and usually fix any issues that your hot melt applicator may be having. On our website, we offer a search functionality that cross references thousands of product IDs from other manufacturers to make it easy to see which USSE parts are a perfect fit for your old system. However, not only do we support the old, but we manufacture new equipment that will function the same as your old and hopefully last longer. In order to help increase the life expectancy of your hot melt equipment, we offer a recommended maintenance schedule for any maintenance manager so that they can keep up with the life of their products and know when to replace important parts.
Another value add is the fact that we stock over 10,000 items at all times. Not only do we have hundreds of different styles and diameter nozzles in stock, we also stock pumps, control boards, filters, hoses, applicator guns, modules and we always stock tanks. Unlike most manufacturers, that make to order tanks, hoses and guns, we have one of the largest in stock inventory of any other hot melt manufacturer. And everything ships from the US, which means that you can typically get it within the week or overnight service if needed.
If you are ever in need of technical support for your old melter or hot melt equipment, do not hesitate to call us at (561) 272-5442. We are here to use our strengths, to help you add value.
Universal Systems SE has been manufacturing hot melt equipment since 1981. Starting with hoses and nozzles, then moving into applicators, pumps and tanks. Our first ProBilt tank was launched in 1990. Since then, our melter has only had a couple of generational upgrades. We believe that this is what sets us apart from other hot melt equipment manufacturers in the industry today. We have never believed upgrading our equipment or technology so much that it makes our old tanks in operation obsolete. We have added features and improved upon what we initially launched in 1990, but we have not let technology negatively impact the operational ease of our machines.
USSE believes in the importance of long-term product support and cross compatibility. There are hot melt system manufacturer’s in the industry, like Nordson®, who have discontinued not only production but also product support of their old melters. Both the 2300 series and 3000 series melters, while discontinued by Nordson®, are still in operation in hundreds of packaging facilities across America. Unlike Nordson®, Universal Systems still supports those old melters because we appreciate the fact that many of these melters, similar to the ProBilt melters, continue to run even 20+ years after initial operation. We are one of the only manufacturers in existence to still make and service 2300 & 3000 series pumps.
We also believe in product uniformity across all of our melters. That is why when we designed our melters, we made sure that all of Universal Systems’ ProBilt machines run the same control boards, pumps and tank filters. In most cases, facilities run several ProBilt melters, but only need to stock 1 or 2 of each spare part. That uniformity creates a streamlined and more simplistic inventory process.
As we move deeper into 2021 and our new normal continues to change, think about how the importance of long-term product support and a streamlined inventory process can help keep your packaging lines up and running. For more information about Universal Systems and our ProBilt line of melters please email firstname.lastname@example.org.
It’s been a wild ride over the last year, but the pandemic has brought on several advances in the pharmaceutical industry. Hot melt application in the pharmaceutical industry has always been important, but now more than ever. As the US pushes forward with millions of vaccines, each medication needs to be precisely packaged to make sure that it arrives safely to its destination.
Universal Systems manufactures ProBilt Zero Cavity Modules to apply a thin line of hot melt along medication boxes. Zero cavity modules have a very specific look, with a matched needle and nozzle assembly which eliminates minute material pockets that can cause nozzle clogging or dripping. They also come with an E-Z Micro Adjust option to that allows the operator to “dial in” on an exact adhesive extrusion and precise bead placement. 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 the precision requirements, 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 nozzle 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 email@example.com or call (561) 272-5442.
It’s finally here, 2021! It felt like 2020 took forever to end, but now that it is gone, we need to make 2021 the best and most efficient year yet. Due to the struggles that we all faced last year, company strategies have changed, not because we wanted them to but because they had to. And like most industries, the packaging industry has also seen a lot of changes. We are now allowed less people in the office and on the line. Since workers have to be 6 feet apart, we cannot operate as many packaging lines as we want or need to. That means that we are getting less budget to spend on materials, supplies and equipment. Now, operating managers are finding themselves being more particular about cost and efficiencies. That is where Universal Systems comes into the mix. Our ProBilt line of hot melt equipment is made in the USA and has some of the strongest warranties in the industry. We have been manufacturing since 1981 and know what it means to work hard and take pride in that hard work. As we move out of a pandemic and into a new world, we have a few suggestions to help manage our “new normal” in the packaging world.
Catalog Your Inventory – while this may seem like a tedious task, it is worth it in the long run. Once you know what you have and how much you are using of an item, you will be able to estimate your budget needed for the new year.
Research Your Vendor Options – change is hard, but sometimes the best options are ones you haven’t even known about. Take some time to price out vendors for your packaging needs. There may be options out there that you don’t even know about that can save you a lot of money and be just as efficient and high quality as what you have been buying.
Learn How to Troubleshoot & Maintain – Pre-COVID, when the economy was thriving and budgets were high, packaging facilities had maintenance managers, operations managers, line operators, buyers, etc. Now, you may find yourself doing a little bit of everything. At Universal Systems, we believe that knowledge is power. The more you know about the equipment you are running and how to maintain and fix the issues will save you from overspending in the future. We have technicians that have over 40 years of experience in hot melt, that are here to help you if needed. Just call (561) 272-5442.
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 firstname.lastname@example.org
Pattern controllers come on the packaging lines themselves and not typically with a hot melt application system. But, while it is not something that many hot melt manufacturers make, it is very important to the glue application process.
Pattern controllers are used for specific glue applications and patterns. The latest pattern controllers have 4 channel controller capability to do both time and distance-based application programming. They can store up to 9 programs and have the capability of operating in “stitch mode” for substantial glue savings. Another unique feature is the low speed cutoff in distance mode to keep the glue off the side guides when the machine is slowed.
So, when do you need to use a pattern controller and which options do you need? Below are the definitions of both constant speed and variable speed controllers to help you figure out which option is best for your application process.
Constant speed pattern controllers are also known as time-based controllers. The glue is dispensed consistently between .001 – 9.999 seconds, depending on the time that you set. They are designed to trigger a 24VDC Solenoid Valve and have on the fly program adjustments, so nothing is set in stone. Most constant speed pattern controllers have up to 4 programmable glue pattern events available and up to 9 programs can be stored in memory and remain in memory even after the system is shut down.
Variable speed pattern controllers come with an encoder and are also known as distance-based. This means that the glue can be dispensed in set distances apart from the last application. Variable speed pattern controllers measure in tenths of inches, trigger a 24VDC Solenoid Valve and the encoder offers 1200 pulses per revolution. There is a low speed cut off and easy to use program adjustments. Like the constant speed controller, the variable speed controller has 4 programmable glue pattern events and 9 programs can be stored in memory and remain in memory even after the system is shut down.
There is also a hybrid version pattern controller that allows you to do both constant speed and variable speed.
To learn more about pattern controllers, their benefits and which one is right for you, please call (561) 272-5442 or reach out to a Sales Representative at email@example.com.
As we return back to work from the shut down earlier this year, facilities may be experiencing several new situations or issues that they have either never dealt with before, or maybe they are new to the industry and need help with understanding how best to operate a high-speed packaging line. We are hearing from a lot of our customers, both old and new, that good adhesion has become a problem. Even though we are moving into the summer and the weather is no longer a potential cause of adhesion issues, there are a few other checklist items that you can walk through to help correct any lack of adhesion.
The first thing to check is the distance of your application gun and nozzle tip to the container or carton you are trying to glue together. If there is too much distance between the tip and the box, the glue could be cooling mid-air, not allowing the cartoner to get full adhesion when moving the box to the folding stage. This solution could be a simple mounting adjustment to lessen the space between the nozzle tip and the box.
Another item to review is the viscosity and melt rate of the glue you are using. It is imperative to educate your line operators on the glue specifications to make sure they are heating it to the correct temperature. On the flip side of that, make sure they are not over-heating it and making the glue too thin, creating a longer open time for the adhesive. Knowing the specifications of your glue will also help you to regulate the amount of glue you are using on your applications, hopefully keeping your operating budget down.
In addition to the above listed items, we also highly recommend regular maintenance on your hot melt system to limit the amount of char building up in the tank. Performing regular maintenance such as changing out tank filters, in-line filters and cleaning out the tank quarterly, will lessen the effects of char through the line. If you do have a lot of char build up, that can and will transfer through the system and onto the box. Too much char mixed in with your glue can be causing adhesion issues. Once the glue dries and hardens around the char, the char can separate from the box.
If you are experiencing any adhesion issues or have any other troubleshooting questions that you would like to review with a technician, please call Universal Systems SE at (561) 272-5442 or email firstname.lastname@example.org.
As a manufacturer, Universal Systems SE, understands the importance of quality. That is why all of our hot melt application systems and components go through an extensive quality assurance process before they leave our facility.
Each technician at Universal Systems has a specialty. For example, building circuit boards, assembling tanks, building & testing pumps, building applicators, winding hoses, pressing in seals and assembling modules, pressing and drilling nozzles, etc. With over 10,000 parts in stock, quality assurance and having a double check (or even triple check) system in place is essential to ensure all of our customers are getting high quality products that will last for years.
Each technician takes immense pride in their work. However, even the best of the best need to be checked. Our typical QA process requires the build technician to go through their assembly process and initial each step, which confirms to the QA technician that they have in fact followed the correct order. This is important since most of the time our build technicians are building multiples of the same product at one time. We want to guarantee that a step is not skipped. After the build technician has initialed their paperwork, the product is then moved to the QA department. A QA professional is assigned to the project and reviews all of the key items on their checklist. Once the component QA is complete, the item is boxed, dated and initialed by the QA professional. The next time you receive an order from us, check to see that there is a green QA sticker with initials on it. That is your QA professional!
For any further questions regarding our QA process or if there are any technical questions you have about any Universal Systems product, please email email@example.com or call us at (561) 272-5442.
Now you may be asking yourself, why am I reading about chillers on a hot melt blog? The answer is easy, Universal Systems SE manufactures heated hoses that can be used for transferring many more substances other than glue. And when there are applications that do not include glue, the manufacturing lines may need chillers.
Our heated hoses, while mainly used for high speed packaging glue application, can also be used for heating and transferring a plethora of other materials. Our Teflon lined hoses can transfer anything from candy, make up, wax and much more! Depending on the use and application of different substances, the packaging line can be filling at high rates of speed. Heating and filling formed containers for candle wax, as an example, can be tricky because in this application the wax needs to cool quickly so that it can be formed, packaged and shipped out to end users. One of the most common questions we get in this situation is: How can I keep my forming operation running at a high-speed pace from start to finish? The answer here is chillers. Essentially how a chiller works is it is built into the conveyor line. So, the product would be heated in a melt pot, transferred through the heated hose, dispensed into containers, and then fed along a chiller that is built into the line. The product goes from hot to cool in a matter of seconds.
If you have any other questions on how we can help you keep your production lines running at high-speed capabilities, please reach out to firstname.lastname@example.org or call to speak with a technician (561) 272-5442.
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!