ProBilt Glue Systems Meet the Demands & Needs of Packaging Lines
The trend in packaging for many CPGs has been to move away from in-house packaging solutions and more towards co-packers and contract packagers. Rather than dedicating complete in-house lines, CPGs and processors can be more flexible with their budgets by putting the responsibility of capital investments for machinery in the hands of the contract packagers. In addition, the CPGs no longer have to worry about hiring line operators for the packaging machines. In the last few years, it has become clear that hiring, retaining and training employees is a challenge for every company. CPGs are finding that if they move the responsibility of packaging to contract companies, they no longer have to deal with that potential issue.
The move to contract packaging is not a bad thing for glue equipment OEMs, like Universal Systems SE. We enjoy working with contract packagers because they are equipped with the skills and knowledge to focus on packaging lines and, in most cases, know what they want and need from a hot glue machine, more than a CPG will.
Below is a list of requirements we are hearing about from Contract Packagers for their packaging equipment, and an explanation as to why Universal Systems ProBilt systems will work best to fulfill these needs.
- Quick changeovers to limit downtime – USSE’s ProBilt systems are plug and play. They are easy to set up and disable for cleaning, preventative maintenance, component replacement, etc.
- Preventative maintenance schedules – USSE believes that preventative maintenance is key to maintain the efficiency and longevity of any piece of machinery. A hot glue tank is no different. Universal Systems offers up a preventative maintenance schedule upon request, along with recommendations on what parts to keep on the shelf and how many of each part is needed to keep your operation up and running at all times.
- Streamlined equipment so that system components are interchangeable – Universal Systems prides ourselves in being the most streamlined OEM of hot melt machines in the market. Not only do all of our tanks take the same pumps, filters, valves, etc., all of our components are interchangeable with our top competitors including hoses, guns, modules and nozzles.
- Versatility for different packaging setups – Universal Systems manufactures over 100 different types of applications options, as well as the option to custom CNC any configuration needed.
- Easy-to-operate machines – Our ProBilt tanks are by far the easiest in the industry to operate. We focus on longevity and simplicity so that anyone can set up and operate our tanks with ease. We also offer online videos on how to set temperature and utilize our setback feature.
For more information on Universal Systems and our ProBilt line of products please reach out to sales@ussefl.com or call (561) 272-5442.
Mini Modules and Gun Applicators
Several Years ago, Nordson® introduced the MBII gun applicators and modules. Initially, the small module and applicator manifold was made for packaging lines that were designed with little room for glue application. Then, they started offering them in a low-profile design for case sealers. Over time, Nordson® started using MBII guns and modules as standard equipment on all of their packaging line set ups. Why? Even though it is not clear the need for the MBII in most standard application setups that have room for an H200, the price surely made it a much more profitable product in Nordson’s® arsenal. The MBII is more than double the price of a standard H200 module and gun applicator.
The key question to ask is, when do you need to use a MBII applicator versus a standard H200 applicator? Like we mentioned earlier, a MBII applicator is essential on packaging lines that have about half the space to fit an applicator than typical lines. Not only is the manifold about half the length and height of a standard H200 gun, the modules measure a mere 1” x 2” in size. Additionally, MBII applicators have the filter built into the manifold. This is a space saver because it eliminates the need for the in-line filter assembly off of the back of a standard gun into a hose. This allows for the MBII gun to attach directly to the hose and still be able to filter out all of the char and debris travelling through the hose and into the manifold. MBII guns also are air open, air close systems, so you can only run them if you have your line set up with two air lines running to the gun. MBII modules do still fit all of the standard H200 nozzle tips. So, even though you cannot use your standard H200 module on the MBII manifold, you can use all of your current stock nozzles.
If your new packaging line comes in with a MBII system installed, our recommendation is to measure the space where the applicator is mounted. If you have room for a standard H200 applicator and in-line filter assembly, you can always switch to a standard H200 set up. The only thing you will need to change out is the gun, filter assembly and solenoid. This will save you thousands of dollars in the future…but only if it fits.
For more information about the mini modules and applicators manufactured by Universal Systems SE, please visit https://www.ussefl.com/products/applicator-gun-heads/h201t-guns/#1544128561143-eeff57c6-9818.
Spring Cleaning for Your Hot Melt Systems
It’s that time of year again, when the days are longer and everyone is motivated to do some Spring Cleaning. That should also apply to your hot melt equipment. Like most machinery, your hot melt tanks, hoses, guns, filters and nozzles need regular preventative maintenance and cleaning. Below is the maintenance recommendation schedule that Universal Systems SE provides to all of its customers regarding our ProBilt line of products.
ProBilt Melters
- Replace tank filter every 500 hours or 3 months, whichever comes first
- Clean tank with Purge Plus every 1,000 hours or 3 months, whichever comes first
*stock 2 – 3 tank filters per tank and 1 Purge Plus cleaner
ProBilt Pumps
- Clean and Flush Pump every 2,500 hours utilizing Pump Service Kit B100-900
- Replace Pump every 5,000 hours or until Pump stops pumping
*stock at least 1 pump to reduce any potential down time
ProBilt Hose
- Flush out hoses when cleaning tank with Purge Plus every 1,000 hours
*make sure to disconnect hoses from guns when flushing with Purge Plus
*stock at least 1 hose per length needed to reduce any potential down time
In-Line Filters
- Replace every 150 hours
*stock 5 spare filters for each filter body
Gun Applicator
- Only replace when it stops functioning –either the heater or RTD
*stock 1 spare gun applicator per line
Module
- Replace module every 1,000 hours or every 6 months, whichever comes first
*stock 2 – 6 modules depending on how many modules are on each gun being used
Nozzles
- Replace nozzles every 120 hours or when they clog
*stock a minimum of 6 nozzles per line
*If you clean nozzles, we recommend cleaning them with kit # 1658 every 100 hours or when they clog
To keep your stock up to date please give us a call at (561) 272-5442. A USSE sales rep will quote you pricing and lead time on anything you need.
Glue Gun vs. Module vs. Nozzle
One of the largest misconceptions of hot melt packaging machinery is that maintenance on a glue applicator gun means replacing the entire assembly. That is not always the case. While sometimes, glue guns do need to be replaced, there are other times when a module or nozzle could be a cheaper solution to your problem.
What’s the difference?
It is pretty simple. The glue gun is the entire assembly (minus the nozzle). This includes the cordset, heating element, RTD, manifold and module. Essentially, if you order a glue gun, once you receive it the only thing you need to do is plug it in, attach the in-line filter assembly though the back fitting, screw on a nozzle and you are good to go. The reason to replace the entire gun would be if you get an error code on your melter main board that the gun zone is either not heating or not reading the RTD. If you get the gun zone heater error, that means that the heating element has stopped working and the gun needs to be replaced. If you get the gun zone RTD error, that means that the temperature can no longer be regulated and the gun needs to be replaced.
However, if you get no main board error code, but your gun is dripping or not dispensing glue at all, that could be a module or nozzle issue.
Modules are the mechanisms that attach to the front of the glue gun manifold to dispense the glue. These modules are operated by air and springs within the module body that control the piston to dispense the glue for easy release and clean cut off. If you are experiencing dripping, or no clean glue cut off, then most likely there is char in the spring that is holding the piston up and leaving the module open. Or, in some cases, the seals within the module could be stiff from usage and wear, and no longer creating the tight seal required for precision dispensing. In either of these instances, the module would need to be replaced.
If you are getting no glue at all to come out of the module, most likely your nozzle is clogged. The nozzle, or tip, is typically attached to the module and can easily be changed by screwing it off and on. In some cases, such as zero cavity or reduced cavity modules, the nozzle is fixed and can only be replaced by rebuilding the entire module, replacing the tip, piston and seals.
If you have any questions about which part of your glue gun you need to replace, please give us a call at 561-272-5442 or email sales@ussefl.com.
Cold Weather Impacts to Your Hot Glue Melter
As we move into the holiday season, we also experience a change in the weather. In most places in the US, the winter months mean that the climate inside most packaging plants change. With that, line operators need to take that temperature change into consideration when working with hot glue machines on their packaging lines.
Hot melt consistency, heated hose and gun temperature consistency and glue stringing are all potential problems that maintenance managers can deal with during the winter months. One of the most important things to look at is where your packaging line is located within your facility. Most melters are located at the end of the line, which leaves them close to an exterior wall, door or window. The cold temperature outside 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. If your glue pellets are colder than normal, it will take a longer amount of time to heat them.
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 use larger sized extensions and filter housings. 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.
If you have any questions about how to reduce the impact of winter weather on your hot melt system, please reach out to a technical rep at sales@ussefl.com.
How to Choose the Best Applicator for your Packaging Line
Oftentimes, a packaging line comes with standard, one module applicator guns. While that is the most common applicator on the market, there are several other application options available.
When figuring out your packaging line configuration, it may become apparent that a standard one module applicator will not work for you. It really depends on what you are closing up with hot melt. Are you running a case sealer? What size and style boxes are you sealing? How many edges do you need to hit with the glue and how do they fold together in the line? All of these questions need to be addressed before purchasing an applicator.
To help out, below is a list of some other common case sealer applicators. All of these items are in stock and ready to ship!
Low Profile
Low profile guns are one of the most commonly used guns on cartoners. Here at Universal Systems SE, we manufacture two module and four module versions to allow for easy glue distribution on small to large box sizes. Their name comes from their unique gun body design which is angled on each side. The angled design sides allow for the box flaps to flawlessly close while the gun is applying the adhesive on to the boxes.
Multi-Module Applicators
If you are running a high-speed line creating cartons that have multiple folds, such as a Douglas case erector, you may want to consider installing multiple module applicators. Universal Systems SE manufacture 2 module, 3 module, 4 module and 5 module applicators. There are various lengths between centers for each model. We recommend that you review all gun specs on our website.
For any other questions you may have regarding purchasing a new gun for your application, please give us a call at (561) 272-5442. We are happy to help create the best and most efficient hot melt application system possible.
The Importance of Product Support
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 sales@ussefl.com.
Packaging in the Pharmaceutical Industry
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 sales@ussefl.com or call (561) 272-5442.
When You Should Use a Pattern Controller
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
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
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 sales@ussefl.com.
How to Obtain Maximum Adhesion on Your Packaging Line
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 tech@ussefl.com.