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.
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.
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.
Tried and True: How Reliability and Innovation Don’t Always Go Hand in Hand
Innovation is important in any industry, including packaging. However, the latest and greatest isn’t always the best for your operation. There are several reasons as to why it is better to stick with the old tried and true systems.
Reliability
If it ain’t broke don’t fix it. I am sure you have heard that saying before. There is a reason. If you have a system that has run great for you in the past, stick with it. Getting something new is not for everyone. With new equipment comes more complications such as line operator training, all new inventory, potential downtime due to the learning curve, etc. In addition, most all new equipment comes with new technology that, while it is probably meant to be helpful and less time consuming, becomes over complicated and more time consuming. Universal Systems ProBilt has kept its reliable technology for decades. And while that sounds like we are not innovating, that is not true. We are sticking with what we know works. We have found the secret sauce, why over complicate it?
Ease of Use
With every innovation, comes new challenges. Learning new ways to do things is not easy for everyone and can slow most people down. That is true in our everyday lives, just like it is in packaging. It’s called high-speed packaging for a reason, and every new technology feature opens the door to potentially slowing people down. If your network connection is slow, or the on-board computer screen doesn’t want to keep up with the operation. All these new luxuries can cause slowdowns. Our Universal Systems ProBilt tanks and components are easy to operate with our plug and play style. The board’s simplicity is our greatest asset. It lowers the number of faults and tells you the exact problem if there is a fault. With our ProBilt AccuScan Control Panel, you don’t need a book of faults to reference, the screen tells you what the issue it. Keeping it simple for all operations on the line.
Knowledge is Power
If you have a ProBilt melter, then your line operators know how to set it up, how to use it and the maintenance required to keep it running for decades. As we see other companies in the industry switching out their systems and discontinuing product lines, we have decided to keep with what we know. Inherently allowing our customers to keep with what they have been running for as long as they have worked with us. At Universal Systems, we don’t have any planned obsolescence. You will never not be able to get help with any of our equipment because we no longer support it. We make sure that we support everything we have ever made and will stay that way.
Under Pressure: How changing air pressure impacts your hot glue lines
Universal Systems manufactures pneumatic hot melt systems, which means that our equipment operates via air pressure. It is important to understand how air pressure can put stress on equipment and why the correct pressure points are essential to run a consistent, well-maintained hot melt system.
The way that a pneumatic hot melt system works is that an airline goes into the pump, to move the pump shifter, air motor and pump piston up and down to pump the glue from the tank, through the manifold, through the hoses, into the guns and onto the boxes. There is also going to be another air line into the guns to get the module pistons to open, apply the glue, and in some cases there will be an additional air line the air to close the pistons.
Let’s start with the air pressure to the pump. The air pressure to the pump is very important and should always be set between 20 psi – 40 psi, with an ideal setting in the middle at 30 psi. If your technician thinks the pump is running too fast and lowers the psi to under 20, then the pump might not have enough pressure to move the shifter. In most cases, a pump will run at as low as 18 psi. If your technician comes to you and states that the pump was running too slow, so they increased the air pressure to over 40 psi, that could cause damage to the seals inside the pump’s air motor. It is important to note that if the air pressure on the pump is set to 40 and the pump is still not pumping efficiently, then there is another issue at hand. Most likely there is dirty air inside the shifter or a clog in the tank filter. The air pressure should never be increased to fix other issues stopping up your pump.
The second air pressure point in your hot melt system is at the applicator gun. The air going into the gun should be set at a minimum of 60 psi. In most cases, 60 is the perfect setting for the guns. If your technician tells you they need to set the psi higher to get the guns to fire, then there is a clog in the in-line filter and that filter should be replaced. If the psi to the guns is anything higher than 80, you could blow a seal on the module and have issues with application.
If you have any questions about air pressure, please call us at (561) 272-5442 or email sales@ussefl.com.
Wine & Packaging
Why not combine my two favorite things: wine & packaging!
Winemaking is as much an art as it is a science, the same can be said for manufacturing packaging equipment. Winemakers need an OEM that has in-depth knowledge and experience in packaging products as high-end and fragile as wine bottles. At Universal Systems, we work with several large wineries to help them utilize the most cost-effective and capable line of hot melt equipment to seal their most valuable assets.
When wineries look to an OEM for their packaging needs, below are 5 things they need to focus on.
- QUALITY: All Universal Systems SE equipment is compliant with all international standards in addition to offering OSHA compliance.
- RELIABILITY: At USSE, we work with all wineries to make sure their hot melt equipment is optimized and running smoothly, and we have since 1981. We focus on matching the packaging needs with the tank capacity of the melter and the ease of operation on all machines for line workers. The easier the operation, the less potential for downtime. All of our hot melt tanks have the same components, this allows for you to streamline your inventory as well. We also provide you with advanced engineering and design with expert tech support.
- FLEXIBILITY: Your wine-making facility and process is unique, and you need an OEM that works with you to provide flexible solutions that support your business goals. Whether you need just a single machine or a full hot melt system, Universal System has a multitude of products that you can use for different glue applications.
- AFFORDABILITY: When you invest in new equipment, working directly with the equipment manufacturer eliminates the increased costs charged by a 3rd party representative of an OEM. Such investments should readily produce improved efficiencies that positively impact your bottom line. Our clients can attest to the fact that their investment in USSE equipment results in proven, accelerated ROI and a lower total cost of ownership. Plus, all of our equipment is proudly made in the USA.
- SUPPORT: Avoid frustrations of unanswered questions and unsolved problems by choosing to work with an OEM that provides excellent US-based customer service. That way, your operation can quickly get the assistance they need. Universal Systems is a US company who only has offices in the USA. We are proud to offer made in the USA products to our favorite US winemakers!
Call (561) 272-5442 today to speak with a sales rep to see how Universal Systems can help with your packaging needs.
Case & Carton Packaging for Pharmaceuticals
The pharmaceutical industry is no stranger to growth, but over the last few years, it has seen an unprecedented increase. Because of rising healthcare spending, the launch of new treatments, and rising frequency of chronic diseases, the pharmaceuticals market is expanding. This will allow low-cost generic alternatives to enter the market, which will spur demand for pharmaceutical packaging equipment.
When you think about pharmaceuticals, packaging isn’t top of mind, but it is a key factor in distribution and cost effectiveness. At Universal Systems, we realize that pharmaceutical companies need precise, accurate, reliable packaging equipment in order to get the latest medications out into the world. We have been working on perfecting specific precision hot melt application equipment for over 35 years when we initially launched our ProBilt® Zero Cavity Modules.
Zero cavity modules apply a thin line of hot melt along medication boxes, effectively sealing each box for mass distribution. 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.
Not many hot melt application manufacturers offer zero-cavity modules. At Universal Systems, we believe in innovating for the pharmaceutical industry rather than trying to use case and carton machines for such precision application.
If you are sealing pharmaceuticals, call or email us today for a quote!
What Empty Grocery Shelves Mean for the Hot Melt Industry
If you are like me, you walk down the aisles of the grocery store searching for your favorite staple items and can’t find them. The space for the product is still there, but it is empty. With budgets tight and good help hard to find, the struggle to keep grocery shelves stocked is a difficult one. In addition, inflation is demolishing the grocery market with the average consumer spending 60% more for items that actually contain less food.
How does that transfer over to packaging? Easy, with less product demand, the storage facilities start to fill with products that have been packaged but not ordered by grocery stores. This causes CPGs to shut down front end packaging lines and look to see where they can cut costs on equipment.
If this scenario sounds familiar, there is a long-term solution. Universal Systems provides high-quality, cost-effective packaging machinery options that can fit into your budget all year long. And as an OEM, we manufacture everything in the US and stock all items for same day shipping. With packaging needs changing day to day, and many suppliers out of stock on standard maintenance items, CPGs can find it difficult to stay in production. Here at USSE, we focus on helping you stay up and running with the most cost-effective options. We also offer full time tech support to walk you through any line issues that arise and help with the glue tanks and components.
One way that Universal Systems adds value is that we also offer Nordson® compatible parts. So, if you are finding it difficult to get Nordson® parts or if you are currently running a Nordson® discontinued system, we manufacture all of the parts that you will need to stay up and running. Our products work with case packing lines, tray formers and folding cartons in all industries including food and beverage, pharma and healthcare, electronics, cosmetics and many more.
Hopefully we start to see grocery shelves get back to normal supply and demand. USSE can work with you and your packaging needs through both the good times and bad. We will get you up and running when needed, and keep you there, so that when grocery stores are ready, we can fill up the shelves once more.
For more information on our ProBilt® line of hot melt products that are all compatible with Nordson® please call or email us today.
Are you running a Nordson® ProBlue®?
If you are running a Nordson® ProBlue®, then you might be worried about how long it’s been taking you to get parts for your tank. You should be. Recent reports from industry insiders are calling out the 3-month lead time on Nordson® ProBlue® tanks and parts. The same industry insiders are confirming that Nordson® has decided to discontinue their most popular line of hot melt tanks.
What does that mean for you?
Currently, the only facilities who are running into an issue are the ones who need new hot melt tanks. Without the ProBlue® as an option, your next best Nordson® tank is the Flex®, which can run you upwards of $20K. That is where we come in. Universal Systems SE has a line of high quality, low maintenance, affordable, reliable hot melt tanks called ProBilt®. Our ProBilt® line of hot melt tanks are designed to be an easy to use, plug and play style machine, with interchangeable parts no matter what capacity size pot you order. We offer 8 lb. – 20 lb. tank capacities, but they all use the same control board, pump and tank filters. That means, you can streamline your inventory, not having to worry about which part goes with which tank. All our ProBilt® tanks start under $8K, are made in the USA and are in stock. You won’t need to wait 3 months to be up and sealing, only a few days for shipping.
But is USSE as good?
We always get the question; how do you compare to Nordson®? The proof is in our story. We have been in business for over 40 years and have always manufactured in the US. We have real time tech support and answer any and all questions quickly. But will our ProBilt® tanks last? The simple answer is yes, but if you don’t believe us, they all come with a 10-year heater warranty. In addition, they are built using 316 stainless steel which will stand the test of time.
So, don’t feel like you are being forced to bust your budget and buy plastic hot melt tanks that require so much technology your facility can’t support it and your operators can’t run it. Keep it simple and reliable with Universal Systems ProBilt® stainless steel tanks. We also manufacture ALL of the components that will pair up with your existing Nordson® tanks and our ProBilt® tanks. Hoses, guns, modules, nozzles and so much more!
Interested in a USSE ProBilt® melter? Call or email us today and find out how to get one in only a few days!
Inflate Your Inventory, Not Your Budget
As we head into 2023, all Americans are impacted by the largest increase in inflation that we have seen in decades. With inflation comes several other economic impacts on society, including companies lowering budgets, changes in workforce, families not being able to afford bare essentials and many other challenges. With that said, companies still need to find ways to stay fully operational while staying within their newly defined restrictions.
Here at Universal Systems SE, we pride ourselves on producing high quality products at economical prices and have since 1981. All of our products are made in the USA and we keep almost every item in stock at all times. If you are having issues getting Nordson® products, or feel like the recent price increases from Nordson® aren’t allowing you to stay up and running at all times, please reach out to us. We will send you a quote within 24 hours.
The importance of “in stock” has never been more valuable. We realize that and are dedicated to continue to invest in stocking products so that our customers can get their most vital items in a timely and cost-effective manner.
For pricing on our most popular products, please reach out to sales@ussefl.com.