Help When You Need It

In the post-pandemic age of industry, every company is finding themselves in need of more help. Whether it is qualified technicians with experience in the field, or technical support and customer service from their vendors. A lot of large companies, like Nordson®, have gotten rid of their technical support and customer service representatives, replacing them with automated systems or remote sales reps that do not have a detailed knowledge of each customers purchase history or equipment needs. That is making it difficult for CPGs to troubleshoot issues or for new maintenance managers to know what to order.

Many line operators of hot melt machines are new to the industry, since companies saw their long-term employees retire during the pandemic. At Universal Systems, we not only stayed open and kept all of our employees during the pandemic, we have kept detailed reports of our customers purchase history, as well as a cross reference list of our products to Nordson®. We are always here to take any technical calls or offer Nordson® replacement parts when you need them. With the “supply chain shortage” impacting all Americans, we made sure to back our bets here at USSE. We have ramped up our inventory by double its normal size to ensure that you can get products when you need them and not be held hostage to overseas competitor parts. We make everything in the USA and use all US suppliers. We stand behind our products and feel certain that we would be able to help you with any issue that may arise with your hot melt equipment.

For any technical support please email tech@ussefl.com or call 561-272-5442.

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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.

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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.

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Lowering Downtime on Your Packaging Line

As CPGs continue to change their packaging lines to try and cut costs but stabilize runtime, there are a few things to consider when analyzing the cause of machine downtime and how to prevent it.

The below statistics were taken from the Fall 2021 issue of OEM Magazine:

Causes reports by respondents at CPG companies as the most common cause of packaging machine downtime: 26.3% general wear and tear, 21.1% operator error, & 22.1% product changeover.

General wear and tear is pretty self-explanatory. This would depend on how many hours and days per week a facility runs their packaging lines. If they are running 24/7, then the percentage of general replacement parts purchased will be higher than a plant that is only open 8 hours per day, 5 days a week. To lower downtime, each facility should stock at least 1 -3 replacements, at all times, of the following items: Heated Hoses, Glue Applicators, Modules, Nozzles, Tank filters, and In-Line filters. Another way to lower downtime is preventative maintenance. If CPGs were to prioritize preventative maintenance, then their packaging machinery would last longer and lead to less overall downtime. We recommend PM practices that include changing tank and gun filters, as well as maintaining an even level of heated glue in the glue reservoir of the tank. If done on the regular, general wear and tear percentages would go down.

Operator error is also another large concern for CPGs and the cause of most packaging line downtime. That is because Nordson® and other large corporate OEMs are making their melters more technologically advanced.  Unfortunately, this increased technology does not come with increased training. While technology can create less human interaction, if the line operators are not trained on how to work the equipment, it can lead to more errors. Also, several of the new systems need to run on a network in order to work, so if there is any network downtime, that will now impact the packaging machinery and shut down the line. Universal Systems has maintained our simple to use systems and provides YouTube videos on how to work our machines, along with error codes and how to navigate the control board.

The final most common cause of packaging line downtime is product changeover. To lower overall costs, many CPGs use the same machines to package multiple types of items, which requires a changeover of parts. This downtime might be harder to avoid, however if the line operators are well versed in the machinery and understand the usage need of the machine in all areas, this can be lowered.

For more information on our Universal Systems line of hot melt products, please contact a sales rep at sales@ussefl.com.

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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.

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The Right Melter for Your Packaging Line

Finding the right melter for your packaging line can impact not only your productivity, but also your bottom line. Most commonly, maintenance managers and buyers simply replace the current OEM melter with the latest model. That is not always necessary. Universal Systems SE ProBilt™ melters have the same footprint as most all Nordson® systems and can easily fit into where the original tank is positioned. Just because your current packaging line has a Nordson® melter does not mean you have to replace it with another expensive Nordson®. Plus, all of our ProBilt™ melters are in stock and can ship same day!

There are several key points to take into consideration when choosing a hot melt system for your packaging line. The most important are: Melt Rate, Durability, & Cost-Effectiveness.

Melt Rate

The melt rate is the rate at which the tank melts the adhesive pellets as they are filled into the reservoir. This is where the tank capacity comes into play. Before moving forward with any hot melt adhesive system, first you need to understand how many pounds you need to melt per hour. The melt rate is dependent on how many hoses and gun applicators you are running and how many boxes are being sealed per minute on your packaging line. The most common tank capacity is the 20 lb. (10 Liter) ProBilt™ 20, with a melt rate of 23 lbs. per hour. If you are only running one line with one hose and gun applicator, then you may only need the 15 lb. (7 Liter) ProBilt™ 15 which melts 18 lbs. per hour or the 12 lb. (6 Liter) unit which melts 15 lbs. per hour.

Durability

Depending on how many shifts you are running, you need a melter that will work consistently and effectively. All ProBilt™ melters come with a 10-year heater warranty, which is the highest in the industry. In addition, all melters come standard with 4 hose / 4 gun capability and a set-back functionality that allows for easy start up and shut down. ProBilt™ melters are constructed out of 316 stainless steel, not only for its sleek look that will seamlessly blend with your packaging line, but also for its durability and sustainability on your production line floor.

Cost-Effectiveness

The economy is a huge question mark lately, being impacted by the lasting effects of the COVID-19 pandemic. With that, large CPGs are cutting back not only in personnel but in spending budgets for packaging. These tighter budgets won’t always allow for a buyer to simply purchase the latest Nordson® melter. Here at Universal Systems SE, we have seen more and more companies trying to repair older melters and plug any current issues with band-aids to stretch their fixed budgets as far as they can. Since we manufacture parts that are compatible with old Nordson® tanks, we have been able to help a lot of companies cost effectively navigate the times. In addition to our parts business, all of our ProBilt™ series melters are cost effective replacements for any Nordson®. We are currently running a 15% off and free shipping in the USA promotion to help out CPGs and support US based companies.

To learn more about Universal Systems SE’s ProBilt™ series of melters and components, please reach out to a customer service representative at sales@ussefl.com or call (561) 272-5442.

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Top 5 Tips to Hot Melt Machine Maintenance

Packaging lines are complicated pieces of machinery and knowing the ins and outs of each component is important. When you install a new hot melt system onto your packaging line, there are 5 helpful tips to take into consideration to ensure smooth operation and getting the most out of your equipment.

Read and Keep the Manual

The best practice for maintaining your hot melt tank is to read the manual and keep it handy. So many times, maintenance managers will install the tank, but not read the instructions on how to wire it or program it. That can lead to so many issues. In other instances, a tank may be running for some time, but someone hits a button accidentally and changes a setting, then doesn’t know how to change it back. If only they had read the manual or kept it on hand. It sounds like such a common-sense thing, but oftentimes manuals are discarded with the shipping crate. For this reason, we keep a digital manual on our website for anyone to reference.

Replace the Filters

Preventative maintenance is one of the most important tasks to keep your machine running efficiently and reduce down time for your packaging line. When your tank filters are clogged, that is good, it means that they are doing their job and filtering out char. Changing them on a regular basis and spending a small amount on a tank filter will save you thousands in the future.

Monitor Your Hot Melt System

Line operators are tasked with monitoring tanks on a daily basis. It is important to make sure that the pump is pumping smoothly, the solenoid is not lagging and the guns and hoses are heating to temperature and staying there consistently. Even a minor change in any of those tasks can mean that it is time to proactively replace a component, or at least make sure there is a back up on the shelf.

Know Your Options

Knowing your options ties all three previous tips together. If you have read the manual, you will know what your options are when something goes down. If you are doing preventative maintenance, then you know it is not the tank filters. And if you are monitoring your system, you know what components you replace most often and what inventory you have on the shelf. In addition, you should also know what options you have should you need to replace your current system. Is the current technology working for you or do you want to upgrade to an auto-fill system? It is always good to be prepared and know your options.

Listen to Your Workers

Line operators are on the front lines, literally. They watch particular lines and machines on each line all day, every day. They know what parts are running effectively and where the problems may lie. It is important that you listen to them. They might not be the maintenance manager by job title, but they are the most knowledgeable about the equipment they are in charge of and their opinion should be the first requested.

 

For more tips on keeping your hot melt systems running to the best of their ability, please give us a call at (561) 272-5442 or email tech@ussefl.com.

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When to Use Micro-Adjust Modules

Hot melt system modules are located on the front of your applicator guns. There are several different types of modules and in most cases, they can be easily replaced on the manifold versus replacing the entire gun assembly. Changing out a module is a more cost-effective way to increase productivity and lower glue costs. Typically, modules need to be replaced when they are having glue dripping issues or major leaking from the nozzle. This is caused by normal wear or char getting stuck in the piston chamber, not allowing it to seat securely.

When replacing a module, you have the option of buying a standard case sealer module or a micro-adjust module. This refers to the module’s adjustment cap on the module body. A standard case sealer module comes pre-set and typically needs no adjustment. This is our most popular style module. A micro-adjust module cap is typically sold on Zero Cavity or ProBead Reduced Cavity modules. These modules have a user-friendly adjustable screw top that changes the pressure of the glue through the nozzle. This allows the operator to dial in a precise glue bead. Typically, zero cavity and ProBead reduced cavity modules have micro-adjustable caps for this reason. For example, they are used on medication boxes or beauty supplies. Another advantage to a zero cavity or ProBead reduced cavity micro-adjust module is the self-cleaning functionality, limiting charring and clogging.

For more information about micro-adjust modules please reach out to a technical sales rep at sales@ussefl.com or call (561) 272-5442.

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How to Change Out a Melter Pump

There are several reasons why a melter’s pump might stop working. The most common reasons are clogging of the ball and seat from foreign matter such as carton dust, and the actuator clogging due to dirty or oily air. No matter what the reason, if your pump stops pumping it needs to be replaced. Obviously, it much more cost effective to change out a pump then to replace the entire unit. However, it is not always easy to switch out a pump, especially if you are new to the line. Below are a few tips to help ease you through the process.

  • Make sure the circuit breaker on the front of the unit is set to OFF once the applicator has reached normal application temperature.
  • Shut OFF the input air to the pump.
  • Set the pump regulator to zero and trigger all guns to relieve system pressure.
  • When removing the old pump, rotate it slightly to break the suction and then pull it straight up and out.
  • When installing the new pump, make sure to torque the screws 15-16 ft-lbs.
  • Connect the pump electrical plug to tank receptacle and turn tank back on.
  • Once the tank board reads that the tank has reached set temperature, wait 15 minutes. This will allow the glue around the pump hydraulics to get to temperature.
  • After waiting 15 minutes, reinstall the air regulator and connect the airline and activate air.

 

If you have any further technical questions and want to speak with a technical sales rep, please call (561) 272-5442 or email sales@ussefl.com.

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Know Your Strengths

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.

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