Graphite seals and PTFE are used in all of Universal Systems SE’s pumps and modules to increase the longevity and life of those products. But why? In order to understand how we can boast about the quality of our products, it is first important to understand the quality and reasoning behind using certain key components.
Graphite seals are used in both the pumps and modules to create a smooth seal for the piston to move seamlessly through. Below are a few bullet points that explain why this particular component is so important.
- Excellent heat resistance – up to 500°F – most all hot melt adhesive systems will heat up to 450°F, so even if a packaging line runs at the highest temperature allowed by the system, the graphite seals will remain unscathed.
- It has a medium to high pressure rating – the maximum operating pressure on any pump should not exceed 35 – 45 psi. The most common operating pressure is 20 – 25 psi. These seals are rated perfectly for this type of application.
- Excellent abrasion resistance – some packaging lines are not run with the cleanest adhesives, so utilizing graphite seals allows for any adverse environmental condition.
- Very resistant to chemicals – this allows the end user the ability to not only use multiple types of adhesives, but cleaners as well.
- Excellent extrusion resistance in severe conditions.
If you are interested in learning more about the components used to manufacture Universal Systems line of ProBilt™ equipment, please call (561) 272-5442 or email email@example.com.
Keeping your hot melt adhesive system clean may seem like an impossible task. Take a look at your melter now, it is probably bronzed and blackened with old melted glue. Well guess what…that is what travels through your application system and onto your boxes. Also, do you see all of the little bits of blackened glue? That is called char, and it is a big problem for your equipment. Even though your melter looks like this now, it is possible to keep it clean “ish”. Now, this melter runs in a packaging line, most likely 8 – 12 hours per day, every day, so there is no way that tit is going to stay pristine or even look clean after its first use. However, there are a few tricks of the trade to keep your melter looking good and running even better for decades to come.
Universal Systems SE sells a product called Purge Plus™ that, when used properly, will clean almost any melter. The directions for use are simple:
- Drain all hot melt from tank reservoir
- Fill reservoir with Purge Plus™
- Heat Purge Plus to 350°F – 375°F for approximately 45 minutes
- Open tank drain valve and remove tank filter assembly
- Slowly start pump and run Purge Plus™ through the tank manifold and into a meal container until reservoir is empty
- Stop pump, replace filter assembly and close drain valve
- Carefully wipe any remaining contaminants from tank reservoir
- Add new hot melt and recirculate through system
- Drain one cup from each hose
In addition to cleaning the tank reservoir and heated hot melt hoses, if you are running a ProBilt™ series melter, the exterior is manufactured out of 316 grade stainless steel. So, any stainless steel cleaner will shine the exterior of the tank.
For any additional questions about Purge Plus or how to properly clean your tank and hoses, please call a Universal Systems service technician at (561) 272-5442 or email firstname.lastname@example.org.
Have you ever purchased a case of soda or carton of coffee cups and can’t get the box open? Of course, we all have. In the packaging industry, especially for hot melt machine manufacturers, that is a red flag. Whenever we get a box that has too much hot glue on it means that the packaging line is not set up properly or not being cleaned regularly.
If you are wondering why too much glue means that the line is not set up properly or not being cleaned regularly it is because one of two issues is occurring (or sometimes even both). The first issue is most likely that the line operators and/or maintenance managers are not cleaning the tank regularly and the lines are clogging up with char, which will subsequently clog nozzles. Instead of cleaning the tanks and hoses, and replacing the tank filter and in-line gun filters, most operations just buy bigger nozzles. If the diameter of the nozzle orifice is larger, then it will allow through more bits of char and not clog up as easily. Unfortunately, this is not a long-term solution. Putting down more hot glue will drive up the amount that facilities spend on adhesive pellets, and ultimately the annoyance will trickle down to the consumer when they can’t get their box open. The solution is simple…utilize Purge Plus to clean your tank every 1,000 hours. For some facilities that could mean cleaning every quarter and for others that could be twice a year, it all depends on the facility. In addition to cleaning the tank and hoses with Purge Plus, make sure that the tank filters are changed every 500 hours. The in-line gun filters should be changed every 150 hours to ensure that no char travels into the gun applicator, through the module and nozzle and onto the box.
The second issue that could cause too much glue on boxes, is that the line was not set up correctly from initial purchase. A lot of cartoners have standard hoses, guns, modules and nozzles that will work for most case packers, but not for all. Make sure to take into consideration the temperature of your packaging facility (which can impact the adhesion and viscosity of the glue as it travels through the application process), the distance that the guns are to the box upon application, and the surface area of the box you are covering. The longer the bead of glue you place, the less likely you are to need a larger diameter nozzle. The shorter the range you are covering, you might need more glue to make sure that maximum adhesion occurs, which means you need a larger diameter nozzle.
If you think you are putting down too much glue on your packaging line and need help, call one of Universal Systems’ technicians at (561) 272-5442. We have the most knowledgeable technicians in the business that can help you with almost any question.
Case packing and sealing in packaging lines depends on several components to run steadily and reliably. In order for a system to run continuously at all times, each piece of equipment needs to be concisely installed. The usual suspects of precision engineering on your case sealer adhesive systems are the pump, applicators and nozzles. Most line operators undervalue the importance of heated hose length in the overall operation and efficiency of the line.
Heated adhesive hoses get attached to the hot melt tank and run from the tank to the application gun, which is mounted on the packaging line itself. Heated hoses are typically attached to the tank with a straight connector, but can have both a 45 degree or 90 degree connection option, depending on where the tank is placed on the line. The applicator plug at the end of the hose is also sent out as a straight connection, but can be switched to a 90 degree plug if needed. There are typically two – four hoses used on each packaging line. With a two hose line, one hose will run up the line, across the top and down to the applicators. This hose transfers the adhesive that will seal the top of the carton and is mounted using straps. The second hose will typically run straight along the side of the packaging line to seal the bottom of the case. No matter how many hoses you run or how you mount them, it is very important to have the correct length hose.
Our technicians visit several packaging facilities each year, and their biggest take away is that most purchasing agents are ordering the wrong length hose. Typically, the hoses that we see are too long. They are either running extra length on the ground, which is a safety hazard, or there is excess hanging before the applicator connection, which can cause heating inconsistency issues. It is important to measure from the tank through the entire hose travel process, including mounting straps, before ordering. Universal Systems SE manufactures our ClearFlow™ line of heated hoses in 2 ft increments. So, if you measure 6 ft, order a 6 ft hose and if you measure 7 ft, order an 8ft hose. Make sure that you measure precisely! If need a hose longer than 24 ft, we can custom make you any length up to 50 ft.
To speak with a USSE representative about our ClearFlow™ hoses or to consult with a technician about the hose length you need, please call (800) 848-5018 or email email@example.com.
An interesting fact about the packaging industry that most people don’t realize, is that purchasing agents become avid internet hunters when it comes to finding parts for their old equipment. There are several resources out there, the largest being eBay, for purchasing agents to find and buy parts for their old adhesive melters. The problem is, when buying from a bid platform, you never know what you are going to get. If you are looking for an old part, for a melter that is more than 20 years old, the part you find online could either be used or the wrong part. Also, with most online bid platforms, you get what you get. There are no returns or exchanges for your actual part. And in most cases, you get what you pay for.
Universal Systems SE realizes how important it is to be an online resource of purchasing agents, which is why we have invested in becoming “searchable”. In the last couple of years, we have launched a new website, added more products, and increased the number of cross-reference IDs on our website. We have added pictures, spec sheets and custom contact forms to help purchasing agents get exactly what they need. We are also working on making sure that we show up in the search results when purchasing agents Google old part numbers or manufacturers.
The benefit of buying from USSE is that all of our equipment is new, in stock and you can talk with a technician to make sure it will fit with your current equipment. Another key aspect of working with USSE is our staff of knowledgeable engineers that have been around adhesive melters and packaging line equipment for over 40 years. If you have a question about your old melter, we are most likely the only company in the industry that can answer it.
To test out the knowledge of our technicians, give us a call at (800) 848-5018. We are certain we can get your old equipment back up and running in record time.
A trend that we were seeing in 2019 in the packaging industry was repair, repurpose, repeat. No one seemed to want to spend the money on new equipment. It did not really come as much of a surprise since the political atmosphere of the United States was so polarizing. With inconsistency in government and leadership, comes inconsistency in the business world. Large CPGs were not interested in allocating budget to new equipment, but trying to repair old equipment.
What large CPGs fail to realize is that band-aiding an issue with a packaging system, only delays the inevitable. Having to invest in new equipment. This process can be a long and tedious one. Getting multiple quotes from different manufacturers and lead times. Also, needing to know availability and compatibility with your current packaging line. The new tank buying process could take months, and if your old equipment fails while in the middle of that process, your lines could be down and production at a standstill. That is a very big risk to take.
At Universal Systems SE, we offer six different hot melt tanks and application systems that could fit almost any packaging line. All of our ProBilt™ tanks are the same physical footprint as most Nordson® tanks and compatible with most Nordson® equipment, both old and new. Universal Systems SE also offers a Trade In Trade Up Program, where you can send us back your old melter, no matter who manufactured it, and we will give you a credit towards your new ProBilt™ tank.
All Universal Systems SE standard ProBilt™ systems are in stock and can ship within one business day of ordering. So, if you are ever in a bind, or your current systems goes down and is unrepairable, we can have you up and running with a brand-new system the next day. The only system that requires a lead time is the Phoenix Auto-fill System, which is usually customized per order.
Another unbeatable aspect of investing in a ProBilt™ systems is the 10-year heater warranty that Universal Systems SE offers. It is the longest warranty in the industry.
For more information on Universal Systems SE’s line of ProBilt™ equipment or how you can get a new melter in 2020, call us at (800) 848-5018 or email firstname.lastname@example.org.
There are a few brands to consider when shopping for a hot melt system for your packaging line. Universal Systems SE’s ProBilt™ product line has been around for over 40 years and has several key features that can help influence purchasing agents, as well as line operators, on why it is the best in the industry.
4 Hose / 4 Gun Standard Capability
Unlike any other hot melt tank option on the market, the ProBilt™ line of melters all come equipped with 4 hose and 4 gun capability. This is a standard option that is usually an add on from other manufacturers, like Nordson®. Nordson® has both the 2 hose/ 2 gun and 4 hose/ 4 gun melters, each differing in price. The ProBilt™ melters all come with 4 hose/ 4 gun capability at a lower price point than any Nordson®. This allows our customers versatility and the option to grow.
Easy to Program Control Board
One of the many benefits to owning a ProBilt™ system is the easy to operate, AccuScan™ Control Board. If you are plugging in a brand new tank, the board will be programmed to our factory settings. The line operator, can scan through the hose, gun and tank settings and set them to the temperatures needed. There are also a few fail safes installed in the machine. For example, if it is a cold start set up, the hoses and tank will heat first, then the guns will start to heat once the hose and tank are within 35 degrees of the set point. The reason for this is so that the gun doesn’t char, since the gun heats up faster than the hose and tank. Once temperature is reached, the “Heat On” light will blink and you are ready to use. The control board also comes equipped with alarm settings and a set back functionality, our next two key features.
Set Back Functionality
The set back functionality is one of the most important features that comes standard on all ProBilt™ tanks. Essentially, when the shift is over and you no longer need to run your packaging line, you push the set back button. This will “set back” the temperature of the tank, hoses and guns to 165 degrees. Allowing the glue already in the system to sit overnight without charring. When the morning comes, or the next shift starts, simply hit the set back button again, and all previous temperature settings will re-engage. This will decrease the start up time on the hot melt system significantly and allow your lines to be fully operational within minutes.
Another key feature to the AccuScan™ Control Board are the alarm options it provides. The first alarm option allows for the panel to tie to an alarm light in your facility. In case anything happens that stops the system from running effectively, an alarm light can go off, alerting the line operator immediately. Another feature is the ability to tie it to the packaging line itself, called PMI or Parent Machine Interface. Parent Machine Interface will signal the packaging line when the glue is at full temperature thus preventing the line to start up until it receives the signal.
Please watch our video on how to set the ProBilt™ melter temperatures. For more information on our ProBilt™ systems please call today (561) 272-5442 or email email@example.com
The most common type of hot melt system used on packaging lines is a manual fill system. With manual fill systems, there are several roadblocks that can occur with safety and productivity that many companies are experiencing. Universal Systems SE took those concerns into consideration when designing our ProBilt™ Phoenix auto-fill system.
It is first important to understand how a hot melt system works. Hot melt adhesive application systems house a Teflon® coated interior tank, where the glue pellets are added and melted. The glue is then pumped out, travelling through a heated hose, into an applicator gun, through a module and nozzle, finally landing the glue at its final destination.
Universal Systems SE has ProBilt™ tanks that range from an 8 lb (4L) capacity, up to a 20 lb (10 L) capacity. Depending on how many hours per day the packaging line is operated, and the size of the glue tank needed, line operators are in charge of making sure that there are always glue pellets in the melter. Running low on glue inside the melter tank can cause a plethora of issues with the system. One of the most common issues is running the pump dry. If a line operator lets the tank run dry and the pump “shotguns”, the pump or shifter can fail. Honestly, that is the most common cause for pump rebuilds that we see in our shop. The easy solution to this is making sure that the tank is always full with pellets.
However, consistent tank filling can increase the risk of other potential issues. The first, is that it increases the risk to employees. Since the tank runs anywhere between 200 – 400 degrees, it is HOT. If a line operator is in a rush or makes one careless move, they can easily be burned by the pot. Another issue is that when you open the tank lid to refill with pellets, cold air flows into the tank and cools down the internal temperature. If the glue is continuously getting hot and cold, it could negatively impact its bonding ability.
These potential issues prompted Universal Systems to develop and release our ProBilt™ Phoenix auto-fill system in 2018. Unlike with manual filling, the automatic filling process does not require the line operator to fill glue pellets directly into the hot tank. Operators fill the free-standing container, which is separate from the tank. The glue pellets are then deposited into the internal pot via the vacuum and wand system when the internal tank glue level is low. The Phoenix is available in two tank capacities, the 15 lb and 20 lb units. Each glue container has maximum and minimum fill lines so that line operators know how much or how little to fill the pellets. Since the containers can hold much more glue than a standard heated pot, line operators no longer need to worry about checking the melters as often as with a manual system. This will also ensure that line operators will not get burned and that the glue inside the pot will stay consistently heated, creating maximum bonding ability.
If you follow the packaging industry, whether through news articles, industry periodicals or first hand through direct buyers at CPG companies, one of the largest drivers in packaging is the stress on workforce demands. This can include how difficult it is to find reliable workers that are dedicated to the success of the company. It can also be in the aspect that most of the line operators working the packaging line equipment are not trained properly on that piece of equipment and all of its capabilities.
As the packaging industry tries to modernize technology, not all of their workforce can keep up. As a hot melt equipment manufacturer, one of our core competencies is our knowledgeable technical support. If you have any Universal Systems SE equipment or ProBilt™ machines on your packaging lines, you can rest assured that you will get speedy, knowledgeable sales and technical support. However, in many instances, line operators do not have that type of experience or knowledge base. That can lead to “on the fly” fixes, which usually equates to weakened product and voided warranties. At Universal Systems SE we understand that knowledge is power, and we want to make line operators jobs easier, not harder. With that in mind, we have kept all of the ProBilt™ hot melt application systems uniform and easy to operate. We also try to make our clients smarter when they call with issues, asking questions to help them learn or giving them some simple troubleshooting tips to follow for the future.
In addition to being able to help line operators with questions and knowledge, we also make sure to include in every shipment all of the pertinent manuals and information guidelines needed. For example, if your company is ordering ClearFlow™ heated hoses (Universal Systems SE’s proprietary line of heated hot melt hoses), each shipment will include installation and care instructions. The same goes for our ProBilt™ applicator guns. With the purchase of any ProBilt™ application gun, we include a list of maintenance recommendations on the gun, modules and nozzles.
So, as CPGs continue to have concerns with their workforce, we here at Universal Systems SE we will continue to do everything in our power to ensure that we keep them knowledgeable on our equipment.
As we continue through 2019, it is clear that big brand CPG budgets are getting tighter when it comes to packaging. Larger companies are no longer bleeding money on big brands that offer not much more than a brand name and pretty blue logo. We have often asked ourselves how companies like Nordson® can get away with charging so much for the same quality product that Universal Systems SE manufactures. Especially since those big brands are not even manufacturing in the USA. That trend is starting to change.
As the American economy continues to change, it is clear that companies need an alternative to the brand name big price tags. It all comes down to shopping around for quality manufacturing that can be done in a more cost-effective way. And yes…it can be done. Cost-effective manufacturing should be the main focus of all companies when it comes to packaging their products. Americans no longer care about a name, they care about performance, quality and cost. Just because it is the most expensive thing on the market, doesn’t make it the best or most reliable. And that rings true for packaging manufacturers as well.
Many CPGs are losing the battle for shelf space and margin growth, which is increasing the pressure on suppliers such as packaging manufacturers to decrease costs. With more brands on the shelf and less market share, big CPGs need to start thinking smartly about their packaging solutions. It might not be the best idea to bring in a company like Nordson® to customize a hot melt solution that will cost you an exorbitant amount of money and take 6 months to get, when you can go with a company like Universal Systems SE who has engineers with over 40 years of experience that actually understand what you need because they have pretty much seen it all.
Not only is cost-effective manufacturing a pull in the marketplace, but knowledgeable customer service and support. If your packaging line goes down, it could cost you thousands of dollars a minute. A large brand with an untrained rep isn’t going to be able to get you up and running with a phone call. Universal Systems SE will! Think about that the next time you place an order for a new hot melt system or components.
Whatever you might need for your hot melt machines, we manufacture it at our Florida facility. Whether it is heated hoses, applicators, filters, modules, nozzles, etc. We also can walk you through troubleshooting any issues or help you with customized set ups. Call Universal Systems SE today at (561) 272-5442.