Piston Pump Troubleshooting
There are several things that can cause a piston pump to stop working. The most common reason is that it is clogged. Unfortunately, not all line operators take the time to close the lid on a glue tank. With a lot of carton dust in the air at any facility, this dust gets into the glue pot and melts in with the glue. When the pump shifter runs to pump the glue from the pot into the hose, that carton dust gathers around the pump which can cause it to seize. The simple solution to this is to make sure that all shift line operators are diligent about closing the tank covers, that’s why they are on there.
If carton dust is not your issue, and the pump fails, below are a few other possible causes and the corresponding solutions.
- Adhesive not sufficiently heated – check the tank temperature and required melt temperature of your adhesive and set accordingly.
- Inadequate or no input air to pump – increase the air pressure from the plant air supply and see if the pump will run.
- Dry running – when a tank drops below a certain adhesive level in the pot, the pump does not have enough glue to operate at full capacity. The glue that runs through the pump acts as a padding so that the shifter does not pound against the top and bottom of the pump itself. When that padding is less, the pounding shifter can cause damage to the magnets and create an issue with the shifter. The only solution to this is to get a new shifter and potentially invest in an auto fill on-demand system that fills the glue into the tank for you, leaving less pressure on the line operators to fill the pot.
- No Tank Screen or Clogged Tank Screen – the tank screen lives at the bottom of the tank and is the first line of defense against any foreign debris getting into the pump. Sometimes the tank screen gets removed or never cleaned. That can cause debris build up and seize your pump. It is easily cleaned by lifting out of the empty tank and then cleaning the tank with Purge Plus™.
- Clogged Tank Filter – the tank filter screws into the side of the tank and filters the glue after it leaves the tank. If the tank filter is clogged, then the adhesive will back up in the pump, causing the pump to seize.
- Pump solenoid is not on – if the tank is not within 35 degrees of the setpoint temperature on the control panel, the pump solenoid will not turn on. Check the setpoint temperature and make sure it is correct. If the setpoint temperature is correct and reading properly, then it might be a failed solenoid that needs to be replaced.
If you go through all of these troubleshooting steps and still have an issue with your pump, please call (561) 272-5442 or email sales@ussefl.com.
What Diameter Nozzle Should You Use?
Hot melt adhesive application nozzles, or nozzle tips as they are commonly called, are the component that apply the glue onto boxes in packaging lines. Universal Systems nozzles are made out of brass with stainless steel tips to withstanding any beating they might take from box flaps in the packaging line.
Nozzles comes in many shapes and sizes, and are usually the part on the adhesive system that is most experimented with. Most nozzles are easily changed out by simply unscrewing them from the module. Other nozzles, like the ones on reduced cavity, zero cavity and ProBead modules are called integrated nozzles. We sell replacement nozzle kits for integrated nozzles that include the nozzle tip, needle, brass needle guide and installation tool.
The diameter of the nozzle tip determines the amount of adhesive that is distributed onto the box flap. Because you can easily switch them out, most line operators experiment with diameter to enhance productivity. For example, smaller, more precise glue application will require a smaller diameter nozzle. Larger, faster cartoners, will most likely run larger diameter nozzles to distribute a greater amount of glue and quickly seal boxes. Keep in mind that the larger the diameter nozzle, the more adhesive your tank will process. So make sure that your line operators are keeping a close eye on the adhesive level in the tanks. Dry running a machine can compromise your pump and create a costlier repair.
Because most adhesive systems run 24/7, the nozzle is the most commonly clogged component on your line. This is due to char or debris travelling from the tank, through the hose, into the gun and through the module. Because the nozzle is the smallest orifice on your system, most char will get stuck and you will be unable to get a consistent adhesive flow. Universal Systems SE offers nozzle cleaning kits that you can purchase instead of replacing nozzles. However, most line operators find the cleaning of nozzles a tedious process, even though when done correctly it works. Nozzle cleaning kits can save you money in the long run on replacing nozzles.
Another important aspect of nozzle diameter correlates to the size of the mesh in-line filter used on your system. The larger the diameter nozzle, the lower number mesh you should use. The smaller the diameter nozzle, the finer mesh you should use. For example, with a .024 diameter nozzle, you should have a 50 mesh filter size. With a .012 diameter nozzle, you should use 200 mesh filters.
For more information about what diameter nozzle you should be using, call (561) 272-5442 or email sales@ussefl.com.
Preventative Tips to NOT Char Your Glue
One of the most dangerous, yet inevitable, occurrences running hot melt systems in your packaging lines is char. Universal Systems SE has updated technology running in our ClearFlow™ hoses that reduces char, however the main char that runs through the hoses comes from the tank itself. Once your tank is infested with char, no matter how efficiently your hoses and guns run, there is always the potential to transfer this char onto your packages. You also run the risk of char clogging your nozzles and modules, which can back up through your guns and kill your pumps. Our Universal Systems SE technicians have seen it all. That is why we have created a list of preventative tips that each line operator should follow to effectively reduce char and keep your ProBilt® system running at top capacity.
Preventative Maintenance
Universal Systems Se recommends a complete hot melt system cleaning at least twice a year using our Purge Plus™ system cleaner.
Contaminated Adhesive
Hot melt adhesive should always be stored in a strong container such as a heavy-duty plastic waste container. Do not set boxes or open bags of adhesive on the floor or on the top of the container. The container should be labeled “Adhesive Only” and include your adhesive part number.
Low Quality Adhesive
With hot melt adhesives, higher price usually means higher quality, the opposite is also true. Adhesive manufacturing is a highly un-regulated industry and many companies use low cost waxes and fillers in their products to reduce cost. These products tend to burn quickly. Due to the fillers and heavy waxes, low cost adhesives can greatly reduce your adhesive mileage whereas high quality adhesives are lighter and have a lower specific gravity. The bottom line is a higher dollar per pound does not necessarily translate to higher packaging costs. We also recommend that you do not mix old adhesives with new brand adhesives. Please read our past blog to help you understand why.
Old Equipment
Hot melt systems are not cheap, so most of the ones in operation today have been on their packaging lines for 10 – 20 years, whether they are running properly or not. That means that most likely, these older machines have char built up in their tanks. It may be time to evaluate the performance and efficiency of your aging equipment and trade up to a new ProBilt®.
To get the latest pricing on ClearFlow™ hoses, Purge Plus™ system cleaner or ProBilt® adhesive melters, please email sales@ussefl.com. If you are experiencing issues with char, please feel free to call one of our technicians at (800) 848-5018 and we would be happy to help you.
What Hot Melt System is Best for Your Company
Hot melt adhesive can be used as a sealant solution for several different types of businesses. The most common use is with case packer systems, but it can also be used on product containers such as protein shake cartons, frozen pizza boxes, and so much more. There are several key elements that you need to take into consideration when choosing the perfect hot melt system such as efficiency, glue distribution, glue usage, and limiting downtime.
The first step in identifying what type of hot melt system is best for your company is to evaluate how much adhesive your packaging lines use in a day. If you are running a continuous packaging line with a large diameter glue nozzle, then you should research fill on-demand systems. A fill on-demand system, like Universal Systems’ ProBilt™ Phoenix, has a vacuum hose that continuously fills the melter tank with adhesive pellets from an adhesive storage container. Your line operators will only have to worry about filling up the adhesive storage container, which holds up to 6107 cui, allowing them to free up their time to tend to other tasks on the floor. If you are only running your packaging line for certain products, then you might want to look into limiting your tank capacity to either a 12 lb., 15 lb. or 20 lb. tank. The most commonly utilized tank size on today’s packaging lines is the 20 lb. tank, such as Universal Systems’ ProBilt 20.
Another topic to consider when choosing a melter system is how you will be distributing the adhesive onto the packages. Will you be laying down a line, spraying on the glue, or laying dots? This will be determined by the type of nozzle you are running on your modules. If you have a spray or swirl nozzle, then you will be using more glue than if you are using a straight small diameter nozzle. This knowledge will also help you choose the correct tank capacity melter needed.
To learn more about the different types of melters Universal Systems manufactures and which is right for you, please call us at (561) 272-5442 or email us at sales@ussefl.com.
Why Tape Doesn’t Hold Up
There are two main options in the market available for sealing your packages: Adhesive vs. Tape. Much like Batman vs. Superman, this is a largely debated topic in the packaging industry. Many carton packaging line manufacturers have been changing their machines from hot glue to tape. They claim that this will cut costs and reduce downtime. Here is why that is the WRONG move!
The largest complaint among manufacturers is downtime. Downtime leads to higher product costs, higher labor overhead and material waste, especially when it comes to tape. Cartoner machines that seal packages with tape commonly run into the following issues:
- Changeover Downtime – tape roll capacities are not as abundant as hot melt adhesive. Adhesive pellets are not only cheaper than tape, but with the new on-demand adhesive application systems, the adhesive flow process is seamless with fewer interruptions.
- Poor Tape Adhesion – One of the things you will never hear a complaint about when it comes to hot melt adhesive is that it does not stick. However, that is the top complaint of packaging line operators when it comes to tape machines.
- Uncut Tape – when the line fails to cut the tape at proper lengths, all of the cartons are held together. That results in the line being shut down and operators are forced to manually cut the tape. With hot melt adhesive, this is never a problem.
- Broken Tape – this is a result from poor tension control which causes the tape to stretch and break. Another issue you will never experience from running an adhesive system.
Hot melt adhesive equipment, when maintained properly will last you decades and reduce your downtime overall.
To find out what the best hot melt adhesive application system is best for your packaging line, please call (561) 272-5442 or email sales@ussefl.com.
Modules: The Glue That Holds Your Adhesive Melter Together
Modules, they are the most used product on your packaging line, yet so many operators don’t understand how they are constructed or when to replace them. Like an oil filter on your car, a hot melt module’s main job is to be the conduit for applying adhesive on your packages and should be replaced every 1,000 hours. Replacing a module is simple, and the part itself is fairly inexpensive, but not changing them out could lead to extremely expensive repercussions.
There are two different ways that hot melt can be pumped through the module. First, there is an air on, spring off module (AO/SC). This type of module is the most common in the packaging industry, and the easiest module type to replace. It works by the gun pumping air into the module, to open the flood gates and pump the adhesive through the nozzle, on to the packaging material. When the airflow stops, a spring inside the module closes the opening and stops the adhesive from flowing. The other type of module is an air open, air close (AO/AC). This is a less common type of module and patented by Nordson®. If your machine operates with an air open, air close module then the replacements will be more costly and harder to find. Essentially, this module operates with air pumping through the gun to open the flow of adhesive, and then uses an air intake from the side of the module to stop the flow of adhesive. Keep in mind, that if you operate using an air open, air close module, you can replace it with an air open, spring close module by bypassing the air intake line. However, you cannot run an air open, air close module on an air open, spring close gun.
O-rings are an important component on any module. These tiny ring-shaped seals keep your module from clogging up, increases the efficiency of your system and limits the downtime of your lines. When replacing modules on your guns, make sure that the o-rings are placed securely on the module. If they get clogged with glue, then your module will clog and become defective.
Another important point to note when learning about your module, is the type of nozzle it takes. Not all nozzles and modules are the same. For example, zero cavity modules come with an integrated nozzle seat which allows for a no drip, positive cut off of adhesive. Each zero cavity module needs to be ordered by diameter size. A standard H200 module, however, does not come with any nozzle. You need to order nozzle separately and they come in multiple orifice sizes.
For more information on modules and how they can help improve your packaging line efficiency, reach out to Universal Systems SE at (561) 272-5442 or sales@ussefl.com. You can also view all of our ProBilt® series modules by visiting the Hot Melt Modules section of our website.
A Class Above the Rest
There are five main components that should go into your search for the right hot melt equipment manufacturer: Innovation, Knowledge, Quality, Price & Compatibility. Universal Systems SE has made it our top priority, over the last four decades, to ensure our customers get all of these. We do not compromise price for service and we stand behind all of our equipment with the strongest warranty program in the industry.
Innovation
Universal Systems SE has just launched our latest product in the ProBilt Series: The ProBilt Phoneix. This on-demand melter system allows packagers to melt and use adhesive only when they need it. The adhesive storage container eliminates the need to manually fill the melter tank, reducing adhesive spillage and waste, while improving safety. Our state of the art adhesive sensor and innovative vacuum technology will automatically fill your tank with adhesive to your desired level.
Universal Systems SE also manufactures 8 lb., 12 lb., 15 lb., 20 lb. and 40 lb. tanks that are the same footprint as most Nordson melters on the market. Our ProBilt systems continue to lead the industry with minimal down-time, easy to operate components and consumer flexibility.
Knowledge
When researching manufacturers to partner with, knowledge and availability are key. Our technicians have over 40 years’ experience in the hot melt industry and can help solve almost every issue you might run in to, because we have seen it all! Universal Systems SE’s facility is located in the United States and we are available for service calls, even if it’s a video conference to walk through any issues you might be experiencing.
Warranty, Price, Compatibility
We stand behind all of our products 100%, which is why we offer the longest warranty in the industry on our ProBilt tanks, 10 years! Also, if you find a cheaper rate from another direct manufacturer, which we are confident you won’t, we will match that price! Whether the pricing is from Nordson, Graco, ITW Dynatec or Robatech. We also ensure that almost all of our equipment is Nordson compatible. This means that even if you bought your main hot melt machine from Nordson you don’t have to stay with them forever. Even if your Nordson melter has been discontinued, such as the 2300 or 300 Series, you can still buy all of your replacement parts from USSE. We will warranty all parts that you buy from us, even if they are being paired with a competitor part.
For more information on Universal Systems SE or the ProBilt Series, please contact us at (561) 272-5442 or email us at sales@ussefl.com.
Hot Melt Equipment Compatibility
Most all packaging lines come with an already installed hot melt adhesive system. This is the entire system that melts the adhesive pellets and transfers that adhesive to the boxes before they are sealed.
It is important to know that just because your packaging line comes with a hot melt system, that does not mean you need to buy the exact brand name replacement parts. Universal Systems SE manufactures an array of hot melt components and equipment at economical prices, that are most likely compatible with your current system.
The key term to focus on is compatibility. The devices and parts used to construct an applicator system are in depth, and we know they can get confusing. Not only do you need the melter itself, but you also need applicator gun heads, modules, nozzles, hoses and pumps.
Choosing the right part, or replacement part, to best fit your company’s needs may be difficult. Universal Systems SE has tried to make this process easier by building our technology to be compatible with all of our largest competitors. We also offer online search capabilities and list all cross-reference part numbers on our website, so that you can match your current part with our Universal Systems part number. This helps to eliminate confusion when ordering replacement components.
Example Cross-Reference Compatibility Comparisons:
ProBilt™ 20 Melter – Compatible to Nordson® P10, 3500 Series, 2300 Series
ClearFlow™ Hoses 4100 Series – Compatible to Nordson® 107286, 107287, 107288, 107289, 107310, 104008, 223838, 100832
ProBilt™ H200 Module #29219 – Compatible to Nordson® 1052925, 1048115
In addition to compatibility, Universal Systems offers one of the longest product warranties in the market. So not only will you be purchasing a component that is more economical for your budget, it will last you longer than your current parts.
With a combined experience of over 40+ years in the hot melt industry, Universal Systems offers the highest level of technical support. If you have a question on a part or if your machine is no longer running at its maximum capacity, just call in and speak with a technician.
If you need more information on how you can get the best pricing on hot melt applicator units, call USSE today at 1-800-848-5018 or visit our website at www.ussefl.com. When you click on a product of interest on the site, USSE will show you all of the cross-referenced product numbers from our competitors that this part is compatible with.
From Leaves and Baskets to Hot Melt and High Speed Packaging
People have been packaging products for thousands of years. From the time the earliest humans stepped out to go on a long hunt, it was necessary to wrap food for the journey in something – be it leaves or grass – in order to keep the food from spoiling. As time progressed, new innovations allowed new foods to be packaged for transportation. And innovations were made to package non-food items, as well. Packaging allows for the easy transport of anything and everything that people produce.
But fast-forward a few thousand years. People no longer produce things on a small scale. Even when an entire year’s worth of a harvest was required to be packaged for transport across the country, it did not compare to the production capacity of the twentieth century. New manufacturing technology has made it possible to produce thousands of pieces of a product in a single day. Anyone who has walked into a big-box store or supermarket has experienced firsthand the overwhelming mass production that is possible with modern techniques.
With high-speed production comes the need for high-speed packaging. This is not something that can be accomplished by hand, and requires specialized machines and technology for the process. An important part of high-speed packaging is hot melt equipment. Since hot melt is literally what holds the packaging in an industrial world together.
Hot melt glue has the ability to rapidly cool and bond materials, which allows manufacturers to quickly seal and secure products. Companies across all industries know if items are not properly packaged and available to ship immediately after production, they will lose money. Humans continue to build on the idea of wrapping things in leaves and putting items in a containers for transport. The key to continued progress is incorporating new technologies as well as adapting to the needs of an ever changing global market.
Know Your Equipment, Not Just the Part Numbers
The hot melt equipment industry has evolved over the last 40 years. Each manufacturer has made design and material modifications to their product line, which has had a significant impact on the creation and assignment of part numbers. Unfortunately for our particular niche industry there have also been an abundance of variations created solely for clerical purposes. These superfluous numbers make it extremely difficult to place orders and keep inventory organized.
Let’s say you are looking for a single orifice right angle nozzle with a .014 inch diameter hole. The correct manufacturer number can be 244519, 244-519, 244 519, 24-4519US, 320014, 320-014, 320 014, 32-0014US, 1011014, 1011014US, or SR19014. These are all correct manufacturer parts numbers and as you can see the variations are sometimes nothing more than a space or dash. This has already created a very high level of confusion, but wait, it gets even worse.
If you are not purchasing directly from the manufacturer you add a whole other coded level of alpha numeric characters, dashes and mystery spaces. Each buying house has their own system, each aftermarket dealer makes up their own numbers, and even legitimate distributes from time to time will add a character to a part number purely for tracking purposes.
It is important for anyone using hot melt systems to understand the function of each piece of equipment so that there is not a complete dependency on just a part number. We at Universal Systems SE work with our customers to identify parts through a combination of part numbers, descriptions, and photographs. It is especially important to take the time to talk to one of our associates if you haven’t ordered a replacement part in several years or are order a new part for the first time. Our website has a part number search function for your convince; but know you can always call 1-800-848-5018 for personal assistance.