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.
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.
ProBilt Glue Systems Meet the Demands & Needs of Packaging Lines
The trend in packaging for many CPGs has been to move away from in-house packaging solutions and more towards co-packers and contract packagers. Rather than dedicating complete in-house lines, CPGs and processors can be more flexible with their budgets by putting the responsibility of capital investments for machinery in the hands of the contract packagers. In addition, the CPGs no longer have to worry about hiring line operators for the packaging machines. In the last few years, it has become clear that hiring, retaining and training employees is a challenge for every company. CPGs are finding that if they move the responsibility of packaging to contract companies, they no longer have to deal with that potential issue.
The move to contract packaging is not a bad thing for glue equipment OEMs, like Universal Systems SE. We enjoy working with contract packagers because they are equipped with the skills and knowledge to focus on packaging lines and, in most cases, know what they want and need from a hot glue machine, more than a CPG will.
Below is a list of requirements we are hearing about from Contract Packagers for their packaging equipment, and an explanation as to why Universal Systems ProBilt systems will work best to fulfill these needs.
- Quick changeovers to limit downtime – USSE’s ProBilt systems are plug and play. They are easy to set up and disable for cleaning, preventative maintenance, component replacement, etc.
- Preventative maintenance schedules – USSE believes that preventative maintenance is key to maintain the efficiency and longevity of any piece of machinery. A hot glue tank is no different. Universal Systems offers up a preventative maintenance schedule upon request, along with recommendations on what parts to keep on the shelf and how many of each part is needed to keep your operation up and running at all times.
- Streamlined equipment so that system components are interchangeable – Universal Systems prides ourselves in being the most streamlined OEM of hot melt machines in the market. Not only do all of our tanks take the same pumps, filters, valves, etc., all of our components are interchangeable with our top competitors including hoses, guns, modules and nozzles.
- Versatility for different packaging setups – Universal Systems manufactures over 100 different types of applications options, as well as the option to custom CNC any configuration needed.
- Easy-to-operate machines – Our ProBilt tanks are by far the easiest in the industry to operate. We focus on longevity and simplicity so that anyone can set up and operate our tanks with ease. We also offer online videos on how to set temperature and utilize our setback feature.
For more information on Universal Systems and our ProBilt line of products please reach out to sales@ussefl.com or call (561) 272-5442.
How to Determine Heated Hose Length for Your Packaging Line
One of the most important things to consider when setting up your packaging line is the best length hose that you should use for both the top and bottom applications. While most maintenance managers think the longer the better, that is not always the case. Heated hoses should be treated with care to ensure durability and run time. At Universal Systems SE we recommend that you map out where the tank will be situated and then where the guns will be mounted. When setting up the top applicator line, make sure to account for hose mounting brackets and try not to make too many turns. The hose line should run as direct as possible to the applicators. We recommend that the hose mounts be hanging mounts for top applications. This will cause no kinks or damage to the exterior hose casing and ensure the long run life of the hose.
When setting up the bottom line, the hose should be mounted down the side of the packaging machine itself. You can use hanging mounts here as well. Make sure not to lay or run the hose on the floor. Also, do not coil the hose under the tank. If you have any leftover hose that you need to coil…your hose is too long. Running the hose on the ground and coiling the heated hose could cause a plethora of issues such as power shortages, heating issues or tripping hazards, all dangerous to your employees. Make sure to keep the area around the tank and hoses clean and hazard free.
The most common hose lengths sold are 6’, 8’, 10’ and 12’. However, Universal Systems does manufacture 2’, 4’, 16’, 20’ and 24’ hoses that we stock. Our biggest piece of advice is to take your time measuring and setting up the mounting brackets. This will ensure that your hoses will last longer and your packaging line will be as efficient as possible.
For more information on our USSE heated hoses, call a sales rep today at (561) 272-5442 or email sales@ussefl.com.
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.
When to Use a Water-Washdown Hose & Gun
Water washdown hoses and guns are important for plants that package items required by the FDA to get washed down with water either during or after operating hours. Water washdown hoses and guns are different than our standard high flex hoses and standard guns. The difference between the two is easy to tell. Washdown hoses and guns have a high temperature, extremely durable, waterproof jacketing encasing the electronics of each item. The connectors for each are also different than a standard set up. For washdown hoses and guns, the connectors will be a round pin connector, lined with a silicone seal and screw on connection plate for a water tight fit. Standard hoses and guns come with a rectangular connector that simply snaps into place. Washdown guns are also equipped with water tight gasketing on either end plate to ensure that the heating element and RTD are safe from any high powered washdown practices.
For more information on Universal Systems’ wide range of washdown products, please contact a sales rep at sales@ussefl.com
Cold Weather Impacts to Your Hot Glue Melter
As we move into the holiday season, we also experience a change in the weather. In most places in the US, the winter months mean that the climate inside most packaging plants change. With that, line operators need to take that temperature change into consideration when working with hot glue machines on their packaging lines.
Hot melt consistency, heated hose and gun temperature consistency and glue stringing are all potential problems that maintenance managers can deal with during the winter months. One of the most important things to look at is where your packaging line is located within your facility. Most melters are located at the end of the line, which leaves them close to an exterior wall, door or window. The cold temperature outside could be impacting, not only the viscosity of your glue, but the heating time of your glue and its adhesion ability. Every time your line operator opens the fill door on the hot melt tank, the external air hits the existing glue and cools it off. Even if the lid on your tank is only open for a few minutes, that could impact not only the current glue in the tank reservoir, but the glue you are adding to the tank. If your glue pellets are colder than normal, it will take a longer amount of time to heat them.
Another important task would be to inspect your system setup for any cold joints. A cold joint would be any unnecessary extensions that you have added throughout the adhesive application process. Most cold joints are found on older machines that use larger sized extensions and filter housings. The more cold joints on the system, the more inconsistent the glue will heat and stay heated throughout the entire application process.
If your main problem is glue stringing in the colder months, an easy solution would be to shorten the distance from the nozzle tip to the top of the box. Limiting the amount of time the glue has to travel in the air will help to lessen the problem of stringing, which can cause a weakened seal on the box.
If you have any questions about how to reduce the impact of winter weather on your hot melt system, please reach out to a technical rep at sales@ussefl.com.
The Importance of Product Support
Universal Systems SE has been manufacturing hot melt equipment since 1981. Starting with hoses and nozzles, then moving into applicators, pumps and tanks. Our first ProBilt tank was launched in 1990. Since then, our melter has only had a couple of generational upgrades. We believe that this is what sets us apart from other hot melt equipment manufacturers in the industry today. We have never believed upgrading our equipment or technology so much that it makes our old tanks in operation obsolete. We have added features and improved upon what we initially launched in 1990, but we have not let technology negatively impact the operational ease of our machines.
USSE believes in the importance of long-term product support and cross compatibility. There are hot melt system manufacturer’s in the industry, like Nordson®, who have discontinued not only production but also product support of their old melters. Both the 2300 series and 3000 series melters, while discontinued by Nordson®, are still in operation in hundreds of packaging facilities across America. Unlike Nordson®, Universal Systems still supports those old melters because we appreciate the fact that many of these melters, similar to the ProBilt melters, continue to run even 20+ years after initial operation. We are one of the only manufacturers in existence to still make and service 2300 & 3000 series pumps.
We also believe in product uniformity across all of our melters. That is why when we designed our melters, we made sure that all of Universal Systems’ ProBilt machines run the same control boards, pumps and tank filters. In most cases, facilities run several ProBilt melters, but only need to stock 1 or 2 of each spare part. That uniformity creates a streamlined and more simplistic inventory process.
As we move deeper into 2021 and our new normal continues to change, think about how the importance of long-term product support and a streamlined inventory process can help keep your packaging lines up and running. For more information about Universal Systems and our ProBilt line of melters please email sales@ussefl.com.
Chillers on Your Manufacturing Line
Now you may be asking yourself, why am I reading about chillers on a hot melt blog? The answer is easy, Universal Systems SE manufactures heated hoses that can be used for transferring many more substances other than glue. And when there are applications that do not include glue, the manufacturing lines may need chillers.
Our heated hoses, while mainly used for high speed packaging glue application, can also be used for heating and transferring a plethora of other materials. Our Teflon lined hoses can transfer anything from candy, make up, wax and much more! Depending on the use and application of different substances, the packaging line can be filling at high rates of speed. Heating and filling formed containers for candle wax, as an example, can be tricky because in this application the wax needs to cool quickly so that it can be formed, packaged and shipped out to end users. One of the most common questions we get in this situation is: How can I keep my forming operation running at a high-speed pace from start to finish? The answer here is chillers. Essentially how a chiller works is it is built into the conveyor line. So, the product would be heated in a melt pot, transferred through the heated hose, dispensed into containers, and then fed along a chiller that is built into the line. The product goes from hot to cool in a matter of seconds.
If you have any other questions on how we can help you keep your production lines running at high-speed capabilities, please reach out to sales@ussefl.com or call to speak with a technician (561) 272-5442.
Heated Hoses Can Transport More Than Adhesives
While adhesive application is Universal Systems’ main focus, several of our customers utilize our heated hoses for more than just adhesive. Our standard line of ClearFlow™ heated hoses can heat up to 450 degrees, run at 240v and have a maximum operating pressure of 1500 psi. We also manufacture custom transfer hoses which run at 120v and typically transfer material that heats at a lower temperature. For example, cosmetics, wax and chocolate or candy.
There are several CPGs out there that utilize heated hoses for more than just packaging. Our hoses can transfer any of the following materials:
- Cosmetics
- Chocolate
- Candy
- Wax
- Air
- Vape Liquid
- Polyethylene
- Paint
- Tar
- Food Oils
- Water
- Ink
One of our clients is a great example of how versatile our hoses are. They are a cosmetic packaging company that recently utilized our services to bottle a hair gel product, specifically made for curly hair. Their conveyer worked methodically to fill the bottle with water, then moved to fill with the hair gel formula. The combination of water and product created a foam, which needed to be eliminated quickly in order to keep the process moving. A spurt of hot air down into the top of the bottle is just what was needed before capping. Our heated hoses transferred, not only the water and hair gel product, but also the hot air needed to eliminate the foam.
We also have several clients who utilize our entire hot melt system to heat wax pellets, transfer them through the heated hoses and fill plastic molds. After the wax is transferred into the form mold, it is then moved to a cooling tray to harden and get ready to package. A separate Universal Systems ProBilt™ system is then used to seal the product box and ultimately the case.
So, if you are interested in utilizing a ProBilt™ system or ClearFlow™ hose for more than just adhesives and final packaging, give us a call and we can help! Please call (800) 848-5018 or email sales@ussefl.com for more information.