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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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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When to Replace a Module

One of the most commonly replaced items on any hot melt packaging line is the module. Typically confused with an applicator gun head, the module attaches to the front of the applicator gun and dispenses the glue through the nozzle and onto the applicable surface. If you are experiencing clogging issues with your hot melt line or dripping from the tip of the nozzle, most likely the module has reached it’s end of life and needs to be replaced.

Replacing a module is fairly simple. First make sure the air is disconnected from the applicator. Always wear Kevlar gloves and eye protection when replacing any parts on your active hot melt system. The parts get hot and extending downtime might not be an option, so operator safety is very important. Then, remove the front two screws from the module and pull the module off the surface of the gun manifold. Make sure that you use the new o-rings and screws that come in your new module replacement kit. This will ensure that the new seal is tight and will not leak once operations restart. Also, make sure you are replacing the existing module with the correct replacement module. Below is a list of module options:

Finally, we also recommend to put a new nozzle on every new module. This will ensure that no clogging will occur. If you have a zero cavity or ProBead module, then the nozzle will already be attached.

If you need any more information about modules for your packaging line, please email sales@ussefl.com or call (561) 272-5442.

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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.

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Packaging in the Pharmaceutical Industry

It’s been a wild ride over the last year, but the pandemic has brought on several advances in the pharmaceutical industry. Hot melt application in the pharmaceutical industry has always been important, but now more than ever. As the US pushes forward with millions of vaccines, each medication needs to be precisely packaged to make sure that it arrives safely to its destination.

Universal Systems manufactures ProBilt Zero Cavity Modules to apply a thin line of hot melt along medication boxes. 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.

Because zero cavities have a matched piston nozzle needle and seat, when they finally wear out, most manufacturers require customers to replace the entire module. Universal Systems does not. We manufacture a rebuild kit specifically for zero cavity modules for a fraction of the price of replacing an entire module. Check out our rebuild kits here: https://www.ussefl.com/products/hot-melt-modules/module-rebuild-kits/.

Not many hot melt application manufacturers offer zero-cavity modules. Luckily, here at Universal Systems we have been manufacturing this specific module for over 25 years. If you would like to learn more about zero cavity modules or get a price quote, please reach out to sales@ussefl.com or call (561) 272-5442.

 

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Safety in Switching Out Glue Equipment

The best way to keep your packaging line up and running as efficiently as possible is to do preventative maintenance. Here at Universal Systems SE, we have advocated for regular packaging line maintenance, including all of your glue melter equipment and components. However, it is not only important to know when to do maintenance, it is also important to know how to do that maintenance. There are more mistakes made in the switching out of glue equipment and components than you may think. Whether you are changing out a filter or switching a pump, there are steps to take in order to ensure a smooth transition, with the least amount of downtime. Here are a few tips on switching some of our ProBilt hot melt equipment products.

Tank Filters

First and foremost, it is important to know the model of your tank. Even though that sounds like standard knowledge, there are many tanks that look similar but have different tank capacities, pump types and filters. Once you know the tank model, you can look up if you need to replace the entire tank filter or if you can replace just the screen. On USSE’s ProBilt tanks, for example, you have the option to change only the tank screen. This allows you to save some money long term, while still maintaining your tank. It is recommended that you make the change while the tank is in setback and to wear Kevlar gloves so that you don’t burn yourself. The tank filter is located on the side of the tank. It can be removed with a flat head screw driver. Once the complete filter assembly is removed, there is a long screw that secures the screen to the assembly. Simply remove that screw, switch the screen, and replace the filter assembly. If you are changing out the tank screen, make sure that you do not damage the filter bung or o-rings when making the switch. Also, be careful, the glue inside the filter is HOT.

In-line Gun Filters

These are the easiest of filters on your glue line to change out. In most cases, the filters can be reordered in packs of 5. Locate where the filter is on the filter assembly body and use a wrench to loosen and remove. Kevlar gloves should be worn, as the outside of the filter will be hot and there will be glue on the filter you are removing. Simply put the new filter in place and tighten.

Modules

Usually modules are switched out because they are dripping or leaking. This is typically caused by either char or end of life of seat and piston. Switching out a module is fairly simple. Before taking off the old module and replacing with the new, make sure that the system is not running. Each replacement module comes with 2 o-rings and 2 screws. Place the o-rings on the back of the module and secure it on the gun applicator with the new screws.

If you are running an H200, zero cavity or reduced cavity module, there are rebuild kits available.

Pumps

Switching out a glue pump is the least common practice on a packaging line. However, this is also simpler than you would think. Most technicians think that in order to change out a pump, you need to turn the tank off and let the glue cool. That is not always the case. If you are running a ProBilt tank and have an experience technician, he can switch out the pump while the system is still on. First, make sure you are wearing Kevlar gloves because the system will be hot. Turn off the air running to the system, this will limit any injuries. Remove the 3 bolts holding in the pump, use needle-nose pliers and do this carefully. Put the old pump on a large piece of cardboard where the glue can drain, cool and harden. Carefully put the new pump in, secure it with the 3 bolts and turn back on the air.

For any other questions about tank maintenance, please contact one of Universal Systems’ experienced technicians at (561) 272-5442 or email tech@ussefl.com

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The Importance of Graphite Seals & PTFE in Hot Melt Equipment

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 tech@ussefl.com.

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Zero Cavity Modules and What They Are Used For

There are several different set ups available for your hot melt application. That’s because not all industries use glue application for the same reason. The most common form of hot glue application is standard case packers for mass production high speed packaging. Typically, those lines use standard H200 modules. However, glue application is used to seal other, more specific products. For example, swirl pattern modules are used for glue application on feminine hygiene products, diapers and also for sealing air filters. This blog is going to specifically explain zero cavity modules and what industries use them and why.

Zero cavity modules have a very specific look, with a nozzle head attachment rather than a screw on nozzle. They also come with an E-Z Micro Adjust attachment to manage precision glue application. This nozzle & micro-adjust feature is custom manufactured for precise glue placement on smaller boxes, such as crayon boxes or pharmaceutical products. 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 this precise requirement, 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.

Because zero cavities have a matched piston needle and seat, when they finally wear out, most manufacturers require customers to replace the entire module. Universal Systems does not. We manufacture a rebuild kit specifically for zero cavity modules for a fraction of the price of replacing an entire module. Check out our rebuild kits here: https://www.ussefl.com/products/hot-melt-modules/module-rebuild-kits/.

Not many hot melt application manufacturers offer zero-cavity modules. Luckily, here at Universal Systems we have been manufacturing this specific module for over 25 years. If you would like to learn more about zero cavity modules or get a price quote, please reach out to sales@ussefl.com or call (561) 272-5442.

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The Importance of Utilizing Cross-Referencing

The packaging industry is entering the time of year when budgets are getting tight, but replacement parts are still needed. Universal Systems SE will cross-reference any of our competitor item numbers and get you high quality replacements. Cross-referencing Nordson item numbers to Universal Systems SE item numbers will help to lower your cost and keep your packaging lines running longer!

You will also notice that our competitors change their part number often. This is why we offer the search bar on our website for any cross-reference numbers you might have. Some of the most common cross references are listed below. If you purchase any of the parts listed on a regular basis, please feel free to call us today! We guarantee that all of our products are quality control tested before leaving our facility and we stand by all of our products with strong warranties.

Adhesive Systems:

P10, 1022234, 1022235, 276881, 276882, 276883, 276884, 276885, 276886, 276033, 276034, 238310, 243666, 168204, 166535 à ALL of these item numbers match USSE # D100-644

Heated Hoses:

4 Ft. Hose:

107288, 129556, 100120, 274791, 276151 –> 4104

6 Ft. Hose:

107286, 129557, 100121, 274792, 276152 –> 4106

8 Ft. Hose:

107287, 129559, 100122, 274793, 276153 –> 4108

10 Ft. Hose:

107289, 129561, 100123, 274794, 276154 –> 4110

12 Ft. Hose:

107310, 129562, 100124, 274795, 276155  –> 4112

16 Ft. Hose:

104008, 129564, 100125, 274796, 276156 –> 4116

20 Ft. Hose:

223838, 223836 –> 4120

24 Ft. Hose:

129565, 100832, 100126, 274797 –> 4124

Applicator Guns:

H200 1 Module AO/AC

8503717, 8505756, 8505768 –> 39105

H200 1 Module (AO/SC)

274596, 224939, 8503591, 8503686 –> 39107

Modules:

H200 (AO/AC)

1052927 –> 29215

H200 (AO/SC)

272282, 276119, 326583, 331979, 1048115, 2210, 2219, 2400, 2410 –> 29219

 

For any other questions on cross-referencing, please call (561) 272-5442 or email sales@ussefl.com.

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