Hands On Hot Melt Machinery vs. Remote Access Equipment
The hot melt industry has been changing over the years and most recently has made a push for remote access machinery, or even Bluetooth enabled equipment. At Universal Systems, we believe in the old school “hands on” approach to high speed packaging. Having a human component to troubleshoot and catch issues before they even start, in our opinion, is the only way to effectively manage your manufacturing systems. However, some of our competitors are moving toward human-less systems, where one person can manage the line from afar. With the equipment telling the person what they need and when they need it. There are pros and cons to each.
Here are the reasons why we feel like the “hands on” approach to line operators is still important.
Experience
Real time on the spot decision making based on experience will always be irreplaceable.
Troubleshooting
If something were to happen on the line, a line operator can real-time troubleshoot and fix the issue faster and more efficiently than a computer.
Eyes on the Problem
Putting your eyes on the actual problem helps you to better understand what the issue is and how to fix it. Reading an error code or getting an alert that you then must spend time researching is not always the best solution. If you can see why the line is down, then you have a better chance of getting it fixed and back up and running quickly.
Makeshift Fixes
Not that we are a proponent of makeshift fixes, sometimes it is necessary. With someone on the line, they can quickly switch out a filter or unclog a nozzle without there being much downtime. If you are working remotely, you would then have to call down to someone on the floor to make the switch, which could take more time than your operation can afford.
Overall, while computers and technology can be helpful and advance the industry, nothing can effectively replace a valuable line operator with experience and the ability to think on their feet. The same goes for technical support. It is invaluable to be able to work with a company who can offer you real-time technical support. At Universal Systems, you can always speak to someone who can help. We don’t send you through teleprompts or force you to send an email that may or may not get answered in a timely manner. We pride ourselves in our response times and helping our customers who are on the floor and putting in the work to get their equipment running at maximum capacity. For any technical support or customer services give us a call at (561) 272-5442 or email sales@ussefl.com.
How to Make a 4-Way Solenoid work as a 3-Way
There are several different types of solenoid valves used for hot melt application equipment. We are specifically referencing gun applicator solenoids in this article. The gun solenoid is what is used to fire the gun and apply the glue onto boxes in a packaging line. The two most common types of solenoids used to fire automatic pneumatic glue guns are 4-way and 3-way. The difference between the two is simple: a 4-way solenoid is used when you have an air open/air closed gun and a 3-way is used for an air open/spring closed gun. Essentially, a 4-way solenoid utilizes pneumatic pressure to open the piston, initiating glue flow, and close the piston to shut off glue flow. Whereas a 3-way solenoid utilizes pneumatic pressure to open the piston and when the air shuts off an internal spring closes the piston, shutting off glue flow.
Now let us say your packaging facility has multiple glue lines, and some are air open/air close applicator systems and some are air open/spring close applicator systems. You can standardize your inventory by purchasing only 4-way solenoids and converting them to 3-way on an as needed basis. However, please note that you cannot run a 3-way as a 4-way.
Below are the steps to change a 4-way solenoid valve into a 3-way solenoid valve:
- Remove air line #2 from solenoid
- Plug air line #2 on solenoid with a ¼ NPT flush plug
It’s that easy!
For any further questions about solenoids, give a sales rep at Universal Systems a call at 561-272-5442 or email us at sales@ussefl.com.
How to Properly Mount Your Hot Glue Gun
When setting up your cartoner or tray former, you need to think through placement of hot melt equipment for maximum glue hold and minimal glue usage. That includes both determining the ideal length of hoses needed, as well as the placement of the glue applicator. There are a few things that you really need to take into consideration for both, but this article will focus on properly mounting your glue gun.
- Make sure that wherever you are placing the applicator guns, the module and nozzle are positioned approximately an inch to an inch and a half away from the sub-straight. That will lessen stringing and popping. The shorter the distance the glue must travel in the air to hit the sub-straight, the less likely it is to cool and cause stringing and poor adhesion.
- Fit and position the module so that you can easily hit the sub-straight with either a straight or right-angled nozzle. If you are tight on space, consider using a slim-line or mini applicator so that you have more maneuverability of the manifold. You want to set it up so that both the module and nozzle are easy to access for replacement and or troubleshooting.
- Placement of an in-line filter assembly is also key for maximum long-term efficiency. You need to be able to get the filter body positioned in a way where you can easily access and replace the filter. Take into consideration utilizing a right angle or 45 degree fitting to make it easier to access.
- Try to mount the gun so that the in-line filter assembly can go directly into the hose without kinking the hose. The more secure the hose is, the longer it will last you.
If you are struggling with the logistics on how to set up your glue system within your packaging line, reach out to a Universal Systems technician, who will be able to get your hose and gun mounted in the best possible way.
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.
Tried and True: How Reliability and Innovation Don’t Always Go Hand in Hand
Innovation is important in any industry, including packaging. However, the latest and greatest isn’t always the best for your operation. There are several reasons as to why it is better to stick with the old tried and true systems.
Reliability
If it ain’t broke don’t fix it. I am sure you have heard that saying before. There is a reason. If you have a system that has run great for you in the past, stick with it. Getting something new is not for everyone. With new equipment comes more complications such as line operator training, all new inventory, potential downtime due to the learning curve, etc. In addition, most all new equipment comes with new technology that, while it is probably meant to be helpful and less time consuming, becomes over complicated and more time consuming. Universal Systems ProBilt has kept its reliable technology for decades. And while that sounds like we are not innovating, that is not true. We are sticking with what we know works. We have found the secret sauce, why over complicate it?
Ease of Use
With every innovation, comes new challenges. Learning new ways to do things is not easy for everyone and can slow most people down. That is true in our everyday lives, just like it is in packaging. It’s called high-speed packaging for a reason, and every new technology feature opens the door to potentially slowing people down. If your network connection is slow, or the on-board computer screen doesn’t want to keep up with the operation. All these new luxuries can cause slowdowns. Our Universal Systems ProBilt tanks and components are easy to operate with our plug and play style. The board’s simplicity is our greatest asset. It lowers the number of faults and tells you the exact problem if there is a fault. With our ProBilt AccuScan Control Panel, you don’t need a book of faults to reference, the screen tells you what the issue it. Keeping it simple for all operations on the line.
Knowledge is Power
If you have a ProBilt melter, then your line operators know how to set it up, how to use it and the maintenance required to keep it running for decades. As we see other companies in the industry switching out their systems and discontinuing product lines, we have decided to keep with what we know. Inherently allowing our customers to keep with what they have been running for as long as they have worked with us. At Universal Systems, we don’t have any planned obsolescence. You will never not be able to get help with any of our equipment because we no longer support it. We make sure that we support everything we have ever made and will stay that way.
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.
Wine & Packaging
Why not combine my two favorite things: wine & packaging!
Winemaking is as much an art as it is a science, the same can be said for manufacturing packaging equipment. Winemakers need an OEM that has in-depth knowledge and experience in packaging products as high-end and fragile as wine bottles. At Universal Systems, we work with several large wineries to help them utilize the most cost-effective and capable line of hot melt equipment to seal their most valuable assets.
When wineries look to an OEM for their packaging needs, below are 5 things they need to focus on.
- QUALITY: All Universal Systems SE equipment is compliant with all international standards in addition to offering OSHA compliance.
- RELIABILITY: At USSE, we work with all wineries to make sure their hot melt equipment is optimized and running smoothly, and we have since 1981. We focus on matching the packaging needs with the tank capacity of the melter and the ease of operation on all machines for line workers. The easier the operation, the less potential for downtime. All of our hot melt tanks have the same components, this allows for you to streamline your inventory as well. We also provide you with advanced engineering and design with expert tech support.
- FLEXIBILITY: Your wine-making facility and process is unique, and you need an OEM that works with you to provide flexible solutions that support your business goals. Whether you need just a single machine or a full hot melt system, Universal System has a multitude of products that you can use for different glue applications.
- AFFORDABILITY: When you invest in new equipment, working directly with the equipment manufacturer eliminates the increased costs charged by a 3rd party representative of an OEM. Such investments should readily produce improved efficiencies that positively impact your bottom line. Our clients can attest to the fact that their investment in USSE equipment results in proven, accelerated ROI and a lower total cost of ownership. Plus, all of our equipment is proudly made in the USA.
- SUPPORT: Avoid frustrations of unanswered questions and unsolved problems by choosing to work with an OEM that provides excellent US-based customer service. That way, your operation can quickly get the assistance they need. Universal Systems is a US company who only has offices in the USA. We are proud to offer made in the USA products to our favorite US winemakers!
Call (561) 272-5442 today to speak with a sales rep to see how Universal Systems can help with your packaging needs.
Inflate Your Inventory, Not Your Budget
As we head into 2023, all Americans are impacted by the largest increase in inflation that we have seen in decades. With inflation comes several other economic impacts on society, including companies lowering budgets, changes in workforce, families not being able to afford bare essentials and many other challenges. With that said, companies still need to find ways to stay fully operational while staying within their newly defined restrictions.
Here at Universal Systems SE, we pride ourselves on producing high quality products at economical prices and have since 1981. All of our products are made in the USA and we keep almost every item in stock at all times. If you are having issues getting Nordson® products, or feel like the recent price increases from Nordson® aren’t allowing you to stay up and running at all times, please reach out to us. We will send you a quote within 24 hours.
The importance of “in stock” has never been more valuable. We realize that and are dedicated to continue to invest in stocking products so that our customers can get their most vital items in a timely and cost-effective manner.
For pricing on our most popular products, please reach out to sales@ussefl.com.
Best Practices to Ease Supply Chain Burdens
It is no secret that everyone is experience supply chain issues this year. While there may be no end in sight, Universal Systems can only try and help ease the burdens on our end users. Below are a few of the best practices that we have implemented that we can recommend for our customers.
Keep an Open Line of Communication
With several of our competitors experiencing supply chain issues due to their overseas manufacturing and shipping issues in the current cultural climate, Universal Systems, being a USA manufacturer has received a lot of new business from large end users of hot melt equipment who would normally be buying from the big-name brand manufacturers. With the new influx of business, we have been open and honest with customers as to what we stock and what we make custom. If a new customer who is used to buying from Nordson calls and asks us lead time on standard stock items, we are happy to communicate that we can ship same day. However, if they have a custom gun or hose, we are honest regarding lead time and ship dates, normally 3-5 business days.
Plan Ahead
It is so important for companies to try and plan ahead with their inventory. While we realize this may be hard for many buyers due to lack of budget or their inability to get “out of the weeds” from being so far behind during Covid lockdowns, it is the only way to ensure there is no downtime on your packaging lines. Universal Systems offers all of our customers a preventative maintenance schedule and inventory recommendation list, so that you know what to keep on the shelf based on the equipment you are running.
Try New Products
Many of us get stuck in our ways and don’t realize there are other options out there that might improve our operations or way of doing business. Now that some large brand name companies, who have spent years manufacturing overseas, are feeling the crunch of no inventory due to low supply chain, many packagers should see this as an opportunity to work with Universal Systems. We have been manufacturing hot melt equipment in the USA for over 40 years and are well versed in packaging line needs and set ups. We manufacture most of the same products as our largest competitors and stock over 10,000 items at all times.
Think Outside the Box
With over 40 years of experience in packaging equipment, Universal Systems’ technicians are most skilled in thinking outside of the box. Whether it is troubleshooting an issue with an old machine that has been around since the dawn of day, or setting up a new line configuration, sometimes the most common answers don’t always work. We urge our customers to keep an open mind and work with us to figure out the best solutions to your packaging needs.
For more information about Universal Systems’ ProBilt line or products please reach out to sales@ussefl.com or call (561) 272-5442.
Mini Modules and Gun Applicators
Several Years ago, Nordson® introduced the MBII gun applicators and modules. Initially, the small module and applicator manifold was made for packaging lines that were designed with little room for glue application. Then, they started offering them in a low-profile design for case sealers. Over time, Nordson® started using MBII guns and modules as standard equipment on all of their packaging line set ups. Why? Even though it is not clear the need for the MBII in most standard application setups that have room for an H200, the price surely made it a much more profitable product in Nordson’s® arsenal. The MBII is more than double the price of a standard H200 module and gun applicator.
The key question to ask is, when do you need to use a MBII applicator versus a standard H200 applicator? Like we mentioned earlier, a MBII applicator is essential on packaging lines that have about half the space to fit an applicator than typical lines. Not only is the manifold about half the length and height of a standard H200 gun, the modules measure a mere 1” x 2” in size. Additionally, MBII applicators have the filter built into the manifold. This is a space saver because it eliminates the need for the in-line filter assembly off of the back of a standard gun into a hose. This allows for the MBII gun to attach directly to the hose and still be able to filter out all of the char and debris travelling through the hose and into the manifold. MBII guns also are air open, air close systems, so you can only run them if you have your line set up with two air lines running to the gun. MBII modules do still fit all of the standard H200 nozzle tips. So, even though you cannot use your standard H200 module on the MBII manifold, you can use all of your current stock nozzles.
If your new packaging line comes in with a MBII system installed, our recommendation is to measure the space where the applicator is mounted. If you have room for a standard H200 applicator and in-line filter assembly, you can always switch to a standard H200 set up. The only thing you will need to change out is the gun, filter assembly and solenoid. This will save you thousands of dollars in the future…but only if it fits.
For more information about the mini modules and applicators manufactured by Universal Systems SE, please visit https://www.ussefl.com/products/applicator-gun-heads/h201t-guns/#1544128561143-eeff57c6-9818.