ClearFlow Hot Melt Heated Hoses
Heated hoses are an important component for your production line and have several uses. Universal Systems SE manufactures our ClearFlow™ line of heated hoses that can transfer most any heated material needed for different applications. ClearFlow™ hoses offer the latest technology in heating and insulation to lengthen the life of your hose. Our newly designed insulated jacket will keep a steady, consistent temperature, improving molten flow and reduce charring and curing. Given that char is the biggest cause of gun misfires and nozzle clogs, the reduction in char will lengthen not only the life of the hose, but your entire system.
The key benefits of using a ClearFlow™ hose over any other hose manufactured today includes the upgraded insulation and nylon fiberglass cuffs that improve the durability of the hose connection. Those factors, coupled with our heat flow technology that keeps your materials heated at a consistent temperature throughout your production process, will reduce downtime, maintenance costs and increase overall efficiency.
In some cases, your lines may require waterproof hoses, which we also manufacture. All of the above benefits are the same, but come with a secure waterwash connection between the hose and glue head. All ClearFlow™ waterwash hoses are encased with state of the art, high temperature, extremely durable waterproof jacketing.
Whether you are transferring hot melt adhesive or other materials such as cosmetics, it is important to understand the materials being used to manufacture the correct hose needed for your business.
Below is a list of the key factors needed when ordering a heated hose:
Diameter of Core:
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.
The Purpose of Cartridge Heaters
The purpose of a cartridge heater is the heat metal parts by inserting them into predetermined spaces of the parts. The most common use of cartridge heaters in the hot melt industry, is for heating all automatic applicators, all hand guns, and sometimes even melters. They are very easy to install as the heaters are made slightly undersized relative to their nominal diameter.
It is recommended that the watt density of a cartridge heater only be as high as needed. Under normal applications maximum watt density is not required. Safety margins usually are rated by using less than the maximum allowed. Rather than having the highest possible wattage per heater, heaters should be selected that give a more even heat pattern.
In the hot melt equipment industry, watt densities are usually high rather than medium. In machining the applicators that receive the heaters, holes are drilled and reamed to exact tolerances. In a high watt density application, a very close fit is important. This style cartridge heater should have a hole tolerance of plus or minus .003. After holes have been properly drilled and reamed they should be cleaned and degreased to remove any remaining cutting debris.
Watt density is the heat flow rate or surface loading of a cartridge heater. It is the number of watts per square inch of a heated surface area. Watt density calculation would be as follows.
Watt Density = wattage / (pi x diameter x heated length)
The heater cartridges in hot melt systems and their components are normally controlled by a master temperature controller on the hot melt units themselves. The temperature controllers on the hot melt units read RTD sensors to control the temperature of the heaters. RTD sensors are found in all components of a hot melt system including the tank, the heated hoses, and all heated applicators.
To find out more about our cartridge heaters please visit our website at www.universalsystemsse.com or call us at (561) 272-5442 or email us at sales@ussefl.com.
The Difference Between a Glue Gun Head and Module
By far, the most commonly asked question we receive is – what is the difference between a glue gun and a module? A misconception that many packaging line buyers make is that when a module fails, you need to replace the entire gun. That is not true. In most cases, the modules attach to the gun and can be easily removed and replaced.
Below is a breakdown of the components that comprise a hot melt adhesive gun application system:
- Gun Head – this is the gun body that attaches to the packaging line and initiates the application of melted adhesive into the module. There are a variety of different style gun heads, ranging from 1 module to multi module capacities.
- Module – the module attaches to the gun head via two screws. Each gun applicator will come with modules, but these can be replaced regularly once they get clogged. The module is the conduit that applies the adhesive to the package.
- Nozzles (not always included when you purchase a gun) – at the end of every module is a nozzle. Most standard nozzles will screw on to the end of the module. The diameter of the nozzle will determine how much hot melt is applied to each package. Some modules, such as reduced cavity, zero cavity and ProBead’s, will come with an integrated nozzle seat attached. Replacement kits for these integrated nozzles are sold separately, instead of buying a brand-new module.
If you only need to replace the module, and not the entire gun applicator, make sure you check which type of module you need. Below is a list of the most common modules in use today.
- Standard H200 Module
- ProBead Self-Cleaning Module
- Reduced Cavity H200 Module
- Zero Cavity Micro Adjust H200 Module
- Swirl Pattern Modules
- Weave Pattern Modules
- H20 Modules
If you have any questions on which items you may need, please reach out to a sales representative by either calling (561) 272-5442 or emailing sales@ussefl.com. We manufacture all products in the United States and are here to offer the best price possible to get your packaging line up and running as quickly as possible.
Important Notes for Hot Melt Purchasing Agents
The packaging industry is unique, and can be a tough industry to buy for. It is important for purchasing agents to understand how their hot melt systems operate in order to ensure they are buying the correct parts. Hot melt manufacturers are full of highly educated engineers that have honed their skills over time. At Universal Systems SE, we combine our experience of over 40+ years to keep our products ever evolving and ensure we are still at the top of the industry, while offering our expertise to help our customer purchasing agents make the right choices.
Keeping up to date on the latest trends is not only important for us as manufacturers, but it is also important for buyers. Below are 5 important facts that every hot melt equipment buyer needs to keep in mind before making a purchase.
- Durability – at USSE, we stand behind the durability and craftsmanship of our products. That means that we offer a solid warranty, longer than all of our competitors.
- In Stock Products & Compatibility – whenever you call to inquire about the pricing on a melter or replacement part, make sure you remember to ask if the part is in stock. There are several choices that you have when ordering both main and replacement parts. Most all companies make their parts compatible with industry standards.
- Tank Capacity – make sure your melter’s tank capacity matches your packaging line output. This will ensure that you have the correct tank needed for the job.
- Match Your Adhesive and Your Pump – the pump needs to match the viscosity of your chosen hot melt adhesive. This is key to making sure that you are ordering the correct style pump to dispense the adhesive on your packaging materials.
- Usability – the best melters will be easy to operate, easy to change out replacement parts, and easy to clean and maintain. They will also come with smart features like USSE offers on all of our ProBilt adhesive melters.
At Universal Systems SE we are dedicated to the education of both our customers and the next generation of hot melt engineers.
If you are interested in learning more about hot melt equipment tips and facts, please call one of our customer service specialists today at 1-800-848-5018 or email sales at sales@ussefl.com. You can also view these facts and several other key features of our ProBilt™ Melters by visiting us on YouTube.
Top 10 Tips for Maintaining Your Hot Melt Machine
Hot melt machines are an important investment into the efficiency of your packaging line. Just like any important investment, you want to make sure that you are maintaining your hot melt machines to limit downtime and minimize expenses.
Below are the top 10 maintenance recommendations to ensure you get the most out of your Universal Systems machine.
1) Replace Melter Filter after 500 Hours
2) Clean Melter Tank with Purge Plus™ after 1,000 Hours
3) Clean and Flush Pump after 2,500 Hours
4) Replace Pump after 5,000 Hours
5) Replace Hose only when it stops heating
6) Replace In-Line Filters after 150 Hours
7) Replace Gun Head only when it stops heating
8) Change Module Every 1,000 Hours
9) Replace Nozzle Every 120 Hours
10) Depending on how many lines you are running, make sure you keep enough spares of each in stock.
Universal Systems SE stocks all of the above and can ship almost anything same day. For more information on how to operate your hot melt systems or perform maintenance on your system, please check out our YouTube channel.
For pricing on any items, please reach out to one of our sales representatives at sales@ussefl.com or feel free to call our corporate office at 1-800-848-5018.
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.
How Cartridge Heaters are Made and Why They Fail
There are two methods of manufacturing cartridge heaters to ensure a useful life and not have them fail prematurely. The first is a standard cartridge heater and the second is a swaged cartridge heater. Even though both cartridge heaters might look identical on the outside, they are constructed very differently. Standard cartridge heaters are the most commonly used, but if you need to operate at higher temperatures and vibration applications, then you will need a swagged cartridge heater.
A standard cartridge heater has nichrome wire heater coils that are weaved through holes in the ceramic tubing. Pure magnesium oxide filler is vibrated into the holes, heating the coils to allow maximum heat transfer to the stainless-steel sheath.
A swaged cartridge heater’s nichrome wire is wound tightly around a ceramic core, to situate it in close proximity to the heater sheath. Pure magnesium oxide is vibrated in and the heater is swaged to a specific diameter. This compresses the magnesium oxide so it becomes an improved conductor of heat from the wire while maintaining its dielectric properties. This is why it works so well with high temperatures.
The useful life of a cartridge heating element is determined by how quickly the heat generated in the resistance wire can be dissipated to the outside sheath. So why do cartridge heaters fail and sometimes prematurely? The reasons include improper fit, moisture, watt density is too high or if you are using the incorrect voltage.
Improper fit is the most common cause of cartridge heater failure. If the cartridge does not fit into the hole it is inserted, then the heater cannot dissipate the heat being generated by contact with the sheath. So, in effect, the temperature inside the heater will continue to rise until the magnesium oxide or resistance wire breaks down and the heater fails.
If moisture or impurities are present they can be drawn into the heater. Because magnesium oxide is hydroscopic, every time power to electric heaters is eliminated, an internal vacuum occurs which draws in air from the surrounding area. This vacuum can cause a short circuit.
Finally, make sure that the wattage density isn’t too high and that you are using the correct voltage. Either of these issues can a cartridge heater to fail.
If you have any other questions about your cartridge heaters, please call us at (561) 272-5442 and one of our technicians can help you diagnose any cartridge heater problems.