Packaging lines are complicated pieces of machinery and knowing the ins and outs of each component is important. When you install a new hot melt system onto your packaging line, there are 5 helpful tips to take into consideration to ensure smooth operation and getting the most out of your equipment.
Read and Keep the Manual
The best practice for maintaining your hot melt tank is to read the manual and keep it handy. So many times, maintenance managers will install the tank, but not read the instructions on how to wire it or program it. That can lead to so many issues. In other instances, a tank may be running for some time, but someone hits a button accidentally and changes a setting, then doesn’t know how to change it back. If only they had read the manual or kept it on hand. It sounds like such a common-sense thing, but oftentimes manuals are discarded with the shipping crate. For this reason, we keep a digital manual on our website for anyone to reference.
Replace the Filters
Preventative maintenance is one of the most important tasks to keep your machine running efficiently and reduce down time for your packaging line. When your tank filters are clogged, that is good, it means that they are doing their job and filtering out char. Changing them on a regular basis and spending a small amount on a tank filter will save you thousands in the future.
Monitor Your Hot Melt System
Line operators are tasked with monitoring tanks on a daily basis. It is important to make sure that the pump is pumping smoothly, the solenoid is not lagging and the guns and hoses are heating to temperature and staying there consistently. Even a minor change in any of those tasks can mean that it is time to proactively replace a component, or at least make sure there is a back up on the shelf.
Know Your Options
Knowing your options ties all three previous tips together. If you have read the manual, you will know what your options are when something goes down. If you are doing preventative maintenance, then you know it is not the tank filters. And if you are monitoring your system, you know what components you replace most often and what inventory you have on the shelf. In addition, you should also know what options you have should you need to replace your current system. Is the current technology working for you or do you want to upgrade to an auto-fill system? It is always good to be prepared and know your options.
Listen to Your Workers
Line operators are on the front lines, literally. They watch particular lines and machines on each line all day, every day. They know what parts are running effectively and where the problems may lie. It is important that you listen to them. They might not be the maintenance manager by job title, but they are the most knowledgeable about the equipment they are in charge of and their opinion should be the first requested.
For more tips on keeping your hot melt systems running to the best of their ability, please give us a call at (561) 272-5442 or email firstname.lastname@example.org.
Knowing your strengths and the value add that you provide are important keys to success for any business. Universal Systems SE’s strength is the in-house manufacturing, QA process and customer service that we provide to our customers all year. The value add is the high-quality material and product that we put to market at a more affordable rate than most of our competitors.
Every day we have maintenance managers or co-packers calling in to find out if we can support their old Nordson® tank. The simple answer is yes. We can support old melters and usually fix any issues that your hot melt applicator may be having. On our website, we offer a search functionality that cross references thousands of product IDs from other manufacturers to make it easy to see which USSE parts are a perfect fit for your old system. However, not only do we support the old, but we manufacture new equipment that will function the same as your old and hopefully last longer. In order to help increase the life expectancy of your hot melt equipment, we offer a recommended maintenance schedule for any maintenance manager so that they can keep up with the life of their products and know when to replace important parts.
Another value add is the fact that we stock over 10,000 items at all times. Not only do we have hundreds of different styles and diameter nozzles in stock, we also stock pumps, control boards, filters, hoses, applicator guns, modules and we always stock tanks. Unlike most manufacturers, that make to order tanks, hoses and guns, we have one of the largest in stock inventory of any other hot melt manufacturer. And everything ships from the US, which means that you can typically get it within the week or overnight service if needed.
If you are ever in need of technical support for your old melter or hot melt equipment, do not hesitate to call us at (561) 272-5442. We are here to use our strengths, to help you add value.
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 email@example.com.
It’s finally here, 2021! It felt like 2020 took forever to end, but now that it is gone, we need to make 2021 the best and most efficient year yet. Due to the struggles that we all faced last year, company strategies have changed, not because we wanted them to but because they had to. And like most industries, the packaging industry has also seen a lot of changes. We are now allowed less people in the office and on the line. Since workers have to be 6 feet apart, we cannot operate as many packaging lines as we want or need to. That means that we are getting less budget to spend on materials, supplies and equipment. Now, operating managers are finding themselves being more particular about cost and efficiencies. That is where Universal Systems comes into the mix. Our ProBilt line of hot melt equipment is made in the USA and has some of the strongest warranties in the industry. We have been manufacturing since 1981 and know what it means to work hard and take pride in that hard work. As we move out of a pandemic and into a new world, we have a few suggestions to help manage our “new normal” in the packaging world.
Catalog Your Inventory – while this may seem like a tedious task, it is worth it in the long run. Once you know what you have and how much you are using of an item, you will be able to estimate your budget needed for the new year.
Research Your Vendor Options – change is hard, but sometimes the best options are ones you haven’t even known about. Take some time to price out vendors for your packaging needs. There may be options out there that you don’t even know about that can save you a lot of money and be just as efficient and high quality as what you have been buying.
Learn How to Troubleshoot & Maintain – Pre-COVID, when the economy was thriving and budgets were high, packaging facilities had maintenance managers, operations managers, line operators, buyers, etc. Now, you may find yourself doing a little bit of everything. At Universal Systems, we believe that knowledge is power. The more you know about the equipment you are running and how to maintain and fix the issues will save you from overspending in the future. We have technicians that have over 40 years of experience in hot melt, that are here to help you if needed. Just call (561) 272-5442.
With the reopening of many packaging facilities in full swing, here at Universal Systems SE, we are getting a lot of technical calls that pertain to glue and not the packaging machinery itself. Not a lot of technicians realize that some of the problems they are experiencing with their equipment are actually being caused by the glue. By the way, this has always been the case. Since knowledge is power, below are 2 issues that we get a lot of calls about that are glue related and not machine related.
#1 Glue Related Issue – Char
Many line operators and line technicians have experienced char in their hot melt application systems and most of them think that the char is caused by the machine. That is not actually accurate. The hot melt tank will heat the glue, but only to the temperature that is set by the operator. It is very important to understand how recommended temperature ranges effects viscosity which allows the glue to run at its optimal level. Most charring is due to overheating the glue. That char will travel through your application equipment and cause clogs which will require you to replace equipment or its components. However, that will not fix the long-term problem of charring. If the charring is not corrected, when you install the new equipment it will clog again. That is not a machinery issue, that is a glue issue. Our suggestion is to speak with your glue provider and find out all of the specifications on the glue you are using such as ball and ring, optimal temperature and viscosity. That will save you a lot of money in the long run and should reduce any excessive charring.
#2 Glue Related Issue – Coagulation
There is no doubt about it, glue is expensive. In most cases, the glue can be more expensive than the application equipment. The reason is because most facilities use a lot of it. As we all know, the world has been a crazy place this year, and with the re-opening of a lot of packaging plants, comes new, reduced operating budgets. We have heard from a lot of customers that in order to save on costs, they have had to change glue, whether it is moving to a more inexpensive glue, or a system that lays down less glue but with a stronger adhesion. Either way, if you change glue and do not meticulously clean your glue application system, you can have coagulation causing clogs. We recommend cleaning your tank and hoses with Purge Plus or a similar cleaning substance before changing glues.
At Universal Systems SE, we are always happy to help with any issues that you might have. But keep in mind that sometimes, your issue might be something that you need to discuss with your glue manufacturer. In the meantime, please feel free to reach out to us with any questions at firstname.lastname@example.org.
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.
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.
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.
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.
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 email@example.com
As we return back to work from the shut down earlier this year, facilities may be experiencing several new situations or issues that they have either never dealt with before, or maybe they are new to the industry and need help with understanding how best to operate a high-speed packaging line. We are hearing from a lot of our customers, both old and new, that good adhesion has become a problem. Even though we are moving into the summer and the weather is no longer a potential cause of adhesion issues, there are a few other checklist items that you can walk through to help correct any lack of adhesion.
The first thing to check is the distance of your application gun and nozzle tip to the container or carton you are trying to glue together. If there is too much distance between the tip and the box, the glue could be cooling mid-air, not allowing the cartoner to get full adhesion when moving the box to the folding stage. This solution could be a simple mounting adjustment to lessen the space between the nozzle tip and the box.
Another item to review is the viscosity and melt rate of the glue you are using. It is imperative to educate your line operators on the glue specifications to make sure they are heating it to the correct temperature. On the flip side of that, make sure they are not over-heating it and making the glue too thin, creating a longer open time for the adhesive. Knowing the specifications of your glue will also help you to regulate the amount of glue you are using on your applications, hopefully keeping your operating budget down.
In addition to the above listed items, we also highly recommend regular maintenance on your hot melt system to limit the amount of char building up in the tank. Performing regular maintenance such as changing out tank filters, in-line filters and cleaning out the tank quarterly, will lessen the effects of char through the line. If you do have a lot of char build up, that can and will transfer through the system and onto the box. Too much char mixed in with your glue can be causing adhesion issues. Once the glue dries and hardens around the char, the char can separate from the box.
If you are experiencing any adhesion issues or have any other troubleshooting questions that you would like to review with a technician, please call Universal Systems SE at (561) 272-5442 or email firstname.lastname@example.org.
This is most definitely a new reality that we are all facing. Never before have so many companies had to shut down several, if not all, of their packaging lines because of a global pandemic. However, it was a scary and necessary measure taken to prevent further outbreaks of COVID-19. Now, as we slowly start to reopen as a nation, so does our packaging facilities. State by state, Governors are rolling out the reopening phases that each company, both essential and non-essential must follow.
With the reopening happening, that may mean you are going to run into a few speed bumps. As we all know, machines that typically run seven days a week, don’t like being shut down for three months. Especially if they are not shut down and cleaned out properly before they sat around idle. So, when you switch the power button back to “ON”, everything might not turn green.
In an effort to help with troubleshooting, we have put together a quick list of potential fixes.
1. CLEAN YOUR TANK. We cannot stress this enough. Even if your team drained the glue in the tank reservoir before shut down, there will still be old residue that will impact your restart. Cleaning your tank is fairly simple. First, make sure to detach all guns from the hoses before running the cleaner through. Utilizing our Purge Plus cleaner, fill the tank reservoir and heat. Place the end of the hose inside a bucket and flush the cleaner through the tank and out through the hose.
2. CHANGE ALL FILTERS. This includes both the tank filter and in-line gun filter. Starting with new fresh filters is the smart way to go.
3. NOZZLES MIGHT GET CLOGGED UPON INITIAL RESTART. Nozzles have small orifices that dispense the glue onto packages. If there is any left-over char in the tank from restart, the nozzles could get clogged up first. Try switching the nozzle to see if that fixes the issue.
4. REBUILD KITS. There are a few items that can be rebuilt on your adhesive melter system. For example, your pump. If you think that your seals have dried up from sitting idle through the down time, and you have a skilled mechanic trained to work on the equipment, try ordering a rebuild kit. This will save you money on purchasing a new pump.
If you experience any other issues during your restart, please call us directly at (561) 272-5442 and a technician will walk you through troubleshooting any issue. Stay Safe!
As we navigate through this pandemic of 2020, we are noticing more and more packaging partners not getting the budgets to do much of anything with their packaging equipment. Even with the increase in demand for consumer goods like toilet paper and hand sanitizer, many packaging lines have limited shifts due to social distancing guidelines, making sure to keep their employees safe and healthy. As the country starts to slowly re-open, so will packaging lines…and nothing good comes out of a glue pot that has been sitting idle for over 6 weeks. That is why our number one recommendation to all facilities, other than to clean the pots before restart, is to make sure to keep spares on the shelf!
The most common hot melt equipment that should be replaced upon restarting a line are tank filters and in-line filters. Those filters will help with any char that is created once the line starts back up and running again. Another recommendation is to clean the pot with Purge Plus. It is so important to get the old glue out of the pot, before putting the new pellets in. It is also smart to keep spare modules and nozzles on the shelf. Those items can easily clog with char. Luckily, Universal Systems keeps over 10,000 items in stock and on the shelf for easy shipment whenever you need them.
If you are getting ready to restart a line and have any questions on best practices or the steps you should take to ensure a smooth manufacturing process, please call to speak with a technical rep at (561) 272-5442 or email email@example.com.
An interesting fact about the packaging industry that most people don’t realize, is that purchasing agents become avid internet hunters when it comes to finding parts for their old equipment. There are several resources out there, the largest being eBay, for purchasing agents to find and buy parts for their old adhesive melters. The problem is, when buying from a bid platform, you never know what you are going to get. If you are looking for an old part, for a melter that is more than 20 years old, the part you find online could either be used or the wrong part. Also, with most online bid platforms, you get what you get. There are no returns or exchanges for your actual part. And in most cases, you get what you pay for.
Universal Systems SE realizes how important it is to be an online resource of purchasing agents, which is why we have invested in becoming “searchable”. In the last couple of years, we have launched a new website, added more products, and increased the number of cross-reference IDs on our website. We have added pictures, spec sheets and custom contact forms to help purchasing agents get exactly what they need. We are also working on making sure that we show up in the search results when purchasing agents Google old part numbers or manufacturers.
The benefit of buying from USSE is that all of our equipment is new, in stock and you can talk with a technician to make sure it will fit with your current equipment. Another key aspect of working with USSE is our staff of knowledgeable engineers that have been around adhesive melters and packaging line equipment for over 40 years. If you have a question about your old melter, we are most likely the only company in the industry that can answer it.
To test out the knowledge of our technicians, give us a call at (800) 848-5018. We are certain we can get your old equipment back up and running in record time.