The most common type of hot melt system used on packaging lines is a manual fill system. With manual fill systems, there are several roadblocks that can occur with safety and productivity that many companies are experiencing. Universal Systems SE took those concerns into consideration when designing our ProBilt™ Phoenix auto-fill system.
It is first important to understand how a hot melt system works. Hot melt adhesive application systems house a Teflon® coated interior tank, where the glue pellets are added and melted. The glue is then pumped out, travelling through a heated hose, into an applicator gun, through a module and nozzle, finally landing the glue at its final destination.
Universal Systems SE has ProBilt™ tanks that range from an 8 lb (4L) capacity, up to a 20 lb (10 L) capacity. Depending on how many hours per day the packaging line is operated, and the size of the glue tank needed, line operators are in charge of making sure that there are always glue pellets in the melter. Running low on glue inside the melter tank can cause a plethora of issues with the system. One of the most common issues is running the pump dry. If a line operator lets the tank run dry and the pump “shotguns”, the pump or shifter can fail. Honestly, that is the most common cause for pump rebuilds that we see in our shop. The easy solution to this is making sure that the tank is always full with pellets.
However, consistent tank filling can increase the risk of other potential issues. The first, is that it increases the risk to employees. Since the tank runs anywhere between 200 – 400 degrees, it is HOT. If a line operator is in a rush or makes one careless move, they can easily be burned by the pot. Another issue is that when you open the tank lid to refill with pellets, cold air flows into the tank and cools down the internal temperature. If the glue is continuously getting hot and cold, it could negatively impact its bonding ability.
These potential issues prompted Universal Systems to develop and release our ProBilt™ Phoenix auto-fill system in 2018. Unlike with manual filling, the automatic filling process does not require the line operator to fill glue pellets directly into the hot tank. Operators fill the free-standing container, which is separate from the tank. The glue pellets are then deposited into the internal pot via the vacuum and wand system when the internal tank glue level is low. The Phoenix is available in two tank capacities, the 15 lb and 20 lb units. Each glue container has maximum and minimum fill lines so that line operators know how much or how little to fill the pellets. Since the containers can hold much more glue than a standard heated pot, line operators no longer need to worry about checking the melters as often as with a manual system. This will also ensure that line operators will not get burned and that the glue inside the pot will stay consistently heated, creating maximum bonding ability.
The scenario is usually the same, a packaging line melter goes out in the middle of the busiest time of year. Most commonly, maintenance directors and buyers simply replace the current OEM melter with the latest model. That is not always necessary. Universal Systems SE ProBilt™ melters have the same footprint as most all Nordson® systems and can easily fit into where the original tank is positioned. Just because your current packaging line has a Nordson® melter does not mean you have to replace it with another expensive Nordson®. Plus, all of our ProBilt™ melters are in stock and can ship same day!
There are several key points to take into consideration when choosing a hot melt system for your packaging line. The most important are: Melt Rate, Durability, & Cost-Effectiveness.
The melt rate is the rate at which the tank will melt the adhesive you put into the reservoir. This is where the tank capacity comes into play. Before moving forward with any hot melt adhesive system, first you need to understand how many pounds you need to melt per hour. The melt rate is dependent on how many hoses and gun applicators you are running and how many boxes are sealed per minute on your packaging line. The most common tank capacity is the 20 lb. (10 Liter) ProBilt™ 20, with a melt rate of 23 lbs. per hour. If you are only running one line with one hose and gun applicator, then you may only need the 15 lb. (7 Liter) ProBilt™ 15 which melts 18 lbs. per hour.
Depending on how many shifts you are running, you need a melter that will work consistently and effectively. All ProBilt™ melters come with a 10-year heater warranty, which is the highest in the industry. In addition, all melters come standard with 4 hose / 4 gun capability and a set-back functionality that allows for easy start up and shut down. ProBilt™ melters are constructed out of 316 stainless steel, not only for its sleek look that will seamlessly blend with your packaging line, but also for its durability and sustainability through the tough elements a packaging line ensures.
The economy has become a roller-coaster in the last year. With that, large CPGs are cutting back not only in personnel but in spending budgets for packaging. These tighter budgets won’t always allow for a buyer to simply purchase the latest Nordson® melter. Here at Universal Systems SE, we have seen more and more companies trying to repair older melters and plug any current issues with band-aids to stretch their fixed budgets as far as they can. Since we manufacture parts that are compatible with old Nordson® tanks, we have been able to help a lot of companies cost effectively navigate the times. In addition to our parts business, all of our ProBilt™ series melters are cost effective replacements for any Nordson®.
To learn more about Universal Systems SE’s ProBilt™ series of melters and components, please reach out to a customer service representative at firstname.lastname@example.org or call (561) 272-5442.
If you follow the packaging industry, whether through news articles, industry periodicals or first hand through direct buyers at CPG companies, one of the largest drivers in packaging is the stress on workforce demands. This can include how difficult it is to find reliable workers that are dedicated to the success of the company. It can also be in the aspect that most of the line operators working the packaging line equipment are not trained properly on that piece of equipment and all of its capabilities.
As the packaging industry tries to modernize technology, not all of their workforce can keep up. As a hot melt equipment manufacturer, one of our core competencies is our knowledgeable technical support. If you have any Universal Systems SE equipment or ProBilt™ machines on your packaging lines, you can rest assured that you will get speedy, knowledgeable sales and technical support. However, in many instances, line operators do not have that type of experience or knowledge base. That can lead to “on the fly” fixes, which usually equates to weakened product and voided warranties. At Universal Systems SE we understand that knowledge is power, and we want to make line operators jobs easier, not harder. With that in mind, we have kept all of the ProBilt™ hot melt application systems uniform and easy to operate. We also try to make our clients smarter when they call with issues, asking questions to help them learn or giving them some simple troubleshooting tips to follow for the future.
In addition to being able to help line operators with questions and knowledge, we also make sure to include in every shipment all of the pertinent manuals and information guidelines needed. For example, if your company is ordering ClearFlow™ heated hoses (Universal Systems SE’s proprietary line of heated hot melt hoses), each shipment will include installation and care instructions. The same goes for our ProBilt™ applicator guns. With the purchase of any ProBilt™ application gun, we include a list of maintenance recommendations on the gun, modules and nozzles.
So, as CPGs continue to have concerns with their workforce, we here at Universal Systems SE we will continue to do everything in our power to ensure that we keep them knowledgeable on our equipment.
As we continue through 2019, it is clear that big brand CPG budgets are getting tighter when it comes to packaging. Larger companies are no longer bleeding money on big brands that offer not much more than a brand name and pretty blue logo. We have often asked ourselves how companies like Nordson® can get away with charging so much for the same quality product that Universal Systems SE manufactures. Especially since those big brands are not even manufacturing in the USA. That trend is starting to change.
As the American economy continues to change, it is clear that companies need an alternative to the brand name big price tags. It all comes down to shopping around for quality manufacturing that can be done in a more cost-effective way. And yes…it can be done. Cost-effective manufacturing should be the main focus of all companies when it comes to packaging their products. Americans no longer care about a name, they care about performance, quality and cost. Just because it is the most expensive thing on the market, doesn’t make it the best or most reliable. And that rings true for packaging manufacturers as well.
Many CPGs are losing the battle for shelf space and margin growth, which is increasing the pressure on suppliers such as packaging manufacturers to decrease costs. With more brands on the shelf and less market share, big CPGs need to start thinking smartly about their packaging solutions. It might not be the best idea to bring in a company like Nordson® to customize a hot melt solution that will cost you an exorbitant amount of money and take 6 months to get, when you can go with a company like Universal Systems SE who has engineers with over 40 years of experience that actually understand what you need because they have pretty much seen it all.
Not only is cost-effective manufacturing a pull in the marketplace, but knowledgeable customer service and support. If your packaging line goes down, it could cost you thousands of dollars a minute. A large brand with an untrained rep isn’t going to be able to get you up and running with a phone call. Universal Systems SE will! Think about that the next time you place an order for a new hot melt system or components.
Whatever you might need for your hot melt machines, we manufacture it at our Florida facility. Whether it is heated hoses, applicators, filters, modules, nozzles, etc. We also can walk you through troubleshooting any issues or help you with customized set ups. Call Universal Systems SE today at (561) 272-5442.
Do you have an old series 2300 or 3000 melter that you are still using but need to find parts for? If you do, your packaging line is running a melter that is 15 – 20 years old. That means that your line operators are maintaining your packaging lines well and spending money in the right areas to keep efficiency and durability a priority. With that said, not everything will last forever. While you can probably keep the control panels of the 2300 or 3000 melter, some of the internal and exterior parts may need to be replaced. The reality is that Nordson® no longer supports these tanks. However, Universal Systems SE does. Universal Systems SE manufactures pumps, filters, hoses, guns, modules and nozzles that are compatible with your old melters.
The first thing to go on your old melter, will most likely be your pump. Once that stops working, it will become very clear that your OEM no longer manufactures replacements for that part. So now you have to decide between purchasing a new melter from them for $15,000+, or trying to replace your pump. Universal Systems SE manufactures new series 2300 and 3000 pumps for a fraction of the price of a new Nordson® melter. Check out our full line of pneumatic pumps.
If you have experience with rebuilding pumps, Universal Systems also manufactures the pump shifter and fork for the ProBilt™ series 2300 and 3000 pumps. This is another item you will not be able to find with the OEM because it has been discontinued.
Since your series 2300 or 3000 melters have been operating on the line for so many years, your line operators probably change out the tank filters frequently. As the years have gone by, you may find it more difficult to find reasonably priced, or readily available tank filters. Universal Systems manufactures the tank filter assemblies, filter cores and filter screens to fit your series 2300 and 3000 melters.
If you have gone through all of the steps to fix the problem with your old melter and find out that it is the control panel, which has been discontinued, Universal Systems SE has a solution for that as well. Our ProBilt™ melters have the same footprint and dimensions as your current series 2300 or 3000 melter. That means that your NEW ProBilt™ melter, that comes with a 10-year heater warranty, will fit right in where your old melter comes out.
For more information or to contact a technician that can help you troubleshoot issues with your old melter, call (561) 272-5442 or email email@example.com.
Universal Systems SE manufactures a premiere line of hot melt adhesive systems. Our ProBilt™ line of tanks all come with our patented AccuScan™ Control Panel. The AccuScan™ Control Panel is exclusive to ProBilt™ machines and is easy for any line operator to use.
One of the most common feedback points we hear from customers is that they like simplified operational equipment. Usually line operators are understaffed and overworked. Simplifying how they use our equipment is a big selling point and the AccScan™ Control Panel is a great example of that.
Universal Systems SE developed our AccuScan™ Control Panel to simplify the operation of our adhesive melter systems. The main control screen lists the operational settings for up to 4 hoses and guns and the main tank. You can filter through these sections by pressing the Zone button. Once you choose the zone you wish to set the temperature for, press and hold the Set button. Then, using the up arrow, the digital screen will show the temperature setting increase until you reach your desired temperature setting. Once the tank or hose zones are set to desired temperatures, release the Set button. We also offer a Set Back button on the main screen. The Set Back feature puts the machine in an idle state, heating only to 165 degrees.
For further step by step instructions, we have put a video on our Universal Systems SE YouTube channel. Please check it out at https://youtu.be/QhSCXZs-8wY.
For any further instructions or information about our AccuScan™ Control Panel please call (561) 272-5442 or email firstname.lastname@example.org.
When purchasing a hot melt adhesive system, it is important to know your desired melt rate and pump rate. It is also important to understand the difference.
All Universal Systems SE ProBilt™ tanks are equipped with a 14:1 ratio pneumatic pump assembly. Pneumatic pumps are most common and have a maximum pump rate of 75 lbs. per hour. No matter what the tank capacity is, whether it is 12 lb., 15 ob., or 20 lb., the pump will max out at 75 lbs. If you need to pump more adhesive then that per hour, you will need to transition to a gear pump system with a larger tank capacity.
The melt rate is the rate at which the tank will melt the adhesive you put into the reservoir. This is where the tank capacity comes into play. Before moving forward with any hot melt adhesive system, first you need to understand how many pounds you need to melt per hour. The melt rate is dependent on how many hoses and gun applicators you are running and how many boxes are sealed per minute on your packaging line. The most common tank capacity is the 20 lb. (10 Liter) ProBilt™ 20, with a melt rate of 23 lbs. per hour. If you are only running one line with one hose and gun applicator, then you may only need the 15 lb. (7 Liter) Probilt™ 15 which melts 18 lbs. per hour.
A common misconception is that the on-demand autofill system, the ProBilt™ Phoenix, will have a larger melt rate and pump rate. That is incorrect. The tank capacity on any auto fill system is the same as a regular tank such as the ProBilt™ 20. However, the advantage to the auto fill is that the line operators will not have to watch the adhesive level in the tank as closely. The vacuum system connected to the tank will sense when the adhesive level is low and automatically fill the tank. This helps eliminate dry running and pumps will last longer. However, the pump rate on this system will still max out at 75 lbs. per hour.
For additional information about melt rate and pump rate on all of our ProBilt™ tanks, please call (561) 272-5442 or email email@example.com.
Understanding hot melt tank systems is no simple task. It usually takes years of experience to learn how to effectively manage adhesive systems and keep your packaging line running efficiently and effectively. Universal Systems SE understands that new line operators come into work and might need help learning which items to replace and how to replace them the correct way. That is why we offer technical support to all of our ProBilt™ customers!
There are several maintenance tasks that we recommend be completed on a regular basis to keep your adhesive system free of char and debris, which is the number one culprit in bringing down a line. Below is an easy maintenance checklist that each line operator should have in hand.
We recommend that you print this checklist out and give it to every shift that operates the packaging line. Keep in mind that changing out items such as gun heads, modules, filters and pumps all require you to clear the old lines and remove the air pressure before re-installation. Releasing the air pressure and removing all old adhesive will ensure that all seals stay intact and reduces the char transferred from the old to the new parts.
If you need help changing out parts or have questions about which items need to be changed regularly, please call (561) 272-5442 or email firstname.lastname@example.org.
One of the most common issues that many packaging line operators experience with their adhesive melter is stringing. Stringing is when the adhesive is applied to the box, but before the flaps are closed on the cartoner, the glue starts to dry and string like cotton candy floating through the air.
There are a couple of fixes for this issue. Whether you are using a straight, right angle or swirl pattern nozzle, try moving the applicator gun closer to the box flap where you are applying the adhesive. The stringing could be caused because it is travelling too far of a distance from the applicator gun to the box. The shock from hitting the cooler factory air could be causing it to lose viscosity and start drying before it even hits the box. Not only will that cause stringing, that might also compromise the integrity of the glue hold on your product packaging.
Another cause of stringing glue could be temperature. Every adhesive is different and each one might require a different melt temperature. In order to keep the adhesive a consistent viscosity, make sure that the temperature on your glue tank and applicator guns are set correctly per the adhesive requirements. If the adhesive is too viscous then you might need to increase the tank temperature or change to an adhesive with a lower viscosity. If your tank temperature is correct, but your guns are not hot enough, then the glue could start to cool while travelling from the tank to the applicator gun. In this scenario, you would see that the thickness of the glue as it leaves the nozzle. Some line operators might try fixing the issue by putting a larger diameter nozzle on the module, which could be a temporary fix, but the real issue could be the temperature setting on the gun. Simply increase the gun temperature as needed to ensure a smooth, consistent adhesive flow.
There could also be an issue with the adhesive you are using on your packaging line. Like many products, if the adhesive is too old, has been sitting for too long, or has been heated and cooled too many times, this could cause stringing. We recommend that you drain all old adhesive from your tank, clean the tank with a cleaner such as Purge Plus™, and refill with fresh adhesive.
Universal Systems SE recommends trying to correct stringing if it is happening to your packaging line. Some line operators may think it is not that big of an issue, or they might blame the adhesive manufacturers, when in fact it could be a simple and important fix.
For more information or technical support to help you better understand how to fix your stringing glue, please call Universal Systems SE at (561) 272-5442 or email email@example.com.
Hot melt adhesive application nozzles, or nozzle tips as they are commonly called, are the component that apply the glue onto boxes in packaging lines. Universal Systems nozzles are made out of brass with stainless steel tips to withstanding any beating they might take from box flaps in the packaging line.
Nozzles comes in many shapes and sizes, and are usually the part on the adhesive system that is most experimented with. Most nozzles are easily changed out by simply unscrewing them from the module. Other nozzles, like the ones on reduced cavity, zero cavity and ProBead modules are called integrated nozzles. We sell replacement nozzle kits for integrated nozzles that include the nozzle tip, needle, brass needle guide and installation tool.
The diameter of the nozzle tip determines the amount of adhesive that is distributed onto the box flap. Because you can easily switch them out, most line operators experiment with diameter to enhance productivity. For example, smaller, more precise glue application will require a smaller diameter nozzle. Larger, faster cartoners, will most likely run larger diameter nozzles to distribute a greater amount of glue and quickly seal boxes. Keep in mind that the larger the diameter nozzle, the more adhesive your tank will process. So make sure that your line operators are keeping a close eye on the adhesive level in the tanks. Dry running a machine can compromise your pump and create a costlier repair.
Because most adhesive systems run 24/7, the nozzle is the most commonly clogged component on your line. This is due to char or debris travelling from the tank, through the hose, into the gun and through the module. Because the nozzle is the smallest orifice on your system, most char will get stuck and you will be unable to get a consistent adhesive flow. Universal Systems SE offers nozzle cleaning kits that you can purchase instead of replacing nozzles. However, most line operators find the cleaning of nozzles a tedious process, even though when done correctly it works. Nozzle cleaning kits can save you money in the long run on replacing nozzles.
Another important aspect of nozzle diameter correlates to the size of the mesh in-line filter used on your system. The larger the diameter nozzle, the lower number mesh you should use. The smaller the diameter nozzle, the finer mesh you should use. For example, with a .024 diameter nozzle, you should have a 50 mesh filter size. With a .012 diameter nozzle, you should use 200 mesh filters.
For more information about what diameter nozzle you should be using, call (561) 272-5442 or email firstname.lastname@example.org.