Realistic Product Expectations: How long should your hot glue machinery last?
When evaluating equipment, it is important to understand life expectancy. Life expectancy of equipment is dependent on several key factors, including but not limited to, daily usage, preventative maintenance, and daily operation. This goes for equipment in packaging lines as well. The reason why most glue systems get termed “End of Life” is not because they have stopped working and are not fixable, but because they either look to be not fixable or no one knows how to fix them properly. Whether your technicians do not fully understand the equipment, or the equipment has not been maintained and may look bad, that does not mean it is time to EOL your hot glue system. The question of “How long should my melter last?” can vary based on your company’s maintenance schedule.
With correct preventative maintenance and usage of the system, your hot melt tank can last decades. However, that doesn’t always happen. Preventative maintenance is rarely practiced and when it is, the components that are being replaced are often reinstalled incorrectly. Potentially worsening the problem and creating even more issues. That is why it is important to inquire with the OEM or request installation instructions with each component. Educating yourself about the equipment you are running is key to maximum runtime on your packaging line.
That being said, failing to follow installation instructions on equipment does not mean that equipment will not work. It will most likely run for a short time until it then fails again. For example, if you were to install the pump shifter incorrectly, without the fork on the correct placement of the shaft, the shifter will still shift, but it will shorten the pump stroke and over time it will stop up. Same thing goes for installing at the correct In/lbs torque. There are specific instructions that come along with every shifter specifying the exact In/lbs torque requirements, which is usually not followed. The shifter will still run, but the air pressure over time will cause potential issues in the seals and how the shifter shifts.
Regarding hot melt systems components, such as hoses and guns, the number of hours you run the system will help you to determine the EOL for those components. In almost every case the hose and gun will run for years without losing their ability to hold heat. The problem you will run into with guns will be clogging which is also preventable by running and regularly changing in-line filters.
If you think that your hot melt equipment is at its end of life, please call or email a Universal Systems SE technician and we will help you understand what products you need to get back up and running at full capacity.
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.
The Lost Art of Troubleshooting
Troubleshooting is most definitely a lost art. In today’s throwaway society, we have lost touch with our ability to fix things ourselves. That is true in all aspects of business and most definitely prevalent in the packaging world.
For us, in the hot melt application industry, we have seen it get progressively worse over the last few years. Ever since the pandemic, it seems that most hot melt manufacturers no longer stand behind their equipment and help with troubleshooting. Industry giants, like Nordson, want you to buy new machines, they don’t want you to fix what you already have. Here at Universal Systems, that is the exact opposite of our company culture. We are here to help, we believe in our equipment, and that the art of troubleshooting isn’t something that should be lost forever.
That being said, troubleshooting a pump not running doesn’t mean hitting it with a wrench until it moves. There is an art to it. Using deductive thinking to pinpoint the cause of the issue versus just replacing each piece until it starts working again. For example, your line is running a multi-module gun, and the last module on the line isn’t getting glue. In order to figure out where the real issue lies you first need to make sure all of your key points are met. First, is your glue heated to the correct temperature? What is the consistency of the glue out of the first module in the gun versus the second, etc.? If the gun isn’t heated to temperature, your glue’s viscosity may not be correct to run through the manifold to all modules. Second, have you checked your in-line filters? There could be a clog in the filter not allowing enough glue to flow into the gun to get to all modules. There could also be a clog in manifold itself. Once you eliminate all potential variables, you will be able to deduct what your actual problem may be.
Training on equipment is also very important in practicing the art of troubleshooting. If you have line operators that understand how your equipment works, they will be better equipped to troubleshoot potential issues. If your line operators or floor managers are not fully versed with your equipment, you should be able to call the equipment manufacturer to go through troubleshooting steps with you. At Universal Systems, we pride ourselves in our customer service and ability to walk any customer through troubleshooting. If you have a manufacturer, like Nordson, that will not take that time with you, maybe it’s time for a change to USSE.
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.
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.
Universal Systems Plug & Play Machinery
With what some industry professionals are calling “The Great Resignation” driving the packaging industry, it is so important to have equipment that is easy to use and operate. Recent studies report that the labor shortages in the packaging industry are due to employees not returning to work after Covid-induced shutdowns, as well as the increase in quit rates with most new employees not lasting longer than a month. Food industry production lines are reportedly standing idle because of lack of staffing where processors specifically pinpointed high retirement rates. This is a hard reality for many CPGs, and consumers are seeing this direct result in our local grocery and retail stores.
With over 40 years of experience in the hot melt packaging industry, Universal Systems is here to help. We have worked with hundreds of new maintenance managers and plant managers to help them learn about the equipment they are running. Whether they are running a competitor tank with our USSE components or our ProBilt system, we have the skills and knowledge of both old and new equipment to help relieve some of the stress that many companies may be feeling due to the loss of their most experienced workers.
Many CPGs also cite a lack of skilled labor capable of operating and troubleshooting complex packaging machinery. This is why Universal Systems’ line of ProBilt equipment is the perfect match for these end users. Our ProBilt equipment is in fact plug and play, with the easiest controls in the industry and the most flexibility by offering up to a 4-hose capability on all tanks. While many of our overseas manufactured competitors spent the last five years releasing “upgraded” equipment, they have lacked the foresight to see that they have ultimately overcomplicated the machinery for end user operators. Universal Systems’ ProBilt tanks have not changed much in the last 20 years. We have continued to manufacture our easy to program Accuscan control board and standardized components that we have prided ourselves on. Here at Universal Systems, we believe in quality, longevity and sustainability. Our products have proved time and time again that they work hard, for a long time, and without much training needed.
In addition, CPGs have been requesting more online videos and tutorials to help them train their new workforce on the machinery in their packaging lines. Universal Systems has listened to this call and we offer videos online on how to set melter temperature, as well as how the setback functionality on our tanks work.
We are here to support all of our customers, both old and new, as they navigate through their workforce troubles. By stocking over 10,000 items, we also help keep our customers up and running so you don’t have to wait out long lead times for standard operating equipment.
For more information about Universal Systems and our line of ProBilt products, please reach out to sales@ussefl.com or call (561) 272-5442.
ProBilt Glue Systems Meet the Demands & Needs of Packaging Lines
The trend in packaging for many CPGs has been to move away from in-house packaging solutions and more towards co-packers and contract packagers. Rather than dedicating complete in-house lines, CPGs and processors can be more flexible with their budgets by putting the responsibility of capital investments for machinery in the hands of the contract packagers. In addition, the CPGs no longer have to worry about hiring line operators for the packaging machines. In the last few years, it has become clear that hiring, retaining and training employees is a challenge for every company. CPGs are finding that if they move the responsibility of packaging to contract companies, they no longer have to deal with that potential issue.
The move to contract packaging is not a bad thing for glue equipment OEMs, like Universal Systems SE. We enjoy working with contract packagers because they are equipped with the skills and knowledge to focus on packaging lines and, in most cases, know what they want and need from a hot glue machine, more than a CPG will.
Below is a list of requirements we are hearing about from Contract Packagers for their packaging equipment, and an explanation as to why Universal Systems ProBilt systems will work best to fulfill these needs.
- Quick changeovers to limit downtime – USSE’s ProBilt systems are plug and play. They are easy to set up and disable for cleaning, preventative maintenance, component replacement, etc.
- Preventative maintenance schedules – USSE believes that preventative maintenance is key to maintain the efficiency and longevity of any piece of machinery. A hot glue tank is no different. Universal Systems offers up a preventative maintenance schedule upon request, along with recommendations on what parts to keep on the shelf and how many of each part is needed to keep your operation up and running at all times.
- Streamlined equipment so that system components are interchangeable – Universal Systems prides ourselves in being the most streamlined OEM of hot melt machines in the market. Not only do all of our tanks take the same pumps, filters, valves, etc., all of our components are interchangeable with our top competitors including hoses, guns, modules and nozzles.
- Versatility for different packaging setups – Universal Systems manufactures over 100 different types of applications options, as well as the option to custom CNC any configuration needed.
- Easy-to-operate machines – Our ProBilt tanks are by far the easiest in the industry to operate. We focus on longevity and simplicity so that anyone can set up and operate our tanks with ease. We also offer online videos on how to set temperature and utilize our setback feature.
For more information on Universal Systems and our ProBilt line of products please reach out to sales@ussefl.com or call (561) 272-5442.
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.