Glue Gun vs. Module vs. Nozzle
One of the largest misconceptions of hot melt packaging machinery is that maintenance on a glue applicator gun means replacing the entire assembly. That is not always the case. While sometimes, glue guns do need to be replaced, there are other times when a module or nozzle could be a cheaper solution to your problem.
What’s the difference?
It is pretty simple. The glue gun is the entire assembly (minus the nozzle). This includes the cordset, heating element, RTD, manifold and module. Essentially, if you order a glue gun, once you receive it the only thing you need to do is plug it in, attach the in-line filter assembly though the back fitting, screw on a nozzle and you are good to go. The reason to replace the entire gun would be if you get an error code on your melter main board that the gun zone is either not heating or not reading the RTD. If you get the gun zone heater error, that means that the heating element has stopped working and the gun needs to be replaced. If you get the gun zone RTD error, that means that the temperature can no longer be regulated and the gun needs to be replaced.
However, if you get no main board error code, but your gun is dripping or not dispensing glue at all, that could be a module or nozzle issue.
Modules are the mechanisms that attach to the front of the glue gun manifold to dispense the glue. These modules are operated by air and springs within the module body that control the piston to dispense the glue for easy release and clean cut off. If you are experiencing dripping, or no clean glue cut off, then most likely there is char in the spring that is holding the piston up and leaving the module open. Or, in some cases, the seals within the module could be stiff from usage and wear, and no longer creating the tight seal required for precision dispensing. In either of these instances, the module would need to be replaced.
If you are getting no glue at all to come out of the module, most likely your nozzle is clogged. The nozzle, or tip, is typically attached to the module and can easily be changed by screwing it off and on. In some cases, such as zero cavity or reduced cavity modules, the nozzle is fixed and can only be replaced by rebuilding the entire module, replacing the tip, piston and seals.
If you have any questions about which part of your glue gun you need to replace, please give us a call at 561-272-5442 or email sales@ussefl.com.
How to Regulate Your Glue Usage
Many customers call in and request a larger size glue nozzle, because they are having issues with the amount of glue they are putting onto boxes in their packaging line. While it can be effective to increase the diameter orifice of the nozzle to put out more glue, it might not always be the best solution long term. The best chance of long-term cost savings and overall efficiency of your packaging machinery, is to find the actual cause of your glue nozzle issue.
Glue nozzles are merely a pointing mechanism for your hot glue. They create the direction the glue flows and the amount of glue allowed to flow. However, it is important to note that air pressure can also impact the amount of glue sent out through the nozzle. If the air pressure is increased, the rate at which the glue flows out of the nozzle will increase, ultimately putting more glue on the sub-straights of your boxes. If you have increased air pressure, and still not enough glue is getting dispensed, you could be too far away from the sub-straights you are trying to glue. If possible, move the glue gun head closer to the boxes. If your packaging line does not allow for movement of the gun head, then a larger orifice nozzle may be the solution.
Charring or clogging could be a potential issue as well. If your nozzles are getting clogged, or even partially clogged, you may think that getting a larger size nozzle is your only solution. That is not always the case. It is recommended that you first check your in-line gun filters. If the filter is clogged, not enough glue could be running through to the nozzle. Tank filters should also be changed regularly. They prevent charring from the glue reservoir itself to pump through the hose, into the gun and ultimately through the nozzle. If your glue reservoir is charred up from years of use, scheduling a quarterly maintenance cleaning could also help with the amount of glue and quality of glue you are putting on your boxes.
For more helpful tips and a full preventative maintenance schedule, contact a Universal Systems sales rep at sales@ussefl.com
Cold Weather Impacts to Your Hot Glue Melter
As we move into the holiday season, we also experience a change in the weather. In most places in the US, the winter months mean that the climate inside most packaging plants change. With that, line operators need to take that temperature change into consideration when working with hot glue machines on their packaging lines.
Hot melt consistency, heated hose and gun temperature consistency and glue stringing are all potential problems that maintenance managers can deal with during the winter months. One of the most important things to look at is where your packaging line is located within your facility. Most melters are located at the end of the line, which leaves them close to an exterior wall, door or window. The cold temperature outside could be impacting, not only the viscosity of your glue, but the heating time of your glue and its adhesion ability. Every time your line operator opens the fill door on the hot melt tank, the external air hits the existing glue and cools it off. Even if the lid on your tank is only open for a few minutes, that could impact not only the current glue in the tank reservoir, but the glue you are adding to the tank. If your glue pellets are colder than normal, it will take a longer amount of time to heat them.
Another important task would be to inspect your system setup for any cold joints. A cold joint would be any unnecessary extensions that you have added throughout the adhesive application process. Most cold joints are found on older machines that use larger sized extensions and filter housings. The more cold joints on the system, the more inconsistent the glue will heat and stay heated throughout the entire application process.
If your main problem is glue stringing in the colder months, an easy solution would be to shorten the distance from the nozzle tip to the top of the box. Limiting the amount of time the glue has to travel in the air will help to lessen the problem of stringing, which can cause a weakened seal on the box.
If you have any questions about how to reduce the impact of winter weather on your hot melt system, please reach out to a technical rep at sales@ussefl.com.
Remote Buying & Troubleshooting is the New Reality
After the world shut down in 2020, then slowly started to reopen, it became clear that certain job roles no longer needed to be in an office and could work from home. For the packaged goods industry, that impacted purchasing agents. Now, as maintenance managers run the floor and manage the inventory, purchasing agents are at home trying best to communicate the company needs to suppliers. Realizing the potential that purchasing departments might rely on supplier websites, here at Universal Systems, we focused on updating our website and making sure that there are competitor OEM cross reference numbers easily searchable throughout the site. We also have sales reps that can handle almost any product question and return quotes within 24 hours.
Another impact the pandemic has had on the packaging industry is workforce. There might not be as many skilled and experienced engineers on the floor to troubleshoot issues as they arise. As a manufacturer, we have also experienced setbacks with sending technical reps out to facilities to help them troubleshoot. In an effort to virtually help our customers, we provided YouTube videos on how to set up our ProBilt line of tanks, how to program our control boards and how to set temperatures. We also have several very skilled engineers in house that can walk customers through any issue they may be experiencing. We’ve found ourselves utilizing technology more and more for troubleshooting. Since less techs are allowed in facilities, we have started doing virtual meeting via Facetime or through texting photos. Both have shown to be pretty effective.
Hopefully, one day soon, we get back to workers being allowed to be in the office to physically check inventory and see what they need to order. But until then, we will continue to help our customers as much as we can remotely. If you have any hot melt questions, please feel free to reach out to sales@ussefl.com.
When to Use Micro-Adjust Modules
Hot melt system modules are located on the front of your applicator guns. There are several different types of modules and in most cases, they can be easily replaced on the manifold versus replacing the entire gun assembly. Changing out a module is a more cost-effective way to increase productivity and lower glue costs. Typically, modules need to be replaced when they are having glue dripping issues or major leaking from the nozzle. This is caused by normal wear or char getting stuck in the piston chamber, not allowing it to seat securely.
When replacing a module, you have the option of buying a standard case sealer module or a micro-adjust module. This refers to the module’s adjustment cap on the module body. A standard case sealer module comes pre-set and typically needs no adjustment. This is our most popular style module. A micro-adjust module cap is typically sold on Zero Cavity or ProBead Reduced Cavity modules. These modules have a user-friendly adjustable screw top that changes the pressure of the glue through the nozzle. This allows the operator to dial in a precise glue bead. Typically, zero cavity and ProBead reduced cavity modules have micro-adjustable caps for this reason. For example, they are used on medication boxes or beauty supplies. Another advantage to a zero cavity or ProBead reduced cavity micro-adjust module is the self-cleaning functionality, limiting charring and clogging.
For more information about micro-adjust modules please reach out to a technical sales rep at sales@ussefl.com or call (561) 272-5442.
How to Effectively Clean Your Melter
Keeping your hot melt adhesive system clean may not be on the top of your priority list. However, take a look at your melter now, it is probably bronzed and blackened with old melted glue and char in the glue reservoir. That is what travels through your application system and onto your boxes. That is also what is potentially causing clogging issues and why you are replacing so many nozzles. Even though your melter looks like this now, it is possible to clean it and positively impact the longevity of your system. We recommend that you clean your system at least once every quarter. If you are running 24-hour shifts, 7 days a week, then you might want to schedule cleaning once a month.
Universal Systems SE sells a product called Purge Plus™ that, when used properly, will clean almost any melter. The directions for use are simple:
- Drain all hot melt from tank reservoir
- Fill reservoir with Purge Plus™
- Heat Purge Plus to 350°F – 375°F for approximately 45 minutes
- Open tank drain valve and remove tank filter assembly
- Slowly start pump and run Purge Plus™ through the tank manifold and into a meal container until reservoir is empty
- Stop pump, replace filter assembly and close drain valve
- Carefully wipe any remaining contaminants from tank reservoir
- Add new hot melt and recirculate through system
- Drain one cup from each hose
In addition to cleaning the tank reservoir and heated hot melt hoses, if you are running a ProBilt™ series melter, the exterior is manufactured out of 316 grade stainless steel. So, any stainless steel cleaner will shine the exterior of the tank.
For any additional questions about Purge Plus or how to properly clean your tank and hoses, please call a Universal Systems service technician at (561) 272-5442 or email tech@ussefl.com.
When to Replace a Module
One of the most commonly replaced items on any hot melt packaging line is the module. Typically confused with an applicator gun head, the module attaches to the front of the applicator gun and dispenses the glue through the nozzle and onto the applicable surface. If you are experiencing clogging issues with your hot melt line or dripping from the tip of the nozzle, most likely the module has reached it’s end of life and needs to be replaced.
Replacing a module is fairly simple. First make sure the air is disconnected from the applicator. Always wear Kevlar gloves and eye protection when replacing any parts on your active hot melt system. The parts get hot and extending downtime might not be an option, so operator safety is very important. Then, remove the front two screws from the module and pull the module off the surface of the gun manifold. Make sure that you use the new o-rings and screws that come in your new module replacement kit. This will ensure that the new seal is tight and will not leak once operations restart. Also, make sure you are replacing the existing module with the correct replacement module. Below is a list of module options:
- Standard H200 Module
- Reduced Cavity H200 Module
- ProBead Self-Cleaning Module
- Zero Cavity Standard H200 Module
- Zero Cavity Micro Adjust H200 Module
- Swirl Pattern Modules
- Weave Pattern Modules
- H20 Modules
Finally, we also recommend to put a new nozzle on every new module. This will ensure that no clogging will occur. If you have a zero cavity or ProBead module, then the nozzle will already be attached.
If you need any more information about modules for your packaging line, please email sales@ussefl.com or call (561) 272-5442.
How to Change Out a Melter Pump
There are several reasons why a melter’s pump might stop working. The most common reasons are clogging of the ball and seat from foreign matter such as carton dust, and the actuator clogging due to dirty or oily air. No matter what the reason, if your pump stops pumping it needs to be replaced. Obviously, it much more cost effective to change out a pump then to replace the entire unit. However, it is not always easy to switch out a pump, especially if you are new to the line. Below are a few tips to help ease you through the process.
- Make sure the circuit breaker on the front of the unit is set to OFF once the applicator has reached normal application temperature.
- Shut OFF the input air to the pump.
- Set the pump regulator to zero and trigger all guns to relieve system pressure.
- When removing the old pump, rotate it slightly to break the suction and then pull it straight up and out.
- When installing the new pump, make sure to torque the screws 15-16 ft-lbs.
- Connect the pump electrical plug to tank receptacle and turn tank back on.
- Once the tank board reads that the tank has reached set temperature, wait 15 minutes. This will allow the glue around the pump hydraulics to get to temperature.
- After waiting 15 minutes, reinstall the air regulator and connect the airline and activate air.
If you have any further technical questions and want to speak with a technical sales rep, please call (561) 272-5442 or email sales@ussefl.com.
The Importance of Product Support
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 sales@ussefl.com.
Managing Your Packaging Line in the New Year
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.