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.
The Right Melter for Your Packaging Line
Finding the right melter for your packaging line can impact not only your productivity, but also your bottom line. Most commonly, maintenance managers 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.
Melt Rate
The melt rate is the rate at which the tank melts the adhesive pellets as they are filled 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 being 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 or the 12 lb. (6 Liter) unit which melts 15 lbs. per hour.
Durability
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 on your production line floor.
Cost-Effectiveness
The economy is a huge question mark lately, being impacted by the lasting effects of the COVID-19 pandemic. 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®. We are currently running a 15% off and free shipping in the USA promotion to help out CPGs and support US based companies.
To learn more about Universal Systems SE’s ProBilt™ series of melters and components, please reach out to a customer service representative at sales@ussefl.com or call (561) 272-5442.
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 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.
Know Your Strengths
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.
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.
When to Call Your Glue Manufacturer vs. Your Packaging Machinery Technician
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 tech@ussefl.com.
When You Should Use a Pattern Controller
Pattern controllers come on the packaging lines themselves and not typically with a hot melt application system. But, while it is not something that many hot melt manufacturers make, it is very important to the glue application process.
Pattern controllers are used for specific glue applications and patterns. The latest pattern controllers have 4 channel controller capability to do both time and distance-based application programming. They can store up to 9 programs and have the capability of operating in “stitch mode” for substantial glue savings. Another unique feature is the low speed cutoff in distance mode to keep the glue off the side guides when the machine is slowed.
So, when do you need to use a pattern controller and which options do you need? Below are the definitions of both constant speed and variable speed controllers to help you figure out which option is best for your application process.
Constant Speed
Constant speed pattern controllers are also known as time-based controllers. The glue is dispensed consistently between .001 – 9.999 seconds, depending on the time that you set. They are designed to trigger a 24VDC Solenoid Valve and have on the fly program adjustments, so nothing is set in stone. Most constant speed pattern controllers have up to 4 programmable glue pattern events available and up to 9 programs can be stored in memory and remain in memory even after the system is shut down.
Variable Speed
Variable speed pattern controllers come with an encoder and are also known as distance-based. This means that the glue can be dispensed in set distances apart from the last application. Variable speed pattern controllers measure in tenths of inches, trigger a 24VDC Solenoid Valve and the encoder offers 1200 pulses per revolution. There is a low speed cut off and easy to use program adjustments. Like the constant speed controller, the variable speed controller has 4 programmable glue pattern events and 9 programs can be stored in memory and remain in memory even after the system is shut down.
There is also a hybrid version pattern controller that allows you to do both constant speed and variable speed.
To learn more about pattern controllers, their benefits and which one is right for you, please call (561) 272-5442 or reach out to a Sales Representative at sales@ussefl.com.
The Importance of Air Quality in Packaging
Air quality is important in all aspects of life, but for some reason usually overlooked in packaging lines. Almost all hot melt application equipment will require air to operate, especially if they are pneumatic. Universal Systems’ line of ProBilt™ hot melt equipment utilizes air in several different points of operation. The pneumatic pumps require air in order to shift the actuator and pump the glue through the system. Also, modules require air to open the piston and, in some cases, even to close the piston. Of the two operations in your hot melt application process that require air, it is most important for the pump to receive clean air.
Universal Systems pneumatic pumps are manufactured with extreme precision and delicacy. The most important part of the pump is the actuator, otherwise known as the shifter. The shifter’s main components are the spool and sleeve, which is how the shifter “shifts”. The spool and sleeve are machined in pairs, hand measured, calibrated, cleaned and assembled. The shifter is attached to the side of the pump. If you have a ProBilt™ tank and pump, take a look at the label on the side of the shifter. It reads: “The air supplied to the pump should be dry, filtered and non-lubricated.” If the air supplied to the pump, that goes through the shifter, is lubricated, your shifter will seize over time. The reason is that the oil in the air will build up in the millimeters of space between the shifter spool and sleeve, not allowing it to smoothly shift. If you do have unfiltered air running to your hot melt pump, we sell a ¼ NPT filter regulator that you can attached to the air lines and filter the air before it goes into the pump. Check it out on our website here.
If you have any questions regarding your pneumatic pump or modules, please call us at (561) 272-5442 and one of Universal Systems’ technicians will be happy to help. You can also email sales@ussefl.com.