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.

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Top 5 Tips to Hot Melt Machine Maintenance

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 tech@ussefl.com.

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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.

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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.

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Safety in Switching Out Glue Equipment

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.

Tank Filters

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.

In-line Gun Filters

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.

Modules

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.

Pumps

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 tech@ussefl.com

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How to Obtain Maximum Adhesion on Your Packaging Line

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 tech@ussefl.com.

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Quality Assurance

As a manufacturer, Universal Systems SE, understands the importance of quality. That is why all of our hot melt application systems and components go through an extensive quality assurance process before they leave our facility.

Each technician at Universal Systems has a specialty. For example, building circuit boards, assembling tanks, building & testing pumps, building applicators, winding hoses, pressing in seals and assembling modules, pressing and drilling nozzles, etc. With over 10,000 parts in stock, quality assurance and having a double check (or even triple check) system in place is essential to ensure all of our customers are getting high quality products that will last for years.

Each technician takes immense pride in their work. However, even the best of the best need to be checked. Our typical QA process requires the build technician to go through their assembly process and initial each step, which confirms to the QA technician that they have in fact followed the correct order. This is important since most of the time our build technicians are building multiples of the same product at one time. We want to guarantee that a step is not skipped. After the build technician has initialed their paperwork, the product is then moved to the QA department. A QA professional is assigned to the project and reviews all of the key items on their checklist. Once the component QA is complete, the item is boxed, dated and initialed by the QA professional. The next time you receive an order from us, check to see that there is a green QA sticker with initials on it. That is your QA professional!

For any further questions regarding our QA process or if there are any technical questions you have about any Universal Systems product, please email sales@ussefl.com or call us at (561) 272-5442.

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Chillers on Your Manufacturing Line

Now you may be asking yourself, why am I reading about chillers on a hot melt blog? The answer is easy, Universal Systems SE manufactures heated hoses that can be used for transferring many more substances other than glue. And when there are applications that do not include glue, the manufacturing lines may need chillers.

Our heated hoses, while mainly used for high speed packaging glue application, can also be used for heating and transferring a plethora of other materials. Our Teflon lined hoses can transfer anything from candy, make up, wax and much more! Depending on the use and application of different substances, the packaging line can be filling at high rates of speed. Heating and filling formed containers for candle wax, as an example, can be tricky because in this application the wax needs to cool quickly so that it can be formed, packaged and shipped out to end users. One of the most common questions we get in this situation is: How can I keep my forming operation running at a high-speed pace from start to finish? The answer here is chillers. Essentially how a chiller works is it is built into the conveyor line. So, the product would be heated in a melt pot, transferred through the heated hose, dispensed into containers, and then fed along a chiller that is built into the line. The product goes from hot to cool in a matter of seconds.

If you have any other questions on how we can help you keep your production lines running at high-speed capabilities, please reach out to sales@ussefl.com or call to speak with a technician (561) 272-5442.

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Have Spares on the Shelf

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 sales@ussefl.com.

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When Consumers Can’t Open their Boxes

Have you ever purchased a case of soda or carton of coffee cups and can’t get the box open? Of course, we all have. In the packaging industry, especially for hot melt machine manufacturers, that is a red flag. Whenever we get a box that has too much hot glue on it means that the packaging line is not set up properly or not being cleaned regularly.

If you are wondering why too much glue means that the line is not set up properly or not being cleaned regularly it is because one of two issues is occurring (or sometimes even both). The first issue is most likely that the line operators and/or maintenance managers are not cleaning the tank regularly and the lines are clogging up with char, which will subsequently clog nozzles. Instead of cleaning the tanks and hoses, and replacing the tank filter and in-line gun filters, most operations just buy bigger nozzles. If the diameter of the nozzle orifice is larger, then it will allow through more bits of char and not clog up as easily. Unfortunately, this is not a long-term solution. Putting down more hot glue will drive up the amount that facilities spend on adhesive pellets, and ultimately the annoyance will trickle down to the consumer when they can’t get their box open. The solution is simple…utilize Purge Plus to clean your tank every 1,000 hours. For some facilities that could mean cleaning every quarter and for others that could be twice a year, it all depends on the facility. In addition to cleaning the tank and hoses with Purge Plus, make sure that the tank filters are changed every 500 hours. The in-line gun filters should be changed every 150 hours to ensure that no char travels into the gun applicator, through the module and nozzle and onto the box.

The second issue that could cause too much glue on boxes, is that the line was not set up correctly from initial purchase. A lot of cartoners have standard hoses, guns, modules and nozzles that will work for most case packers, but not for all. Make sure to take into consideration the temperature of your packaging facility (which can impact the adhesion and viscosity of the glue as it travels through the application process), the distance that the guns are to the box upon application, and the surface area of the box you are covering. The longer the bead of glue you place, the less likely you are to need a larger diameter nozzle. The shorter the range you are covering, you might need more glue to make sure that maximum adhesion occurs, which means you need a larger diameter nozzle.

If you think you are putting down too much glue on your packaging line and need help, call one of Universal Systems’ technicians at (561) 272-5442. We have the most knowledgeable technicians in the business that can help you with almost any question.

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