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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Correct Hose Length

Case packing and sealing in packaging lines depends on several components to run steadily and reliably. In order for a system to run continuously at all times, each piece of equipment needs to be concisely installed. The usual suspects of precision engineering on your case sealer adhesive systems are the pump, applicators and nozzles. Most line operators undervalue the importance of heated hose length in the overall operation and efficiency of the line.

Heated adhesive hoses get attached to the hot melt tank and run from the tank to the application gun, which is mounted on the packaging line itself. Heated hoses are typically attached to the tank with a straight connector, but can have both a 45 degree or 90 degree connection option, depending on where the tank is placed on the line. The applicator plug at the end of the hose is also sent out as a straight connection, but can be switched to a 90 degree plug if needed. There are typically two – four hoses used on each packaging line. With a two hose line, one hose will run up the line, across the top and down to the applicators. This hose transfers the adhesive that will seal the top of the carton and is mounted using straps. The second hose will typically run straight along the side of the packaging line to seal the bottom of the case.  No matter how many hoses you run or how you mount them, it is very important to have the correct length hose.

Our technicians visit several packaging facilities each year, and their biggest take away is that most purchasing agents are ordering the wrong length hose. Typically, the hoses that we see are too long. They are either running extra length on the ground, which is a safety hazard, or there is excess hanging before the applicator connection, which can cause heating inconsistency issues. It is important to measure from the tank through the entire hose travel process, including mounting straps, before ordering. Universal Systems SE manufactures our ClearFlow™ line of heated hoses in 2 ft increments. So, if you measure 6 ft, order a 6 ft hose and if you measure 7 ft, order an 8ft hose. Make sure that you measure precisely! If need a hose longer than 24 ft, we can custom make you any length up to 50 ft.

To speak with a USSE representative about our ClearFlow™ hoses or to consult with a technician about the hose length you need, please call (800) 848-5018 or email sales@ussefl.com.

 

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Utilizing Key Features of the ProBilt™ Hot Glue System

There are a few brands to consider when shopping for a hot melt system for your packaging line. Universal Systems SE’s ProBilt™ product line has been around for over 40 years and has several key features that can help influence purchasing agents, as well as line operators, on why it is the best in the industry.

4 Hose / 4 Gun Standard Capability

Unlike any other hot melt tank option on the market, the ProBilt™ line of melters all come equipped with 4 hose and 4 gun capability. This is a standard option that is usually an add on from other manufacturers, like Nordson®. Nordson® has both the 2 hose/ 2 gun and 4 hose/ 4 gun melters, each differing in price. The ProBilt™ melters all come with 4 hose/ 4 gun capability at a lower price point than any Nordson®. This allows our customers versatility and the option to grow.

Easy to Program Control Board

One of the many benefits to owning a ProBilt™ system is the easy to operate, AccuScan™ Control Board. If you are plugging in a brand new tank, the board will be programmed to our factory settings. The line operator, can scan through the hose, gun and tank settings and set them to the temperatures needed. There are also a few fail safes installed in the machine. For example, if it is a cold start set up, the hoses and tank will heat first, then the guns will start to heat once the hose and tank are within 35 degrees of the set point. The reason for this is so that the gun doesn’t char, since the gun heats up faster than the hose and tank. Once temperature is reached, the “Heat On” light will blink and you are ready to use. The control board also comes equipped with alarm settings and a set back functionality, our next two key features.

Set Back Functionality

The set back functionality is one of the most important features that comes standard on all ProBilt™ tanks. Essentially, when the shift is over and you no longer need to run your packaging line, you push the set back button. This will “set back” the temperature of the tank, hoses and guns to 165 degrees. Allowing the glue already in the system to sit overnight without charring. When the morning comes, or the next shift starts, simply hit the set back button again, and all previous temperature settings will re-engage. This will decrease the start up time on the hot melt system significantly and allow your lines to be fully operational within minutes.

Alarm Options

Another key feature to the AccuScan™ Control Board are the alarm options it provides. The first alarm option allows for the panel to tie to an alarm light in your facility. In case anything happens that stops the system from running effectively, an alarm light can go off, alerting the line operator immediately. Another feature is the ability to tie it to the packaging line itself, called PMI or Parent Machine Interface. Parent Machine Interface will signal the packaging line when the glue is at full temperature thus preventing the line to start up until it receives the signal.

Please watch our video on how to set the ProBilt™ melter temperatures. For more information on our ProBilt™ systems please call today (561) 272-5442 or email sales@ussefl.com

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The Importance of Keeping Products Made in the USA

Over the years, large CPG companies moved away from manufacturing and packaging their products in the USA. There are is one obvious reason for that, cutting costs. The cost of materials and the cost of labor are both cheaper overseas. But cheaper isn’t always better. Yes, it increases overall profitability, which is essential for a company’s success, but cutting costs can also equate to lower quality products, poor customer service and lack of reliability.

Well, times are changing! With impending tariffs worldwide, it might not be the best option for you to work with a company that manufactures overseas.

Here at Universal Systems SE, we are proud to stamp “Made in the USA” on all of our components. Whether you are buying a nozzle or ProBilt™ tank, you can rest assured that they were 100% made here in the USA. We source all of our raw materials from US companies, and try to keep them “in the family” of small business owners. Not only do we believe in keeping everything home grown, we support small businesses, the true bread and butter of this great nation.

There is also the advantage of immediate customer service, when dealing with a US company like Universal Systems SE. We are here when you need us, to troubleshoot any questions or if you need products overnight. Since our manufacturing facility is in Delray Beach, FL, we operate on EST, so even companies on the west coast can catch us in the morning or early afternoon.

For more information on the products that we manufacture here in the USA, please email sales@ussefl.com or call us at (800) 848-5018.

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CPGs Wrestle with Workforce

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.

To learn more about our ClearFlow™ hoses or any other ProBilt™ products, please reach out to sales@ussefl.com or call (561) 272-5442.

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RTD Sensors

RTD Sensors (resistance temperature detectors) are used in hot melt packaging systems because of their precision in sensing and proportioning temperature. They consistently maintain a temperature control stability of +/- 1-degree Fahrenheit. With the ever-increasing price of adhesive, it is important that RTD sensors are used in all of Universal Systems’ hot melt hoses and glue applicators for steady adhesive application. When combined with USSE’s patented AccuScan™ solid-state control system, RTD sensors provide precise bead uniformity for all of our ProBilt™ applicators.

Since RTD sensors are so key to the adhesive application process, it is important to check them first whenever you notice glue inconsistencies. If you see that your glue bead is not sticking properly or getting clogged, it could be caused by inconsistent glue temperature. There are several causes of inconsistent glue temperature. For example, if your tank operators are opening the cover to add glue, that will cause a temperature change. RTDs control that process, by notifying the heater to turn on and run longer when those situations occur. If your RTD is weak, then the heater will not be able to maintain steady temperature. It is the easiest, most overlooked and one of the least expensive components in your application process, but is worth it’s weight in glue!

When it comes to understanding the components that make up your adhesive application system, we believe that knowledge is power. So, if you have any questions, or think that you may be having issues with your RTD sensor, do not hesitate to call Universal Systems at (800) 848-5018 to speak with one of our technicians. We can walk your line operator through testing RTD sensors and how to switch them out correctly and safely.

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Zero Cavity Modules and What They Are Used For

There are several different set ups available for your hot melt application. That’s because not all industries use glue application for the same reason. The most common form of hot glue application is standard case packers for mass production high speed packaging. Typically, those lines use standard H200 modules. However, glue application is used to seal other, more specific products. For example, swirl pattern modules are used for glue application on feminine hygiene products, diapers and also for sealing air filters. This blog is going to specifically explain zero cavity modules and what industries use them and why.

Zero cavity modules have a very specific look, with a nozzle head attachment rather than a screw on nozzle. They also come with an E-Z Micro Adjust attachment to manage precision glue application. This nozzle & micro-adjust feature is custom manufactured for precise glue placement on smaller boxes, such as crayon boxes or pharmaceutical products. This unique technology allows for line operators to place a small amount of glue on a small, predetermined location without creating any stringing. Typically, because of this precise requirement, most zero cavity modules are made with either a .008 or a .012 diameter orifice, so that there can never be too much glue applied.

Because zero cavities have a matched piston needle and seat, when they finally wear out, most manufacturers require customers to replace the entire module. Universal Systems does not. We manufacture a rebuild kit specifically for zero cavity modules for a fraction of the price of replacing an entire module. Check out our rebuild kits here: https://www.ussefl.com/products/hot-melt-modules/module-rebuild-kits/.

Not many hot melt application manufacturers offer zero-cavity modules. Luckily, here at Universal Systems we have been manufacturing this specific module for over 25 years. If you would like to learn more about zero cavity modules or get a price quote, please reach out to sales@ussefl.com or call (561) 272-5442.

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The Importance of Utilizing Cross-Referencing

The packaging industry is entering the time of year when budgets are getting tight, but replacement parts are still needed. Universal Systems SE will cross-reference any of our competitor item numbers and get you high quality replacements. Cross-referencing Nordson item numbers to Universal Systems SE item numbers will help to lower your cost and keep your packaging lines running longer!

You will also notice that our competitors change their part number often. This is why we offer the search bar on our website for any cross-reference numbers you might have. Some of the most common cross references are listed below. If you purchase any of the parts listed on a regular basis, please feel free to call us today! We guarantee that all of our products are quality control tested before leaving our facility and we stand by all of our products with strong warranties.

Adhesive Systems:

P10, 1022234, 1022235, 276881, 276882, 276883, 276884, 276885, 276886, 276033, 276034, 238310, 243666, 168204, 166535 à ALL of these item numbers match USSE # D100-644

Heated Hoses:

4 Ft. Hose:

107288, 129556, 100120, 274791, 276151 –> 4104

6 Ft. Hose:

107286, 129557, 100121, 274792, 276152 –> 4106

8 Ft. Hose:

107287, 129559, 100122, 274793, 276153 –> 4108

10 Ft. Hose:

107289, 129561, 100123, 274794, 276154 –> 4110

12 Ft. Hose:

107310, 129562, 100124, 274795, 276155  –> 4112

16 Ft. Hose:

104008, 129564, 100125, 274796, 276156 –> 4116

20 Ft. Hose:

223838, 223836 –> 4120

24 Ft. Hose:

129565, 100832, 100126, 274797 –> 4124

Applicator Guns:

H200 1 Module AO/AC

8503717, 8505756, 8505768 –> 39105

H200 1 Module (AO/SC)

274596, 224939, 8503591, 8503686 –> 39107

Modules:

H200 (AO/AC)

1052927 –> 29215

H200 (AO/SC)

272282, 276119, 326583, 331979, 1048115, 2210, 2219, 2400, 2410 –> 29219

 

For any other questions on cross-referencing, please call (561) 272-5442 or email sales@ussefl.com.

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Custom Manifolds & Gun Applicators

There are not many manufacturers in the hot melt industry that have the ability to work with clients and create custom manifolds and gun applicators to fit their unique needs. Universal Systems SE has that ability and is willing to pair up our engineers with our client’s team to ensure that we manufacture the exact applicator needed for any job.

Over the last forty years, Universal Systems SE has manufactured an array of different custom manifolds and gun applicator systems for different types of industries. Not only can our custom gun manifolds distribute adhesive onto boxes in packaging lines, but they can be used for distributing make-up, candle gel, etc. Depending on the viscosity and melt rate of the substance needed to make the transfer, our custom manifolds and applicators will work with several different types of materials.

The custom manifold and gun process is simple. Contact one of Universal Systems SE’s customer service representatives, by either calling in to (561) 272-5442 or submitting a custom gun online form. You will then be connected with a USSE mechanical engineer. After all of the client’s needs are communicated with our engineering team and all questions answered, USSE will provide the customer with a custom manifold drawing for approval. The drawing will include dimensions of the manifold, spacing of modules, type of modules and all cordsets that are included and the location of those cordsets. Once the drawing is signed off on by the customer, we then manufacture the manifold body. After a vigorous quality control process, each custom manifold is inspected and tested to ensure all dimensions are correct and that the custom gun matches the approved drawing. Once the manifold passes all initial testing, modules are added and the custom gun is created and tested internally by two different QC Engineers. Once there is approval by both engineers, the final product is cleaned and ready for shipping.

The normal process for custom manufactured manifolds and completed guns is four to six weeks, with extra time potentially added in depending on customer turnaround time for drawing approvals.

If you are interested in learning more about the types of custom manifolds and gun applicators that Universal Systems SE can engineer for you, please call (561) 272-5442 or email sales@ussefl.com.

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