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.

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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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Hot Melt Glue is Not Just for DIY Projects

Hot melt glue is a thermoplastic adhesive that melts and flows when heated and solidifies when cooled. Most of the time, when someone mentions hot melt glue we think of do-it-yourself craft projects. However, hot melt is actually used in many different industrial applications because of its drying time, shelf life, and bond strength.

The drying time for most hot melt products is nearly instant. As soon as the adhesive product is dispensed from the applicator the temperature rapidly falls and begins to turn back to a solid state. A great example of the final result is the dots of glue that hold together the top of cereal boxes. Hot melt can adhere to nearly any kind of material and creates an immensely strong weather resistant bond. Most products held together with hot melt will stay for years, which is another reason why hot melt is used instead of other water based adhesives.

Companies across the globe take advantage of these traits and use hot melt for bookbinding, lamination, automotive assembly, appliance manufacturing, even the creation of diapers and air filters. Not to mention, it is the most convenient and widely used method for sealing boxes. We often encounter hot melt on primary packaging like the boxes that protect products like frozen food, cosmetics and toys. These boxes are actually shipped in layers of secondary packaging like inside corrugated cardboard cases or palletized, both of which use hot melt.

The technology used to heat and apply hot melt continues to change, but the overall need and use of hot melt remains the same. If you would like to increase efficiency and add hot melt equipment to your packaging application, please give us a call or send us an email.

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