How Dirty Air Impacts Your Pneumatic Systems
Pneumatic hot melt systems are run by air in both the pump and the applicator guns. One of the most important ways to ensure the longest run time out of any pneumatic system is to make sure that the air is clean and dry. That can be easier said than done. Most all packaging facilities have oil, water, or debris in their air. That is just the way it is. Some factories will install air cleaning systems and then add lubricators to lines to ensure that other equipment that requires oil runs smoothly. But even with the most expensive and elaborate air filtration system, there will always be some type of substance that gets by and can lead to issues in the pneumatic pumps of hot melt units. The simplest solution is to install an oil removal filter regulator to the air line running to the pump.
Oily air is our most commonly found issue inside facilities that have pumps stop up. The reason is because the shifters are manufactured with very specific tolerance clearance between the shifter spool and sleeve. This design is a necessity in order to get the pump to shift. Too much clearance and the air will just blow by the spool, never building up enough air pressure to pump. Too little clearance and the shifter will jam. That being said, if you have oily air or dirty air being run through the shifter, over time, that will cause a film to build up inside the shifter and cause a jam. Depending on the amount of oil or dirt in your air, and the number of hours the systems is run for, will determine how long this will take to happen. However, if you feel like your facility air is questionable, we suggest that you use the oil-removal filter regulator to prevent any shifter stop ups.
Another pump issue that can be caused by dirty or oily air is that it can get into the air motor and damage the rulon seals. The seals need to be tight to snuggly move up and down the air motor and if they get damaged by oil or dirt, that can lead to your pump not efficiently pumping. These seals can be replaced over time and should be checked every 2,000 hours.
Universal Systems offers pump rebuild kits for the seals, as well as sells the shifter valves in case you ever run into a pump issue caused by dirty, oily air. For more information on our pump rebuilding services, or for any technical support you might need, please call (561) 272-5542 or email sales@ussefl.com.
Under Pressure: How changing air pressure impacts your hot glue lines
Universal Systems manufactures pneumatic hot melt systems, which means that our equipment operates via air pressure. It is important to understand how air pressure can put stress on equipment and why the correct pressure points are essential to run a consistent, well-maintained hot melt system.
The way that a pneumatic hot melt system works is that an airline goes into the pump, to move the pump shifter, air motor and pump piston up and down to pump the glue from the tank, through the manifold, through the hoses, into the guns and onto the boxes. There is also going to be another air line into the guns to get the module pistons to open, apply the glue, and in some cases there will be an additional air line the air to close the pistons.
Let’s start with the air pressure to the pump. The air pressure to the pump is very important and should always be set between 20 psi – 40 psi, with an ideal setting in the middle at 30 psi. If your technician thinks the pump is running too fast and lowers the psi to under 20, then the pump might not have enough pressure to move the shifter. In most cases, a pump will run at as low as 18 psi. If your technician comes to you and states that the pump was running too slow, so they increased the air pressure to over 40 psi, that could cause damage to the seals inside the pump’s air motor. It is important to note that if the air pressure on the pump is set to 40 and the pump is still not pumping efficiently, then there is another issue at hand. Most likely there is dirty air inside the shifter or a clog in the tank filter. The air pressure should never be increased to fix other issues stopping up your pump.
The second air pressure point in your hot melt system is at the applicator gun. The air going into the gun should be set at a minimum of 60 psi. In most cases, 60 is the perfect setting for the guns. If your technician tells you they need to set the psi higher to get the guns to fire, then there is a clog in the in-line filter and that filter should be replaced. If the psi to the guns is anything higher than 80, you could blow a seal on the module and have issues with application.
If you have any questions about air pressure, please call us at (561) 272-5442 or email sales@ussefl.com.
Wine & Packaging
Why not combine my two favorite things: wine & packaging!
Winemaking is as much an art as it is a science, the same can be said for manufacturing packaging equipment. Winemakers need an OEM that has in-depth knowledge and experience in packaging products as high-end and fragile as wine bottles. At Universal Systems, we work with several large wineries to help them utilize the most cost-effective and capable line of hot melt equipment to seal their most valuable assets.
When wineries look to an OEM for their packaging needs, below are 5 things they need to focus on.
- QUALITY: All Universal Systems SE equipment is compliant with all international standards in addition to offering OSHA compliance.
- RELIABILITY: At USSE, we work with all wineries to make sure their hot melt equipment is optimized and running smoothly, and we have since 1981. We focus on matching the packaging needs with the tank capacity of the melter and the ease of operation on all machines for line workers. The easier the operation, the less potential for downtime. All of our hot melt tanks have the same components, this allows for you to streamline your inventory as well. We also provide you with advanced engineering and design with expert tech support.
- FLEXIBILITY: Your wine-making facility and process is unique, and you need an OEM that works with you to provide flexible solutions that support your business goals. Whether you need just a single machine or a full hot melt system, Universal System has a multitude of products that you can use for different glue applications.
- AFFORDABILITY: When you invest in new equipment, working directly with the equipment manufacturer eliminates the increased costs charged by a 3rd party representative of an OEM. Such investments should readily produce improved efficiencies that positively impact your bottom line. Our clients can attest to the fact that their investment in USSE equipment results in proven, accelerated ROI and a lower total cost of ownership. Plus, all of our equipment is proudly made in the USA.
- SUPPORT: Avoid frustrations of unanswered questions and unsolved problems by choosing to work with an OEM that provides excellent US-based customer service. That way, your operation can quickly get the assistance they need. Universal Systems is a US company who only has offices in the USA. We are proud to offer made in the USA products to our favorite US winemakers!
Call (561) 272-5442 today to speak with a sales rep to see how Universal Systems can help with your packaging needs.
What Empty Grocery Shelves Mean for the Hot Melt Industry
If you are like me, you walk down the aisles of the grocery store searching for your favorite staple items and can’t find them. The space for the product is still there, but it is empty. With budgets tight and good help hard to find, the struggle to keep grocery shelves stocked is a difficult one. In addition, inflation is demolishing the grocery market with the average consumer spending 60% more for items that actually contain less food.
How does that transfer over to packaging? Easy, with less product demand, the storage facilities start to fill with products that have been packaged but not ordered by grocery stores. This causes CPGs to shut down front end packaging lines and look to see where they can cut costs on equipment.
If this scenario sounds familiar, there is a long-term solution. Universal Systems provides high-quality, cost-effective packaging machinery options that can fit into your budget all year long. And as an OEM, we manufacture everything in the US and stock all items for same day shipping. With packaging needs changing day to day, and many suppliers out of stock on standard maintenance items, CPGs can find it difficult to stay in production. Here at USSE, we focus on helping you stay up and running with the most cost-effective options. We also offer full time tech support to walk you through any line issues that arise and help with the glue tanks and components.
One way that Universal Systems adds value is that we also offer Nordson® compatible parts. So, if you are finding it difficult to get Nordson® parts or if you are currently running a Nordson® discontinued system, we manufacture all of the parts that you will need to stay up and running. Our products work with case packing lines, tray formers and folding cartons in all industries including food and beverage, pharma and healthcare, electronics, cosmetics and many more.
Hopefully we start to see grocery shelves get back to normal supply and demand. USSE can work with you and your packaging needs through both the good times and bad. We will get you up and running when needed, and keep you there, so that when grocery stores are ready, we can fill up the shelves once more.
For more information on our ProBilt® line of hot melt products that are all compatible with Nordson® please call or email us today.
Are you running a Nordson® ProBlue®?
If you are running a Nordson® ProBlue®, then you might be worried about how long it’s been taking you to get parts for your tank. You should be. Recent reports from industry insiders are calling out the 3-month lead time on Nordson® ProBlue® tanks and parts. The same industry insiders are confirming that Nordson® has decided to discontinue their most popular line of hot melt tanks.
What does that mean for you?
Currently, the only facilities who are running into an issue are the ones who need new hot melt tanks. Without the ProBlue® as an option, your next best Nordson® tank is the Flex®, which can run you upwards of $20K. That is where we come in. Universal Systems SE has a line of high quality, low maintenance, affordable, reliable hot melt tanks called ProBilt®. Our ProBilt® line of hot melt tanks are designed to be an easy to use, plug and play style machine, with interchangeable parts no matter what capacity size pot you order. We offer 8 lb. – 20 lb. tank capacities, but they all use the same control board, pump and tank filters. That means, you can streamline your inventory, not having to worry about which part goes with which tank. All our ProBilt® tanks start under $8K, are made in the USA and are in stock. You won’t need to wait 3 months to be up and sealing, only a few days for shipping.
But is USSE as good?
We always get the question; how do you compare to Nordson®? The proof is in our story. We have been in business for over 40 years and have always manufactured in the US. We have real time tech support and answer any and all questions quickly. But will our ProBilt® tanks last? The simple answer is yes, but if you don’t believe us, they all come with a 10-year heater warranty. In addition, they are built using 316 stainless steel which will stand the test of time.
So, don’t feel like you are being forced to bust your budget and buy plastic hot melt tanks that require so much technology your facility can’t support it and your operators can’t run it. Keep it simple and reliable with Universal Systems ProBilt® stainless steel tanks. We also manufacture ALL of the components that will pair up with your existing Nordson® tanks and our ProBilt® tanks. Hoses, guns, modules, nozzles and so much more!
Interested in a USSE ProBilt® melter? Call or email us today and find out how to get one in only a few days!
Cold Weather Impacts Your Hot Glue
Most facilities are located in parts of the US impacted by the cold weather months. As the weather gets colder, so does the interior of the factories where most packaging lines operate. It seems like common sense that as the environment around your hot melt system gets colder, so will your hot glue unless you increase the temperature. Below are a few key factors to realizing you need to up your temperature.
Hot Melt Consistency
Hot melt consistency is the number one problem in most high-speed packaging lines during the winter months. This includes not only the consistency of the glue within the heated reservoir, but also the consistency of the glue to stay at temperature as it travels down that line. Just because your glue looks viscous inside the pot, doesn’t mean it is holding the same viscosity throughout the travel process. If your glue looks stringy or your guns are not firing consistently, then you most likely have a glue temperature problem. Try increasing the temperature of the tank, hoses and guns by 15 degrees. Please note that your hoses and guns should already be set 15 degrees higher than your tank. A minor adjustment like this will not char your glue, but should help keep it consistently viscous throughout the travel process.
Locate Cold Joints
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 you cannot eliminate cold joints, increasing the temperature settings of the tank, hoses and guns will be helpful.
Location of your Line
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. Since you cannot move the line, increasing the set temperature of your tank, hoses and guns will help eliminate glue inconsistency during the winter months.
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.
Inflate Your Inventory, Not Your Budget
As we head into 2023, all Americans are impacted by the largest increase in inflation that we have seen in decades. With inflation comes several other economic impacts on society, including companies lowering budgets, changes in workforce, families not being able to afford bare essentials and many other challenges. With that said, companies still need to find ways to stay fully operational while staying within their newly defined restrictions.
Here at Universal Systems SE, we pride ourselves on producing high quality products at economical prices and have since 1981. All of our products are made in the USA and we keep almost every item in stock at all times. If you are having issues getting Nordson® products, or feel like the recent price increases from Nordson® aren’t allowing you to stay up and running at all times, please reach out to us. We will send you a quote within 24 hours.
The importance of “in stock” has never been more valuable. We realize that and are dedicated to continue to invest in stocking products so that our customers can get their most vital items in a timely and cost-effective manner.
For pricing on our most popular products, please reach out to sales@ussefl.com.
Universal Systems Plug & Play Machinery
With what some industry professionals are calling “The Great Resignation” driving the packaging industry, it is so important to have equipment that is easy to use and operate. Recent studies report that the labor shortages in the packaging industry are due to employees not returning to work after Covid-induced shutdowns, as well as the increase in quit rates with most new employees not lasting longer than a month. Food industry production lines are reportedly standing idle because of lack of staffing where processors specifically pinpointed high retirement rates. This is a hard reality for many CPGs, and consumers are seeing this direct result in our local grocery and retail stores.
With over 40 years of experience in the hot melt packaging industry, Universal Systems is here to help. We have worked with hundreds of new maintenance managers and plant managers to help them learn about the equipment they are running. Whether they are running a competitor tank with our USSE components or our ProBilt system, we have the skills and knowledge of both old and new equipment to help relieve some of the stress that many companies may be feeling due to the loss of their most experienced workers.
Many CPGs also cite a lack of skilled labor capable of operating and troubleshooting complex packaging machinery. This is why Universal Systems’ line of ProBilt equipment is the perfect match for these end users. Our ProBilt equipment is in fact plug and play, with the easiest controls in the industry and the most flexibility by offering up to a 4-hose capability on all tanks. While many of our overseas manufactured competitors spent the last five years releasing “upgraded” equipment, they have lacked the foresight to see that they have ultimately overcomplicated the machinery for end user operators. Universal Systems’ ProBilt tanks have not changed much in the last 20 years. We have continued to manufacture our easy to program Accuscan control board and standardized components that we have prided ourselves on. Here at Universal Systems, we believe in quality, longevity and sustainability. Our products have proved time and time again that they work hard, for a long time, and without much training needed.
In addition, CPGs have been requesting more online videos and tutorials to help them train their new workforce on the machinery in their packaging lines. Universal Systems has listened to this call and we offer videos online on how to set melter temperature, as well as how the setback functionality on our tanks work.
We are here to support all of our customers, both old and new, as they navigate through their workforce troubles. By stocking over 10,000 items, we also help keep our customers up and running so you don’t have to wait out long lead times for standard operating equipment.
For more information about Universal Systems and our line of ProBilt products, please reach out to sales@ussefl.com or call (561) 272-5442.
ProBilt Glue Systems Meet the Demands & Needs of Packaging Lines
The trend in packaging for many CPGs has been to move away from in-house packaging solutions and more towards co-packers and contract packagers. Rather than dedicating complete in-house lines, CPGs and processors can be more flexible with their budgets by putting the responsibility of capital investments for machinery in the hands of the contract packagers. In addition, the CPGs no longer have to worry about hiring line operators for the packaging machines. In the last few years, it has become clear that hiring, retaining and training employees is a challenge for every company. CPGs are finding that if they move the responsibility of packaging to contract companies, they no longer have to deal with that potential issue.
The move to contract packaging is not a bad thing for glue equipment OEMs, like Universal Systems SE. We enjoy working with contract packagers because they are equipped with the skills and knowledge to focus on packaging lines and, in most cases, know what they want and need from a hot glue machine, more than a CPG will.
Below is a list of requirements we are hearing about from Contract Packagers for their packaging equipment, and an explanation as to why Universal Systems ProBilt systems will work best to fulfill these needs.
- Quick changeovers to limit downtime – USSE’s ProBilt systems are plug and play. They are easy to set up and disable for cleaning, preventative maintenance, component replacement, etc.
- Preventative maintenance schedules – USSE believes that preventative maintenance is key to maintain the efficiency and longevity of any piece of machinery. A hot glue tank is no different. Universal Systems offers up a preventative maintenance schedule upon request, along with recommendations on what parts to keep on the shelf and how many of each part is needed to keep your operation up and running at all times.
- Streamlined equipment so that system components are interchangeable – Universal Systems prides ourselves in being the most streamlined OEM of hot melt machines in the market. Not only do all of our tanks take the same pumps, filters, valves, etc., all of our components are interchangeable with our top competitors including hoses, guns, modules and nozzles.
- Versatility for different packaging setups – Universal Systems manufactures over 100 different types of applications options, as well as the option to custom CNC any configuration needed.
- Easy-to-operate machines – Our ProBilt tanks are by far the easiest in the industry to operate. We focus on longevity and simplicity so that anyone can set up and operate our tanks with ease. We also offer online videos on how to set temperature and utilize our setback feature.
For more information on Universal Systems and our ProBilt line of products please reach out to sales@ussefl.com or call (561) 272-5442.
Best Practices to Ease Supply Chain Burdens
It is no secret that everyone is experience supply chain issues this year. While there may be no end in sight, Universal Systems can only try and help ease the burdens on our end users. Below are a few of the best practices that we have implemented that we can recommend for our customers.
Keep an Open Line of Communication
With several of our competitors experiencing supply chain issues due to their overseas manufacturing and shipping issues in the current cultural climate, Universal Systems, being a USA manufacturer has received a lot of new business from large end users of hot melt equipment who would normally be buying from the big-name brand manufacturers. With the new influx of business, we have been open and honest with customers as to what we stock and what we make custom. If a new customer who is used to buying from Nordson calls and asks us lead time on standard stock items, we are happy to communicate that we can ship same day. However, if they have a custom gun or hose, we are honest regarding lead time and ship dates, normally 3-5 business days.
Plan Ahead
It is so important for companies to try and plan ahead with their inventory. While we realize this may be hard for many buyers due to lack of budget or their inability to get “out of the weeds” from being so far behind during Covid lockdowns, it is the only way to ensure there is no downtime on your packaging lines. Universal Systems offers all of our customers a preventative maintenance schedule and inventory recommendation list, so that you know what to keep on the shelf based on the equipment you are running.
Try New Products
Many of us get stuck in our ways and don’t realize there are other options out there that might improve our operations or way of doing business. Now that some large brand name companies, who have spent years manufacturing overseas, are feeling the crunch of no inventory due to low supply chain, many packagers should see this as an opportunity to work with Universal Systems. We have been manufacturing hot melt equipment in the USA for over 40 years and are well versed in packaging line needs and set ups. We manufacture most of the same products as our largest competitors and stock over 10,000 items at all times.
Think Outside the Box
With over 40 years of experience in packaging equipment, Universal Systems’ technicians are most skilled in thinking outside of the box. Whether it is troubleshooting an issue with an old machine that has been around since the dawn of day, or setting up a new line configuration, sometimes the most common answers don’t always work. We urge our customers to keep an open mind and work with us to figure out the best solutions to your packaging needs.
For more information about Universal Systems’ ProBilt line or products please reach out to sales@ussefl.com or call (561) 272-5442.