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.

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Spring Cleaning for Your Hot Melt Systems

It’s that time of year again, when the days are longer and everyone is motivated to do some Spring Cleaning. That should also apply to your hot melt equipment. Like most machinery, your hot melt tanks, hoses, guns, filters and nozzles need regular preventative maintenance and cleaning. Below is the maintenance recommendation schedule that Universal Systems SE provides to all of its customers regarding our ProBilt line of products.

ProBilt Melters

  • Replace tank filter every 500 hours or 3 months, whichever comes first
  • Clean tank with Purge Plus every 1,000 hours or 3 months, whichever comes first

                 *stock 2 – 3 tank filters per tank and 1 Purge Plus cleaner

ProBilt Pumps

  • Clean and Flush Pump every 2,500 hours utilizing Pump Service Kit B100-900
  • Replace Pump every 5,000 hours or until Pump stops pumping

*stock at least 1 pump to reduce any potential down time

ProBilt Hose

  • Flush out hoses when cleaning tank with Purge Plus every 1,000 hours

                 *make sure to disconnect hoses from guns when flushing with Purge Plus

                *stock at least 1 hose per length needed to reduce any potential down time

In-Line Filters

  • Replace every 150 hours

*stock 5 spare filters for each filter body

Gun Applicator

  • Only replace when it stops functioning –either the heater or RTD

*stock 1 spare gun applicator per line

Module

  • Replace module every 1,000 hours or every 6 months, whichever comes first

                *stock 2 – 6 modules depending on how many modules are on each gun being used

Nozzles

  • Replace nozzles every 120 hours or when they clog

*stock a minimum of 6 nozzles per line

                *If you clean nozzles, we recommend cleaning them with kit # 1658 every 100 hours or when they clog

 

To keep your stock up to date please give us a call at (561) 272-5442. A USSE sales rep will quote you pricing and lead time on anything you need.

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How to Regulate Your Glue Usage

Many customers call in and request a larger size glue nozzle, because they are having issues with the amount of glue they are putting onto boxes in their packaging line. While it can be effective to increase the diameter orifice of the nozzle to put out more glue, it might not always be the best solution long term. The best chance of long-term cost savings and overall efficiency of your packaging machinery, is to find the actual cause of your glue nozzle issue.

Glue nozzles are merely a pointing mechanism for your hot glue. They create the direction the glue flows and the amount of glue allowed to flow. However, it is important to note that air pressure can also impact the amount of glue sent out through the nozzle. If the air pressure is increased, the rate at which the glue flows out of the nozzle will increase, ultimately putting more glue on the sub-straights of your boxes.  If you have increased air pressure, and still not enough glue is getting dispensed, you could be too far away from the sub-straights you are trying to glue. If possible, move the glue gun head closer to the boxes. If your packaging line does not allow for movement of the gun head, then a larger orifice nozzle may be the solution.

Charring or clogging could be a potential issue as well. If your nozzles are getting clogged, or even partially clogged, you may think that getting a larger size nozzle is your only solution. That is not always the case. It is recommended that you first check your in-line gun filters. If the filter is clogged, not enough glue could be running through to the nozzle. Tank filters should also be changed regularly. They prevent charring from the glue reservoir itself to pump through the hose, into the gun and ultimately through the nozzle. If your glue reservoir is charred up from years of use, scheduling a quarterly maintenance cleaning could also help with the amount of glue and quality of glue you are putting on your boxes.

For more helpful tips and a full preventative maintenance schedule, contact a Universal Systems sales rep at sales@ussefl.com

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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.

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The Importance of IN STOCK

Over the last two years, as both manufacturers and consumers, we have learned a lot about the importance of having our most vital items in stock. As we head into the end of 2021 and move into 2022, we have to believe that getting products for both our business and personal lives is going to get increasingly difficult. As large US CPGs have relied more and more on packaging machinery made in China, like Nordson®, they are finding it increasingly difficult to get products. Large corporations have been incentivized for years to move their manufacturing facilities overseas, not only because labor is cheaper, but raw material is cheaper and more readily available. With that, however, the cost of their products has increased due to tariffs and greed, and they are now unable to ship to the US, putting some large CPG facilities in a bad situation.

Here at Universal Systems, we have prided ourselves on being Made in the USA and stocking thousands of items. We still do and will remain sourcing all of our raw material within the USA, as well as keep our most popular products built and on the shelf for our valued customers that need them in order to keep their production and packaging lines up and running. If there are any CPG companies out there that are having issues getting Nordson® products, please reach out to us. We will quote pricing and lead time 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.

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How to Choose the Best Applicator for your Packaging Line

Oftentimes, a packaging line comes with standard, one module applicator guns. While that is the most common applicator on the market, there are several other application options available.

When figuring out your packaging line configuration, it may become apparent that a standard one module applicator will not work for you. It really depends on what you are closing up with hot melt. Are you running a case sealer? What size and style boxes are you sealing? How many edges do you need to hit with the glue and how do they fold together in the line?  All of these questions need to be addressed before purchasing an applicator.

To help out, below is a list of some other common case sealer applicators. All of these items are in stock and ready to ship!

Low Profile

Low profile guns are one of the most commonly used guns on cartoners. Here at Universal Systems SE, we manufacture two module and four module versions to allow for easy glue distribution on small to large box sizes. Their name comes from their unique gun body design which is angled on each side. The angled design sides allow for the box flaps to flawlessly close while the gun is applying the adhesive on to the boxes.

Multi-Module Applicators

If you are running a high-speed line creating cartons that have multiple folds, such as a Douglas case erector, you may want to consider installing multiple module applicators. Universal Systems SE manufacture 2 module, 3 module, 4 module and 5 module applicators. There are various lengths between centers for each model. We recommend that you review all gun specs on our website.

 

For any other questions you may have regarding purchasing a new gun for your application, please give us a call at (561) 272-5442. We are happy to help create the best and most efficient hot melt application system possible.

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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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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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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.

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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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