Cost-Effective Manufacturing

As we continue through 2019, it is clear that big brand CPG budgets are getting tighter when it comes to packaging. Larger companies are no longer bleeding money on big brands that offer not much more than a brand name and pretty blue logo. We have often asked ourselves how companies like Nordson® can get away with charging so much for the same quality product that Universal Systems SE manufactures. Especially since those big brands are not even manufacturing in the USA. That trend is starting to change.

As the American economy continues to change, it is clear that companies need an alternative to the brand name big price tags. It all comes down to shopping around for quality manufacturing that can be done in a more cost-effective way. And yes…it can be done. Cost-effective manufacturing should be the main focus of all companies when it comes to packaging their products. Americans no longer care about a name, they care about performance, quality and cost. Just because it is the most expensive thing on the market, doesn’t make it the best or most reliable. And that rings true for packaging manufacturers as well.

Many CPGs are losing the battle for shelf space and margin growth, which is increasing the pressure on suppliers such as packaging manufacturers to decrease costs. With more brands on the shelf and less market share, big CPGs need to start thinking smartly about their packaging solutions. It might not be the best idea to bring in a company like Nordson® to customize a hot melt solution that will cost you an exorbitant amount of money and take 6 months to get, when you can go with a company like Universal Systems SE who has engineers with over 40 years of experience that actually understand what you need because they have pretty much seen it all.

Not only is cost-effective manufacturing a pull in the marketplace, but knowledgeable customer service and support. If your packaging line goes down, it could cost you thousands of dollars a minute. A large brand with an untrained rep isn’t going to be able to get you up and running with a phone call. Universal Systems SE will! Think about that the next time you place an order for a new hot melt system or components.

Whatever you might need for your hot melt machines, we manufacture it at our Florida facility. Whether it is heated hoses, applicators, filters, modules, nozzles, etc. We also can walk you through troubleshooting any issues or help you with customized set ups. Call Universal Systems SE today at (561) 272-5442.

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How to Keep Old Melters Operable

Do you have an old series 2300 or 3000 melter that you are still using but need to find parts for? If you do, your packaging line is running a melter that is 15 – 20 years old. That means that your line operators are maintaining your packaging lines well and spending money in the right areas to keep efficiency and durability a priority. With that said, not everything will last forever. While you can probably keep the control panels of the 2300 or 3000 melter, some of the internal and exterior parts may need to be replaced. The reality is that Nordson® no longer supports these tanks. However, Universal Systems SE does. Universal Systems SE manufactures pumps, filters, hoses, guns, modules and nozzles that are compatible with your old melters.

Pneumatic Pumps

The first thing to go on your old melter, will most likely be your pump. Once that stops working, it will become very clear that your OEM no longer manufactures replacements for that part. So now you have to decide between purchasing a new melter from them for $15,000+, or trying to replace your pump. Universal Systems SE manufactures new series 2300 and 3000 pumps for a fraction of the price of a new Nordson® melter. Check out our full line of pneumatic pumps.

Actuator

If you have experience with rebuilding pumps, Universal Systems also manufactures the pump shifter and fork for the ProBilt™ series 2300 and 3000 pumps. This is another item you will not be able to find with the OEM because it has been discontinued.

Tank Filters

Since your series 2300 or 3000 melters have been operating on the line for so many years, your line operators probably change out the tank filters frequently. As the years have gone by, you may find it more difficult to find reasonably priced, or readily available tank filters. Universal Systems manufactures the tank filter assemblies, filter cores and filter screens to fit your series 2300 and 3000 melters.

Same Footprint

If you have gone through all of the steps to fix the problem with your old melter and find out that it is the control panel, which has been discontinued, Universal Systems SE has a solution for that as well. Our ProBilt™ melters have the same footprint and dimensions as your current series 2300 or 3000 melter. That means that your NEW ProBilt™ melter, that comes with a 10-year heater warranty, will fit right in where your old melter comes out.

For more information or to contact a technician that can help you troubleshoot issues with your old melter, call (561) 272-5442 or email sales@ussefl.com.

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Simplify with the AccuScan™ Control Panel

Universal Systems SE manufactures a premiere line of hot melt adhesive systems. Our ProBilt™ line of tanks all come with our patented AccuScan™ Control Panel. The AccuScan™ Control Panel is exclusive to ProBilt™ machines and is easy for any line operator to use.

One of the most common feedback points we hear from customers is that they like simplified operational equipment. Usually line operators are understaffed and overworked. Simplifying how they use our equipment is a big selling point and the AccScan™ Control Panel is a great example of that.

Universal Systems SE developed our AccuScan™ Control Panel to simplify the operation of our adhesive melter systems. The main control screen lists the operational settings for up to 4 hoses and guns and the main tank. You can filter through these sections by pressing the Zone button. Once you choose the zone you wish to set the temperature for, press and hold the Set button. Then, using the up arrow, the digital screen will show the temperature setting increase until you reach your desired temperature setting. Once the tank or hose zones are set to desired temperatures, release the Set button. We also offer a Set Back button on the main screen. The Set Back feature puts the machine in an idle state, heating only to 165 degrees.

For further step by step instructions, we have put a video on our Universal Systems SE YouTube channel. Please check it out at https://youtu.be/QhSCXZs-8wY.

For any further instructions or information about our AccuScan™ Control Panel please call (561) 272-5442 or email sales@ussefl.com.

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Melt Rate vs. Pump Rate

When purchasing a hot melt adhesive system, it is important to know your desired melt rate and pump rate. It is also important to understand the difference.

All Universal Systems SE ProBilt™ tanks are equipped with a 14:1 ratio pneumatic pump assembly. Pneumatic pumps are most common and have a maximum pump rate of 75 lbs. per hour. No matter what the tank capacity is, whether it is 12 lb., 15 ob., or 20 lb., the pump will max out at 75 lbs. If you need to pump more adhesive then that per hour, you will need to transition to a gear pump system with a larger tank capacity.

The melt rate is the rate at which the tank will melt the adhesive you put into the reservoir. This is where the tank capacity comes into play. Before moving forward with any hot melt adhesive system, first you need to understand how many pounds you need to melt per hour. The melt rate is dependent on how many hoses and gun applicators you are running and how many boxes are sealed per minute on your packaging line. The most common tank capacity is the 20 lb. (10 Liter) ProBilt™ 20, with a melt rate of 23 lbs. per hour. If you are only running one line with one hose and gun applicator, then you may only need the 15 lb. (7 Liter) Probilt™ 15 which melts 18 lbs. per hour.

A common misconception is that the on-demand autofill system, the ProBilt™ Phoenix, will have a larger melt rate and pump rate. That is incorrect. The tank capacity on any auto fill system is the same as a regular tank such as the ProBilt™ 20. However, the advantage to the auto fill is that the line operators will not have to watch the adhesive level in the tank as closely. The vacuum system connected to the tank will sense when the adhesive level is low and automatically fill the tank. This helps eliminate dry running and pumps will last longer. However, the pump rate on this system will still max out at 75 lbs. per hour.

For additional information about melt rate and pump rate on all of our ProBilt™ tanks, please call (561) 272-5442 or email sales@ussefl.com.

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From Leaves and Baskets to Hot Melt and High Speed Packaging

People have been packaging products for thousands of years. From the time the earliest humans stepped out to go on a long hunt, it was necessary to wrap food for the journey in something – be it leaves or grass – in order to keep the food from spoiling. As time progressed, new innovations allowed new foods to be packaged for transportation. And innovations were made to package non-food items, as well. Packaging allows for the easy transport of anything and everything that people produce.

But fast-forward a few thousand years. People no longer produce things on a small scale. Even when an entire year’s worth of a harvest was required to be packaged for transport across the country, it did not compare to the production capacity of the twentieth century. New manufacturing technology has made it possible to produce thousands of pieces of a product in a single day. Anyone who has walked into a big-box store or supermarket has experienced firsthand the overwhelming mass production that is possible with modern techniques.

With high-speed production comes the need for high-speed packaging. This is not something that can be accomplished by hand, and requires specialized machines and technology for the process. An important part of high-speed packaging is hot melt equipment. Since hot melt is literally what holds the packaging in an industrial world together.

Hot melt glue has the ability to rapidly cool and bond materials, which allows manufacturers to quickly seal and secure products. Companies across all industries know if items are not properly packaged and available to ship immediately after production, they will lose money. Humans continue to build on the idea of wrapping things in leaves and putting items in a containers for transport. The key to continued progress is incorporating new technologies as well as adapting to the needs of an ever changing global market.

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Combat Downtime

Downtime for an average production line can cost a company, at minimum, between $150 – $170 per minute. This makes it vital for companies to identify factors and equipment that impact production capacity.

Why are Hot Melt Adhesive Systems so important?

Hot melt adhesive systems are often overlooked as just a cog in the production packaging line. However the reality is that these small systems are vital to processes like primary paperboard packaging as well as the key to ensuring protective secondary packaging. Furthermore any disruption to the heating, transferring and adhesive application process results in the slowing if not complete shut down of a production line.

While literal monetary translation of the 1-10-100 principal is debatable, there is no question a proactive approach to maintenance that considers prevention cost, corrective cost and failure cost will reduce downtime and yield significant savings.

How to optimize Hot Melt Part Maintenance and Purchases

To ensure quality, longevity, and support for hot melt glue equipment one should purchase from a well-established manufacturer such as Universal Systems SE, Nordson, Graco, ITW Dynatec or Robatech. All these companies have engineers on staff to discuss equipment selection, technicians to address maintenance questions, and sales representatives who can assist with product procurement and replacement.

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