Help When You Need It
In the post-pandemic age of industry, every company is finding themselves in need of more help. Whether it is qualified technicians with experience in the field, or technical support and customer service from their vendors. A lot of large companies, like Nordson®, have gotten rid of their technical support and customer service representatives, replacing them with automated systems or remote sales reps that do not have a detailed knowledge of each customers purchase history or equipment needs. That is making it difficult for CPGs to troubleshoot issues or for new maintenance managers to know what to order.
Many line operators of hot melt machines are new to the industry, since companies saw their long-term employees retire during the pandemic. At Universal Systems, we not only stayed open and kept all of our employees during the pandemic, we have kept detailed reports of our customers purchase history, as well as a cross reference list of our products to Nordson®. We are always here to take any technical calls or offer Nordson® replacement parts when you need them. With the “supply chain shortage” impacting all Americans, we made sure to back our bets here at USSE. We have ramped up our inventory by double its normal size to ensure that you can get products when you need them and not be held hostage to overseas competitor parts. We make everything in the USA and use all US suppliers. We stand behind our products and feel certain that we would be able to help you with any issue that may arise with your hot melt equipment.
For any technical support please email tech@ussefl.com or call 561-272-5442.
Lowering Downtime on Your Packaging Line
As CPGs continue to change their packaging lines to try and cut costs but stabilize runtime, there are a few things to consider when analyzing the cause of machine downtime and how to prevent it.
The below statistics were taken from the Fall 2021 issue of OEM Magazine:
Causes reports by respondents at CPG companies as the most common cause of packaging machine downtime: 26.3% general wear and tear, 21.1% operator error, & 22.1% product changeover.
General wear and tear is pretty self-explanatory. This would depend on how many hours and days per week a facility runs their packaging lines. If they are running 24/7, then the percentage of general replacement parts purchased will be higher than a plant that is only open 8 hours per day, 5 days a week. To lower downtime, each facility should stock at least 1 -3 replacements, at all times, of the following items: Heated Hoses, Glue Applicators, Modules, Nozzles, Tank filters, and In-Line filters. Another way to lower downtime is preventative maintenance. If CPGs were to prioritize preventative maintenance, then their packaging machinery would last longer and lead to less overall downtime. We recommend PM practices that include changing tank and gun filters, as well as maintaining an even level of heated glue in the glue reservoir of the tank. If done on the regular, general wear and tear percentages would go down.
Operator error is also another large concern for CPGs and the cause of most packaging line downtime. That is because Nordson® and other large corporate OEMs are making their melters more technologically advanced. Unfortunately, this increased technology does not come with increased training. While technology can create less human interaction, if the line operators are not trained on how to work the equipment, it can lead to more errors. Also, several of the new systems need to run on a network in order to work, so if there is any network downtime, that will now impact the packaging machinery and shut down the line. Universal Systems has maintained our simple to use systems and provides YouTube videos on how to work our machines, along with error codes and how to navigate the control board.
The final most common cause of packaging line downtime is product changeover. To lower overall costs, many CPGs use the same machines to package multiple types of items, which requires a changeover of parts. This downtime might be harder to avoid, however if the line operators are well versed in the machinery and understand the usage need of the machine in all areas, this can be lowered.
For more information on our Universal Systems line of hot melt products, please contact a sales rep at sales@ussefl.com.
Remote Buying & Troubleshooting is the New Reality
After the world shut down in 2020, then slowly started to reopen, it became clear that certain job roles no longer needed to be in an office and could work from home. For the packaged goods industry, that impacted purchasing agents. Now, as maintenance managers run the floor and manage the inventory, purchasing agents are at home trying best to communicate the company needs to suppliers. Realizing the potential that purchasing departments might rely on supplier websites, here at Universal Systems, we focused on updating our website and making sure that there are competitor OEM cross reference numbers easily searchable throughout the site. We also have sales reps that can handle almost any product question and return quotes within 24 hours.
Another impact the pandemic has had on the packaging industry is workforce. There might not be as many skilled and experienced engineers on the floor to troubleshoot issues as they arise. As a manufacturer, we have also experienced setbacks with sending technical reps out to facilities to help them troubleshoot. In an effort to virtually help our customers, we provided YouTube videos on how to set up our ProBilt line of tanks, how to program our control boards and how to set temperatures. We also have several very skilled engineers in house that can walk customers through any issue they may be experiencing. We’ve found ourselves utilizing technology more and more for troubleshooting. Since less techs are allowed in facilities, we have started doing virtual meeting via Facetime or through texting photos. Both have shown to be pretty effective.
Hopefully, one day soon, we get back to workers being allowed to be in the office to physically check inventory and see what they need to order. But until then, we will continue to help our customers as much as we can remotely. If you have any hot melt questions, please feel free to reach out to sales@ussefl.com.
When to Replace a Module
One of the most commonly replaced items on any hot melt packaging line is the module. Typically confused with an applicator gun head, the module attaches to the front of the applicator gun and dispenses the glue through the nozzle and onto the applicable surface. If you are experiencing clogging issues with your hot melt line or dripping from the tip of the nozzle, most likely the module has reached it’s end of life and needs to be replaced.
Replacing a module is fairly simple. First make sure the air is disconnected from the applicator. Always wear Kevlar gloves and eye protection when replacing any parts on your active hot melt system. The parts get hot and extending downtime might not be an option, so operator safety is very important. Then, remove the front two screws from the module and pull the module off the surface of the gun manifold. Make sure that you use the new o-rings and screws that come in your new module replacement kit. This will ensure that the new seal is tight and will not leak once operations restart. Also, make sure you are replacing the existing module with the correct replacement module. Below is a list of module options:
- Standard H200 Module
- Reduced Cavity H200 Module
- ProBead Self-Cleaning Module
- Zero Cavity Standard H200 Module
- Zero Cavity Micro Adjust H200 Module
- Swirl Pattern Modules
- Weave Pattern Modules
- H20 Modules
Finally, we also recommend to put a new nozzle on every new module. This will ensure that no clogging will occur. If you have a zero cavity or ProBead module, then the nozzle will already be attached.
If you need any more information about modules for your packaging line, please email sales@ussefl.com or call (561) 272-5442.
Safety in Switching Out Glue Equipment
The best way to keep your packaging line up and running as efficiently as possible is to do preventative maintenance. Here at Universal Systems SE, we have advocated for regular packaging line maintenance, including all of your glue melter equipment and components. However, it is not only important to know when to do maintenance, it is also important to know how to do that maintenance. There are more mistakes made in the switching out of glue equipment and components than you may think. Whether you are changing out a filter or switching a pump, there are steps to take in order to ensure a smooth transition, with the least amount of downtime. Here are a few tips on switching some of our ProBilt hot melt equipment products.
Tank Filters
First and foremost, it is important to know the model of your tank. Even though that sounds like standard knowledge, there are many tanks that look similar but have different tank capacities, pump types and filters. Once you know the tank model, you can look up if you need to replace the entire tank filter or if you can replace just the screen. On USSE’s ProBilt tanks, for example, you have the option to change only the tank screen. This allows you to save some money long term, while still maintaining your tank. It is recommended that you make the change while the tank is in setback and to wear Kevlar gloves so that you don’t burn yourself. The tank filter is located on the side of the tank. It can be removed with a flat head screw driver. Once the complete filter assembly is removed, there is a long screw that secures the screen to the assembly. Simply remove that screw, switch the screen, and replace the filter assembly. If you are changing out the tank screen, make sure that you do not damage the filter bung or o-rings when making the switch. Also, be careful, the glue inside the filter is HOT.
In-line Gun Filters
These are the easiest of filters on your glue line to change out. In most cases, the filters can be reordered in packs of 5. Locate where the filter is on the filter assembly body and use a wrench to loosen and remove. Kevlar gloves should be worn, as the outside of the filter will be hot and there will be glue on the filter you are removing. Simply put the new filter in place and tighten.
Modules
Usually modules are switched out because they are dripping or leaking. This is typically caused by either char or end of life of seat and piston. Switching out a module is fairly simple. Before taking off the old module and replacing with the new, make sure that the system is not running. Each replacement module comes with 2 o-rings and 2 screws. Place the o-rings on the back of the module and secure it on the gun applicator with the new screws.
If you are running an H200, zero cavity or reduced cavity module, there are rebuild kits available.
Pumps
Switching out a glue pump is the least common practice on a packaging line. However, this is also simpler than you would think. Most technicians think that in order to change out a pump, you need to turn the tank off and let the glue cool. That is not always the case. If you are running a ProBilt tank and have an experience technician, he can switch out the pump while the system is still on. First, make sure you are wearing Kevlar gloves because the system will be hot. Turn off the air running to the system, this will limit any injuries. Remove the 3 bolts holding in the pump, use needle-nose pliers and do this carefully. Put the old pump on a large piece of cardboard where the glue can drain, cool and harden. Carefully put the new pump in, secure it with the 3 bolts and turn back on the air.
For any other questions about tank maintenance, please contact one of Universal Systems’ experienced technicians at (561) 272-5442 or email tech@ussefl.com
Starting Back Up After a Pandemic
This is most definitely a new reality that we are all facing. Never before have so many companies had to shut down several, if not all, of their packaging lines because of a global pandemic. However, it was a scary and necessary measure taken to prevent further outbreaks of COVID-19. Now, as we slowly start to reopen as a nation, so does our packaging facilities. State by state, Governors are rolling out the reopening phases that each company, both essential and non-essential must follow.
With the reopening happening, that may mean you are going to run into a few speed bumps. As we all know, machines that typically run seven days a week, don’t like being shut down for three months. Especially if they are not shut down and cleaned out properly before they sat around idle. So, when you switch the power button back to “ON”, everything might not turn green.
In an effort to help with troubleshooting, we have put together a quick list of potential fixes.
1. CLEAN YOUR TANK. We cannot stress this enough. Even if your team drained the glue in the tank reservoir before shut down, there will still be old residue that will impact your restart. Cleaning your tank is fairly simple. First, make sure to detach all guns from the hoses before running the cleaner through. Utilizing our Purge Plus cleaner, fill the tank reservoir and heat. Place the end of the hose inside a bucket and flush the cleaner through the tank and out through the hose.
2. CHANGE ALL FILTERS. This includes both the tank filter and in-line gun filter. Starting with new fresh filters is the smart way to go.
3. NOZZLES MIGHT GET CLOGGED UPON INITIAL RESTART. Nozzles have small orifices that dispense the glue onto packages. If there is any left-over char in the tank from restart, the nozzles could get clogged up first. Try switching the nozzle to see if that fixes the issue.
4. REBUILD KITS. There are a few items that can be rebuilt on your adhesive melter system. For example, your pump. If you think that your seals have dried up from sitting idle through the down time, and you have a skilled mechanic trained to work on the equipment, try ordering a rebuild kit. This will save you money on purchasing a new pump.
If you experience any other issues during your restart, please call us directly at (561) 272-5442 and a technician will walk you through troubleshooting any issue. Stay Safe!
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.
Important Notes for Hot Melt Purchasing Agents
The packaging industry is unique, and can be a tough industry to buy for. It is important for purchasing agents to understand how their hot melt systems operate in order to ensure they are buying the correct parts. Hot melt manufacturers are full of highly educated engineers that have honed their skills over time. At Universal Systems SE, we combine our experience of over 40+ years to keep our products ever evolving and ensure we are still at the top of the industry, while offering our expertise to help our customer purchasing agents make the right choices.
Keeping up to date on the latest trends is not only important for us as manufacturers, but it is also important for buyers. Below are 5 important facts that every hot melt equipment buyer needs to keep in mind before making a purchase.
- Durability – at USSE, we stand behind the durability and craftsmanship of our products. That means that we offer a solid warranty, longer than all of our competitors.
- In Stock Products & Compatibility – whenever you call to inquire about the pricing on a melter or replacement part, make sure you remember to ask if the part is in stock. There are several choices that you have when ordering both main and replacement parts. Most all companies make their parts compatible with industry standards.
- Tank Capacity – make sure your melter’s tank capacity matches your packaging line output. This will ensure that you have the correct tank needed for the job.
- Match Your Adhesive and Your Pump – the pump needs to match the viscosity of your chosen hot melt adhesive. This is key to making sure that you are ordering the correct style pump to dispense the adhesive on your packaging materials.
- Usability – the best melters will be easy to operate, easy to change out replacement parts, and easy to clean and maintain. They will also come with smart features like USSE offers on all of our ProBilt adhesive melters.
At Universal Systems SE we are dedicated to the education of both our customers and the next generation of hot melt engineers.
If you are interested in learning more about hot melt equipment tips and facts, please call one of our customer service specialists today at 1-800-848-5018 or email sales at sales@ussefl.com. You can also view these facts and several other key features of our ProBilt™ Melters by visiting us on YouTube.