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.

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When to Use Micro-Adjust Modules

Hot melt system modules are located on the front of your applicator guns. There are several different types of modules and in most cases, they can be easily replaced on the manifold versus replacing the entire gun assembly. Changing out a module is a more cost-effective way to increase productivity and lower glue costs. Typically, modules need to be replaced when they are having glue dripping issues or major leaking from the nozzle. This is caused by normal wear or char getting stuck in the piston chamber, not allowing it to seat securely.

When replacing a module, you have the option of buying a standard case sealer module or a micro-adjust module. This refers to the module’s adjustment cap on the module body. A standard case sealer module comes pre-set and typically needs no adjustment. This is our most popular style module. A micro-adjust module cap is typically sold on Zero Cavity or ProBead Reduced Cavity modules. These modules have a user-friendly adjustable screw top that changes the pressure of the glue through the nozzle. This allows the operator to dial in a precise glue bead. Typically, zero cavity and ProBead reduced cavity modules have micro-adjustable caps for this reason. For example, they are used on medication boxes or beauty supplies. Another advantage to a zero cavity or ProBead reduced cavity micro-adjust module is the self-cleaning functionality, limiting charring and clogging.

For more information about micro-adjust modules please reach out to a technical sales rep at sales@ussefl.com or call (561) 272-5442.

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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:

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.

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How to Change Out a Melter Pump

There are several reasons why a melter’s pump might stop working. The most common reasons are clogging of the ball and seat from foreign matter such as carton dust, and the actuator clogging due to dirty or oily air. No matter what the reason, if your pump stops pumping it needs to be replaced. Obviously, it much more cost effective to change out a pump then to replace the entire unit. However, it is not always easy to switch out a pump, especially if you are new to the line. Below are a few tips to help ease you through the process.

  • Make sure the circuit breaker on the front of the unit is set to OFF once the applicator has reached normal application temperature.
  • Shut OFF the input air to the pump.
  • Set the pump regulator to zero and trigger all guns to relieve system pressure.
  • When removing the old pump, rotate it slightly to break the suction and then pull it straight up and out.
  • When installing the new pump, make sure to torque the screws 15-16 ft-lbs.
  • Connect the pump electrical plug to tank receptacle and turn tank back on.
  • Once the tank board reads that the tank has reached set temperature, wait 15 minutes. This will allow the glue around the pump hydraulics to get to temperature.
  • After waiting 15 minutes, reinstall the air regulator and connect the airline and activate air.

 

If you have any further technical questions and want to speak with a technical sales rep, please call (561) 272-5442 or email sales@ussefl.com.

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When to Call Your Glue Manufacturer vs. Your Packaging Machinery Technician

With the reopening of many packaging facilities in full swing, here at Universal Systems SE, we are getting a lot of technical calls that pertain to glue and not the packaging machinery itself. Not a lot of technicians realize that some of the problems they are experiencing with their equipment are actually being caused by the glue. By the way, this has always been the case. Since knowledge is power, below are 2 issues that we get a lot of calls about that are glue related and not machine related.

#1 Glue Related Issue – Char

Many line operators and line technicians have experienced char in their hot melt application systems and most of them think that the char is caused by the machine. That is not actually accurate. The hot melt tank will heat the glue, but only to the temperature that is set by the operator. It is very important to understand how recommended temperature ranges effects viscosity which allows the glue to run at its optimal level. Most charring is due to overheating the glue. That char will travel through your application equipment and cause clogs which will require you to replace equipment or its components. However, that will not fix the long-term problem of charring. If the charring is not corrected, when you install the new equipment it will clog again. That is not a machinery issue, that is a glue issue. Our suggestion is to speak with your glue provider and find out all of the specifications on the glue you are using such as ball and ring, optimal temperature and viscosity. That will save you a lot of money in the long run and should reduce any excessive charring.

#2 Glue Related Issue – Coagulation

There is no doubt about it, glue is expensive. In most cases, the glue can be more expensive than the application equipment. The reason is because most facilities use a lot of it. As we all know, the world has been a crazy place this year, and with the re-opening of a lot of packaging plants, comes new, reduced operating budgets. We have heard from a lot of customers that in order to save on costs, they have had to change glue, whether it is moving to a more inexpensive glue, or a system that lays down less glue but with a stronger adhesion. Either way, if you change glue and do not meticulously clean your glue application system, you can have coagulation causing clogs. We recommend cleaning your tank and hoses with Purge Plus or a similar cleaning substance before changing glues.

At Universal Systems SE, we are always happy to help with any issues that you might have. But keep in mind that sometimes, your issue might be something that you need to discuss with your glue manufacturer. In the meantime, please feel free to reach out to us with any questions at tech@ussefl.com.

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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

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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!

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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.

 

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Hunting Down Old Adhesive Melter Parts

An interesting fact about the packaging industry that most people don’t realize, is that purchasing agents become avid internet hunters when it comes to finding parts for their old equipment. There are several resources out there, the largest being eBay, for purchasing agents to find and buy parts for their old adhesive melters. The problem is, when buying from a bid platform, you never know what you are going to get. If you are looking for an old part, for a melter that is more than 20 years old, the part you find online could either be used or the wrong part. Also, with most online bid platforms, you get what you get. There are no returns or exchanges for your actual part. And in most cases, you get what you pay for.

Universal Systems SE realizes how important it is to be an online resource of purchasing agents, which is why we have invested in becoming “searchable”. In the last couple of years, we have launched a new website, added more products, and increased the number of cross-reference IDs on our website. We have added pictures, spec sheets and custom contact forms to help purchasing agents get exactly what they need. We are also working on making sure that we show up in the search results when purchasing agents Google old part numbers or manufacturers.

The benefit of buying from USSE is that all of our equipment is new, in stock and you can talk with a technician to make sure it will fit with your current equipment. Another key aspect of working with USSE is our staff of knowledgeable engineers that have been around adhesive melters and packaging line equipment for over 40 years. If you have a question about your old melter, we are most likely the only company in the industry that can answer it.

To test out the knowledge of our technicians, give us a call at (800) 848-5018. We are certain we can get your old equipment back up and running in record time.

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How Winter Weather Impacts Your Packaging Line

As we head into the New Year and the weather gets colder, you may be experiencing inconsistencies with the adhesives on your packaging lines. What most line operators and maintenance managers do not realize is that the location of your packaging line in the plant can play a large role in the dependability of your adhesive.

This time of year, we receive several troubleshooting calls regarding hot melt consistency, heated hose and gun temperature consistency and glue stringing. It is important to take the external environment into consideration when attempting the first step in troubleshooting some of these problems. One of the first questions to ask is: where is your packaging line located? For example, if it is at the end of the packaging process, which it most likely is, then it might be on the exterior wall of your plant. Or it might be near an external door or window. If it is on the outskirts of the plant facility, and you are located in a part of the United States that is cold in the winter, then the outside temperature 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. Especially if you are adding in cold glue. If your glue pellets are colder than normal, it will take a longer amount of time to heat them. A solution to this issue would be to invest in an auto-fill hot melt application system. Universal Systems SE manufactures the ProBilt™ Phoenix Auto-Fill Application System. Not only will this system help in the winter months, it helps all year long by drastically reducing the number of times your line operator needs to add glue pellets.

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 used larger sized extensions and filter housings. For example, the older gun filter assemblies had larger filter housings and longer extension joints, that are unnecessary and can inhibit the consistency of hot melt flow. 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.

For any further information on the ProBilt™ Phoenix Auto-Fill Application System, or to speak to a technician about any troubleshooting of your adhesive application system, please call Universal Systems SE at (800) 848-5018 or email sales@ussefl.com.

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