Troubleshooting Tips for Packaging Line Issues

Since Universal Systems SE offers technical support for all of our customers, we get several calls per day with all different kinds of technical issues that line operators experience. Because many packaging lines run 24/7, without regular maintenance of key products there will always be issues after a certain period of time. As always, we recommend changing your filters, nozzles and modules when needed to eliminate any potential issues. However, there may be other parts on your packaging lines causing these issues.

For example, if you are experiencing a dripping or not fully functional module, it is most likely not an issue with the module itself. Especially since all products go through a vigorous quality control process before leaving our facility. Because the modules are air open and spring close, there are a few items to check before switching out the module. First, Universal Systems SE recommends that you check the solenoid valve. The solenoid valve is the air supply that runs into the applicator gun and fires the glue onto the box. If the solenoid valve fails, it will not generate air power to fully open the module. If the solenoid valve is weak, it will not fully exhaust all of the air out of the module, and the module piston will not seat properly, causing a drip. Another potential issue could be that char or debris has been transferred from the tank into the gun and has gotten stuck in the spring close. This piece of char, no matter how small it could be, can limit the spring from fully closing causing “dripping”. Spring tension on the gun module being set too low could also cause “dripping”, so make sure you try to adjust that before switching out modules. Finally, if the line operator has not gone through the correct steps to change out the module, the module could be compromised. The line operator needs to make sure that they lower the air pressure used on the tank before switching modules. If they do not, they could potentially send glue into the air chamber of the gun when removing the old module.

Another common technical issue is that the heated hoses are either not heating or not heating to the correct temperature. The first step is to check and ensure that the hose zone is not set to “off”. If it is, turn the hose zone to “on”. Then, you should check to make sure all connectors are securely tightened and the controller settings are correct. If all of those are working, you next need to check the ohms reading on the hose heater and hose RTD, and all of the board fuses.  A USSE technical support representative can walk you through this check process and help identify the real issue.

For more information or if you need technical support not mentioned, please call (561) 272-5442 or email sales@ussefl.com

Read More

Piston Pump Troubleshooting

There are several things that can cause a piston pump to stop working. The most common reason is that it is clogged. Unfortunately, not all line operators take the time to close the lid on a glue tank. With a lot of carton dust in the air at any facility, this dust gets into the glue pot and melts in with the glue. When the pump shifter runs to pump the glue from the pot into the hose, that carton dust gathers around the pump which can cause it to seize. The simple solution to this is to make sure that all shift line operators are diligent about closing the tank covers, that’s why they are on there.

If carton dust is not your issue, and the pump fails, below are a few other possible causes and the corresponding solutions.

  • Adhesive not sufficiently heated – check the tank temperature and required melt temperature of your adhesive and set accordingly.
  • Inadequate or no input air to pump – increase the air pressure from the plant air supply and see if the pump will run.
  • Dry running – when a tank drops below a certain adhesive level in the pot, the pump does not have enough glue to operate at full capacity. The glue that runs through the pump acts as a padding so that the shifter does not pound against the top and bottom of the pump itself. When that padding is less, the pounding shifter can cause damage to the magnets and create an issue with the shifter. The only solution to this is to get a new shifter and potentially invest in an auto fill on-demand system that fills the glue into the tank for you, leaving less pressure on the line operators to fill the pot.
  • No Tank Screen or Clogged Tank Screen – the tank screen lives at the bottom of the tank and is the first line of defense against any foreign debris getting into the pump. Sometimes the tank screen gets removed or never cleaned. That can cause debris build up and seize your pump. It is easily cleaned by lifting out of the empty tank and then cleaning the tank with Purge Plus™.
  • Clogged Tank Filter – the tank filter screws into the side of the tank and filters the glue after it leaves the tank. If the tank filter is clogged, then the adhesive will back up in the pump, causing the pump to seize.
  • Pump solenoid is not on – if the tank is not within 35 degrees of the setpoint temperature on the control panel, the pump solenoid will not turn on. Check the setpoint temperature and make sure it is correct. If the setpoint temperature is correct and reading properly, then it might be a failed solenoid that needs to be replaced.

 

If you go through all of these troubleshooting steps and still have an issue with your pump, please call (561) 272-5442 or email sales@ussefl.com.

Read More

Custom Manifolds & Gun Applicators

There are not many manufacturers in the hot melt industry that have the ability to work with clients and create custom manifolds and gun applicators to fit their unique needs. Universal Systems SE has that ability and is willing to pair up our engineers with our client’s team to ensure that we manufacture the exact applicator needed for any job.

Over the last forty years, Universal Systems SE has manufactured an array of different custom manifolds and gun applicator systems for different types of industries. Not only can our custom gun manifolds distribute adhesive onto boxes in packaging lines, but they can be used for distributing make-up, candle gel, etc. Depending on the viscosity and melt rate of the substance needed to make the transfer, our custom manifolds and applicators will work with several different types of materials.

The custom manifold and gun process is simple. Contact one of Universal Systems SE’s customer service representatives, by either calling in to (561) 272-5442 or submitting a custom gun online form. You will then be connected with a USSE mechanical engineer. After all of the client’s needs are communicated with our engineering team and all questions answered, USSE will provide the customer with a custom manifold drawing for approval. The drawing will include dimensions of the manifold, spacing of modules, type of modules and all cordsets that are included and the location of those cordsets. Once the drawing is signed off on by the customer, we then manufacture the manifold body. After a vigorous quality control process, each custom manifold is inspected and tested to ensure all dimensions are correct and that the custom gun matches the approved drawing. Once the manifold passes all initial testing, modules are added and the custom gun is created and tested internally by two different QC Engineers. Once there is approval by both engineers, the final product is cleaned and ready for shipping.

The normal process for custom manufactured manifolds and completed guns is four to six weeks, with extra time potentially added in depending on customer turnaround time for drawing approvals.

If you are interested in learning more about the types of custom manifolds and gun applicators that Universal Systems SE can engineer for you, please call (561) 272-5442 or email sales@ussefl.com.

Read More

Know Your Equipment, Not Just the Part Numbers

The hot melt equipment industry has evolved over the last 40 years. Each manufacturer has made design and material modifications to their product line, which has had a significant impact on the creation and assignment of part numbers. Unfortunately for our particular niche industry there have also been an abundance of variations created solely for clerical purposes. These superfluous numbers make it extremely difficult to place orders and keep inventory organized.

Let’s say you are looking for a single orifice right angle nozzle with a .014 inch diameter hole. The correct manufacturer number can be 244519, 244-519, 244 519, 24-4519US, 320014, 320-014, 320 014, 32-0014US, 1011014, 1011014US, or SR19014. These are all correct manufacturer parts numbers and as you can see the variations are sometimes nothing more than a space or dash. This has already created a very high level of confusion, but wait, it gets even worse.

If you are not purchasing directly from the manufacturer you add a whole other coded level of alpha numeric characters, dashes and mystery spaces. Each buying house has their own system, each aftermarket dealer makes up their own numbers, and even legitimate distributes from time to time will add a character to a part number purely for tracking purposes.

It is important for anyone using hot melt systems to understand the function of each piece of equipment so that there is not a complete dependency on just a part number. We at Universal Systems SE work with our customers to identify parts through a combination of part numbers, descriptions, and photographs. It is especially important to take the time to talk to one of our associates if you haven’t ordered a replacement part in several years or are order a new part for the first time. Our website has a part number search function for your convince; but know you can always call 1-800-848-5018 for personal assistance.

Read More

Hot Melt Adhesive Equipment: Troubleshooting Tips

Whether you’ve already invested in hot melt glue equipment, or you’re considering it, knowing how to troubleshoot any potential problems is highly advised by any hot melt adhesive machinery as well as equipment distributors and manufacturers. However, before we get into common troubleshoots; let’s define what hot melt adhesive systems actually do.

What is a Hot Melt Adhesive System?

Hot melt adhesive systems are composed of different pieces of equipment that come in a variety of pump, hopper, and hose gun connection sizes in order to satisfy your individual production needs. Hot melt glue machinery can be used to assist several different industries including, but not limited to:

  • Bookbinding
  • Breweries
  • Graphic Arts
  • Labeling / Laminating
  • Packaging

Troubleshooting Mechanical Problems With Your Hot Melt System

Now, we don’t advise that you should try and troubleshoot a hot melt dispensing unit on your own unless you’re a qualified professional. If you are a qualified professional, observe and follow the safety instructions within your OEM manual that you were given for your specific machine.

  • IF YOUR PISTON PUMP ISN’T WORKING PROPERLY

    First, check to see if the unit has reached its operating temperature, if it has, then there could be a problem with your air supply, the solenoid valve, or there’s something wrong with the assembly of the shifter valve.

  • IF THE PISTON PUMP IS STROKING ERRATICALLY

    If this problem is occurring, then you may be low on adhesive, if you’re adhesive level is fine, then check to make sure that the adhesive is actually melted. You’ll also want to check the pump seats in case anything became lodged within them, as well as make sure that the o-ring in the crossover tube isn’t broken.

  • IF THE GEAR PUMP IS NOT PUMPING PROPERLY

    One of the first things to check if your gear pump is not pumping properly is the motor. If the motor is not running, you want to check the motor control as well as the capacitor. If you don’t see anything wrong with the motor than look for any fault indicators, as well as making sure that the pump ready light is on. In the event that none of these tips help, then there may be a blown fuse.

  • IF NO ADHESIVE IS PUMPING OUT

    If your motor is running, but there’s no adhesive being pumped out, then you’ll need to check your adhesive levels and make sure it’s melted. There’s a chance that the nozzle could be clogged on the head however, if it’s not then you’ll need to check the inline head filters, the tank filters, the coupler between the motor and the pumped, and the pressure regulator.

Read More