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Problems such as loose packaging boxes, improper sealing, and electrical malfunctions are common on packaging machine production lines. Many times people are busy repairing, but they don’t realize that most of the faults are due to improper parameter setting or lack of daily maintenance. Downtime means a direct loss of profits on the production line, and to keep the crop rate, you have to have a set of troubleshooting logic.
The following are some high-frequency fault handling suggestions I have compiled, hoping to help you avoid the pit.
Most of the time, it is because the setting parameters do not keep up with the rhythm, or the sensor is dusty. According to experience, this kind of problem is preferred to check the matching degree of feeding speed and machine processing capacity.
Countermeasures: regular cleaning of dust is the basis. Check the tension of the feed roller and confirm that the position of the sensors is offset to ensure that they can accurately capture the trajectory of the product.
This is mostly due to the fact that the 3 parameters temperature, pressure or residence time are not matched.
Countermeasures: calibrate the sealing temperature against the characteristics of the standard material. Check whether the sealing mold is worn, the most critical point is to confirm the parallelism of the upper and lower seals, even if the difference is a few tenths of a millimeter, the yield will be affected.
The film went crooked and the packed bags were all crooked. This is usually a problem with the paper path or the alignment of the former.
Countermeasures: Re-wear the film according to the instructions. Adjust the angle of the tension roller to ensure that the film is absolutely centered as it enters the former.
Vertical sealing servo, heat sealing servo
cold sealing servo, cutter servo
Precision weighing or multi-head scales ensure consistent bag weight, with quality sensors enhancing packaging accuracy.
Automatically complete the processes of bag making, measuring, filling, sealing, bag cutting, etc., greatly improving the packaging speed.
The film slips or the photo eye does not read the color mark, which will lead to this situation.
Countermeasures: clean up the drive belt to increase friction and adjust the tension by the way. In addition, check whether the photo eye is covered by dust and remember to recalibrate its sensitivity.
If the system suddenly and completely “goes down”, it is usually a wiring harness, fuse or sensor.
Countermeasures: First check the power supply and air switch, and use a multimeter to measure the sensor signal. Sometimes the fault point is very hidden, must ensure that all terminals are tight state.
The friction of gears and chains caused by inadequate lubrication is the culprit of premature aging of equipment.
Countermeasures: don’t love lubricating oil. Establish a strict preventive maintenance list, and regularly clean and lubricate high-frequency moving parts.
If the sensor has no signal or cannot be read correctly, the labeling position will float randomly.
Countermeasures: Regularly calibrate the labeling machine, wipe the sensor probe with a special cleaning agent, and restore its sensing sensitivity.
It is better to spend time on prevention than to fix it when something goes wrong.
In a word, the test of troubleshooting is to control the details. I hope these suggestions can help your production line run more smoothly.
Author: Jack Miller
I am a Senior Packaging Systems Engineer with over 11 years of hands-on experience in industrial automation and production line optimization. Having spent the better part of my career on the factory floor, I specialize in diagnosing complex mechanical failures and implementing preventive maintenance protocols that minimize downtime.
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