Packaging Machinery Problem Solving

A Technical Service Publication

CAMPBELL WRAPPER HFFS TROUBLESHOOTING

I. Backstand (Unwind) Section

A. Web Breaks

1. Cause: Roll (wrapping material) nicked or damaged. Web breaks just after unwinding from roll or in some cases the break may occur in another area of the machine where web tension is greater.

Solution: Discard roll if damage is severe. Damage to the outer portion can be cut away and the remainder of the roll used. With minor bead damage, a damp cloth or towel applied to the damaged edge can be effective. Also use minimum amounts of unwind breaking.

2. Cause: Transfer roll surface damaged.

Solution: Locate roll and remove damage (nicks, burrs) with sandpaper or emery cloth.

B. Poor Web Tracking

1. Cause: Insufficient unwind braking - web wanders back and forth.

Solution: Increase unwind braking.

2. Cause: Roll (wrapping material) is not centered on mandrel - web runs off center of former.

Solution: Relocate roll so web is properly positioned on the former.

3. Cause: Transfer roll misaligned - web tracks to one side.

Solution: Check alignment of rolls with level and/or measurement.

II. Former, Fin and Lap Sealer and Tubing Belt Section

A. Poor Web Tracking

1. Cause: Dancer roll set incorrectly. Web will be marked and puckered on the corners of the former if the dancer roll is set too high. With the roll set too low, film may roll over the former edges.

Solution: Set the dancer roll so that the web path is approximately the same angle as the former wings.

2. Cause: Former set up incorrectly – tube forming not consistent

Solution: Center former on machine. Set bottom plate on winged end of the former 1/32" below the nose plate and the exit end 1/32"' above the tubing plate.

NOTE: Check height of the conveyer dogs to make sure they do not strike the former.

3. Cause: Tubing belt speed too slow - web will not track properly due to low tensioning through the former.

Solution: Increase speed by adjusting the variable speed matching drive.

4. Cause: Tubing belts slipping due to insufficient tension - web will not track properly through the former.

Solution: Increase belt tension with adjustment screw located at end of belts.

B. Poor Seals

1. Cause: Sealer temperature incorrect. If temperature is too low, seals will be weak or not made at all. If excessive, the seals will blister and discolor and on machines utilizing wheel sealers, web may stick to wheels.

Solution: Check sealer temperature with pyrometer and adjust as needed. After sufficient time for change to occur, recheck temperatures. If no change is measured, controls, wiring, heaters, etc. should be checked by a qualified person.

2. Cause: Excessive fin wheel pressure - seal shows roughness, and in extreme cases, sealed area has small holes.

Solution: Reduce wheel pressure by adjusting knurled knob to release spring pressure on the wheel.

3. Cause: Insufficient fin wheel pressure - seal is weak and shows a light pattern from the wheel surfaces.

Solution: Increase wheel pressure by adjusting knurled knob to increase spring tension on the sealer wheel.

4. Cause: Faulty bearing in sealer wheel – seal is intermittent; strong to weak.

Solution: Replace faulty bearing. This should be done by a qualified person.

5. Cause: Release treated web reversed on machine - seal weak or fails completely.

Solution: Check web surfaces for release coating and change if incorrect.

6. Cause: Excessive difference in temperature of the sealer wheels. Seal weak and sticking or a build-up (coating) may occur on the hotter wheel.

Solution: Check temperature of each wheel and adjust any imbalance to 10° or less.

7. Cause: Insufficient web width.

Solution: Check required web width for former being used.

III. End Sealers and Knife Section

A. Poor Seals

1. Cause: Incorrect sealer temperatures. Insufficient heat, seals will be weak or not made at all. If excessive, seals will discolor and blister. Sticking may occur on the jaws and in severe cases, seal will be separated.

Solution: Check temperature with pyrometer and make necessary adjustment. After sufficient time for the change to occur, recheck temperatures. If no change is measured, have controls, heating elements, wiring, etc. checked by a qualified person.

2. Cause: Excessive difference in temperature of upper and lower sealer. Package sticks to hotter jaw, weakening or separating seal.

Solution: Check temperature and adjust difference to 10° F or less.

3. Cause: Incorrect down pressure on upper jaw. Inadequate down pressure, seals weak and show a light serrated pattern. Excessive pressure, seals will be damaged and/or cut.

Solution: Adjust down pressure with screws located each end of upper jaw.

4. Cause: Uneven pressure on upper jaw. Seals weak and show light serrations on one end while the opposing end is satisfactory or may show damage.

Solution: Balance down pressure with adjusting screws.

5. Cause: Anvil set too high preventing adequate jaw pressure on seals.

Solution: With the jaws at operating temperature, loosen lock screws on the knife and make sure knife is completely seated and even in the slot. Lock knife in place. Loosen anvil locking and adjusting screws and turn jaws to the cutting position. Tighten adjusting screws lightly until no light shows between the knife and anvil. Tighten locking screws sufficiently to hold anvil and test with two thicknesses of the wrapping material. By trial, tighten adjusting screws until a clean, even cut is made across the face of the blade and machine operates without knives pounding.

6. Cause: Release treated surface of web reversed. Seals weak or open and/or sticking on the jaws.

Solution: Check web surfaces for release coating and position roll so treated side of web contacts the jaws.

7. Cause: Jaws misaligned. Serrations cut seals.

Solution: Align jaws so serrations mesh properly.

B. Poor Package Cut-Off

1. Cause: Knife and anvil improperly adjusted.

Solution: Adjust knife and anvil, see Section III, A-5.

2. Cause: Change in jaw temperature. With a substantial reduction in temperature, cut-off will not be complete. If temperature is increased considerably, jaws may pound and result in weak seals.

Solution: Check temperature with pyrometer and adjust to operating range. If poor cut-off is not corrected, adjust knife and anvil. (See Section A-5)

3. Cause: Knife dull or damaged. Package cut-off is not clean.

Solution: Replace knife and anvil. Knife can be sharpened; however, shims will have to be used under the knife after grinding to retain original height. Adjust in usual manner (Section III, A-5) at operating temperature.

DO BOY HFFS TROUBLESHOOTING

There are four basic models that we will be concerned with and they are the H-400, Mustang, Super Mustang, and Scotty Wrap. Starting from the discharge and working our way back, we first inspect the operation of the crimp jaw.

I. End Seal Problems

A. Open End Seals

1. Cause: Film sticking to sealer jaws because temperature is too high, differential surface film is reversed, or ink on surface printed film is accumulating on sealing jaws.

Solution: Check jaw temperature with pyrometer and adjust temperature accordingly. Check for ink accumulation on jaws when surface printed film is used - an application of silicone release may help to minimize the problem.

2. Cause: Crimp jaws do not heat.

Solution: Check the following - circuit breaker; cartridge heater for open elements, defective thermistor; defective relay, collector rings and brushes, open and/or loose wiring connections and possible defective controller.

3. Cause: Upper jaw jumps out of time in relation to lower jaw.

Solution: Top jaw is spring-loaded and could have jumped out of time when closed on product. If top jaw should jump out of time with relation to lower jaw - jog the machine until lower jaw is in the cut-off position. Then loosen bolts on cutting head and pry up on drive end of upper jaw shaft. Rotate upper jaw shaft until jaw is aligned. Lower the upper jaw shaft and re-tighten bolts.

4. Cause: Jaws do not pause while meshed together.

Solution: Refer to "Packaging Machinery Manual" for epicycle adjustment.

5. Cause: Jaw is not closing on center line of product.

Solution: Raise or lower jaw position to center line of product.

B. Leading Edge of Packages Crushed

1. Cause: Jaws running slower than fin seal wheels.

Solution: Increase jaw speed.

C. Film Snaps at Jaws

1. Cause: Jaw is running faster than fin seal wheels.

Solution: Reduce jaw speed accordingly.

D. End Seal of Package is Crushed and Torn

1. Cause: Crimp jaws too close.

Solution: Adjust jaw clearance by turning bearing space. Try to get a nice clean impression on a single layer of film - so that you have a good strong seal when the film is doubled.

E. Lack of Indentation on End Seal

1. Cause: Insufficient crimp jaw tension.

Solution: Adjust tension screw.

F. Package Has Poor Serrated End Seals

1. Cause: Serrations and crimpers are not meshing properly.

Solution: Loosen cap screws holding lower crimp jaw and move sideways until they are meshed together; then re-tighten.

 

NOTE: All jaw adjustments should be at operating temperature.

G. Poor Package Cut-Off

1. Cause: Blade hangs up in lower jaw.

Solution: Clean out slots and lubricate linkage.


NOTE: Important to lubricate daily; otherwise, the linkage will give off a very loud sound.

2. Cause: Blade hits lower jaw - knife is either out of time or it is penetrating too deep.

Solution: Loosen cam mount until knife cam is in the slowest position. Jog machine until jaw roller and cam are in line and blade extends approximately ¼'' into lower jaw slot.

II. Fin Seal Problems

A. Film Fails to Seal Properly and/or Machine Jams

1. Cause: Film not wide enough or too wide.

Solution: Check film centering and width.

2. Cause: Film may be sticking to wheels if temperature is too high.

Solution: Adjust temperature, check controlled; thermistor; and check heater leads (clean fin wheels).

3. Cause: Fin seal wheels crushed seal.

Solution: Fin seal wheels too close together - check spacing and spring adjustment.

B. Film Does Not Feed Uniformly

1. Cause: One or both sets of fin seal wheels may be open or not closing properly.

Solution: Remove stainless steel guides and check the seal made by each set of wheels.

C. Fin Seal Wheels Cut Film

1. Cause: Serrations on fin seal wheels are out of alignment.

Solution: After locating the set of wheels that are doing the cutting - place a small mirror behind the wheels and observe the mating surfaces. If the wheels mate at a slight angle, loosen mounting screws and tap mounting blocks to bring wheels into alignment. If wheels are parallel but the serrations do not line up, loosen four (4) fin seal wheel mounting screws and run the machine for approximately one minute. This should bring the wheels into alignment; If not, then a new set of wheels may be required.

D. Film bunches at jaw - does not feed uniformly.

1. Cause: Auxiliary fin seal wheels set incorrectly.

Solution: Loosen set screws on auxiliary fin seal wheels and tap to a lower position.

III. Former Problems

A. Film does not feed into fin wheels.

1. Cause: Film not wide enough for product. Front product guides below inside of former floor. Product too large for former.

Solution: Film width should be the circumference of the product plus 1½" possibly wider for some bakery products that may vary in size. Former floor should be approximately 1/32" below front product guides. Select the right size former for the product.

B. Film Pulls Out From the Fin Seal Wheels

1. Cause: Film roll not centered on spindle.

Solution: Position film roll so that it is approximately on center line of former. Move inner and outer cores against roll.

IV. Backstand Problems

A. Film Fails to Feed Into Former Smoothly and Uniformly

1. Cause: Inclination rollers set too high or too low.

Solution: Reset inclination roller. If inclination roller is too high and the angle too steep, the film will have a tendency to pull and pucker in the corners. When roller is too low and the angle is not steep enough, film may roll over the edges and come out of the former.

V. Control Problems

A. Equipment Fails to Operate

1. Cause: Motor does not run.

Solution: Check following - main fuse, motor overload heaters on motor starter; open wire or loose connections, and the motor.

MIRA-PAK HFFS TROUBLESHOOTING

I. Unwind Problems

A. Film and/or Paper Does Not Track Properly

1. Cause: Roll stock may be wound unevenly, former may be improperly installed, or film and/or paper handling rolls may be misaligned.

Solution: Check stock for evenness of wind. Check former installation and then check alignment of film and/or paper handling system. Each roller, including the paper roll shaft, must be aligned, using the front edge of the former carrier as a reference point.

B. Excessive Film Tearing or Slippage

1. Cause: Too much tension on unwind.

Solution: The brake should be adjusted to provide more or less constant tension, delivering the roll stock in a smooth, even manner.

II. Former Problems

A. Creases and Marks on Packaging Material

1. Cause: Excessive former wear or the possibility of former damage.

Solution: Inspect the former. If damaged or worn, the former should be repaired.


NOTE: A badly worn former cannot be repaired. The Mira-Pak former is a highly accurate piece of equipment, and great care should be taken in handling.

B. Continued Tearing of Packaging Material at Former

1. Cause: Not enough clearance between tongue and former.

Solution: Check tongue and former spacing, which should be approximately 1/16".

C. Bag Back Seal Tends to Open

1. Cause: Clearance between tongue and back of former overlap is too great.

Solution: Check spacing between tongue and former overlap, which should be approximately 1/16".

III. Bag Forming Problems

A. Film Tears as Jaws Grab Film

1. Cause: Jaws closing too early or too late.

Solution: If jaws are closing too early, the film will be pushed upward and slack will be created, thus tearing film when the jaw frame starts downward. If jaws are closing too late, the jaws will grab the film at a high speed and also tear the film. To adjust jaw close point, place hand above jaw carrier in such a manner that the carrier will touch the fingers at the very top point of the stroke and listen for the click of the jaws when they close. Adjust jaw close cam until the touch and the click synchronize. After jaw close cam is set, reset interlock #1 cam so that the trailing edge is leaving switch #1 just as the leading edge of the jaw close cam is engaging switch #5.

OLIVER OVERWRAP TROUBLESHOOTING

I. Unwind and Film Feed Section

A. Web Breaks

1. Cause: Excessive unwind tension – web will jerk and snap as film is metered from roll.

Solution: Reduce tension setting to point film is pulled smoothly from roll.

2. Cause: Nicked or damaged roll (film) - web breaks at the roll or prior to entering the metering rolls.

Solution: Reduce roll brake to minimum. Also a damp towel or cloth can be effective on minor bead damage if simply held to the end of roll having damage.

3. Cause: Damaged transfer or idler rolls. Web breaks on or just after a particular roll.

Solution: Check idler and transfer roll for nicks, burrs, cuts, etc. Remove with medium-grit sandpaper or emery cloth.

B. Poor Film Tracking

1. Cause: Insufficient or no unwind braking - roll will continue to travel after metering rolls have stopped.

Solution: Increase braking by turning hand crank clockwise. Roll should stop at same time as metering rolls.

2. Cause: Roll (film) incorrectly positioned will result in excessive film on one end of package and insufficient amount on the opposite end.

Solution: Center roll by turning large wing nut located on same shaft as tension control handcrank.

3. Cause: Misalignment of transfer or idler roll - web will travel to the "high" side of the roll and will usually appear more tensioned on the bead in direction of travel.

Solution: Locate roll by visual check or by use of small level and properly align.

4. Cause: Film feed roll setting incorrect - web will track to tight side of roll.

Solution: Check feed rolls for cleanliness. With rolls clean and the pressure roll in the raised position, use two 1-2" wide strips of film or paper as gauges; place one strip at opposite ends between the feed rolls. Lower pressure roll slightly and pull strips. If either strip slips while the other is held securely, adjust roll until even pressure is exerted on both ends.

NOTE: Excessive pressure may wrinkle film and will cause abnormal wear on feed drive.

C. Jamming or Restraint of Web In Spring Belts

1. Cause: Spring feed belts worn or improperly adjusted. A usual indication of incorrect adjustment is lack of web corrugation.

Solution: Replace worn or frayed belts. Adjustment for a change in the amount of web corrugation is made by re-positioning the eccentric, fiber roll located nearest the elevator. Loosen set screws located at each end of shaft and rotate to activate more overlap of the belts for added web corrugation.

2. Cause: Excessive static electricity - web tends to cling or show restraint, usually more predominant in periods of cold, dry weather.

Solution: Apply damp cloth or towel over the roll. If condition is improved, check machine for static elimination equipment and condition of eliminator if so equipped.

3. Cause: Excessive label sealer temperatures – can cause substantial arching of the web from the label and result in restriction of the sheet as it is pushed through the knife slot.

Solution: Reduce label sealer to minimum temperature for maintaining satisfactory label adhesion.

4. Cause: Knife timed incorrectly. Interference with leading edge of sheet, causing web to ripple or jam in the feed belts.

Solution: Re-time knife, making sure it is fully retracked for the film feed sequence of the wrap cycle and is not cutting before film feed is completed.

NOTE: Timing should be done in accordance with instructions in operating manual.

II. Knife and Elevator Section

A. Poor Film Feeding

1. Cause: Dull or damaged knife will not cut sheet "clean" or completely, causing the sheet to be pulled back at the paper clamp roll during the elevator down-stroke.

Solution: Replace or sharpen knife. On some machines, knife is reversible.

2. Cause: Dirty Knife - interferes with film feed due to sluggish action or does not fully retract.

Solution: Clean knife and lightly lubricate with 20W oil.

3. Cause: Knife timed early - cut is made before film feed is completed. causing web to jam in feed belts.

Solution: Retime knife according to instructions given in machinery manual.

4. Cause: Knife action sluggish - interfering with feeding.

Solution: If knife is clean and properly adjusted*, check bearing, pivot end of knife and lubricate as needed.

*Adjust upper knife, which is spring-loaded, by loosening the lock nuts (rear of knife holder) and turning the hex head machine screw located near each end of knife. Only a slight pressure is required to keep knives in contact. Retighten lock and manually check knife before operating machine.

5. Cause: Obstruction in elevator film slot - web jams or is restricted during feed (film) cycle.

Solution: Remove film, product, etc. from slot In operations where product is iced or jelly filled, make sure slot is also free of these sticky materials.

6. Cause: Elevator incorrectly positioned during film feed. Web is restricted or jams at elevator.

Solution: Stop machine and place elevator in raised position. Check slot alignment with straight edge and adjust as needed.

7. Cause: Paper clamp roll out of time - does not raise during film feed causing bunching or jamming of web.

Solution: Turn machine to start of the feed portion of wrap cycle and adjust cam located on operator's side of machine to give maximum lift to the clamp roll.

8. Cause: Elevator paper clamp not functioning properly - as result of being dirty or insufficient spring pressure. Wrap will shift on package toward discharge side of elevator on the upward stroke leaving the trailing end of the sheet low enough to interfere with the incoming sheet for the next package.

Solution: Clean clamp and slot. Also check shaft, making sure it rotates freely. Additional pressure can be obtained by adding washers to the spring located on end of the elevator opposite the operator's side of machine.

9. Cause: Paper clamp rolls dirty – will interfere with proper feed of the web, causing rippling or waving in the elevator slot.

Solution: Clean build-up of sugar, icing, etc. with damp cloth. Wax deposits can be removed with appropriate solution.

B. Poor Quality in Package Wrap

1. Cause: Paper length varying due to insufficient feed roll pressure or feed rolls being dirty.

Solution: Make sure rolls are clean, check pressure (see I, B-4) and adjust as needed.

2. Cause: Insufficient pressure on paper clamp rolls will allow the cut sheet to slip or be pulled out of rollers as the elevator lowers.

Solution: Check upper paper clamp roll for obstruction and freedom of movement. Pressure is increased by turning the paper clamp adjusting knob clockwise. Knob is located on either front or rear of machine, depending on model.

3. Cause: Elevator paper clamp not functioning properly allowing wrap to shift on package during elevator up-stroke.

Solution: Clean and adjust clamp (see Section ll-A.8).

4. Cause: Poor film cut-off -- sheet momentarily held back causing incorrect positioning on package.

Solution: Check knife for dullness, burrs, etc. and proper adjustment (see Section ll-A.4).

5. Cause: Incorrect amount of drag on elevator slide block. Insufficient drag will result in loose wraps. Excessive drag will mar or damage the leading edge of the package as it is moved onto the elevator.

Solution: Adjust amount of drag on the block by inserting washers to increase, and likewise removing washers for a reduction. Drag is controlled by an internal compression spring and by adding or removing washers, spring compression is changed.

6. Cause: Excessive end sealer pressure - wrap is pulled toward rear of package.

Solution: Adjust sealer pressure on the package just to point of giving good seal.

III. Outfeed and Sealer Section

A. Poor Package Seals

1. Cause: Insufficient heat - weak or no seal.

Solution: Check temperature of sealers (bottom and end) with pyrometer. Increase control setting, wait sufficient time, and recheck temperature with pyrometer. If no increase is measured, heating elements, controls and wiring should be checked by a qualified person.

2. Cause: Excessive heat - seals blistered and/or discolored.

Solution: Check sealer temperatures with pyrometer and reduce heat sufficiently to clear up seals.

3. Cause: Sealers dirty causing excessive drag on hot seals or sticking.

Solution: Clean hot sealer plates with putty knife.

NOTE: On specially coated sealers (teflon, ceramic, etc.) do not scrape or use abrasive materials for cleaning.

B. Poor Package Integrity

1. Cause: Folders and plows dirty (icing, jelly, product) or obstructed-package end folds not neat or made.

Solution: Clean folders and plows and remove obstructions (fragments of U-boards, wrapping material, product, etc.)

BATTLE CREEK PACKAGING MACHINE TROUBLESHOOTING

I. lnfeed Section

A. Film wrinkles before meeting the package.

1. Cause: Obstruction on the paper (film) feed table, i.e., foreign matter; crumbs, icing, etc.

Solution: Clean paper (film) feed table, belts and hold-down rollers.

2. Cause: Feed belt may be off the rollers or sticking. The hold-down rollers may not be rising freely, or they may be sufficiently worn causing them to function poorly or not at all.

Solution: Check belts and hold-down rollers for proper positioning, functionality and wear.

3. Cause: The no-paper (film) detector may be closing too soon or it is out of time.

Solution: Check operation of no-paper (film) detector.

4. Cause: The knife may not be cutting completely across the sheet.

Solution: Check knife to make sure it is cutting the web cleanly.

B. Too much film on discharge side of package.

1. Cause: Film may not be centered on the arbor.

Solution: Center film on arbor.

2. Cause: The no-paper (film) detector may be closing too late causing the sheet to hesitate.

Solution: Inspect functionality of no-paper (film) detector.

3. Cause: The first bottom heater may be sticky.

Solution: Clean bottom heater plate.

4. Cause: The paper stops may beset too close together for the size of the paper (film) cut-off length.

Solution: Reset paper (film) stops.

5. Cause: There may be obstructions on the paper(film) table.

Solution: Clean feed belts and paper (film) table.

C. Too much paper (film) on the front side of the package.

1. Cause: Paper (film) may not be centered on the package.

Solution: Make sure the paper (film) is centered on the package.

2. Cause: The bottom folder and/or front paper (film) feed may be sticky.

Solution: Clean the feed belts.

3. Cause: There may be an obstruction on the paper (film) feed table.

Solution: Remove any obstruction between the bottom and the adjustable side folder, which could cause the film to drag.

D. Paper (film) not meeting the paper (film) stops squarely.

1. Cause: Paper (film) stops may not be square with the center line of the wrapper.

Solution: Square paper stops with center line of wrapper.

2. Cause: The knife may not be cutting cleanly and/or completely across the sheet.

Solution: Sharpen and reset the knife.

3. Cause: One of the paper (film) feed belts may be off the rollers.

Solution: Check paper (film) feed belts for proper position on rollers.

4. Cause: The no-paper (film) detector may be closing too soon and/or out of time.

Solution: Retime no-paper (film) detector.

5. Cause: The paper (film) carrier belt may be loose.

Solution: Retighten paper (film) carrier belts.

E. Package short of film on the operator's side of the wrapper.

1. Cause: Paper (film) roll brake may be too tight or too loose.

Solution: Adjust paper (film) roll brake.

2. Cause: Paper (film) stop may be set too far to the left.

Solution: Check adjustment of paper (film) stops.

3. Cause: Paper (film) feed clutch may be slipping.

Solution: Clean paper (film) clutch.

4. Cause: Machine may be set too wide for the package.

Solution: Check setting of machine for proper package width.

II. Wrapping Section

A. Package shows an open area on the bottom.

1. Cause: Incorrect paper (film) width is being used for the package.

Solution: Measure package to determine proper paper (film) width and check width of paper (film) being used.

2. Cause: The compression plate may be sticking and/or hot from setting on the first heater plate.

Solution: Clean and cool down compression plate.

3. Cause: The no-paper (film) detector may be out of time.

Solution: Check no-paper (film) detector for proper timing.

4. Cause: The package holder may be sticky.

Solution: Clean package holder.

B. Package twists during first end fold operation

1. Cause: Package may not be centered in the machine.

Solution: Center the package in the machine.

2. Cause: Package holder may be out of adjustment.

Solution: Adjust package holder.

3. Cause: The first end folders may be dirty and/or set too close to the product.

Solution: Clean first end folder and set for proper spacing in relation to product.

C. Improper Drop Fold

1. Cause: Transport assembly may be set too far toward the front of the wrapper. The drop folder may be out of time.

Solution: Reset transport assembly and drop folder timing.

2. Cause: First end folder may not be properly set. Improper length of down-stroke.

Solution: Correctly set first end folder and length of down-stroke.

D. Poor Bottom Fold

1. Cause: Folding plate sticky, obstructed or out of line. Package stops frozen or sluggish.

Solution: Clean and line up folding plates.

2. Cause: The paper (film) stops may be set too close for the size of the paper (film) cut-off length.

Solution: Make sure package stops are free. Reset paper (film) stops.

3. Cause: There may be an obstruction on the paper (film) feed table.

Solution: Remove any obstruction from the paper (film) feed table.

4. Cause: The no-paper (film) detector may be closing too late.

Solution: Reset the no-paper (film) detector.

5. Cause: The first bottom heater may be sticky.

Solution: Clean the first bottom heater plate.

E. Package drops toward the front or feed end of the wrapper as the transport assembly withdraws.

1. Cause: First end folders may be dirty or set too tight against the package.

Solution: Clean first end folders and readjust so they are not too tight against the package.

2. Cause: The compression plate may be dirty or hot.

Solution: Clean compression plate and make sure it is cool.

III. Package Discharge Section

A. Package twists while being transported through sealing and cooling sections.

1. Cause: Foreign matter on heater and/or cooling plates.

Solution: Clean away foreign matter from heater and cooling plate sections.

2. Cause: Machine set too tight.

Solution: Adjust machine for proper package spacing.

3. Cause: Transport feet may not be lined up squarely with each other.

Solution: Squarely line up transport feet with each other.

4. Cause: Side sealing plates may be out of line.

Solution: Realign side sealer plate.

5. Cause: Bottom sealer plate may be warped.

Solution: Check bottom heater plate to see if it is warped - replace if it is.

PMC MODEL FA TROUBLESHOOTING

I. Film (Paper) Feed Section

A. Film jams at in-feed before the knife.

1. Cause: The film (paper) corrugating wires are not stiffening the film and preventing it from jamming as it is fed past the feed rollers.

Solution: The corrugating wires must be set parallel with the travel of the film to ensure that the film is fed straight into the feed belts. The bottom set of wires should be adjusted so that their bottom surface will just clear the outside surface of the measuring roll. The top set of wires act only as a top film (paper) guide.

B. Film (paper) fails to centralize over the elevator well position.

1. Cause: Rotary knife out of time and/or film (paper) stops not set properly.

Solution: To adjust rotary knife timing, loosen binding screw on rotary knife gear; then advance or retard knife holder and retighten binder screw. Check film position by feeding a few sheets. If the film overtravels the elevator position, the rotary knife should be retarded to cut off late, or advanced if the film does not arrive in time. The film(paper) stops are adjusted so that a properly positioned sheet just clears them when the rolls drop, and the film is picked up by the package.

C. Film not meeting package on time and/or not squarely.

1. Cause: Incorrect and/or uneven tension in the film (paper) feed belts.

Solution: Adjust film (paper) take-up pulley for correct and balanced belt tension.

D. Film (paper) swings out of line.

1. Cause: Top film (paper) guide on the solvent applicator is set too low, thereby pinching the film between the guide and the solvent applicator wheel, causing the sheet to swing.

Solution: The bottom surface of the top guide should be in line with the outside diameter of the solvent applicator wheel.

E. Film(paper) cut-off length varies.

1. Cause: Too much brake drag will cause film slippage and variation in cut-off length.

Solution: The weight on the brake strap should be only enough to stop the film rolls from unwinding more film than the slackener can accommodate when the machine stops.

II. Wrapping Section

A. Wrapped package has "ears" on the wrap and/or the folds are slack over the corners of the package.

1. Cause: When the folders are set too loosely, the folds will be slack, thus causing "ears,” or slack paper, on the comers of the package.

Solution: The folders should be centralized with the center line of the machine and square with the front edge of the flapper housing. Line up the inside surface of the folders with the inside surface of the tuckers and the side heater plates.

2. Cause: If the top plates are set too high, it will cause the folds to be slack over the comers of the package.

Solution: At the elevator, the top plates should be adjusted so there will be approximately 1/32" clearance between the top of the package and the bottom of the top plate.

B. No side tucks, poor side tucks, and/or package being damaged.

1. Cause: If the tuckers are set too tight, they will push the package forward instead of making the first tuck, or it may cause the tuck to be pulled back as the tuckers return from their forward position. If the tuckers are set too wide, they will not clear the off-set at the end of the first folder.

Solution: The tuckers must be set centrally with the central line of the machine and adjusted only wide enough to allow them to clear the ends of the package as the first tuck is made.

C. Wrap on package too loose or too tight

1. Cause: Timing of release rolls not properly set.

Solution: Cycle the machine by hand until the upcoming package contacts the film. Then loosen the binding screw on the release cam and rotate the cam until the cam level roller is at the top of the drop on the cam. Finally, retighten the binding screw and check packages. Reset the cam if the wrapper is not drawing around the package as desired.

III. Discharge Section

A. Side folds are wrinkled, pulling back and/or not sealed properly.

1. Cause: Side heater plates adjusted too tight, too wide and/or dirty.

Solution: The side heater plates should be adjusted so as to allow the package to pass through the unit freely. Loosen the binding screw and adjust the side heater spacing with the band wheel. Then, retighten the binding screw. Periodically clean the heater plate surface using a fine grade of sandpaper to remove any accumulation. The heater plates should be Teflon-coated in order to reduce the friction between the package and the heater plate surface.

SIMPLEX TROUBLESHOOTING

I. Unwind Section

A. Web Breaks

1. Cause: Excessive brake on unwind.

Solution: Adjust brake so the roll will stop but maintain slight tension on web when draw rolls stop. Film tension may be adjusted either on the tension roller arms or on brake lever. Adjustment can usually be made by adjusting the spring tension on the brake lever while the machine is operating. The tension roll should be adjusted so that it moves up and down smoothly. Make certain the tension roll does not rest on the unwinding roll when moving down and does not hit the idlers when going up. As the roll decreases in size, less brake is required.

2. Cause: Nicked transfer rolls, forming cylinder or forming plate.

Solution: Remove these nicks with fine sandpaper or emery cloth.

3. Cause: Damaged roll of wrapping material.

Solution: Check damaged roll and when possible, cutoff damaged portion; if too severe, replace the roll. In some cases, a damp cloth applied to the damaged area may be sufficient.

B. Poor Web Tracking

1. Cause: Insufficient unwind tension, film will wander

Solution: Check brake and make certain the brake lining as well as the drum brake are free from oil. Clean brake lining and drum with kerosene or cleaning fluid and dry. Adjust to proper tension.

2. Cause: Toe-in roller pressure.

Solution: Toe-in rollers should be adjusted equally. If one has more pressure than the other, it will draw film to that side.

3. Cause: Transfer roll misaligned, web will travel to "high" side of roll.

Solution: Check alignment of rollers with tabletop and correct

4. Cause: Inconsistent roll formation, raised beads, bands, or soft beads may cause tracking problems.

Solution: Tape should be applied to center of transfer roll. No tape is applied to end of roll where bead is loose or floppy.

II. Forming Section

A. Wrinkles in Bags

1. Cause: Forming plate out of alignment

Solution: Align former plate with breaker bar so web will be pulled in a straight line.

2. Cause: Too much heat on back seam sealer bar causes film to stick to the canvas webbing on the former plate.

Solution: Lower the temperature as low as possible while maintaining good seal Use pressure-sensitive Teflon tape on top of canvas.

3. Cause: Forming cylinder wider than former plate.

Solution: Remove and replace cylinder with one the same size as the plate or smaller. Never use a cylinder that is wider than the forming plate.

4. Cause: Forming plate traveling too deep into draw rollers.

Solution: Adjust forming plate travel to a minimum and yet permit draw rolls to continue pulling film.

B. Web Breaks

1. Cause: Misalignment of gussets and former.

Solution: Realign former.

III. Sealing Section

A. Poor Back Seam Seal

1. Cause: Insufficient sealing temperature will cause weak or no seal.

Solution: Check temperature with pyrometer and adjust according to film type and gauge.

2. Cause: Excessive heat will cause charring or discoloring and may result in interfacial sticking inside the formed bag.

Solution: Check temperature and lower accordingly.

3. Cause: Insufficient pressure on sealing bar may cause weak or no seals.

Solution: Increase pressure; it may be necessary to drill holes in heater mount and put in set screws to maintain pressure.

4. Cause: Poor seals may be caused by worn canvas on forming plate.

Solution: Replace with new preshrunk canvas (canvas should be preshrunk by boiling in clean water for 30 to 45 minutes, then drying before using).

5. Cause: Dirty sealing bar.

Solution: Clean with a cleaning fluid. Check with mirror after cleaning. If still dirty, remove bar and clean with very fine sandpaper fastened to a flat surface.

B. Poor Bottom Foldover Seal

1. Cause: Weak or no seals may be caused by insufficient sealing temperature.

Solution: Check temperature with pyrometer and adjust as needed.

2. Cause: Excessive heat will cause discoloring, charring, or interfacial sticking.

Solution: Check temperature with pyrometer and decrease accordingly.

3. Cause: Insufficient pressure on the T-sealing bar may cause weak seals.

Solution: Increase pressure by loosening thumb screw on cam arm and turn adjusting screw clockwise.

C. Poor Formation of Foldover

1. Cause: Stroke too long.

Solution: Reduce stroke to standard 2¼''

2. Cause: Former positioned too far forward on the machine.

Solution: Move the former back 1/ 16" from the edge of the machine table. Be certain the end of the former is parallel to the end of the table and not in a cocked position.

3. Cause: Foldover blades out of line.

Solution: Loosen cap screws and align both blades when they are in their most forward position.

D. Poor Crimp Seal

1. Cause: Weak crimp seals may be caused by jaw misalignment

Solution: Check to see that the jaws mesh properly; if not, loosen lower jaw and realign.

2. Cause: Insufficient heat will cause weak or no seal.

Solution: Increase temperature until good seal is obtained.

3. Cause: Excessive heat will cause discoloring, charring, and sometimes sticking.

Solution: Check temperature with pyrometer and adjust

4. Cause: Excessive difference in temperature of sealing jaws may cause weak seals or sticking.

Solution: Check temperature with pyrometer and adjust or replace beating elements until the jaw temperatures are in reasonable balance.

5. Cause: Dirty sealing jaws may cause weak seals.

Solution: Check jaws for ink or coating buildup and clean.

IV. Bag Cut-off

A. Length variation

1. Cause: Excessive brake.

Solution: Adjust brake until tension roll moves up and down smoothly.

2. Cause: Draw rollers dirty.

Solution: Clean rollers with solvent-dampened cloth, then roughen slightly with sandpaper.

3. Cause: Rubber rings worn out on draw rolls.

Solution: Replace with new rubber rings.

4. Cause: Excessive heat on long heater causing sticking.

Solution: Check temperature of heater and adjust. Check condition of canvas backup strip and replace if worn.

5. Cause: Insufficient film slip.

Solution: Roughen transfer roll with sandpaper or try turning the roll around.

6. Cause: Loss of ratchet on the transfer roll permitting film pullback.

Solution: Repair or replace ratchet.

B. Ragged Cut-off

1. Cause: Nicked or dull knife.

Solution: Remove and sharpen or replace knife.

2. Cause: Draw rolls out of time.

Solution: Check draw rolls; they should be stopped and lifted approximately 1/8 inch while knife is cutting. If they are not, make adjustment accordingly.

C. Bag Not Being Cut Off

1. Cause: Weak springs on top knife.

Solution: Check springs and adjust or replace them.

2. Cause: Shearing angle out of adjustment.

Solution: Check knife and if it is not making a close and smooth pass, adjust by moving the angle iron found at the lower left end of the top knife. This is for foldover setup. To adjust crimp knife, there is a set screw in the lower crimp jaw. After making adjustments, always crank machine through by hand before turning machine on.

WOODMAN VFFS TROUBLESHOOTING

I. Unwind Section

A. Web Breaks

1. Cause: Unwind braking excessive, web snaps during drawstroke.

Solution: Reduce unwind braking on friction belts by decreasing spring tension. On machines having the shoe-to-hub brake, set the adjusting screw so that it just touches the brake shoe when the dancer bar is parallel to the support bracket.

2. Cause: Transfer rolls nicked or damaged, web breaks, at or near a particular roll. However, it is also likely damage will cause web to break at or just after the former.

Solution: Locate roll and remove damage with fine grit emery cloth or sandpaper.

3. Cause: Roll (wrapping material) nicked or damaged, web breaks just after unwinding from roll or, in case of minor damage, break or tear may occur in other areas of the machine.

Solution: Discard roll if damage is severe. If outer portion only shows damage, this can be cut away and the remainder used. In case of minor damage, a damp cloth or towel applied to the damaged bead can be effective.

4. Cause: Product may occasionally fall from scales or overhead conveyor onto the web, breaking the web at idler or draw rolls.

Solution: Shield affected area with cardboard.

B. Poor Web Tracking

1. Cause: Insufficient unwind braking, roll (wrapping material) will over-travel after drawstroke is completed.

Solution: Increase unwind brake on friction belt by relocating book to the next position. On hub and shoe type braking, with the dancer bar parallel to the support bracket, tum adjusting screw clockwise until it contacts the brake shoe.

2. Cause: Transfer or feed roll misaligned, web travels to "high" side of roll.

Solution: Check alignment of rolls with level or by measurement and correct.

3. Cause: Poor roll formation (soft edge, high bead, band at bead) – in severe cases, web will track in direction of tight bead.

Solution: Apply sufficient amount of tape to transfer and/or feed rolls to balance web tension.

4. Cause: Dancer roll raises or falls with uneven stroke.

Solution: Check roll for obstruction caused by foreign matter, and for possible need of lubrication.

II. Former and Back Seal Section

A. Poor Web Tracking

1. Cause: Parent roll not positioned correctly at unwind, causing film to run off center of the former.

Solution: Relocate roll so web is properly positioned on former.

2. Cause: Former misaligned - web travels to side of former.

Solution: Align former squarely with frame of machine. Check vertical alignment and correct if needed with screws located on the mounting plate.

3. Cause: Feed rolls worn or improperly adjusted. Web travels off former.

Solution: Check level and alignment of roll. Rolls should be parallel to the former wing (make sure former is properly aligned). Rolls showing excessive wear should be replaced. If replacement rolls are not readily available, tape applied to the worn area can be a temporary solution.

4. Cause: Feed roll position incorrect. Web does not track uniformly on former.

Solution: Adjust roll so web fully and evenly contacts former surface.

B. Web Breaks

1. Cause: Inadequate clearance between former and tube, web tears in former.

Solution: Adjust clearance so that web moves freely between former and tube. Adjustment is made with screws located front and rear of mounting bolts.

2. Cause: Former surface damaged, slits or tears in web, occurring on surface of the former.

Solution: Remove burrs, pricked areas, etc. with fine grit sandpaper or emery cloth.

3. Cause: Roll (wrapping material) nicked or damaged, web breaks on former usually before back seal is made.

Solution: Remove damaged portion of material from roll, if practical, otherwise discard roll. In a case of minor bead damage, a wet cloth or towel held to the damaged end is effective in salvaging the roll.

4. Cause: Sticking on seam sealer due to excessive heat and/or dirty sealer surfaces.

Solution: Check sealer temperature with pyrometer and reduce accordingly. Remove any build-up of coating, printing ink, etc. from surface of sealer. Care should be used on special coated sealers.

C. Poor Seals

1. Cause: Film width insufficient - no lap in back seam seal.

Solution: Check required width for former being used and web width.

2. Cause: Incorrect sealer temperature. Excessive heat will cause seal to discolor and/or blister. With heat too low, seal will be weak and show little or no fusion of the coating.

Solution: Check sealer temperature with pyrometer and adjust accordingly. Allow sufficient time (5-10 minutes normally) for change to occur and recheck with pyrometer. If no change is measured, controls, wiring, fuses, heating elements, etc. should be checked by a qualified person.

3. Cause: Forming tube not set properly. If tongue points away from carriage tracks, it will tend to open the back seal and make tube diameter excessive. With the tongue positioned too far inward, bag diameter will be too small and folds may occur in seal area.

Solution: Align tube and tongue so the center line of the tube is parallel to the carriage tracks.

4. Cause: Sealer bar misaligned-weak back seal or shows difference in strength from side to side.

Solution: Set sealer arm parallel to the jaws, with the sealer resting on the tube. Center line of the bar must correspond to center line of the tube.

5. Cause: Sealer bar stop and spring tension setting incorrect. Lap of the web is plowed open at the top of sealer or seal is weak.

Solution: Adjust the sealer bar so that a I/ 4" gap is maintained at the top when the bottom of the bar contacts the tube. Adjust the spring tension to just hold the bar against the stop.

NOTE: All pivot points on the seam sealer must be free and should be oiled occasionally.

III. Crimp Jaw Section

A. Poor Seals

1. Cause: Incorrect sealer temperature – excessive temperature seal will blister and/or discolor and sticking on the jaws may also be evident. Insufficient temperature will result in weak or no seal at all.

Solution: Check temperature with pyrometer and adjust as needed. Wait sufficient time for change to occur and recheck. If no change is measured, controls, wiring, heaters, etc. should be checked by a qualified person. Adjust any imbalance between jaws to 10° F or less.

2. Cause: Jaw alignment incorrect. Jaw serrations cut package in the seal area.

Solution: Loosen jaw mounting bolts and slide jaws to achieve proper meshing. Retighten bolts before operating machine.

3. Cause: Low air pressure to jaw cylinders. Seals weak and show a light serrated pattern.

Solution: Check air pressure to the jaws, regular setting, and valve in supply line. Jaw cylinders require 80 psi to function properly.

4. Cause: Milker plates set too close. Plates contact stopping jaws before seal is made.

Solution: Loosen screws holding the movable plate and with the jaws 3/8" apart, set the milker plate gap at .045” and retighten screws. Slight variations may be required depending on wrapping material and product.

5. Cause: Film with differential surface (one side release coated) reversed. Sticking on the jaws, at times to the extent of separating the seals.

Solution: Check both surfaces of web for release coating.

B. Wrapping Material Sticking to Sealer Jaws

1. Cause: Excessive heat on crimp jaws.

Solution: Make a complete check of jaw temperatures, front and rear, also upper and lower section of each jaw if equipped with separate heating elements. Reduce temperature if excessive and adjust any imbalance between jaws to 10° F or less. If seals are satisfactory and clean and sticking is evident at lower temperature, a slight increase (100-200F) in temperature may be effective in improving jaw release.

2. Cause: Jaw surface dirty (coating build-up, product), packages fail to drop freely and tube sticks to upper part of jaws and is carried with the jaws on the upstroke.

Solution: Clean jaws with wire brush. CAUTION: Jaws having special coating (teflon, ceramic) must be cleaned with approved materials. With jaws clean, check temperature and ascertain that release surface is toward jaws, when differential surface material is used.

3. Cause: Knife and slot dirty. Knife does not fully retract.

Solution: Clean knife and slot making sure all pivots are free and oiled.

4. Cause: Jaw surfaces damaged (burrs, cuts) and package does not drop freely. Also sealed area may show damage.

Solution: Remove burrs or cuts, preferably with a triangular file. Sandpaper or a small flat file can be used.

C. Poor Package Cut-Off

1. Cause: Knife dull or broken – package is not cut-off clean or completely.

Solution: Check condition of knife. Replace if broken, worn or dull If no replacement is available, a dull blade may be ground and used until a replacement is obtained.

WRIGHT VFFS TROUBLESHOOTING

I. Unwind Section

A. Web Breaks

1. Cause: Unwind braking excessive, web snaps during drawstroke.

Solution: Reduce braking by turning the adjusting nut counterclockwise.

2. Cause: Transfer or dancer roll surfaces damaged or nicked. Web breaks at or near a particular roll. It is also possible for breaks to occur at or just after the former as a result of damage to the web by the nicked roll surface.

Solution: Locate problem roll(s) and remove damage with fine grit emery cloth or sandpaper.

3. Cause: Roll (wrapping material) nicked or damaged. Web may break just after unwinding from the parent roll or, in case of minor damage, break or tear may occur in other areas of the machine.

Solution: Discard roll if damage is severe. Damage to the outer portion of the roll can be cut away and the remainder used. In cases of minor bead damage, a damp cloth or towel applied to the bead can be effective in preventing.

B. Poor Web Tracking

1. Cause: Insufficient unwind braking. Roll (wrapping material) will over-travel after drawstroke is completed.

Solution: Increase unwind braking by turning adjusting nut clockwise.

2. Cause: Transfer or dancer rolls misaligned. Web will travel to "high" side of roll.

Solution: Check alignment of roll with level or by measurement and correct.

3. Cause: Poor roll formation (soft edges, high bead, band at bead). In severe cases, web will track in direction of the tight bead.

Solution: Apply sufficient amount of tape to transfer and/or dancer rolls to balance web tension.

4. Cause: Dancer roll(s) raises or falls with uneven stroke.

Solution: Check roll for obstruction and/or possible need of lubrication.

II. Former and Back Seal Section

A. Poor Web Tracking

1. Cause: Parent roll not positioned correctly on unwind arbor causing the web to run off center at the former.

Solution:


2. Cause:
Former misaligned. Web travels to one side or wanders on former.

Solution: Align former squarely to former rolls.

3. Cause: Former rollers incorrectly positioned. Film wanders on former.

Solution: Position rollers so that web just contacts former skirt.

4. Cause: Former rollers worn or misaligned. Web travels off former.

Solution: Check alignment and correct if needed. Replace rolls showing excessive wear. If replacement rolls are not readily available, tape applied to worn area can be a temporary solution.

B. Web Breaks

1. Cause: Inadequate gap opening in former lap causing edge fractures and/or breaks in web.

Solution: Check gap opening and set if needed at 1/32" to 1/16".

2. Cause: Former surface damaged. Slits, tears and/or heavy scratch marks occurring on surface of the former.

Solution: Check surface of former and remove burrs, pricked areas, etc. with fine-grit sandpaper or emery cloth.

3. Cause: Vertical sealer too close to former. Film fractures along vertical seal.

Solution: Move sealer away from former.

4. Cause: Vertical seal magnet pressure setting too high. Film "chatters" or breaks under the sealer.

Solution: Reduce vertical seal magnet setting located on control box.

5. Cause: Sticking on vertical sealer due to excessive heat and/or dirty sealer surface.

Solution: Check sealer temperature with pyrometer and reduce accordingly. Remove any build-up (coating, product, printing ink) from surface of sealer. Care should be used on special coated sealers.

C. Poor Seals (Vertical)

1. Cause: Insufficient film width for lap in vertical seal.

Solution: Check film width required for former being used.

2. Cause: Incorrect sealer temperature. Excessive heat will cause seal to blister and/or discolor. If too low, seal will be weak and show little or no fusion of the coating.

Solution: Check sealer temperature with surface pyrometer; adjust accordingly. If adjustment is made, allow sufficient time for change to occur and recheck with pyrometer. If no change is measured, controls, wiring, fuses, heating elements, etc. should be checked by a qualified person.

3. Cause: Vertical seal magnet pressure too low. Seal weak or not made at all.

Solution: Increase vertical magnet setting located on control board.

4. Cause: Clearance between the vertical sealer face and the top of the back-up bar incorrect.

Solution: Check clearance and set at .010 inch.

5. Cause: Vertical sealer not aligned to the back-up bar and tube. Seal weak and/or shows difference in strength from side-to-side.

Solution: Check kick-out latch adjustment.

6. Cause: Back-up bar bent or misaligned. Seal not made over full length. If misalignment of bar is excessive, either toward or away from the machine, tube size may be affected and in turn cause poor seals.

Solution: Check alignment and straightness of back-up bar.

III. Crimp Jaw Section

A. Poor Seals

1. Cause: Incorrect sealer temperature. Excessive heat will cause seal to blister and/or discolor and can result in sticking on the jaws. Insufficient heat will result in weak or no seal at all.

Solution: Check jaw temperature with pyrometer and adjust as needed If adjustment is made, wait sufficient time for change to occur and recheck. If no change is measured, controls, heater elements, fuses, wiring, etc. should be checked by a qualified person. Adjust any imbalance between jaws to 10° F or less.

2. Cause: Incorrect air pressure. If too low, seals will be weak. Excessive pressure can result in cuts in the seal area.

Solution: Check actual air pressure to jaws, regulator and valves.

3. Cause: Jaws not meshing properly. Cuts in the seal area.

Solution: Loosen mounting bolts and move jaws to achieve proper meshing. Retighten bolts before operating machine.

4. Cause: Jaws dirty. Seals damaged or poor in particular area. Sticking may be evident

Solution: Remove any build-up of product, coating, etc. from jaw with wire brush.

NOTE: On jaws having special coating (teflon, ceramic, etc.) follow manufacturers’ suggested method of cleaning.

5. Cause: Excessive air pushing seal out.

Solution: Check stripper blade clearance and set at 1/ 32". Check deflators and ascertain that sufficient pressure is being applied to expel excess air from the bag.

6. Cause: Product in seals. Excessive clearance between stripper blades.

Solution: Check clearance between stripper blades and set at 1/32".

7. Cause: Film with differential surface reversed. Sticking on jaws, at times to the extent of separating seals.

Solution: Check surfaces of web for release coating and position roll on the unwind mandrel so that release treated surface is toward jaws (outside surface of tube).

8. Cause: Jaw surfaces damaged (burrs, cuts) and package does not fall freely. Also seal area may show damage.

Solution: Remove burrs or cuts with, preferably, a small triangular file. Sandpaper or a small flat file can be used.

B. Poor Package Cut-Off

1. Cause: Knife dull or broken. Package not cut clean or completely.

Solution: Check condition of knife. Replace if broken, worn or dull. If no replacement is available, a dull blade may be ground and used until a replacement can be obtained.

2. Cause: Knife and/or slots dirty.

Solution: Remove knife from jaws, scrape away excessive build-up with a putty knife and sand with fine-grit paper or emery cloth. Thoroughly clean knife slots in jaws. Apply a small amount of oil to both sides of knife and replace.

3. Cause: Insufficient penetration of knife into outer jaw. Package cut-off not complete.

Solution: Stop the draw bar with knife cam roller on the highest point of the cam. Adjust linkage so that knife travel stops 1/16" from bottom of slot in the outer jaw (jaws closed).

4. Cause: Knife incorrectly timed.

Solution: Move drawbar down until jaws are closed. Slide cam until cam roller is on the highest point of the cam.

ALLPAC VFFS TROUBLESHOOTING

The investigation of problems on the Allpac equipment can best be accomplished by starting at the discharge of the machine and working back. First inspect the operation of the crimp jaw.

I. Crimp Jaw Area

A. Open End Seals

1. Cause: Film sticking to sealer jaws because temperature is too high, differential surface film is reversed or ink on surface printed film is accumulating on sealing jaws.

Solution: Check jaw temperature with pyrometer and adjust temperature accordingly. Check outside and inside surface of film for release coating and mount roll to position release coating to the outside of the finished package. Check for ink accumulation on jaws when surface printed film is used - an application of silicone release may help to minimize the problem.

2. Cause: Crimp jaws do not heat.

Solution: Check the following - circuit breaker (cartridge heater for open elements, defective thermistor, defective relay, collector rings and brushes, open and/or close wiring connections and possible defective controller.

3. Cause: Upper jaw jumps out of time in relation to lower jaw.

Solution: Top jaw is spring-loaded and could have jumped out of time when closed on product. If top jaw should jump out of time, jog the machine until lower jaw is in the cut-off position. Then loosen bolts on cutting head and pry upon drive end of upper jaw shaft. Rotate upper jaw shaft until jaw is aligned. Lower upper jaw shaft and retighten bolts.

4. Cause: Jaws do not pause while meshed together.

Solution: Refer to "Packaging Machinery Manual" for epicycle (pause) adjustment.

5. Cause: Jaw is not closing on horizontal line of product.

Solution: Raise or lower jaw position to center of product.

B. Leading Edge of Packages Crushed at Jaws

1. Cause: Jaws running slower than fin seal wheels.

Solution: Increase jaw speed by advancing regulating hand wheel located on operator's side of machine.

C. Film Snaps at Jaws

1. Cause: Jaw is running faster than fin seal wheels.

Solution: Reduce jaw speed by retarding regulating band wheel located on operator's side of machine.

D. Package Smashed by Jaws

1. Cause: lnfeed chain out of time with jaws.

Solution: Set hand wheel to place crimp seals in proper relation to product.

E. End seal of Package is Cut or Crushed and Torn

1. Cause: Crimp jaws meshed too tightly.

Solution: Adjust jaw clearance by turning bearing spacer. Try to get a nice clean impression on a single layer of film, so that you have a good strong seal when the film is doubled.

F. Lack of Indentation on End Seal

1. Cause: Insufficient crimp jaw tension.

Solution: Adjust tension screw located on top of head assembly.

G. Package has Poor Serrated End Seals

1. Cause: Serrations and crimpers are not meshing properly.

Solution: Loosen cap screws holding lower crimp jaw and move sideways until top and bottom jaws are meshed together properly, then retighten.

NOTE:
a. All jaw adjustments should be made at operating temperature.
b. Confirm proper meshing with imprint on aluminum foil.

H. Poor Package Cut-Off

1. Cause: Knife dull or not adjusted properly, or insufficient tension on upper jaw.

Solution: Check knife and jaw tension, refer to packaging machine manual for making the adjustments.

II. Fin Seal Problems

A. Film Fails to Seal Properly and/or Machine Jams

1. Cause: Film not wide enough or too wide.

Solution: Check film centering and width.

2. Cause: Film may be sticking to wheels if temperature is too high.

Solution: Adjust temperature, check controller, thermistor, and check heater leads (clean fin wheels).

3. Cause: Fin seal wheels cut seal.

Solution: Fin seal wheels too close together - check spacing and spring adjustment.

4. Cause: Fin seal wheels not aligned.

Solution: Adjust fin wheels to obtain contact with full face of heated surface. (Confirm alignment with imprint on aluminum foil.)

5. Cause: Film pulls out of fin seal wheels.

Solution: See section IV, item B of this manual.

B. Film Bunches at Jaw - Does Not Feed Uniformly

1. Cause: Auxiliary (rubber) draw wheels set with too little tension.

Solution: Remove bedplate, clean and adjust tension.

2. Cause: Bedplate poorly aligned.

Solution: Adjust bedplates approximately 1/8" from center line of machines.

III. Former Problems

A. Film Does Not Feed Into Fin Wheels

1. Cause: Film not wide enough for product.

Solution: Film width should be the circumference of the product plus 1½"' - possibly wider for some bakery products that may vary in size.

2. Cause: Front product guides below inside of former floor.

Solution: Front floor should be approximately 1/ 32" below front product guides.

3. Cause: Product too large for former.

Solution: Select the proper size former for the product.

IV. Backstand Problems

A. Film Pulls Out From the Fin Seal Wheels

1. Cause: Film roll not centered on spindle.

Solution: Align film so that it is on center line of former.

2. Cause: Inclination rollers set too high or too low.

Solution: Reset inclination roller until film is in contact with forming collar. If inclination roller is too high and the angle too steep, the film will have a tendency to pull out of fin sealers. When roller is too low and the angle is not steep enough, wrapping material will be pulled tighter around product.

3. Cause: Excessive unwind tension.

Solution: Adjust unwind brake to maintain minimum tension on film. Avoid any slackness.

4. Cause: Wrapping material too narrow.

Solution: Correct width will be the girth of product plus 1½"' or enough to accommodate maximum product size variation.

5. Cause: Former too large for product size.

Solution: Select correct former for product size.

6. Cause: Tabs on bottom of former require adjustment.

Solution: Widen tabs to hold film in fin wheels.

B. Film Fails to Feed Into Former Properly

1. Cause: Inclination roller set too high or too low.

Solution: Too high: Film will have a tendency to pull and pucker at comer. Too low: Film may roll over the edges and come out of the former.

2. Cause: Lack of unwind brake.

Solution: Adjust unwind brake to maintain minimum tension on film and avoid any slackness.

3. Cause: Film roll not centered on spindle.

Solution: Align film so that it is on center line of former

V. Control Problems

A. Equipment Fails to Operate

1. Cause: Motor does not run.

Solution: Check following:
a. Main fuse
b. Motor overload heaters on motor starter
c. Open wire or loose connections and the motor