Excessive heat will cause seal to blister and/or discolor. Cause: Sealer bar stop and spring tension setting incorrect. Then loosen bolts on cutting head and pry up on drive end of upper jaw shaft. Solution: Remove bedplate, clean and adjust tension. There are four basic models that we will be concerned with and they are the H-400, Mustang, Super Mustang, and Scotty Wrap. Excessive pressure, seals will be damaged and/or cut. Cause: Film width insufficient - no lap in back seam seal. from slot In operations where product is iced or jelly filled, make sure slot is also free of these sticky materials. Insufficient drag will result in loose wraps. First check the film tracking to make sure film is properly loaded, folded, and in position. Cause: Incorrect sealer temperature. Cause: Insufficient unwind tension, film will wander. Cause: Knife and anvil improperly adjusted. Cause: Product in seals. Solution: Retighten paper (film) carrier belts. 5. Web breaks on or just after a particular roll. Cause: Film roll not centered on spindle. Lower the upper jaw shaft and re-tighten bolts. 7. Care should be used on special coated sealers. Cause: Excessive unwind tension web will jerk and snap as film is metered from roll. After sufficient time for the change to occur, recheck temperatures. 2. 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. 1. Cause: Inadequate clearance between former and tube, web tears in former. A usual indication of incorrect adjustment is lack of web corrugation. 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. Before getting into the specifics of your issue, ask yourself 3 general questions: If the environment, temperature, or humidity levels in your facility deviate from what your vertical form fill machine was specified for, this can cause malfunctions. Cause: Upper jaw jumps out of time in relation to lower jaw. 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. However, it is also likely damage will cause web to break at or just after the former. Cause: The first bottom heater may be sticky. 1. 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. 1. By using our website you are consenting to our use of cookies in accordance with our cookies policy. 3. If inclination roller is too high and the angle too steep, the film will have a tendency to pull and pucker in the corners. Cause: Jaws not meshing properly. Solution: Check setting of machine for proper package width. Cause: Paper (film) stops may not be square with the center line of the wrapper. 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. Contact us today. 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. If the tuckers are set too wide, they will not clear the off-set at the end of the first folder. Also seal area may show damage. By trial, tighten adjusting screws until a clean, even cut is made across the face of the blade and machine operates without knives pounding. Solution: Select the proper size former for the product. Solution: Check to see that the jaws mesh properly; if not, loosen lower jaw and realign. Adjust the spring tension to just hold the bar against the stop. 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. 1. Solution: Center roll by turning large wing nut located on same shaft as tension control handcrank. Increase control setting, wait sufficient time, and recheck temperature with pyrometer. Solution: Clean knife and lightly lubricate with 20W oil. 2. 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. Solution: Check alignment of rolls with level or by measurement and correct. Cause: Paper clamp roll out of time - does not raise during film feed causing bunching or jamming of web. Seal weak and sticking or a build-up (coating) may occur on the hotter wheel. Solution: Check roll for obstruction and/or possible need of lubrication. 1. 5. Solution: Clean and cool down compression plate. Cause: Insufficient penetration of knife into outer jaw. Solution: Relocate roll so web is properly positioned on former. Cause: Jaws dirty. If still dirty, remove bar and clean with very fine sandpaper fastened to a flat surface. 1. Cause: Transfer or feed roll misaligned, web travels to "high" side of roll. Starting from the discharge and working our way back, we first inspect the operation of the crimp jaw. Cause: Excessive difference in temperature of sealing jaws may cause weak seals or sticking. Cause: Excessive static electricity - web tends to cling or show restraint, usually more predominant in periods of cold, dry weather. Solution: Check alignment and straightness of back-up bar. 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. Solution: After locating the set of wheels that are doing the cutting - place a small mirror behind the wheels and observe the mating surfaces. Cause: Sticking on seam sealer due to excessive heat and/or dirty sealer surfaces. Solution: Toe-in rollers should be adjusted equally. 2. Cause: Poor film cut-off -- sheet momentarily held back causing incorrect positioning on package. Solution: Reduce unwind braking on friction belts by decreasing spring tension. 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. Film "chatters" or breaks under the sealer. Error messages report issues with the VFFS machine. Solution: Adjust unwind brake to maintain minimum tension on film and avoid any slackness. Solution: Check operation of no-paper (film) detector. Cause: Roll stock may be wound unevenly, former may be improperly installed, or film and/or paper handling rolls may be misaligned. 2. Cause: Insufficient heat will cause weak or no seal. Need help getting started? Solution: Roughen transfer roll with sandpaper or try turning the roll around. 1. Cause: Insufficient unwind braking. With the roll set too low, film may roll over the former edges. Solution: Front floor should be approximately 1/ 32" below front product guides. Select the right size former for the product. Solution: Check jaw temperature with pyrometer and adjust temperature accordingly. Cause: Sealers dirty causing excessive drag on hot seals or sticking. Cause: Incorrect sealer temperature. NOTE: A badly worn former cannot be repaired. This means there is something causing a jam in the sealing jaws. Cause: The bottom folder and/or front paper (film) feed may be sticky. 1. Adjust any imbalance between jaws to 10 F or less. Solution: Fin seal wheels too close together - check spacing and spring adjustment. Cause: Former too large for product size. After making adjustments, always crank machine through by hand before turning machine on. 2. Solution: Tape should be applied to center of transfer roll. Cause: Knife timed early - cut is made before film feed is completed. 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. 4. Solution: Locate problem roll(s) and remove damage with fine grit emery cloth or sandpaper. Replace rolls showing excessive wear. Cause: Excessive end sealer pressure - wrap is pulled toward rear of package. 1. Cause: Roll (wrapping material) nicked or damaged, web breaks on former usually before back seal is made. Solution: If knife is clean and properly adjusted*, check bearing, pivot end of knife and lubricate as needed. 1. 6. 5. 3. Solution: Replace with new preshrunk canvas (canvas should be preshrunk by boiling in clean water for 30 to 45 minutes, then drying before using). 3. with damp cloth. Solution: Discard roll if damage is severe. Then loosen bolts on cutting head and pry upon drive end of upper jaw shaft. 1. 1. In cases of minor bead damage, a damp cloth or towel applied to the bead can be effective in preventing. Solution: Check brake and make certain the brake lining as well as the drum brake are free from oil. Cause: Low air pressure to jaw cylinders. If no replacement is available, a dull blade may be ground and used until a replacement can be obtained. 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: Check air pressure to the jaws, regular setting, and valve in supply line. 4. 4. Cause: The package holder may be sticky. 1. If no change is measured, controls, wiring, fuses, heating elements, etc. Check slot alignment with straight edge and adjust as needed. Cause: Clearance between the vertical sealer face and the top of the back-up bar incorrect. 5. Solution: Make sure rolls are clean, check pressure (see I, B-4) and adjust as needed. Only a slight pressure is required to keep knives in contact. should be checked by a qualified person. Solution: Make sure package stops are free. Check with mirror after cleaning. Cause: Film may not be centered on the arbor. With a substantial reduction in temperature, cut-off will not be complete. Solution: Loosen set screws on auxiliary fin seal wheels and tap to a lower position. 2. Solution: Adjust fin wheels to obtain contact with full face of heated surface. Solution: Reduce tension setting to point film is pulled smoothly from roll. Adjust in usual manner (Section III, A-5) at operating temperature. Solution: Locate roll and remove damage with fine grit emery cloth or sandpaper. 3. Solution: Retime no-paper (film) detector. 3. Solution: Position rollers so that web just contacts former skirt. 1. 8. 4. Solution: Align former squarely to former rolls. Solution: Loosen cap screws holding lower crimp jaw and move sideways until top and bottom jaws are meshed together properly, then retighten. To adjust crimp knife, there is a set screw in the lower crimp jaw. Knob is located on either front or rear of machine, depending on model. Cause: Paper (film) roll brake may be too tight or too loose. Solution: Increase pressure; it may be necessary to drill holes in heater mount and put in set screws to maintain pressure. Adjustment for a change in the amount of web corrugation is made by re-positioning the eccentric, fiber roll located nearest the elevator. 3. 1. 5. 4. Never use a cylinder that is wider than the forming plate. Solution: Clean jaws with wire brush. Lower pressure roll slightly and pull strips. Cause: Tabs on bottom of former require adjustment. Solution: Apply sufficient amount of tape to transfer and/or feed rolls to balance web tension. 3. 4. 2. 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). 2. The tension roll should be adjusted so that it moves up and down smoothly. 5. Cause: Transfer or dancer rolls misaligned. Loosen set screws located at each end of shaft and rotate to activate more overlap of the belts for added web corrugation. Solution: The bottom surface of the top guide should be in line with the outside diameter of the solvent applicator wheel. Cause: Film not wide enough for product. causing web to jam in feed belts. Damage to the outer portion of the roll can be cut away and the remainder used. Cause: Serrations and crimpers are not meshing properly. Solution: Locate roll by visual check or by use of small level and properly align. Knife does not fully retract. Cause: Inclination rollers set too high or too low. Package sticks to hotter jaw, weakening or separating seal. 4. The investigation of problems on the Allpac equipment can best be accomplished by starting at the discharge of the machine and working back. Then, retighten the binding screw. Solution: Check required web width for former being used. 6. 1. Cause: One of the paper (film) feed belts may be off the rollers. 1. Cause: Film with differential surface (one side release coated) reversed. Solution: Clean and line up folding plates. Solution: The folders should be centralized with the center line of the machine and square with the front edge of the flapper housing. Inadequate down pressure, seals weak and show a light serrated pattern. Package stops frozen or sluggish. Cause: Former misaligned - web travels to side of former. This error means thejaws cannot completely open. Solution: Apply damp cloth or towel over the roll. Solution: Clean rollers with solvent-dampened cloth, then roughen slightly with sandpaper. Cause: Release treated surface of web reversed. Solution: Check sealer temperature with pyrometer and adjust as needed. Solution: Check sealer temperature with pyrometer and reduce accordingly. 4. Solution: Check bottom heater plate to see if it is warped - replace if it is. Adjust any imbalance between jaws to 10 F or less. Solution: Check condition of knife. Solution: Reset inclination roller. Sticking on the jaws, at times to the extent of separating the seals. Are the ambient temperature and humidity levels as specified? Solution: Clean compression plate and make sure it is cool. Cause: Knife action sluggish - interfering with feeding. Cause: Excessive heat will cause discoloring, charring, or interfacial sticking. 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. 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. Also sealed area may show damage. Cause: The first end folders may be dirty and/or set too close to the product. Cause: Insufficient pressure on paper clamp rolls will allow the cut sheet to slip or be pulled out of rollers as the elevator lowers. Allow sufficient time (5-10 minutes normally) for change to occur and recheck with pyrometer. NOTE: On specially coated sealers (teflon, ceramic, etc.) 6. Solution: Check temperature with pyrometer and adjust or replace beating elements until the jaw temperatures are in reasonable balance. If damaged or worn, the former should be repaired. Cause: The no-paper (film) detector may be closing too late. 3. Solution: Clean the first bottom heater plate. Solution: Reduce roll brake to minimum. Solution: Check damaged roll and when possible, cutoff damaged portion; if too severe, replace the roll. Cause: The paper (film) carrier belt may be loose. Cause: Release treated web reversed on machine - seal weak or fails completely. Solution: Adjust knife and anvil, see Section III, A-5. Your machine may not have all features listed. Cause: Obstruction in elevator film slot - web jams or is restricted during feed (film) cycle. Cause: Bottom sealer plate may be warped. Solution: Center former on machine. Cause: Auxiliary (rubber) draw wheels set with too little tension. 2. Solution: Make sure the paper (film) is centered on the package. Rolls should be parallel to the former wing (make sure former is properly aligned). 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: Adjust machine for proper package spacing. Cause: Feed rolls worn or improperly adjusted. 2. Cause: Inclination roller set too high or too low. with fine-grit sandpaper or emery cloth. Cause: Film not wide enough or too wide. Main fuseb. Serrations cut seals. 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. If poor cut-off is not corrected, adjust knife and anvil. Retighten bolts before operating machine. 2. Retighten lock and manually check knife before operating machine. Solution: Raise or lower jaw position to center line of product. Solution: Remove burrs or cuts, preferably with a triangular file. Solution: Adjust paper (film) roll brake. Seals weak and show light serrations on one end while the opposing end is satisfactory or may show damage. Cause: Excessive fin wheel pressure - seal shows roughness, and in extreme cases, sealed area has small holes. Are there any other factors that may cause potential issues with the machine, product, or film? If jaws are closing too late, the jaws will grab the film at a high speed and also tear the film. Solution: Clean clamp and slot. Be certain the end of the former is parallel to the end of the table and not in a cocked position. 5. 3. Solution: Widen tabs to hold film in fin wheels. Cause: Anvil set too high preventing adequate jaw pressure on seals. Solution: Clean with a cleaning fluid. Cause: Auxiliary fin seal wheels set incorrectly. When roller is too low and the angle is not steep enough, wrapping material will be pulled tighter around product. Check outside and inside surface of film for release coating and mount roll to position release coating to the outside of the finished package. Solution: Remove any build-up of product, coating, etc. 4. 1. 3. Solution: Check sealer temperatures with pyrometer and reduce heat sufficiently to clear up seals. If adjustment is made, allow sufficient time for change to occur and recheck with pyrometer. 3. 1. Solution: Check adjustment of paper (film) stops. Solution: Align tube and tongue so the center line of the tube is parallel to the carriage tracks. 2. 1. Cause: Paper clamp rolls dirty will interfere with proper feed of the web, causing rippling or waving in the elevator slot. Cause: Machine may be set too wide for the package. 1. With the tongue positioned too far inward, bag diameter will be too small and folds may occur in seal area. Solution: Shield affected area with cardboard. But with proper preventive maintenance and training, vertical form fill seal troubleshooting should be infrequent and easy. 4. Solution: Align former squarely with frame of machine. Cause: Knife dull or damaged. Seal weak and/or shows difference in strength from side-to-side. Solution: Refer to "Packaging Machinery Manual" for epicycle adjustment. Cause: The knife may not be cutting completely across the sheet. Remove with medium-grit sandpaper or emery cloth. Solution: Top jaw is spring-loaded and could have jumped out of time when closed on product. Cause: Damaged roll of wrapping material. Cause: One or both sets of fin seal wheels may be open or not closing properly. 2. Solution: Check sealer temperature with pyrometer and adjust accordingly. Solution: Increase braking by turning hand crank clockwise. Cause: Package holder may be out of adjustment. CAUTION: Jaws having special coating (teflon, ceramic) must be cleaned with approved materials. Cause: Incorrect sealer temperature. Solution: Align former plate with breaker bar so web will be pulled in a straight line. 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. If no change is measured, controls, wiring, heaters, etc. 2. Cause: Vertical sealer too close to former. Solution: Clean first end folder and set for proper spacing in relation to product. Solution: Loosen cam mount until knife cam is in the slowest position. 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. Packaging Machine Support and Maintenance, [VIDEO] VFFS machine maintenance: How to set up the film brake roller, [VIDEO] VFFS machine maintenance: How to tell if a seal bar temp sensor (RTD) has failed, 5 Ways Automated Packaging Equipment Can Deliver a Fast ROI, Viking Masek named a 2022 Top Workplace by Milwaukee Journal Sentinel, Troubleshooting 10 common VFFS packaging machine issues. Motor overload heaters on motor starterc. 3. 3. Solution: Check gap opening and set if needed at 1/32" to 1/16". Solution: Check temperature and lower accordingly. 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. The bottom set of wires should be adjusted so that their bottom surface will just clear the outside surface of the measuring roll. Cause: Film roll not centered on spindle. Cause: Jaw surfaces damaged (burrs, cuts) and package does not drop freely. *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. Solution: Adjust brake until tension roll moves up and down smoothly. Cause: Excessive air pushing seal out. Cause: Jaws running slower than fin seal wheels. 3. Solution: Clean feed belts and paper (film) table. Cause: Insufficient pressure on sealing bar may cause weak or no seals. 1. Cause: Timing of release rolls not properly set. Work with time, temperature, and pressure settings to create acceptable seals. Cause: Former surface damaged, slits or tears in web, occurring on surface of the former. Cause: Insufficient heat - weak or no seal. Cause: Inconsistent roll formation, raised beads, bands, or soft beads may cause tracking problems. 4. Cause: Forming plate traveling too deep into draw rollers. (Confirm alignment with imprint on aluminum foil.). 4. Solution: Check condition of knife. 1. Solution: Remove knife from jaws, scrape away excessive build-up with a putty knife and sand with fine-grit paper or emery cloth. 5. 3. from surface of sealer. Check vertical alignment and correct if needed with screws located on the mounting plate. Solution: Position film roll so that it is approximately on center line of former. Too low: Film may roll over the edges and come out of the former. If replacement rolls are not readily available, tape applied to the worn area can be a temporary solution. If temperature is too low, seals will be weak or not made at all. Cause: Incorrect sealer temperatures. 3. 1. Cause: Former misaligned. Cause: Roll (wrapping material) is not centered on mandrel - web runs off center of former. Cause: The film (paper) corrugating wires are not stiffening the film and preventing it from jamming as it is fed past the feed rollers. Adjust jaw close cam until the touch and the click synchronize.