Like many other industries, the packaging industry has experienced a remarkable pace of technological advancement.
Technologies that were once considered advanced, such as high-efficiency control devices and high-accuracy servo motors, have become commonplace. Furthermore, with the adoption of AI technology, the operating speed and settings for multiple products can now be changed at the touch of a button.

With those advanced electrical control, some may wonder if there is a need for the mechanical adjustment by skilled craftworker we have relied on. There is still great importance of mechanical adjustment as we would like to share the three key points as follows.

The importance of machine adjustment

The machine adjustment is such a critical process that it influences the product quality, productivity and equipment lifespan. No matter how advanced the electrical devices and control systems are, improper machine adjustment can still lead to defective products and reduced productivity. It also would be a factor to accelerate the wear and tear the machine parts.

Here we introduce the main three adjustment points of packaging machine. 

1. The point of heater adjustment

Sealing the film layers for closing is an essential process of packaging. There are some kinds of method of sealing such as heat-sealing or ultrasonic-sealing. Improper adjustment of heater may result sealing failure, parts wear, and parts damage. Although the temperature or vibration setting of ultrasonic are important, proper mechanical adjustment is necessary first.

To achieve uniform sealing, it is necessary to ensure proper heater contact in both the left-right and up-down directions, as well as uniform engagement of the heater teeth.

After adjustment, check each dimension and heater contact by using a Prescale-type film (pressure measurement film) which, is the specifically used for checking the contact pressure.

2. The point of film feeding adjustment

In vertical-form-fill-seal machine, roll type film is used. In order to use a necessary amount of film from the roll, a feeding device is necessary.
In many machines feeding belts are used for film feeding. There are several types of feeding belts, such as single-belt and dual-belt systems, as well as friction and vacuum types.

TAM packaging machines use a dual-belt vacuum feeding system. This is because of the stability of film feeding and the reduction of belt wear and tear. However, if the mechanical adjustment is not properly made, it may cause film meandering and belt wear and tear, failing to achieve its intended performance.
Belt tensioning adjustment and gap adjustment between the belt and forming tube are also essential that are the check point when mechanical adjustment is carried out.

3. The point of alignment adjustment of machine

The meaning of “alignment of machine” includes the main frame, shaft alignment and roller parallelism etc. f there is misalignment, it may cause film meandering or place excessive stress on machine components, leading to premature wear and tear.
Misalignment of course affects to wrapping appearance, and moreover, it may cause abnormal heat generation, or bearing damage, wearing of gear, and excessive vibration and noise.

During the machine assembly and adjustment, alignment and centering process as well as squareness and parallelism are essential to check by using measuring instrument.
It could be a packaging defects but more importantly it can shorten the machine’s service life and machine failures. Therefore, it is a critical point to consider.

Conclusion

There are still necessary adjustment factors other than the above-mentioned points, but maintaining the adjustment with high accuracy of these three critical points- of Heater adjustment, Film feeding and Machine alignment – does more than just reduce defective products.

• Extension of equipment lifetime : reducing excessive stress on machine and preventing sudden crash.
• Productivity improvement : reducing brief stop by minor abnormality and　maximizing the operating rate.
• Securing the safety : reducing abnormal heat generation or breakage that enhance safety.

Machine adjustment should be based not only on experience and intuition but also on standardized criteria established through digitalization (temperature, tension and alignment value), helping to achieve sustainable manufacturing.

The initial adjustment is important, but the regular maintenance and proper adjustment should be routine practice to keep the machine in the best condition that would maximizing the machine life.

Tam Contact to: tam-overseas@tam-tokyo.co.jp