Production Without Stopping: A "First Aid Manual" for Common Filling and Sealing

Production Without Stopping: A "First Aid Manual" for Common Filling and Sealing Machine Malfunctions

For production enterprises, the stable operation of filling and sealing machines directly impacts order fulfillment and product loss. As equipment often operates in humid or even slightly acidic environments for extended periods, scientific maintenance and rapid troubleshooting capabilities are particularly crucial. Here are several common malfunctions and their countermeasures:

1. Poor Sealing (Leakage/Permeation)

This is the most common quality issue.

For metal cans: If the seal is not tight, it is usually caused by wear on the first or second operation seaming rolls or incorrect feed dimensions. The solution is to redress the rolls or adjust the radial feed amount.

For glass bottles with crown caps: If the crimp seal is poor, it might be due to an excessive distance between the press head and the bottle mouth or substandard caps. The sealing head height needs adjustment.

For plastic bottles: If the screw cap is loose, it could be due to insufficient tightening torque or poor thread fit on the bottle mouth. Adjusting the disc spring pressure is required.

2. Inaccurate Fill Volume or "Fobbing"

Underfilling: In isobaric filling, underfilling often occurs because the gas valve opening is insufficient, failing to achieve complete pressure equalization, or because the liquid level in the filling bowl is too low.

Fobbing (Foaming/Overflow): This phenomenon is more common in carbonated beverages. Main causes include excessively high filling temperature, failure to open the pressure relief valve, or too rapid pressure release. In this case, focus on checking the refrigeration system and CO₂ mixing effect, and adjust the stroke of the pressure relief plate to ensure slow, complete pressure release throughout the process.

3. Equipment Inaction or Sensor Malfunction

If the machine fails to start, first check the power supply, fuses, and safety door switches.

On an automatic filling line, if filling does not occur, it may be due to a malfunctioning "no bottle, no fill" detection device or a detached air valve actuator plate.

Sensor failures (such as film tracking detection or cap absence detection) are also common issues. Sensors should be kept clean daily to prevent dust accumulation from affecting sensitivity.

Regular Maintenance Recommendations:

During peak production seasons, worn-out seals should be replaced after approximately three months of continuous operation. After 1-2 years of use, the equipment requires an overhaul to comprehensively inspect transmission components and wear parts. Only through such diligent maintenance can equipment life be effectively extended and production efficiency guaranteed.