Following are the issues that are encountered during the blister packing process:
- Leak test failure
- Wrinkle on Blister
- Cavities Defects
- Blister Cavity stuck in forming Plate
- Forming station does not open fully
- The camera system not working
- PRC out of the bend
- Pinhole detector not working Probable causes:
- Homing not done
- Blister Damage in sealing station
- Motor overload
- Emergency machine stop
- Blister-dropping problem, machine not stared after pressing green button
- Bend Blister or Twisted blister
- Web direction uneven
- Dott Impression on PVC/PVDC foil after pocket formation
- Web slipping at the punching station
- Low air Pressure
- High-temperature cooling water
- Thermocouple check/ perforation blade
1. Leak test Failure:
Probable causes |
Suggested
Action |
Improper
sealing due to less pressure |
Maintain
sealing pressure up to 5 bar |
Sealing
temperature less than required |
Maintain
sealing temperature as per BPR |
Ink
or extra material deposition on sealing roller |
Clean
the sealing roller with a brash brush |
2. Wrinkle on Blister
Probable causes |
Suggested
Action |
Guide
plate alignment with a counter-sealing roller is not proper |
Align
the guide plate properly with the counter-sealing roller |
Aluminum
foil unwinding pressure low |
Increase
the unwinding pressure to the required level |
Guide
roller is not perpendicular to the Front Plate |
Check
if the guide roller is not perpendicular and correct it. |
3. Cavities Defects
Probable causes |
Suggested
Action |
Air
went partially closed in some area |
Check
vent, do clean it if required |
Failure
of heater |
Check
heater properly |
Height
differences between heating and forming station |
Set
heating and forming station height and level. |
4. Blister Cavity is stuck in Developing Plate.
Probable causes |
Suggested
Action |
Forming
plate not sufficiently cleaned |
Check
the cooling system, and reduce the temperature if required |
Ejection
pins are stucks |
Check
ejection pin |
5. Forming station does not open fully
Probable causes |
Suggested
Action |
Maybe
due to jamming in moving Plate |
lubricate
piller bearing |
Servo
motor coupling is loose, or rubber is worn out |
clean
if foreign particles are deposited in the sliding part, replace the rubber |
6. The camera system not working
Probable causes |
Suggested
Action |
Signal
or disconnection camera system |
Check
the signal coming from a camera |
Camera
key in special function is not activated |
Activate
camera key in a special function |
7. PRC out of the bend
Probable causes |
Suggested
Action |
Eye
mark shifted while the machine running |
Teach
the PRC scanner |
Distance
between two eye marks on foil is not as per drawing. |
check
the distance between two eye mark. |
8. Pinhole detector not working Probable causes:
Probable causes |
Suggested
Action |
Input
in PLC is not connected |
Connect
pinhole detector |
Distance
between pinhole and rejection system is not proper |
Input
right distance between pinhole and rejection system |
9. Homing not done
Probable causes |
Suggested
Action |
Homing
is not performed |
Perform
homing of all axis |
10. Blister Damage in a Sealing station
Probable causes |
Suggested
Action |
PRC
setting is not proper |
Set
the PRC |
Improper
sealing station knob tightness |
Fixed
the sealing station |
11. Motor overload
Probable causes |
Suggested
Action |
Motor
is overheated |
-Eliminate
the error, wait until the motor has cooled down |
12. Emergency machine stop
Probable causes |
Suggested
Action |
An
emergency push-button activated |
Unlock
the emergency knob by turning it. |
13. Blister dropping problem, machine not started after pressing Green button.
Probable causes |
Suggested
Action |
Splice
sensor |
-Change
the number of tracks selected in the PLC after the changeover. |
14. Bend Blister or Twisted blister
Probable causes |
Suggested
Action |
Guiding
roller before the indexing roller |
Use
the guiding roller having a diameter of 5mm less than blister width, for
example, blister having 110x45mm which is 110mm in length and 45mm in width
then, use the guiding roller having a diameter of 40mm. (45mm width-5mm=40mm)
to prevent bend blisters. |
15. Web direction uneven
Probable causes |
Suggested
Action |
Forming
plate |
Check
the lower forming plate position, tight the lower screw |
16. Dott Impression on PVC/PVDC foil after pocket formation
Probable causes |
Suggested
Action |
Heating
plate surface |
Use
the heating tap on the identified surface from which impression generated |
17. Web slipping at punching station
Probable causes |
Suggested
Action |
Incomplete
forming cavities, wrong blister setting in indexing roller |
Remove
the web from punching and check causes |
Improper
pickup |
Check
pickup assembly for any damaged vacuum pipe, tight their nuts, Check Vaccum. |
Misalignment
of support plate in punching plate |
Align
The plate as per blister size |
18. Low Air Pressure
Probable causes |
Suggested
Action |
-No
compressed air, leakage in the air pressure line |
Activate
the compressed air supply, check the pressure gauge or maintenance unit |
19. High-temperature of cooling water
Probable causes |
Suggested
Action |
Thermocouple
for cooling water is not connected |
Connect
the thermocouple, replace the defective one |
20. Thermocouple check/ perforation blade
Probable causes |
Suggested
Action |
Actual
pressure of thermocouple blade is below 50°C |
-Check
thermocouple connection |
Conclusion:
The
quality of the blister depends on the material and machine setting as per the
given parameters. But sometimes, small problems can lead to harm to the quality
of products. So, hope topics related to blister defects and remedies are
covered all these problems.
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