How To Troubleshoot Common Capping Machine Problems?
Are you working in the pharmaceutical industry? How many machines do you have to work with every day? I guess your answer would a lot. Although these machines are well-designed, they are not immune to occasional breakdowns.
Capping machine is an important device in pharmaceutical packaging line. If it suddenly breaks down, the whole production schedule will be affected.
So what can we do?
At this point, the key is to master capping machine's important parts and the working principle of the bottle capper. This is an important foundation for successfully troubleshooting your capping machine. You can use this knowledge to determine the cause of its failure and ultimately get your capper on track.
In this article, we will analyze the common malfunctions of capping machines and their causes. Also, some useful troubleshooting methods are covered. Let's jump right to the point!
How to Fix Common Failures of Manual Capping Machines？
A manual capping machine has a simple structure that makes it easy to use. Even so, it can occasionally break down. So lets dig into what can go wrong with the machine and the solutions.
|
Problem |
Possible Cause |
Solution |
|
The cap is too loose on the bottle. |
The cap doesn't line up with the bottle in the first place. |
Reposition the cap. |
|
Use the wrong capping technique. |
Use correct capping technique and apply even pressure. |
|
|
The cap doesn't fit exactly on the container. |
There are loose or worn capper parts. |
Replace faulty parts. |
|
The container doesn't align with the device. |
Adjust the container's position. |
|
|
The cap is cracked or deformed. |
Use the wrong way to press the cap. |
Decrease the pressure or adjust your capping angle. |
|
Cap size or type is not suitable. |
Choose the correct cap size and type. |
How To Troubleshoot Semi-Automatic Capping Machine?
A semi-automatic capping machine is an upgraded version of a manual capper. Its operation relies partly on machine automation. However, it does have a few issues during operation once in a while. Below are some troubleshooting tips that may work for you when these problems occur.
|
Problem |
Possible Cause |
Solution |
|
The motor is not working. |
There is no power supply. |
Connect the power supply. |
|
The fuse is burnt out. |
Change the fuse. |
|
|
The voltage is set too low. |
Turn up the voltage. |
|
|
The motor is damaged. |
Ditch the bad motor and install a brand new one. |
|
|
The pneumatic cylinder stops working. |
There is no or little air pressure. |
Reset air pressure. |
|
The working time is too long. |
Shorten working hours. |
|
|
The flow rate of the throttle valve is not large enough. |
Increase throttle flow. |
|
|
The solenoid valve is faulty. |
Replace the broken solenoid valve. |
|
|
The relay is damaged |
Use a new relay. |
|
|
The timer is broken. |
Replace the old timer. |
|
|
The cap is not tight enough. |
The length of capping process is too short. |
Extend the capping period. |
|
The torque is not strong enough. |
Set the torque higher. |
|
|
The positioning block goes wrong. |
Realign the positioning block. |
|
|
The cap surface is overly smooth. |
Use a more compatible cap. |
|
|
The size of the capping head does not fit. |
Use a capping head with the right size. |
How To Solve The Problems Of Automatic Capping Machines
Among as many as 10 types of capping machines, the fully automatic capper is the most advanced and versatile one. While this machine doesn't easily break down, knowing some of the potential faults and their solutions may serve you well in the future.
|
Problem |
Possible Cause |
Solution |
|
The bottle tips over. |
The conveyor belt is not lying flat. |
Adjust the angle of the conveyor belt to keep it level. |
|
The speed of synchronous belt wheel does not match the conveyor speed. |
Adjust both parts to the same speed. |
|
|
The pressure of the gripper may be either too strong or too weak. |
Set the right gripping strength. |
|
|
The cap is missing. |
The cap stock is running out. |
Check the cap feeder to make sure there are available caps. |
|
The speed of dispensing bottles is way too fast. |
Slow down the speed of the bottle separator. |
|
|
The cap is blocked on its way into the bottle. |
Check the path of the cap leaving the hopper. |
|
|
The cap is screwed too tightly onto the bottle. |
Two sets of capping wheels are too close to each other. |
Adjust the spacing between the two capping wheels. |
|
There is excessive pressure on the friction plates of the capping wheels. |
Loosen the locking nut in the capping wheel. |
|
|
The product spills out of the bottle. |
The gripper belt exerts too much pressure on the bottle. |
Adjust the tightness of the gripper belt. |
How To Maintain A Capping Machine?
In addition to acquiring troubleshooting skills for the capping machine, it is also incredibly important to perform routine maintenance on your machine. This can help you reduce the possibility of your machine failing in the first place.
Without proper maintenance, your capping machine may break down more frequently, which may in turn delay your production schedule. Moreover, long-term regular maintenance can prolong the service life of a capping machine. Below you can find a few useful tips for maintaining your capping machine.
Daily Maintenance
- Remove dust and product residue by wiping down the entire capping machine with a mild detergent and soft rag.
- Lubricate all moving parts on the machine with lubricant recommended by your manufacturer.
- Inspect the capping machine for any damaged or worn parts and replace them immediately.
- Check for loose screws and tighten them.
Weekly Maintenance
- Perform a deep cleaning of the capper once a week, especially focusing on corners that are difficult to reach during daily cleaning.
- Check and clean the air filter. Once the filter is clogged, it is likely to affect the performance of the machine.
- Verify that all electrical connections are tight. Loose connections can lead to danger and machine failure.
- Inspect and adjust capping torque as necessary. Over tightening the cap can damage the container and cap, while loosening it too much can cause leaks.
Monthly Maintenance
- Inspect the entire machine once a month, looking for any damaged or worn parts.
- Regularly record all maintenance tasks such as dates, operator's name, and problems encountered.
The Bottom Line
If you want your capping machine to run smoothly all the time, regular maintenance and timely action in the event of a malfunction are two must-dos on the list. For more information on troubleshooting your capping machine, please contact us. As a leading capping machine manufacturer, IpharMachine has experienced experts available 24/7 to answer your questions.
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