Packaging machines are essential in industries ranging from food and beverage to pharmaceuticals and chemicals. However, like any equipment, they may face operational challenges that impact productivity and packaging quality. Knowing the common problems in packaging machines—and how to fix them—helps reduce downtime, minimize waste, and extend the machine’s life.
1. Poor Sealing Quality
Problem: Bags are not sealing properly, or seals are weak and easy to tear.
Causes:
- Incorrect temperature settings
- Dirty or worn sealing jaws
- Wrong packaging material
Fix:
- Adjust sealing temperature according to film type.
- Clean sealing jaws daily and replace worn Teflon or heating elements.
- Use packaging material compatible with your machine.
2. Film Tracking Issues
Problem: The film drifts to one side, causing uneven or crooked bags.
Causes:
- Misaligned film roll
- Worn film rollers or belts
- Poor film quality
Fix:
- Re-align the film roll on the unwind shaft.
- Inspect rollers and replace if worn.
- Use high-quality, consistent packaging film.
3. Inaccurate Filling or Product Leakage
Problem: Bags contain too much, too little, or spilled product.
Causes:
- Faulty dosing system (auger, pump, or multi-head weigher)
- Blockages in feeding system
- Poor calibration
Fix:
- Recalibrate the filling system regularly.
- Check for product buildup or blockages.
- Replace faulty sensors or weighers.
4. Cutting and Bag Length Errors
Problem: Bags are cut too long, too short, or uneven.
Causes:
- Incorrect bag length setting
- Worn or dull cutting blades
- Faulty photoelectric sensor
Fix:
- Recheck machine parameters for bag length.
- Sharpen or replace blades.
- Adjust or replace the sensor if it fails to detect eye marks.
5. Machine Downtime and Jamming
Problem: The machine frequently stops or product gets jammed inside.
Causes:
- Overfilled hopper or feeding errors
- Improper synchronization of parts
- Lack of lubrication or worn components
Fix:
- Ensure consistent product feeding.
- Synchronize sealing, cutting, and filling operations.
- Lubricate moving parts regularly and replace worn belts or gears.
6. Electrical or Sensor Failures
Problem: Error messages on HMI or the machine fails to start.
Causes:
- Loose wiring or damaged connectors
- Faulty PLC or sensor malfunction
- Power fluctuations
Fix:
- Inspect and tighten electrical connections.
- Replace faulty sensors or PLC modules.
- Use stable power supply with surge protection.
Final Thoughts
Most packaging machine problems can be prevented with proper cleaning, regular maintenance, and correct machine settings. By troubleshooting issues early, businesses can minimize downtime, reduce product waste, and maintain consistent packaging quality.
Need expert help with your packaging machine?
Contact DBAO Packaging Machinery at steven@dbaopack.com for professional guidance and reliable packaging solutions tailored to your production needs.
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