Lesson 1 - The Packaging Mechanic


Packaging operations; Machinery maintenance; Planned maintenance; Lubrication

Learning Objectives:
– Describe types of machines for packing and filling.
– Describe packaging machinery breakdown maintenance procedures.
– List specific requirements for planned packaging machinery maintenance.
– Explain packaging machinery lubrication selection, scheduling, and correct application.

Lesson 2 - Actuating Mechanisms


Cranks; Cams; Intermittent motion mechanisms; Geneva wheels; Drives; Angle-doubling drives; Toggle links; Detents; Overload protection

Learning Objectives:
– Explain the operation of the lever and crank.
– Describe the differences among types of cams.
– Explain how ratchet wheels and Geneva wheels produce intermittent motion.
– Describe reciprocating and oscillating drive mechanisms.

Lesson 3 - Problem Solving Principles


Elements and tolerances of measurement; Types of packaging machines; Troubleshooting machines; Determining causes of trouble

Learning Objectives:
– Describe the differences between intermittent-motion and continuous-motion packaging machines.
– Explain how to time a packaging machine with a timing dial.
– Define the four basic machineelements-timing, position, stroke, and alignment.
– List correct packaging machine troubleshooting steps.

Lesson 4 - Mechanical Drives


Drive mechanisms; Coupling construction and installation; Belt and chain drives; Speed reducers; Gearing

Learning Objectives:
– List the functions of couplings.
– Explain the differences among the more common types of couplings.
– Describe how to check coupling alignment and how to correct a misalignment.
– Compare the different types of belt and chain drives.
– Describe the different types of speed reducers and gearing.

Lesson 5 - Motors and Brakes


Primary drive components; Motor construction classification; Mechanical/electrical speed drives; Clutches; Brakes; Maintenance

Learning Objectives:
– Describe the basic features of ac motors.
– Compare the different types of fractional-horsepower motors and three-phase motors.
– List the features of common and special types of motors.
– Explain how variable-speed units work.
– Describe the operation and use of electric, hydraulic, and mechanical clutches.

Lesson 6 - Electrical Controls


Startup and running sequence; Motor starters; Machine control; Time delay relays; Product control; Adhesive application; Product sensors

Learning Objectives:
– Describe the elements of a packaging machine's start-up sequence.
– Explain how thermal overload and melting alloy starters work.
– Explain the use of detectors and time delays in packaging machine control.
– Describe how adhesive is applied.
– Explain the differences in operation among types of product detectors.

Lesson 7 - Packaging Materials


Shrink and nonshrink materials; Combination and water soluble film; Plain and coated papers; Chip-board cartons; Glass and plastic bottles and jars

Learning Objectives:
– List the characteristics of film.
– Compare the different types of shrink film.
– Name the different types of combination films.
– Describe the uses of water-soluble film, kraft paper, and chipboard.
– List the advantages and disadvantages of glass and plastic bottles and jars.

Lesson 8 - Methods of Filling


Flexible packaging; Vertical and horizontal filling machines; Pouch, weigh, carton, and liquid filling; Filling by count

Learning Objectives:
– Describe the operation of vertical and horizontal flexible film packaging machines.
– Explain how volumetric pouch filters work.
– Explain how carton-filling and liquid-filling machines work.
– Describe methods of filling by count.

Lesson 9 - Methods of Sealing


Tube, film, and high-frequency sealing; Capping; Seaming; Tying; Sewing; Gluing; Stapling; Stitching; Strapping

Learning Objectives:
– Describe how plastic and metal tubes are sealed.
– Explain the operation of different types of film sealers.
– Describe how high-frequency sealers work.
– Explain the basics of cappers and seamers.
– Describe correct procedures for using hot and cold glues.

Lesson 10 - Weighing and Measuring


Units of weight; Volume measurement; Weighing devices; Scale components; Net weighers; Controls; Checkweighers; Installation

Learning Objectives:
– Explain the uses of gross, net, and check weighers.
– Compare the mechanisms of counterbalances and force balance systems.
– List the components in a scalesystem.
– Explain how typical check weighers work.
– Describe proper troubleshooting, maintenance, and installation techniques for scales.