Lesson 1 - Uncasing and Unscrambling


Manual uncasing; Low-volume uncasing and unscrambling; Unscrambling with conveyors; Automatic uncasing; Conveyor chain and care

Learning Objectives:
– List the steps that must occur before an empty container can be processed.
– Tell which types of conveyors are typically used for unscrambling.
– Explain how the pickup head of an automatic uncaser grips different container shapes.
– List important steps in the periodic care and maintenance of roller chain.

Lesson 2 - Cleaning and Washing


Air cleaning; Manual washing with water; Bottle washer/rinser; Metal washers; Container warming; Pasteurization; Maintenance

Learning Objectives:
– Name the two methods by which containers are usually cleaned.
– Describe the automatic air cleaning operation.
– Describe the operation of an automatic bottle washer and rinser.
– Describe the operation of a high-production bottle washer.
– Explain why pasteurization is important.

Lesson 3 - Gathering Machines


Multi-packing machines; Skip-carton detector; Continuous-run accumulator; Stacking sequence; Cycling operations; Case packing, bundling machines; Maintenance

Learning Objectives:
– Name the three types of gathering machines currently in use.
– Describe the operation of a bundling machine.
– Describe the infeed supply operation and cycle of a multipacker.
– Name the two functions of a typical case packer.
– Explain your most important responsibility in gathering machine maintenance.

Lesson 4 - Cartoning Machines


Carton making; Types of cartons and machines; Glue-end cartons; Carton feeding; Product infeed; Machine attachments; Closing and gluing

Learning Objectives:
– Define the following terms: reverse tuck, arthur lock, and crash fold.
– Explain why butt flaps are rarely used.
– Describe the operation of cartoning machines and related carton feeding methods.
– Explain how cartons are typically closed and glued.
– List steps involved in cartoning machine maintenance.

Lesson 5 - Casing Machines


Horizontal and vertical machines; Top, side, and bottom filling machines; Case taping machines; Heatshrink sealing; Maintenance

Learning Objectives:
– Tell how the manner in which cases are filled is determined.
– Explain the function of a compression unit.
– Contrast top filling and side filling machines.
– Explain the purpose and operation of electrical interlocks in an automatic casing machine.
– Identify the source of heat control problems in a shrink film machine.

Lesson 6 - Wrapping Machines


Wrapping materials; Settings and controls; Paper feed; Paper corrugating wires, rollers, cutoff change gears, knife, feed belt, stops, and guides

Learning Objectives:
– Explain the function of registration dots on the continuous roll paper used on wrapping machines.
– Explain the functions of the paper corrugating wires in a wrapping machine.
– Trace the operation of a typical wrapping machine, including timing elements.
– Tell how to clear a jam in a wrapping machine.
– Describe various kinds of glue used in wrapping machines and their application.

Lesson 7 - Strapping and Stitching


Strapping materials; Tensioners; Sealers; Combination tools; Strapping systems; Stitching machines; Stitch defects; Adjustments

Learning Objectives:
– Explain why a tensioner and sealer are sometimes combined into a single assembly.
– Describe the maintenance required by strapping heads.
– Explain the operation of a stitching machine.
– List common stitching machine problems and stitch defects and tell their probably causes.

Lesson 8 - Adhesives and their Application


Properties and types of adhesives; Hot melts; Application systems; Troubleshooting, maintaining, and cleaning equipment

Learning Objectives:
– Define the terms penetration, tackiness, and viscosity as they relate to adhesives.
– Name the most likely source of trouble in hot melt application machinery
– List steps involved in servicing a hot melt dispensing head.
– Explain common maintenance items related to application equipment.
– Describe the storing and handling requirements for liquid adhesives.

Lesson 9 - Labeling and Coding


Label forms; Continuous roll, indirect label feeding; Pressure-sensitive labeling, heads; Coding attachments; Flexographic imprinting

Learning Objectives:
– Name common problems in labeling operations and give their solutions.
– Describe the process of continuous roll feeding.
– Explain the periodic maintenance required of labeling heads.
– Explain the operation of a friction-driven coder and a flexographic imprinter.

Lesson 10 - Maintenance and Safety


Planned maintenance; Spare parts; Lube schedules; Mechanical and electrical maintenance; Fluid components maintenance; Guards

Learning Objectives:
– Identify the key to good planned maintenance.
– Name the two most important factors in drive belt wear on a packaging machine.
– List items to consider when replacing a motor?
– Explain the purpose of recommended color codes for plant equipment.
– Name the leading causes of industrial injuries.