Casing Machinery

Lesson 1: Uncasing and Unscrambling

Topics

How Containers are Received; Manual Uncasing; Low-Volume Uncasing; Low-Volume Unscrambling; Unscrambling with Wire-Mesh Conveyors; Unscrambling with Parallel Conveyors; Automatic Uncasing; Combined Automatic Operations; Unscrambling Plastic Bottles; Unscrambling Plastics Bottles by Gravity; Unscrambling with an Inclined Hopper; Conveyor Chain and Its Care

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

Topics

Why Clean Containers Are Necessary; Container Cleaning Methods; Semiautomatic Air Cleaning; Fully Automatic Air Cleaning; Inverter Air Cleaners; Manual Washing with Water; Combination Bottle Washer and Rinser; Metal Washers; High-Production Washing; Container Warming; Why Pasteurization is Necessary; The Pasteurizer; The Pasteurizing Process; Lubricating a Pasteurizer; Pasteurizer Maintenance

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

Topics

Types of Gathering Machines; Multipacking Machines; Infeed Supply Machinery for Multipacking; Continuous Run Multipacking; Skip-Carton Detector; Continuous Run Accumulator; Stacking Sequence for Continuous Runs; Cycle-Style Multipacking; Cycling Operations; Case Packing Machines; Bundling Machines; Gathering Machine Maintenance

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

Topics

Cartons and Their Application; Basic Steps in Carton Making; Common Types of Cartons; Glue-End Cartons; Types of Cartoning Machines; Methods of Carton Feeding; Expanding Draw Feeding; Rotary Feeding; Product Infeed; Horizontal Carton Loading; Cartoning Machine Attachments; Closing Cartons; Gluing Cartons; Cartoning Machine Maintenance

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

Topics

Casing Machine Types; Case Forming Machines; Horizontal Casing Machines; Vertical Casing Machines; Top Filling Machines; Side Filling Machines; Bottom Filling Machines; Case Taping Machines; Casing Long Narrow Products; Heat Shrink Sealing; Machine Maintenance

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

Topics

Machine Drive; Wrapping Materials; Parts Lists and Changeover Parts; Scale and Dial Settings and Controls; Paper Feed; Adjusting the Paper Feed; Adjusting the Paper Reel; Paper Corrugating Wires; Paper Rollers; Paper Cutoff Change Gears; Paper Cutoff Knife; Paper Feed Belts; Paper Stops and Guides; Starting the Machine; Machine Adjustments; Heat Controls; Glues and Their Application; Package Discharge; Lubrication

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

Topics

Strapping Materials; Tensioner and Sealers; Combination Tools; Combination Tool Maintenance; Strapping Machines; Operation of Strapping Head; Strapping Head Maintenance; Strapping Systems; Stitching Machines; Buckled Stitch Legs; Variance in Stitch Leg Length; Keeping the Wire Straight; Leg Too Short or Too Long; Distorted, Broken Corners; Other Stitch Defects; Adjusting Defective Stitching Machines

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

Topics

Adhesives in Packaging; Properties of Adhesives; Types of Adhesives; Hot Melts; Advantages of Hot Melts; Hot Melt Application Systems; Hot Melt Troubleshooting; Maintaining Hot Melt Equipment; Cleaning Hot Melt Equipment; Other Synthetic Adhesives; Natural Adhesives; Applying Natural Adhesives; Maintaining Application Equipment; Storing and Handling Liquid Adhesives

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

Topics

Purpose of Labeling; Label Forms; Manual Labeling; Semiautomatic Labeling; Automatic Labeling; Continuous Roll Feeding; Indirect Label Feeding; Pressure-Sensitive Labeling; Pressure-Sensitive Labeling Heads; Labeling Head Setup, Maintenance; Automatic Pressure-Sensitive Labeling; Daily and Monthly Maintenance; Coding Attachments; Bottom Coding of Containers; Flexograph Imprinting; Flexograph Imprinter Maintenance

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

Topics

Planned Maintenance; Spare Parts; Lubrication Schedules; Mechanical Maintenance; Electrical Maintenance; Fluid Components Maintenance; Maintenance Safety; Safe Clothing; Using Tools Correctly; Hand Tool Safety; Machine Guards; Material Handling

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.