Self-Inspection Manual for Frontline Operators

Resume production within half an hour and minimize downtime losses

When equipment alarms or unexpected shutdowns occur during production, it can be extremely stressful. Every hour of downtime leads to lost output, delayed deliveries and even potential breach-of-contract risks with customers. In most cases, faults are less serious than they appear. Instead of waiting for after-sales technicians, on-site staff can carry out standard self-inspections to restore operation rapidly.

We have sorted out the 5 most frequent faults of packaging equipment, including root causes and troubleshooting procedures, to help you restart the production line in minimal time.

1. Poor Sealing & Wrinkled Seal Edges

Frequency: ★★★★★ | Inspection Duration: 5–10 mins

Common Causes

Improperly low/high heat sealing temperature; uneven sealing pressure; residual dirt on heat-seal moulds; inconsistent material or thickness of packaging film across batches.

Quick Self-Check Procedures

① Power off and wait for cooling. Thoroughly clean the surface of heat-seal moulds with alcohol-dampened lint-free cloth to remove adhesive residues and dust. ② Match current temperature settings to packaging film specifications (PE, PP and composite films require different temperatures); adjust gradually for testing. ③ Run the machine without products. Check the clamping gap of sealing moulds and turn pressure screws to ensure uniform pressure on both sides.

2. Inaccurate Bag Length & Misaligned Cutter Cutting

Frequency: ★★★★☆ | Inspection Duration: 5–8 mins

Common Causes

Over 90% of such problems result from dust covering the photoelectric tracking sensor, drifting sensitivity parameters, or loose film feeding tension.

Quick Self-Check Procedures

① Gently wipe the lens of the photoelectric eye with clean lint-free cloth; avoid fingerprints and dust blockage. ② Recalibrate the tracking position of the photoelectric eye, confirm clear colour mark recognition, and set sensitivity matching film transparency. ③ Inspect tension of film transport rollers; tighten loose timing belts and film reels to prevent slipping during feeding.

3. Large Fluctuations in Filling Volume

Frequency: ★★★★☆ | Inspection Duration: 10–15 mins

Common Causes

Material bridging/blockage inside hopper; worn & aged metering piston seals; unstable feeding air pressure; uneven feeding caused by low material level.

Quick Self-Check Procedures

① Check material stock in the hopper; ensure no caking or bridging blocking the feed inlet. ② Observe the travel of metering pistons. Replace original manufacturer seals if material leakage appears around sealing areas. ③ Verify air supply pressure readings and maintain stable pressure within the equipment’s rated range.

4. Abnormal Machine Noise & Excessive Vibration

Frequency: ★★★☆☆ | Inspection Duration: 10 mins

Common Causes

Loose fastener screws; slack and under-lubricated transmission chains; dry-worn bearings; foreign objects trapped in moving components.

Quick Self-Check Procedures

① Press the emergency stop button immediately and cut off main power before opening covers for inspection. ② Tighten fixing screws on key components including motors, sprockets and cutter seats sequentially. ③ Check chain tension, apply high-temperature resistant grease, and clear foreign debris from transmission parts. ④ Turn the machine manually to confirm no jamming, then start at low speed for testing.

5. Alarm Codes Pop Up on Touchscreen

Frequency: ★★★★★ | Inspection Duration: 3 mins

Common Causes

Most alarms do not indicate hardware damage. They are triggered when safety conditions are unmet: unreleased emergency stop buttons, loosely closed safety doors, insufficient air supply pressure, motor overload protection.

Quick Self-Check Procedures

① Record the complete alarm code and refer to the equipment manual to identify corresponding faults. ② Check whether all emergency stop buttons are reset and magnetic contacts of safety doors are fully engaged. ③ Read the air pressure gauge to confirm pressure meets the minimum operating requirement of the machine. ④ Perform a simple power cycle to eliminate temporary program errors.

Closing Remarks

The above five categories cover 80% of sudden daily failures on packaging equipment. Following these procedures can restore normal operation in most scenarios. If the fault persists after troubleshooting, do not repeatedly disassemble and test randomly, to avoid secondary damage to the machine.

Boen Machinery provides free remote video diagnosis for all customers. Senior engineers offer one-on-one online guidance to locate faults. Genuine original spare parts can also be arranged for delivery to resume production as fast as possible. Contact our after-sales team directly for technical support.