Professional Pod Making

Liquid detergent packaging machines produce laundry pods involving complex processes. The machine should be efficient and reliable to maintain production quality and consistent output. However, like every other machine in the world, it is prone to numerous problems, be it mechanical issues, electrical malfunctions, software bugs, or inadvertent actuation. This blog post will discuss the most common issues a liquid detergent packaging machine faces and suggest practical solutions accordingly. So, let us get started.


Fixable Problem No.1

Film Misalignment or Wrinkling
During manufacturing, if the water-soluble film used to form the pods is not tensioned correctly, film misalignment or wrinkling can occur. It will lead to uneven pod shapes, poor sealing, and machine stoppages. Such deformed pods are often unable to pass strict quality checks and are rejected there. The leading causes of the defect are improper roller setup, worn-out alignment sensors, and poor film tension control.



Solution to PVA Film Problems
You can avoid it by optimizing the roller setup. Ensure rollers are correctly aligned and lubricated to minimize friction and maintain smooth film movement. Moreover, you should regularly inspect and replace worn-out alignment sensors to ensure proper film edge detection. Finally, using advanced film tension control systems with real-time feedback will precisely control the film tension during manufacturing.





Fixable Problem No.2


Inaccurate Filling of Liquid Detergent
During the manufacturing process, the pods can be underfilled or overfilled with detergent. If they are overfilled, they can leak even after sealing. It results from clogged filling nozzles, detergent viscosity variations, and misconfigured filling systems such as ceramic pumps or augers.



Solution to Inaccurate Filling
To avoid this problem, you should implement regular cleaning protocols for filling nozzles. It will prevent them from getting clogged by detergent residue. Moreover, if viscosity variations are an issue, it is better to preheat the detergent to ensure smooth flow during filling. Lastly, you should invest in programmable logic controllers (PLC) to precisely control filling volumes according to pod size and detergent viscosity.






Fixable Problem No.3
Poor Sealing or Seal Leaks
Seal leaks occur when a pod's top and bottom films are not bonded correctly. This can lead to seal leaks even before the pod is used, such as during transportation. Major causes of seal leaks are inconsistent sealing temperatures, mold misalignment, or foreign material (detergent residue) on the sealing surfaces.



Solution to Poor Sealing and Leaks
Avoiding seal leaks is easy if the following measures are taken: Install temperature control systems to maintain consistent heating across all sealing zones. Use suitable cleaning agents to remove any foreign material from sealing surfaces. Moreover, mold alignment should be regularly checked, and the mold should be calibrated accordingly to avoid gaps in seals.




Fixable Problem No.4


Pneumatic Failures
During laundry pod manufacturing, pneumatic systems control machine functions like film clamping, tensioning, and braking. Pneumatic failures can lead to numerous problems in the final product. For instance, moisture in the compressed air system causes corrosion in valves, leading to pressure drops below 0.6 MPa.





Solution to Pneumatic Failures
You should install air dryers in the compressed air network to resolve such issues. Moreover, it is crucial to maintain pressure levels around 0.6 to 0.8 MPa using pressure gauges and control valves. Pneumatic air lines should be periodically inspected to ensure their timely maintenance.




Fixable Problem No.5

Mold Jamming or Sticking
Mold jamming is common during laundry pod manufacturing. It occurs when detergent residue builds up in cavities or when molds are improperly lubricated. As a result, you will face interruptions in pod manufacturing and wear-on-machine components. For instance, production will stop every few hours due to frequently cleaning detergent residue inside molds.



Solution to Jamming or Sticking of Mold
You can avoid mold jamming problems by ensuring timely lubrication of mold cavities with suitable lubricants. Moreover, it is better to use food-grade mold release agents after cleaning to prevent mold from sticking. However, some residues are stubborn and not easy to get rid of. You can use ultrasonic cleaners to remove their buildup without damaging the molds.




Fixable Problem No.6

PLC or HMI Errors
No matter how advanced the PLC or HMI gets, they are still prone to unwanted errors. The HMI can freeze and become unresponsive, the PLC can execute false commands, or the touchscreen can hang. These issues arise from electrical fluctuations, software bugs, and unstable voltage supply.



Solution to PLC or HMI Problems
To protect electrical components from voltage spikes, you should install surge protectors. Similarly, keeping PLC software updated will help you prevent software glitches. If a software crash happens, it is better to reboot the system and deal accordingly. Moreover, you must inspect the whole system wiring after a power fluctuation.




Fixable Problem No.7

Electrical Component Malfunction
Electrical malfunctions can occur due to power fluctuations, damaged wiring, or worn-out components. For instance, the laundry pod machine can stop frequently if a damaged inverter controls the motor speed.



Solution to Electrical Problems
To eliminate electrical malfunctions during the laundry pod manufacturing process, start by installing voltage stabilizers to ensure a consistent power supply. Inspect motors, sensors, and wiring regularly and replace damaged parts in a timely manner. Always provide proper grounding of electrical systems to prevent faults from propagating.




Fixable Problem No.8

Inconsistent Film Tension
If the tension of the pod film is uneven, it can lead to wrinkled and misaligned films. It occurs due to sensor drift and variations in film roll diameter.



Solution to Film Tensioning Issues
It is crucial to check that film rolls are uniform and meet diameter specifications within tolerance levels of ±2mm before loading. Moreover, inspect the sensors regularly and replace them if you find any signs of drift. Automated dancer roll systems are the best choice to calibrate tension sensors.




Fixable Problem No.9


Product Leakage Inside the Machine
The final pod can leak inside the laundry pod machine if the nozzles overflow or their seals break. This can lead to slippery floors, electrical hazards inside the machine, and corrosion risks.



Solution to Leakages
To fix these problems, you should tighten fittings regularly. A good way to do so is to check all fittings daily for signs of looseness and tighten them accordingly. Ensure the nozzles dispense accurate volumes without overflowing. Even after all these measures, some areas will remain prone to leakage. You can install drip trays beneath them for easy cleanup.




Fixable Problem No.10

Unexpected Safety System Trigger
Safety systems are prone to inadvertent actuation and can trigger unexpected shutdowns. The reason can be loose wires, grounding faults, and false readings from protection sensors. You may not eliminate them, but you can always take measures to minimize them.



Solution to Unwanted Safety System Triggers
To eliminate loose connections, inspect the wiring weekly and tighten loose connections accordingly. To improve the reliability of sensors, upgrade them with IP67-rated components for better performance in wet environments. Similarly, you should conduct periodic tests on leakage protection sensors to ensure accuracy.




Final Thoughts
The laundry pod-making process involves numerous processes and is prone to many problems. However, with proper and timely measures, they can be minimized. For example, calibrate the film tension system and replace faulty sensors to eliminate film tension inconsistency. For software-related issues such as HMI and PLC, constantly update the firmware to ensure the latest software. Mechanical failures such as seal leaks, improper heating, and dirty sealing surfaces are common and easy to eliminate. With regular inspection and timely maintenance, you can avoid most issues.



If you are looking for a reliable laundry pod making machine, consider Tong Chuang products. They provide various eco-friendly packaging machinery that can handle from lab scale to 2000 units per hour. The manufacturer is open to customizable options and has excellent after-sales services and support. Visit their website to find robust and easy-to-maintain laundry pod-making machines.