Wexxar Packaging Inc.

Operation & Service Manual 65-45-7 Effective: February 09, 2018

Replaces: October 02, 2013

BEL 252 V.03 / BEL 252X/XL V.03

Fully-Automatic Top and Bottom Uniform Case Tape Sealers

Wexxar Packaging Inc.

Phone 1-888-565-3219 • Fax (604) 930-9368 •
E-mail: [email protected]
BEL 252 V.03 / 252X/XL V.03 Fully-Automatic Uniform Case Tape Sealers 2

Table of Contents
Introduction ............................................................................................... 4
About this Manual ............................................................................................................... 4
How to Contact Us ............................................................................................................... 4
Machine Transportation and Storage ................................................................................... 4
BEL 252 Standard Machine Specifications ............................................................................ 5
BEL 252X/XL Standard Machine Specifications ..................................................................... 6
Safety ........................................................................................................ 7
Safety Considerations .......................................................................................................... 7
Safety Standards .................................................................................................................. 7
General Precautions ............................................................................................................ 8
Lock-out Compliance ........................................................................................................... 8
Compressed Air ................................................................................................................... 8
Electrical Power ................................................................................................................... 9
Conveyor Belts..................................................................................................................... 9
On-Machine Warning Labels ................................................................................................ 9
Machine Overview ................................................................................... 11
Installing the BEL 252 ............................................................................. 12
Levelling the Machine ........................................................................................................ 12
Air Connection ................................................................................................................... 12
Power Connection ............................................................................................................. 13
Installing the Tape Heads ................................................................................................... 14
Adjustment and Operation ...................................................................... 15
Case Size Adjustments ....................................................................................................... 15
Closed Case Height ‘H’........................................................................................................... 16
Case Width ‘D’ ....................................................................................................................... 17
- D1 Width Adjustment Screw .......................................................................................... 17
- D2 Snap Folder Adjustment ............................................................................................ 18
- Flap Width ‘G’ ................................................................................................................. 19
Snap Folder Return Timer................................................................................................ 20
Operating the Machine ........................................................................... 22
Feeding Cases to the Sealer ............................................................................................... 23
Manual Mode .................................................................................................................... 24
Maintenance and Service Procedures.................................................... 25
Compressed Air Supply ...................................................................................................... 25
Lubrication ........................................................................................................................ 26

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Snap Folder Servicing and Adjustments ............................................................................ 27

Snap Folder Speed Control .................................................................................................... 27
Drawbar & Minor Flap Folder Arm Clearance Adjustment ................................................... 28
Side-Belt Conveyor System ................................................................................................ 30
Belt Tensioning and Tracking Adjustment ............................................................................ 30
Conveyor Side-Belt Replacement .......................................................................................... 30
Uni-Drive Conveyor Chain Drive Tension .............................................................................. 32
Arch Cross-Member Vertical Slide Adjustment ................................................................... 35
Troubleshooting Guide ............................................................................ 36
Section 1 - Corrugated Case Quality & Specifications ......................................................... 36
Section 2 - Case Top Flap Folding ....................................................................................... 39
Section 3 – UNI-DRIVE Conveyor System ......................................................................... 40
Section 4 - General Taping Conditions ................................................................................ 43

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Introduction
The BEL 252 is designed for automatic top flap folding and tape sealing of corrugated cases. The
machine does not require a high level of technical knowledge to operate.

About this Manual

The Installation section in the beginning of the manual is intended for those who will be installing and
maintaining the machine.

The Case Size Adjustments and Operating the Machine sections provide further illustration and
explanation of the instruction labels on the machine and should provide a new operator with the
knowledge needed to adjust and run the machine safely and effectively. No one should operate the
machine without first reading these sections of the manual.

The Service and Maintenance Procedures section is intended for those who will be involved in regular machine
maintenance.

The Troubleshooting section provides solutions to common problems that may occur with the quality of the
corrugated cases used and the effectiveness of the case folding process.

A separate “Technical Reference” document provides details on part kits, part identification and machine
construction for those who service and repair the machine.

How to Contact Us

1-888-565-3219
24 hours a day, 7 days a week
Fax (604) 270-7897
Email [email protected]
Email [email protected]
www.wexxar.com

Wexxar Packaging, Inc.

13471 Vulcan Way
Richmond, B.C.
CANADA V6V 1K4

Machine Transportation and Storage

The BEL 252 should not be stored or transported in extreme temperatures. Transport and store in a
covered environment not directly exposed to the natural elements, such as rain, snow or wind. When
transporting the machine, it should be safely secured to prevent movement.

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BEL 252 Standard Machine Specifications

Length Width Height

Case Size Range Minimum 8” / 203 mm 6” / 152 mm* 5” / 127 mm

NOTE: All sizes listed are Automatic Folding 22” / 559 mm 15.5” / 394 mm
16” / 406 mm
case outside dimensions. Maximum 26” / 660mm** 18” / 457 mm***

Machine Dimensions Base machine 56” / 2422 mm 33” / 838 mm 60” / 1524 mm

In/Outfeed Height Frame 22” / 559 mm

With adjustable leg Minimum 25" / 635 mm

extensions [foot pad] Maximum 32” / 813 mm

Speed Up to 25 cases / min. Note: affected by case length – see Snap

Folder Return Timer manual section

Power Requirements Electrical: 120VAC, 60 Hz., 8A.

(standard): Compressed Air: 80-90 psi (5–6 bar); 0.1
CF / cycle (2.8 L / cycle)

Shipping Weight Approx. 650 lbs. / 295 kg.

*Automatic top flap folding limited to a minimum width of 6” (152 mm). A modification option is available for 5” (127 mm) minimum width or
run in Manual Mode.
**Automatic top flap folding is limited to a maximum case length of 22” (559 mm) longer cases are run with folders in ‘Manual’ mode.
***Standard automatic top flap folding is limited to a maximum case width of 15.5” (394 mm) cases up to 18” (457 mm) wide are run with a
modification option or with the folders in ‘Manual’ mode.
For more machine dimensions, see layout drawing 75-962

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BEL 252X/XL Standard Machine Specifications

Length Width Height

Case Size Range Minimum 252 X 10” / 254mm 6” / 152mm 6” / 152mm
Short Frame
Maximum 252 X 24” / 559mm 20” / 508mm* 20” / 508mm*
Long Frame Minimum 252 XL 10” / 254mm 6” / 152mm 7.8” / 198mm
Maximum 252 XL 26” / 660mm 20” / 508mm* 20” / 508mm*

Machine Dimensions BEL 252X 56” / 1423mm 41” / 1041mm 65.5” / 1664mm

BEL 252XL 64.5” / 1638mm 41” / 1041mm 65.5” / 1664mm

In/Outfeed Height Frame 18” / 457mm

With adjustable leg Minimum 21” / 533mm**
extensions [foot pad] Maximum 28” / 711mm**

Speed Up to 20 cases / min.** *NOTE: Maximum speed is affected by case length -

see Snap Folder Return Timer manual section

Shipping Weight Approx. 700 - 750 lbs. / 318 - 340 kg

For further detail, see Layout Drawing 75-1059 *Median values. Case proportional dimensions determine maximum limits without further
modification. Cases can be up to a maximum of 24” (610mm) wide and up to 22” (559mm)
tall but not both maximums together with the default construction due to the ‘headroom’
requirement of the open top flaps which will be ½ the case width.
**Full in/outfeed height adjustment range requires interchange of 9” and 12” footpad leg
extension screws at conveyor drive corner leg.

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Safety
WARNING

The instructions in this manual are not intended to cover all of the details or
variations in equipment, or to provide for every possible contingency to be met in
connection with installation, operation, or maintenance. Should further
information be desired, or should particular problems arise which are not covered
sufficiently for the purchaser's purposes, the matter should be referred directly to
WEXXAR.

WARNING

Any electrical or mechanical modifications to this equipment without the prior

written consent of WEXXAR may void your warranty. Unauthorized modifications
can also result in personal injury, death, or destruction of the equipment.

Machinery is to be operated only by trained personnel.

Safety Considerations
At WEXXAR, our commitment to workplace safety has made us a world-class leader in the packaging
industry due to our adoption of the following best practices:

• Semi-automatic functionality, requiring minimal operator interaction.

• Advanced safety guarding.
• Lock-out provision on electrical and pneumatic main shut-offs.
• Intuitive cautionary labeling demonstrating electrical and mechanical risks.
• E-STOP shutdown.

Safety Standards
WEXXAR observes the following safety standards:

• ANSI B151.1-2000 Safety Standards for Mechanical Power Transmission Apparatus.

• CSA C22.2.1-02; 0-M91 Canadian Electrical Code Part I and Part II.
• NFPA 79 Electrical Standards for Industrial Machines.
• CSA C22.2 No. 14-95 Industrial Control Equipment.

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• ANSI Z535.4-2002 Product Safety Signs & Labels.

• ANSI B155.1-2000 for Packaging Machinery.
• NEMA 12 UL listed standard electrical control.

General Precautions
Your WEXXAR packaging machine is a rugged piece of industrial machinery. It is equipped with various
guards and other safety features, but it must be treated with respect at all times to avoid the possibility
of personal injury.

• Do not operate the machine until it is completely set up and installed properly, and you
are familiar with its operation.
• Do not operate machine without guards and safety mechanisms in place and
functioning.
• Do not attempt to enter the machine for any reason while it is powered or the air
pressure is still on.
• Do not wear neckties, jewelry, loose clothing, or other items that can get caught in
moving parts or mechanisms near the machine.
• Do not operate, troubleshoot, or maintain the machine while under the influence of any
type of drug or alcohol.
• Always observe all safety warnings and notices on the machine and in this manual.
• Do not use solvents when cleaning or maintaining the machine.
• All installation wiring must comply with applicable local codes.

Lock-out Compliance
• Your machine is lock-out / tag-out compliant on both the electrical and pneumatic main shut-
offs.
• Ensure that you lock out the machine and adhere strictly to the safety precautions listed in
this chapter before clearing any jams or performing any repairs and maintenance.

Compressed Air
• The air valve shuts off when an E-STOP is pushed, or when the main power is switched OFF.
• Before starting service or repair work on the machine, lock out the air supply.
• Exercise caution when switching the compressed air back ON. Stay well clear of all moving
parts, as they may move quickly when the pressure is reapplied. Make sure all personnel are clear
of the machine when switching the compressed air on.

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Electrical Power
• Switch off the main power disconnect switch on the control panel, and lock it out before
starting service or repair work.
• Before performing service work inside of the electrical enclosure, disconnect all electrical
power to the machine.

Conveyor Belts
• Keep fingers well clear of conveyor belts.
• Do not wear loose clothing or accessories when operating WEXXAR packaging machines.

On-Machine Warning Labels

Lock-out power
Lock casters during
and air when
operation.
servicing.

Disconnect power Keep hands clear

cord when of tape head
servicing. knife.

Disconnect power
Do not run without belt
cord when
guards in place.
servicing.

Wear ear
Do not run without Snap-
protection during
Folder guards in place.
operation.

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Electrical hazard. Keep hands clear of chain drive.

Keep hands clear of pinch point

See Maintenance
between the belt and belt
section in manual.
cover.

See Operation
Keep hands clear of tape
and Service
head knife.
manual.

Replace fuse with same type and rating.

Emergency stop

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Machine Overview
Case Height Adjustment
[either side]
Start / Stop Switch and Snap
Folder Auto / Manual Control

Operating Instructions

Bottom Tape
Head Instructions
Snap Folder Auto / Manual
Mode Instructions

Case Size
Adjustment Top Ski Adjustment
Instructions

Compressed Air
Connection

Case Width Adjustment

[either side]

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Installing the BEL 252

Unpack the machine and remove any packing material from the interior or any support used underneath
to protect components during shipping.
Install the threaded leg extensions with either pads or optional casters at each of the four positions on
the machine frame with one nut and washer for each leg underneath the frame and another nut and
washer on the inside of the frame.

Levelling the Machine

The base of the frame should be made level to ensure personnel safety, provide optimum performance,
and avoid frame stress.

Air Connection
CAUTION
Ensure that the red manual air supply lock-out valve is in the OFF position
before connecting an air supply to the machine.

Main compressed Pressure

air connection at Adjustment
lockable shut-off
valve

The supply must be clean factory air. Air pressure should be set to 80 PSI / 5 BAR for most applications
with a minimum setting of 65 PSI / 4 BAR and a maximum of 100 PSI / 7 BAR.

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Power Connection
The BEL 252 is equipped with single-phase 120 VAC / 60 HZ electrics manufactured to NEMA 12
specifications. The conveyor drive system is powered by a 1/2 horsepower TEFC motor that draws eight
amps. The machine is connected to an electrical outlet with a conventional cord and 3-prong plug. A
minimum 14 gauge (AWG) power extension cord with standard three-pin connection must be used to
connect the machine to the power source.
A dedicated electrical circuit is recommended for this machine. If any electrical connections are needed
to install the machine, these must be handled by an electrician qualified in your jurisdiction.

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Installing the Tape Heads

The tape heads are mounted with pins on either side of the head that fit into corresponding slots in the
tape head mounting brackets. There are illustrated instructions for installing the bottom tape head on
the machine conveyor cover. Lower the tape head into the bracket aligning the pins with the slots. The
upper tape head, when pushed firmly toward the rear of the machine in its mounting slots, is held in
position by thumbscrews. Please refer to the illustration on the tape head and the tape head manual for
instructions on the mounting of tape rolls and the proper threading of tape through the applicator head.

Bottom Tape Head

Bottom tape head instructions

and mounting details

Top Tape Head

Thumbscrew used to secure

top tape head in position

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Adjustment and Operation

SAFETY

Set up the BEL 252 to seal a particular case size with adjustments for
Case Size case width (D), closed height (H) and flap width (G).

Adjustments

Case size adjustment instructions

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Closed Case
Height ‘H’

Unlock the height adjustment and rotate the hand-wheel to raise or lower the
top flap folder and tape head sub-assembly to the correct case height.

Case height
reference scale

The top of the case with flaps

closed should be flush with the
top of the silver colored Snap
Folder guide bar.

Lock the case height adjustment.

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Case Width
‘D’

- D1 Width
Adjustment
Screw

Attach the hand crank supplied with the machine on the square shaft that extends
from both sides of the frame. Adjust the width using the reference scale under the
sealer conveyor on the left hand side of the machine.

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Case
Width ‘D’

- D2 Snap
Folder
Adjustment

Loosen both Snap Folder locking handles and adjust to the case width. There should be 1/16” to
1/8” (1.6mm to 3mm] of clearance on each side between the folder guide bar and the side of the
case. Re-tighten the locking handles.

1/16” – 1/8”
[1.6mm – 3mm]
clearance

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Case
Width ‘D’

- Flap
Width ‘G’

For RSC cases, G = ½ D. The top ski must be adjusted so that the rear minor flap does not hit it
when folding down. The ski also must not be adjusted too far back or the flap will unfold
before it is under the ski, also hitting it and damaging the case.

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Snap Folder Return Delay Timer

Standard Snap Folder return timer

location under the rear of the machine

The Snap Folders used to fold down the top case flaps before applying tape have a timer that controls
the actuated or out-time delay of the folder arms before they retract into the housing. The folders need
to stay out long enough that the flaps are held down until the leading end of the case is under the tape
head so that the flaps do not re-open and cause a jam. Shorter cases require a longer delay time than
longer cases due to the greater distance the leading end of the case has to travel after the trailing end
has released the limit switch that operates the folders. Longer cases will take more time to release the
limit switch so they can use a shorter delay timer value as the leading end will already be closer to the
top tape head holder.
For applications where maximum case rate is not critical, generally below 20 cases per minute, the
folder return timer can be left at a setting that will handle a wide range of case lengths, avoiding the
need for adjustment. However for maximum case rate, particularly with longer cases, it is necessary to
reduce the return delay timer value to the minimum setting that will allow the folders to return to their
home position as soon as possible but without releasing the top flaps too soon.

18 1/4" [464mm] Minimum length case

travel distance to flaps secured
1.0 to 1.5 sec. folder timer setting
4 1/4" [109mm] Maximum length case
travel distance to flaps secured
0.5 to 1.0 sec. folder timer setting
The major flaps at the
leading end of the case
are secured from re-
opening after folding by
the case moving under
The Snap flap guides just ahead of
Folders act the tape head
when the limit
switch is
released from
the trailing
end of the
case 8" [203mm]
Minimum case length
22" [559mm] CASE TRAVEL DIRECTION
Maximum case length

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The Snap Folder on-delay timer located at the rear of the machine under the frame determines the
length of time that the Snap Folder mechanisms dwell in the ‘out’ or actuated position so that the flaps
do not re-open before they are captured under the flap guides on the top tape head holder. This timer
is factory set and does not normally need adjustment unless speed needs to be optimized for a wide
range of case lengths. See a more complete explanation under ‘Snap Folder Return Timer’ above.

Folder Actuated Delay Timer

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Operating the Machine

Press the Start switch located on top of the machine arch.

Press Start switch

For normal operation, be

sure the ‘Manual – Auto’
switch is in the ‘Auto’
position.

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Feeding Cases to
the Sealer
Push the case
toward the
conveyor until it
grips the case and
takes it into the
folding and taping
sections (BEL 252
shown here
coupled with a BEL

The Snap
Folders will
automatically
fold down the
top flaps before
tape is applied
to the top and
bottom of the

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Manual
Mode

The standard Snap Folders can only automatically fold the top flaps of cases up to 22” (559mm)
long. For case lengths longer than 22” (559mm) on a standard BEL 252, switch the Snap Folders
to ‘Manual’ mode using the selector switch on the pushbutton station. This mode will lock the
folders in the extended position. Fold down the top flaps of the long cases by hand and feed the
case into the sealer section for taping in manual mode.

Case Length more than

> 22” / 559mm for standard
BEL 252

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Maintenance and Service Procedures

Compressed
Air Supply

Adjusting air
pressure

1. Shut-off
air supply

2. Remove
filter bowls to
replace filters

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Lubrication

Width Height
adjustment adjustment
screws screws

Uni-drive Conveyor

Snap Folder width

adjustment

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Snap Folder Servicing and Adjustments

The function of the Snap Folders is to fold the case minor flaps and major flaps within the shortest
possible travel distance. In each Snap Folder, the rear minor flap and major flap folders are activated
through a single mechanical, progressively linked drive system powered by a pneumatic cylinder.

Snap Folder Speed Control

After checking for wear and replacing any worn parts or after replacing the unit with a factory exchange
/ rebuilt unit, it may be necessary to reset the flow control located on the outside end of each Snap
Folder. The purpose of this flow control is to regulate the speed of the hook-shaped minor folder so
that it has the proper following action to fold down the rear minor flap. This should be set to operate
as quickly as possible but without striking edge of the top major flaps hard enough to damage them.

The quick exhaust flow controls at the case outfeed

end of the Snap Folders regulate the speed of the
folding action. They should be set to keep pace
with the case movement but not open so much that
the folder movement is not cushioned.

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Drawbar & Minor Flap Folder Arm Clearance Adjustment

The square bar attached to the folder cylinder that actuates both the minor and major flap folders
through cam actions is supported by a guide support with bearings and a clearance adjustment. If there
is wear on the clearance adjustment ‘plug’ or if its adjustment screw backs off, the minor flap folder can
drop down to the point where it scrapes on the folder housing.

Folder cylinder

Folder actuating drawbar

Bar guide and clearance adjustment subassembly Z56-2320

If the drawbar nylon adjustment plug wears down or clearance adjustment set screw backs off it can
allow the bar to drop down to the point where the minor flap folder arm scrapes the bottom of the
housing as it extends and retracts.

Downward drift of the folder due to

excessive drawbar adjustment clearance

Minimum 1/16” [2mm] minor

folder to housing clearance

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Guide subassembly Z56-2320

clearance adjustment

The vertical height of the nylon wear plug item # 3 is adjusted by the set screw item # 5 and controls the
clearance with the top guide item # 2 and of the minor folder arm subassembly to the housing. The set
screw must be adjusted to provide the right clearance and secured with blue Loctite. The setscrew can
be accessed through a hole in the bottom of the housing.

Drawbar guide adjustment

access hole on the bottom
of the folder housing.

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Side-Belt Conveyor System

The BEL 252 has a Uni-Drive conveyor system in which both side belts are driven by a single motor and gear
reducer. The Uni-Drive ensures that both belts are synchronized at the same speed, in order to keep cases
square through the taping section of the machine.

Belt Tensioning and Tracking Adjustment

The side belts are tensioned and the tracking is controlled by top and bottom adjustments on both idle pulleys.
The tension of the belts should be just enough to prevent belt slippage or so that approximately one inch (2.54
cm) of play is available when the belt is pulled sideways by hand in the center of the machine. Too much
tension will cause excessive strain and premature wear of the belts and pulley bearings. With the conveyor
running, tighten the upper and lower bolts to position the belt so that it is running true and not trying to ride
up or down on the idler pulley.

Belt tension Belt tracking

adjustment adjustment

Conveyor Side-Belt Replacement

1. Loosen the top and bottom belt tensioning bolts so that the belt is completely slack.

Loosen top belt Make belt

tensioning bolt Loosen bottom belt completely slack
tensioning bolt

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Remove the screws from the top plate and the top belt tensioning bolt from the idle pulley
shaft. Lift off the top plate.
Remove the
Remove the top Remove the top (only)
top plate.
screws belt tensioning bolt.

2. Remove the stainless steel conveyor cover and then remove and replace the belt.

Remove Remove and

conveyor cover replace belt

3. Reassembly is the reverse of disassembly. Re-tension and adjust the tracking of the belts as
described above. Replace the top adjustment plate. Replace all conveyor covers.

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Uni-Drive Conveyor Chain Drive Tension

The Uni-Drive side-belt conveyor is designed to keep the case square during sealing, which results in a
technically stronger seal and a better-finished appearance. This is achieved by linking the drives of both
conveyor belts to a single motor and gear-reducer that inherently synchronizes belt speeds better than
other belt drive systems on the market. Uniform chain tension is maintained automatically during case
width adjustments through a self-compensating serpentine configuration.

Chain tension is preset at the factory but if the drive becomes noisy or needs adjustment then adjust as
shown below. Proper tension is achieved when the horizontal sag in the chain measures between 1/8
inch and 1/4 inch (3.1 and 6.4 mm) with drive belts in a fully opened position.

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1. At the conveyor drive motor corner of the machine, loosen the idle sprocket mounting bolt
enough to allow it move in its slot.
Chain idle sprocket
mounting bolt

2. Unfasten the flexible plastic bellows on top of the stainless steel safety cover and remove the
cover.

3. Loosen the locknut and adjust the tension chain tensioning bolt

Adjustment locknut

Tension adjustment

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4. Re-tighten the idle sprocket mounting bolt

External tension
adjustment access

External
tension
adjustment Re-tighten idle
Idle sprocket
requires ¼” sprocket
mounting bolt
drive and ½” mounting bolt.
hex socket.

SAFETY: The safety covers must be replaced before operating the machine.

The optional BEL 252 Spare Parts Maintenance Kit contains all of the parts necessary for maintaining the
Uni-Drive conveyor. See the Technical Reference manual for details, and contact the factory or your
local Wexxar/BEL distributor for the kit’s price and availability.

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Arch Cross-Member Vertical Slide Adjustment

The machine arch cross-member supports the upper tape head holder on the BEL 150. It mounts to the
arch assembly with vertical slide bar bearings that ride inside the arch columns, allowing the cross
member to move smoothly up and down for case height adjustment.
The bearings are made of a special hardwearing plastic material but may need periodic adjustment to
compensate for wear or for loosening due to frequent adjustment or operating vibration. If worn or
loose, the bearings allow excessive movement of the upper tape head holder and may affect taping
performance.

Vertical slide bar

bearings

If the bearings are loose or worn

they may allow excessive
movement of the top tapehead
holder.

There are wedge-shaped spacers between the bearing bars at the top and bottom with a threaded rod
adjustment between them. Tightening the nuts on the rod will reduce the bearing clearance.

Top slider bearing Bottom slider bearing

adjustment nut adjustment nut

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Troubleshooting Guide
Section 1 - Corrugated Case Quality & Specifications
Corrugated case quality is a major factor in smooth running and quality sealing. The following points will
help determine if you have a case size or quality problem:

Problem Description Solutions

Over-fill or top bulging of the case due • The problem may be due to the
Case
to the fit of the product. There will distribution of product inside the case.
Dimensions usually be a wider gap between the top Leveling the product by hand or with a
major flaps after sealing. With hard case shaker conveyor may solve the
product over-fill, it will often jam cases problem.
inside the machine.
• If the product is compressible, a side
compression option may help. For an
automatic case tape sealer, an active
overfill compression option may be
In addition to applied to push down on the top flaps
avoiding case before taping.
sealing • If the product is not compressible,
problems, re- depending on the sealer model, a floating
sizing of cases top tape head option may be available. It
can often result will both press down on the top flaps and
in cost savings ride over the top bulge resulting from
by using the hard overfill.
correct case
size and Under-fill can cause flaps not to fold • A correctly filled case will help the sealing
material correctly with automatic flap folding. process by supporting the case body
weight. Consult Top flaps may be pushed down into the during flap folding and the top flap
your corrugated case by the top tape head causing poor sealing.
case supplier tape bond or premature cutting of the
for help to • Case flap folding score lines may not be
tape.
achieve this. deep enough to promote flap folding
instead ‘crippling’ or pushing-in the end or
side panels.

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Section 1 - Corrugated Case Quality & Specifications

Problem Description Solutions

Side-bulging of the cases can be due • Reduce the impact of product being filled
to heavy product pushing out on the into the case by more gradual filling or
case side panels. It can prevent the perhaps by using a shaking process rather
top flaps from being folded than a compression process to avoid
automatically and put additional overfill.
stress on side-belt conveyor
• The case material weight may not be
components.
heavy enough for the product and the
score lines may need to be made deeper
to help with flap folding.

When the flap folding score lines are • Ensure that the score lines in the cases are
Fold Score
not deep enough, particularly on light as well defined as possible to help with
Lines or heavy weight material cases, the the automatic folding process. Your
flaps will not fold properly. corrugated case supplier can help with
this by making sure that correct scoring
pressure is used for your case
specification. This is one of the most
common causes of poor case- closing
performance

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Section 1 - Corrugated Case Quality & Specifications

Problem Description Solutions

If the flap corner slots are too narrow, the ends
of the major flaps can block the minor flaps from • If the corner slots are wider,
Flap Corner folding properly. It is often a problem with cases can be automatically
Slots heavier double-wall material cases. folded with a minimum of
interference between major
and minor flaps.

NORMAL NARROW

Above is an example
of good corner slot in
a formed case.

Case The glue joint where the manufacturer glues the

‘Squareness’ flat case together can be a problem if it causes
the case to be wider at one end than the other or
to be twisted from end to end. Both conditions
can cause case jams and poor sealing quality.
Overlapped Cases not properly formed have major flaps that
• Contact your corrugated case
or Gapped over-lap or a gap between them that is too wide.
supplier to have them correct
Case Flaps their manufacturing process.

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Section 2 - Case Top Flap Folding

Problem Description Solutions

The back or front • Check the air pressure and volume.

of the case • Be sure that the case Snap Folder
collapses inward width setting does not hold the
during minor flap case too tightly.
folding • Check that the scoring on the case
is adequate and promotes folding.
There will be a greater need for
good score lines if the product does
not provide inner support of the
end panels.

Major flaps have • Be sure that the air pressure is

difficulty folding adequate and does not drop during
and cause inner the cycle.
edges of minor • Heavy, double-wall cases may have
flaps to be folded poor corner slots and flap scoring
over. that offer too much resistance to
folding. See the ‘Corrugated Case
Quality & Specifications’
troubleshooting section for further
detail.
• Over-filled cases will prevent the
flaps from fully folding down.
Check the levelling of bulk product
in cases and that the case is large
enough for the product.

The rear minor • Top ski position adjustment. The

flap hits the top ski needs to be adjusted far enough
ski when folding back to allow the rear minor flap to
down or popping fold down, but not so far back that
back up. it comes back up in front of the ski
instead of being held down by it.
• Over-filled cases will prevent the
flaps from fully folding down.
Check the levelling of bulk product
in cases and that the case is large
enough for the product.

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Section 3 – UNI-DRIVE Conveyor System

The UNI-DRIVE side-belt conveyor system is designed to keep the case square during sealing to produce
a technically stronger seal and a better looking appearance.

Problem Description Solutions

Be sure:
Case is not Despite the synchronized
sealing so that it side belts of the UNI-DRIVE 1. The case is square before it enters the side-belt
is square conveyor, the cases exit the conveyor.
machine not square after 2. The side belts are correctly adjusted to case
sealing. width by the following method:
A. Adjust the belts in until they lightly
contact case sides, but so that the case
can still slide through belts if pushed
firmly.
B. Remove the case and adjust the belts
inwards one-half turn.
3. That neither of the conveyor belts is slipping on
its drive pulley. See the section on belt
tensioning procedure in the Service and
Maintenance Procedures section.
4. That in the case of round can or bottle products,
the belts are set to grip lightly but firmly on case
sides. Excessive side pressure can cause round
objects to roll ‘over-center’ and push the case
out of square.

There is a If the cases exit the machine • Use the procedure described in item ‘2.’ above
crushed band on with a band of crushed to adjust the conveyor to the case width.
the lower part of corrugation at the level of the
the case conveyor belts, it is likely that
the case is gripped too tightly
in the belts.

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Section 3 – UNI-DRIVE Conveyor System

Problem Description Solutions

There is rubber A dark gray or almost black • Be sure that the case is clearing the belts as it
‘dust’ being shed dust appears beneath the exits the machine and that outfeed conditions
from the belts conveyor belts, particularly do not cause cases to back up into the conveyor.
at the end where the case
• Be sure that belt tensioning and tracking
exits the sealer.
adjustments are correct, as described under
Service and Maintenance Procedures. Incorrect
settings can cause premature belt wear and
possible belt breakage. (See section on UNI-
DRIVE in the machine manual.)

There is a Although pre-stretched • Tighten the chain idler sprocket, as described in

‘rattling’ noise chain is used in the machine the Service and Maintenance Procedures section
coming from the drive, the chain over time
conveyor drive. may loosen and rattle on the
drive cover.

Frequent Belt Belt life will depend on the conditions of machine

Breakage. use, but frequent breakage may be due to one
or more of the following conditions:
• Belt tracking. Ensure that the idler pulley has its
tracking set so that the belt does not try to ride
up or down on the pulleys. See belt tensioning
and tracking adjustment under Service and
Maintenance Procedures
• Belt Tension. The belts may be over-tensioned.
They should be tensioned just enough to
prevent slippage in normal operation. The
correct setting usually allows approximately one
inch (2.54 cm) of deflection on the return side of
the belt at center point of conveyor.
• Idler and drive pulley rotation. Ensure that
pulleys rotate freely and that bearings are not
seized or excessively worn.

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Section 3 – UNI-DRIVE Conveyor System

Problem Description Solutions

Machine Jams Turn OFF the machine as soon as the jam occurs and
Frequently. before clearing it. Open the belts and raise the
top tape head. Remove the jammed case and
debris. Check for the following causes of case
jams:
• The top tape head is adjusted too low.
• The product is overfilled or inconsistent, causing
intermittent jams. See also Troubleshooting
Section 1 - Case Quality & Specifications
• The belts are set too tight, causing machine
overloading.
• Check the position of the top ski on automatic
sealers with top flap folding.

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Section 4 - General Taping Conditions

Problem Description Solutions

Tape does The tape is not bonding to Look for the following conditions:
not stick to the flaps or ends of the case • Under-filled Case. The product does not provide
case surface to provide a secure seal. support under the top flaps so they are simply
pushed down or away from the tape head rather
than having the tape rolled onto the surface. Adjust
the contact roller spring tension to a lighter setting.
Ideally, have the case size made a better fit to the
product.
• Overlapping flaps. If the outside (major) flaps are
allowed to overlap, the ‘step’ created results in an
uneven taping surface, causing poor tape adhesion
that can release during shipping and handling. See
comments on flaps (Troubleshooting Section 1,
Corrugated Case Quality & Specifications)
• Tape-head roller contact. Be sure that the tape
head contact or wipe-down rollers are making good
contact with the case and that the roller spring
tension is correct.
• Dust or dirt. Large amounts of dust or dirt gathering
on the cases or in the air will impair adhesive
effectiveness.
• Temperature. Extremely hot or cold temperature
may require tapes with appropriate adhesive
formulations for good initial bond and permanent
sealing performance.
• Tape adhesive. Check the quality of tape adhesive.
We recommend the ‘hot melt’ type of adhesive over
Acrylic adhesive.

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Section 4 - General Taping Conditions

Problem Description Solutions

The tape is not cut properly
Tape is not
every time. In the worst
cut every
situations, several cases may
time
be taped together.

The tape is not cut properly every time. In the worst

situations, several cases may be taped together.
Check the following conditions:
• Tape head position. If the top tape head is set too
high, the cut-off knife will not be fully activated
resulting in poor cut off. The tape-head side plates
should be within 1/16 to 1/8” (1.6 to 3.2 mm) of the
case. Ensure also that cases ride fully down between
the conveyor belts to provide proper contact with
the bottom head cut off knife.
• Knife extension. Ensure that the knife extends
enough to fully contact the tape during the cutting
stroke.
• Tape tension. Unroll tension should be smooth and
not too tight, as a ‘snap back’ caused by stretched
tape can cause a jagged cut-off and cause tape
pieces to be stuck to the blade.
• Clean knife. Clean the blade and apply a little silicon
or oil to avoid adhesive build-up on the sharp points.
• Knife blade wear or damage. Blades must be very
sharp to work well. The points are easily damaged if
contacted by any hard material. Replace the blade if
it seems dull.
• Cut-off spring tension. Ensure that the spring that
provides power to cut-off arm has enough tension to
cut through the tape. Replace the spring if it is too
weak.

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Section 4 - General Taping Conditions

Problem Description Solutions

Tape tail The end of the tape on the Check for these conditions:
does not back side of the case (as it • Tape tension. Tension should be is smooth and not
stick down leaves the machine) has not too tight. Tape tension ‘snap back’ will cause tape
properly adhered well to the case. tail to recoil and not stick well on the back of the
case.
• Tape head roller contact. Be sure that the wipe-
down roller is actively pushing the tape down and
that the spring is in good condition and set to the
right tension.
• Tape cutter arm adjustment. Retract or shorten the
adjustable arm on the DEKKA 22/23 tape head cutter
cam plate to shorten the length of the tail on the
rear or trailing end of the case. See the DEKKA tape
head manual for further detail.

Tape is off- The line of tape is not Look for the following conditions:
center centered over the gap • Tape roll position. Ensure that the tape roll is fully
between flaps on the top or pushed onto the tape mandrel hub.
bottom of the case.
• Tape head straight. Ensure that the tape head sits
straight in its bracket and is not tilted to one side.
• Tape head tracking adjustment. There is an
adjustment for the arm that mounts the tape roll to
‘steer’ the tape so that it is on-center. See the
DEKKA tape head manual for further detail.
• Obstructions. Look for obstructions that could be
pushing the tape off center.

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Section 4 - General Taping Conditions

Problem Description Solutions

Tape Falls The beginning end of the A curve made across the tape by a guide on the tape
Forward on tape must stand vertically in head together with the spring-loaded ‘finger’ behind the
Bottom front of the tape head front tape help to stiffen it to stand vertically like the curve
Tape Head roller in order to contact the across the ruler of a tape measure. A static electric
leading end of the next case. charge on the tape head rollers also attracts the tape and
helps to keep it in place.
If the bottom tape will not stand vertically, look for the
following conditions:
• Contamination. The tape may be wound around the
roller, or there may be dirt on the roller.
• No static charge. Dust roller surfaces with talcum
powder to the increase static charge on the roller.
• Incorrect tape head guide settings. Ensure that the
plastic tape guide and the finger are set correctly.
They should make the tape curved across its width
but not create conditions for the tape to ‘break’ or
bend over at the guide. See the DEKKA tape head
manual for further detail.
• Inappropriate environment. A strong breeze in the
vicinity of the tape sealer can cause the tape to blow
down. High temperature or humidity may affect the
tape characteristics.
• Inappropriate tape. Some brands and types of tape
have more ‘body’ than others, so a change of tape
may be needed, particularly in difficult ambient
conditions. We recommend that the tape have
minimum thickness of at least 1.7 mil.

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