Troubleshooting Common Tube Filling Machine Issues

Even the most reliable tube filling machines can experience occasional hiccups. Whether you’re using a 415V system for cosmetics, pharmaceuticals, or food products, quick troubleshooting can save you costly downtime. This guide outlines the most common issues and how to fix them.

1. Inconsistent Fill Volume

Symptoms: Some tubes are underfilled while others are overfilled.

Possible Causes:

• Air bubbles in the product feed line.
• Worn-out or damaged piston seals.
• Incorrect fill volume calibration.

Solution: Bleed the feed line to remove air, inspect and replace seals if necessary, and recalibrate the filling volume settings according to the product specification.

2. Tube Not Sealing Properly

Symptoms: Seals are weak, open easily, or appear uneven.

Possible Causes:

• Incorrect sealing temperature.
• Dirty or worn sealing jaws.
• Improper tube positioning.

Solution: Adjust the temperature settings based on tube material, clean sealing jaws regularly, and ensure the tube is perfectly centered before sealing.

3. Machine Jamming or Stopping

Symptoms: The machine halts during operation.

Possible Causes:

• Foreign objects in the tube holder or conveyor.
• Overfilled hopper causing product overflow.
• Electrical sensor faults.

Solution: Remove obstructions, avoid overloading the hopper, and check all sensors and wiring for faults.

4. Product Leakage

Symptoms: Product leaks before or after sealing.

Possible Causes:

• Damaged tube edges.
• Overfilled tubes causing overflow during sealing.
• Incorrect product viscosity for machine settings.

Solution: Inspect tubes before loading, reduce fill volume slightly, or adjust machine parameters to suit product viscosity.

Preventive Maintenance Tips

• Lubricate moving parts regularly.
• Check all electrical connections monthly.
• Replace worn components before failure occurs.
• Train operators on correct machine handling procedures.

With regular maintenance and quick response to issues, your tube filling machine will deliver consistent, high-quality output for years.