Samir Limaye: The essential checklist for auditing your tube-filling machine

Why auditing your tube filling machine is crucial
Regular audits of tube filling machines help identify potential problems before they escalate, ensuring consistent product quality and efficiency. From ensuring proper alignment of sealing jaws to monitoring fill accuracy, each part of the machine must be carefully evaluated. This audit process is especially critical for high-speed production lines, where even minor issues can lead to significant product losses and delays. Stelda - Wimco’s Tubefill Care+ program offers specialised maintenance services to resolve any issues uncovered during audits.

1. Check the tube alignment and holding mechanism
Proper tube alignment is fundamental for accurate filling and sealing. Misalignment can lead to issues such as leaks and product wastage. Ensure that the tube holders are gripping the tubes securely and are in sync with the filling speed. Faulty or worn-out tube holders can cause shifts that disrupt the filling process, leading to uneven fills or seal failures.

2. Inspect filling nozzle precision and cleanliness
Filling nozzles are responsible for directing the product into the tube accurately. Regular inspection is essential to prevent clogs or irregular fill volumes, particularly when working with viscous products. Check for wear and replace nozzles as necessary to maintain consistent product dosing, as nozzle integrity directly affects product quality.

3. Examine hopper and product flow
The hopper holds the product before it is dispensed, and its condition impacts the smoothness of the filling process. Check that the hopper is free from any buildup, which can obstruct flow and cause inconsistent fills. Additionally, ensure that the product flow rate matches the machine’s settings for optimal filling efficiency.

4. Evaluate the sealing mechanism and heat settings
A reliable seal is critical to prevent leaks and contamination. Check that the heating elements are functioning correctly, as uneven or insufficient heat can lead to weak seals. Sealing mechanisms, such as hot air or ultrasonic seals, should be routinely calibrated to match the specific tube materials in use. This is especially crucial for machines handling diverse tube materials, such as plastic or aluminium.

5. Assess machine calibration and sensor accuracy
Tube filling machines rely on sensors to detect tube placement, fill levels, and other crucial steps in the filling process. Regular calibration of these sensors is vital for maintaining accuracy. Miscalibrated sensors can lead to overfills, underfills, or failed seals. During the audit, verify that all sensors are responding accurately and that control settings are optimised.

6. Monitor air pressure and temperature controls
Air pressure and temperature influence the seal’s strength and overall product integrity. Machines with compressed air-driven seals require consistent air pressure to avoid seal weaknesses. Regularly check that the air pressure and temperature settings are calibrated according to the material requirements. Stelda - Wimco’s Tubefill Care+ service includes detailed checks of these parameters to help maintain the sealing quality.

7. Inspect coding jaws and labelling accuracy
In automated tube fillers, coding jaws imprint production information on each tube. Ensure that these jaws are aligned and functioning correctly, as poor alignment can lead to unreadable or misaligned codes. Labelling accuracy is crucial for compliance and traceability, particularly in pharmaceutical applications.

8. Check frame stability and machine mounting
The machine’s frame must be stable and robust to withstand continuous operation without misalignments. Loose or unstable frames can cause vibration and misalignment, impacting fill accuracy and seal quality. Ensure the frame is corrosion-resistant and free from any signs of structural wear, as a compromised frame affects the entire operation.

9. Examine electrical components and control panel
Electrical components, including the control panel, should be regularly inspected for any faults or wear. The control panel manages settings like fill volume, speed, and temperature. Ensure all connections are secure, and the panel is free of dust or moisture. Faulty electrical components can disrupt the entire filling process, leading to unplanned downtime.

10. Review maintenance records and schedule regular upkeep
Maintenance records provide insight into past issues and repairs, helping predict future needs. Reviewing these records helps operators identify any recurring problems, such as frequent nozzle replacements or seal failures, which could indicate a larger machine issue. Scheduled maintenance is essential to avoid sudden breakdowns, and Wimco’s Tubefill Care+ offers comprehensive, preventive maintenance tailored to your production schedule.

Samir Limaye is director at Wimco