Pouch packaging machine Failures and Solutions

1. Bag Retrieval Failure (Suction Cup Fails to Pick Up Bag / Bag Drops During Retrieval)

Causes

Vacuum suction cups are aged, damaged, or lack sufficient suction;

Pre-made bags are stored crookedly, stuck together, or have wrinkled openings preventing proper suction cup contact;

Positioning deviation of the bag retrieval arm, failing to align with the packaging bags in the bag compartment.

Solutions

Replace aged or damaged suction cups and clean any surface contaminants;

Organize pre-made bags to ensure neat arrangement in the compartment. Manually separate stuck bags and remove wrinkled bags;

Fine-tune the arm position to precisely center the suction cup over the bag opening, then recalibrate the retrieval stroke.

2. Bag opening fails / Incomplete opening

Causes

Insufficient suction or misalignment of the bag-opening suction cup;

Excessively tight heat seal at the bag opening, or overly rigid preformed bag material;

Inadequate thrust from the bag-opening cylinder, or insufficient stroke length.

Solutions

Increase the vacuum level of the bag-opening suction cup; adjust suction cup spacing and angle to ensure symmetrical adhesion on both sides of the bag opening;

Contact the feeder manufacturer to adjust heat seal temperature, avoid excessive bag mouth sealing, and prioritize flexible preformed bags;

Increase cylinder working pressure and extend opening stroke to ensure bag mouth fully opens to match discharge aperture.

Filling & Dosing Faults

3. Incomplete Filling / Material Leakage

Causes

Incomplete bag opening by the bag feeder, causing misalignment between the discharge port and bag opening;

Poor material flowability (powder bridging, particle clumping) leading to discharge blockage;

Incorrect metering device parameter settings (e.g., excessive/insufficient screw speed, weighing threshold deviation);

Residual material in the discharge port obstructing the passage.

Solutions

Recalibrate the bag-opening stroke to ensure the bag opening is perfectly aligned with the discharge port; install a feed funnel if necessary;

Enable hopper agitation for powder materials; break up agglomerates in granular materials; pre-treat materials with extremely poor flowability;

Reset metering parameters: reduce screw speed for powders (using slow-fill finishing), adjust vibration frequency for granular materials;

Shut down to clear residual material from discharge port; periodically disassemble discharge channel for deep cleaning.

4. Significant metering accuracy deviation

Causes

Decreased sensitivity or uncalibrated load cells in bag-feeding granular packaging machine;

Significant weight fluctuations in pre-made bags (batch-to-batch grammage variations exceeding standards);

Changes in material density (e.g., powder moisture absorption, uneven particle size distribution);

Material splashing during discharge causing actual fill volume to deviate from set values.

Solutions

Recalibrate load cells, inspect wiring for loose connections, and replace sensors if necessary;

Switch to batch-stable pre-made bags; if bag weight variations remain large, configure “tare compensation” in the system;

Control material storage conditions (moisture-proof, anti-caking) to ensure consistent bulk density; adjust metering parameters for new materials if needed;

Install anti-splash baffles during discharge; use enclosed discharge channels for powder materials to minimize spillage.