We recommend tracing a packing jam back to the first cup or stack that loses support or control. A later film or sealing alarm may be a consequence. Before changing timing, confirm the approved cup format, transfer parts and receiving condition.
A used wrapper can run and still be incomplete
In a public flow-wrapper help thread, a user described product dropping before the former as well as film and sealing difficulties. A later reply from the user reported missing parts. That is a third-party report, not verified inspection evidence or a HANNAI case. It makes checking machine completeness a sensible question before retiming an unfamiliar wrapper.
Map the first product-control failure
Preserve the cup sequence immediately before a stop. Mark the jam location, cup format, stack or batch count, speed state, alarm order and whether the fault follows startup, acceleration, reel change or cup-size changeover. A safe external video can show whether one cup arrives late, rotates, rebounds or catches a guide.
Separate forming-line output from packing-machine behavior. Use the cup collection and counting troubleshooting guide when the packer receives unstable counts or poorly controlled stacks. The packer cannot consistently correct an upstream handoff that already varies.
Classify the jam by its repeatable pattern
Useful categories include a single tilted cup, two cups entering together, an over-compressed stack, a batch that opens during transfer, a cup lip catching one guide, product entering the film at an angle or a fault that repeats after a fixed number of cycles. Keep good and jammed product for comparison.
Inspect cup dimensions, rim shape, sidewall seam, nesting behavior and contamination. A cup-format or quality change can alter friction and stack height even when the packer settings have not moved. Do not widen guides until the product is confirmed against the approved sample.
Use an infeed evidence table
| Observed pattern | Evidence to inspect | Diagnostic direction |
|---|---|---|
| One cup tips at the same guide | Guide surface, cup rim, entry angle and local clearance reference | Check cup geometry, burrs, contamination and alignment |
| Two cups enter together | Separator movement, sensor sequence, product friction and timing | Review de-nesting and release control |
| Jam follows a batch release | Count, stack compression, pusher motion and downstream readiness | Check batch handoff rather than film cutting |
| Good at low speed, unstable after acceleration | Cycle video, motion completion, vibration and product recovery time | Review timing margin and mechanical support |
| Fault begins with a new cup format | Approved sample, recipe, guide positions and changeover record | Confirm the complete format setup |
Clear jams with full isolation
Stop and lock out the machine according to the delivered procedure. Release stored pneumatic or spring energy and wait for heated sealing components to reach a safe condition. Never reach through a guard, defeat an interlock or pull a cup from an energized nip.
Before removing product, photograph its orientation and the first contact point. Inspect guides, belts, pockets, pushers and transfer surfaces for coating residue, film fragments, burrs, loose hardware or wear. Preserve reference marks before moving a guide or support.
Verify product, guides and release timing as one system
Compare the jammed cups with the approved format for top diameter, height, rim condition and stack behavior using the site’s controlled method. Check that the correct recipe and change parts are installed. Check guide and support references under isolation using the approved method; do not manually cycle a pusher or displace stored-energy mechanisms.
From outside the guarded area, compare separator, pusher, gate and downstream-ready signals during an authorized slow cycle. Do not change sensor position and mechanical timing together. Preserve the original reference and use the supplier’s procedure for any adjustment.
Separate infeed faults from film-section faults
A product can be correctly grouped but still meet film that is wrinkled, off-center or late. Conversely, a film-tracking alarm may be the final event after a tilted cup disturbed the web. Use the film feeding, tracking and cutting guide only after identifying which event occurred first.
Preserve alarm history and compare cup position, film position and sealing readiness in one timeline. This avoids adjusting the film path to compensate for a product handoff problem.
Run a staged confirmation
Restore guards, remove tools and restart through the authorized setup stages. Run a small identified batch, then a longer sequence that includes the condition where the jam previously appeared. Record consecutive accepted packs and any near-jam behavior rather than only the absence of a stop.
Verify pack count, cup condition, film presentation, seal quality and downstream handling. Retain the changeover and corrective-action record for the next production shift.
Check the unsupported span as a separate handoff
For the actual supplied packer, compare the delivered transfer drawing and change-part list with what is installed. Identify the last point supporting the cup stack and the first point controlling it on the receiving side. Do not infer that a plate visible on another wrapper belongs on this one, or fabricate a bridge from a forum photograph.
During an authorized observation, note whether the product tips before film contact, after a pusher releases it or only when the next stage is unavailable. Preserve the original event before clearing the jam under isolation. A hot sealing problem is a separate investigation unless the timeline shows it caused the infeed interruption. Omron’s horizontal-wrapper overview illustrates coordinated product and film handling; it is an architecture example, not a HANNAI parts specification.
Discuss the evidence with HANNAI
Use the packing equipment page for product context. Send cup/stack drawings, transfer-part references, first-alarm order and safe sequence evidence through our inquiry page before proposing a timing change.