Installation Guide for Popcorn Automatic Packaging Machine
Phase 1: Preparation before installation
Site survey and preparation:
Space: Ensure that the installation site has sufficient space to accommodate the equipment itself, as well as the connecting devices at the front and rear ends (such as elevators and conveyor belts), and reserve space for operation, maintenance, and access.
Foundation and load-bearing capacity: The ground should be flat, sturdy, and able to withstand the weight of equipment and dynamic loads during operation. Usually requires a concrete floor.
Environmental requirements: The environment should be clean, dry, well ventilated, and avoid places with high dust, high temperature and humidity, and corrosive gases, which can affect equipment life and food hygiene.
Power supply: Confirm that the on-site power supply matches the required voltage (such as 380V), frequency (50Hz/60Hz), and power of the equipment. Prepare an independent air switch (circuit breaker).
Air source (such as pneumatic equipment): Most automatic packaging machines require compressed air. Prepare the air compressor to ensure that the air source pressure meets the equipment requirements (usually 0.6-0.8MPa), and equip it with three components (filter, pressure reducing valve, oil mist device) to provide clean, dry, and stable compressed air.
Open box inspection:
Refer to the equipment packing list and carefully check whether all components, spare parts, and tools are complete.
Check if there are any obvious bumps, damages, or rust on the equipment during transportation. If there are any issues, you should immediately contact the supplier or logistics company.
Tool preparation:
Common tools: Allen wrench, adjustable wrench, screwdriver (straight or cross), level ruler, tape measure, rubber hammer, etc.
Professional tools that may be required: forklifts or cranes (for moving the host), welding machines (if brackets need to be made), etc.
Phase 2: Mechanical installation
Host in place:
Carefully move the host to the designated position using a forklift or crane. During the movement, it is necessary to be stable to prevent overturning or collision.
Place a level ruler on the bottom of the device and adjust the screws (or washers) on the bottom to level the device. This is a crucial step, as poor levelness can lead to issues such as stuck bags, improper film movement, and uneven sealing.
Install the roll film system:
Install the packaging film core shaft onto the support frame.
Install the packaging film roll, pay attention to the direction of the film (front and back), and pass it through each guide roller, tension roller, and correction device according to the schematic diagram in the instruction manual.
Adjust the frictional resistance of the film roll to ensure smooth unwinding.
Connect the conveying system:
If the equipment includes a feeding elevator, material bin, measuring hopper, finished product conveyor belt, etc., connect them to the main machine in the order specified in the manual.
Ensure smooth and seamless interfaces to prevent popcorn from getting stuck or leaking.
Adjust the height and tension of the conveyor belt to ensure smooth connection with the inlet/outlet of the main engine.
Install pneumatic system (if applicable):
Connect the air pipe from the air compressor to the air source interface of the equipment.
Check if all tracheal connections are secure and there is no risk of air leakage.
Phase Three: Electrical and Debugging
Electrical connection:
It must be operated by a professional electrician!
Disconnect the main power supply and connect the device power cord to the prepared independent air switch.
Ensure reliable connection of the ground wire to ensure the safety of operators.
Check if the wiring of all sensors (photoelectric eyes, proximity switches, etc.), motors, and heaters is secure.
Parameter settings:
Connect the power and gas sources.
On the touch screen or control panel, set the initial parameters according to your popcorn product and packaging requirements:
Bag length: Set an initial value.
Temperature: Set the initial temperature for vertical and horizontal sealing (usually starting from a moderate temperature, such as 160-180 ° C, adjusted according to the packaging film material).
Filling amount: Set the target weight or volume of the measuring bucket.
Speed: The initial setting is medium low speed.
Empty machine operation debugging:
Start the equipment without discharging materials and conduct a trial run.
Observing film movement: Check whether the packaging film is running in the center under the control of the correction device, and whether there is any deviation or wrinkling.
Check sealing: Allow the equipment to complete several cycles of bag making and sealing actions. Observe whether the sealing patterns of vertical and horizontal seals are clear and uniform. Gently tear the test bag by hand and check the sealing strength. Adjust the sealing temperature and time according to the situation (if the temperature is too low or the time is too short, it may not seal firmly; if the temperature is too high or the time is too long, it may cause scalding).
Adjust the photoelectric eye (photoelectric eye): Move the position of the photoelectric eye so that it can accurately recognize the color code on the packaging film, ensuring that the cutting position of each bag length is accurate.
Trial operation with materials:
After the empty machine runs normally, start adding popcorn for trial production.
Observe the cutting process: whether it is smooth, whether there is any jamming or sticking phenomenon.
Check filling accuracy: Continuously extract multiple finished bags, weigh them with an electronic scale, and check if they are within the allowable error range. If there is any deviation, adjust the measurement parameters.
Check the final sealing effect: Ensure that the seal remains firm and aesthetically pleasing even after the bag contains the product.
Gradually increase the operating speed while observing whether each link is coordinated and stable, until the ideal production speed is achieved.
Phase Four: Closing and Training
Cleaning and confirmation:
After successful testing, thoroughly clean the equipment to remove oil, dust, and debris.
Confirm again that all screws and fasteners have been tightened.
Operator training:
Supplier engineers should provide training for your operators, including:
Startup, shutdown, and daily operation procedures.
Parameter setting and modification methods.
Daily maintenance and cleaning (such as refueling, cleaning photoelectric eyes, replacing packaging film).
Identification and troubleshooting of common faults (such as film deviation, loose sealing, inaccurate bag cutting, etc.).
Important safety warning
High temperature: The sealing device is extremely hot during operation and immediately after shutdown. It is strictly prohibited to touch it with hands to prevent burns.
Moving parts: When the equipment is running, do not insert your hands or tools into moving parts such as mixers, conveyor belts, cutters, etc.
Electrical safety: Before performing any electrical maintenance, the power must be completely cut off.
Suggestion: The best installation method is for the equipment supplier to provide professional installation and debugging services. They are experienced and able to efficiently complete installations and solve any difficult problems that may arise, ensuring that equipment is put into production in optimal condition and extending its service life.
