INTRODUCTION

One common issue encountered in the ATFXU machines is the breakage of cartons when the front horns open the major flaps. While this problem can be frustrating, it is often due to specific factors that can be addressed through systematic troubleshooting. This article will explore the potential causes of this issue and provide detailed troubleshooting steps to resolve the problem.

POSSIBLE CAUSES

If the carton breaks (flaps tear, jams or crushes) when the front horns open the major flaps, it's likely because front compression rollers are not set correctly. The compression rollers hold the sides of the box while the horns fold the flaps outward. Insufficient compression will allow the sides to bulge from bulky produce. When the horns start folding and the sides of the box are bulged outward, the flaps will resist and tear off or crush instead folding at the score line. Supporting the sides of the box near the scoreline allows the flaps to fold correctly.

Additionally, the entry horns may also need fine tuning.

GENERAL TROUBLESHOOTING TIPS
Carefully take note of the moment when trouble starts. Identify which side of the box is problematic and make adjustments accordingly. Frustration and haste can lead to additional mistakes.   Recording a short video or series videos is invaluable to diagnosing a fast-occurring event. And if the problem cannot be determined onsite, the videos may be sent to BestPack engineers for further diagnosis. 

TROUBLESHOOT STEPS

To resolve the problem of carton breakage during flap opening, follow these troubleshooting steps:

• Adjust Entry Compression rollers: Place an empty box in the entry and push the lid down completely into the bottom half. The rollers should be positioned just below the box's score line. 
  * To adjust the height, loosen the hexagonal knob and move the support bracket up or down accordingly.
  * To adjust the width, loosen the cap screws with a 6mm Allen key and slide the rollers in until they just make contact with the sides of the box. Adjust both sides.  The fit should be loose on an empty, but slightly snug on full, bulging box. 
  

• Fine-tune the Entry Folding horns: Generally, the horns should be positioned in the middle of the adjustment range. The horns should be equidistance from the center so both flaps fold at the same time and the forces on the box are balanced. 

  * Smaller boxes will fold later so the horns may need to be moved toward the center (back and in).

  * Larger boxes should start to fold earlier so the horns may need to be spread further apart (forward and out). 

  Additionally, the horns and mounting brackets may become bent and require replacement.

CONCLUSION

Efficient carton sealing machine operation is essential in any production environment. When faced with the issue of carton breakage during the opening of major flaps, a systematic approach to troubleshooting can be the key to resolving the problem. Adjusting the entry compression rollers correctly will ensure proper folding during the carton sealing process. Identifying the root causes of issues and applying the right troubleshooting steps can significantly contribute to a seamless manufacturing process.