Common Packaging Machine Problems and Troubleshooting Solutions

Even the best packaging machines occasionally experience issues. Knowing how to quickly diagnose and resolve common problems minimizes downtime and keeps your production line running smoothly.

Problem: Poor Seal Quality

Weak or leaking seals often result from incorrect temperature, pressure, or dwell time. Check that sealing jaws are at the correct temperature for your film type. Verify proper pressure—too little creates weak seals, too much can damage film. Ensure adequate dwell time for heat transfer.

Problem: Film Tracking Issues

Film that wanders or wrinkles typically indicates tracking problems. Check that film is threaded correctly through all rollers. Verify tension is consistent across the web. Clean tracking sensors and ensure they’re properly aligned. Replace worn rollers that may cause uneven pulling.

Problem: Inconsistent Filling

Inaccurate fills can stem from multiple sources. Check that product supply is consistent and free from bridging. Verify scale calibration with test weights. Inspect filling nozzles for blockages or wear. For auger fillers, check flight condition and alignment.

Problem: Machine Jams

Jams often result from product or film issues. Ensure product size is within machine specifications. Check that film is properly formed and sealed at each station. Clear any product debris from conveyor paths. Verify timing between machine stations is correct.