Many users always encounter a problem when they first get the AFPAK k cup filling and sealing machine to try to produce, that is, the phenomenon of spreading powder is very serious, resulting in unattractive coffee capsules. This article will analyze in detail the causes and solutions of powder spreading

How does coffee fill into cups?

First of all, to understand the reason for spreading powder, we have to be familiar with the operation logic of powder filling.
The coffee or other powder is rotated inside the filling hopper by the screw/auger, and the powder stored on the screw/auger will flow to the inside of the cup, (this set of mechanisms is not suitable for powder with too good flowability). There is usually a stopper at the lower nozzle to prevent the powder from spreading. And the screw/auger is controlled by a high precision servo motor, and the number of turns of servo rotation to control the amount of powder filling.

Why the coffee will spread out?

Usually, the spreading of powder generated by factors such as wrong parameter settings, cup position is not adjusted correctly, and the powder in the flow of static electricity and other reasons. Next, we will check one by one

1- Cup position:

This is a relatively common situation. Because the hopper needs to be cleaned frequently, it is inevitable that the position deviation will occur during disassembly, so in the case of spreading powder, the position needs to be lined up:.

• whether the hopper is pushed into place: In the process of cleaning, we will lift the hopper position, as well as move out to clean, so in the process of putting back need to pay attention to whether the hopper has been pushed back to the cup-centered position?

• In addition, we also need to check whether the cup has completely touched the material nozzle after the top-up, with no gaps? If there is a gap, the powder will spill through the gap to the outside

In short, the filling process is to ensure that: the cup is facing the filling spout and that the filling spout completely covers the mouth of the cup without gaps, so that the coffee powder will not spill

2- Parameter settings:

After the position are right, if there is still a spreading powder situation, there is a need to check whether the parameter settings are reasonable

The filling parameter setting is made up of two parts: the filling time, and the servo parameters. The two sets of parameters work well with each other to achieve perfect filling

2.1- Filling time:

mainly consists of three parameters: Filling/ Filling UP/Down/blender
The filling is to control the time from the beginning to the end of the coffee powder filling, generally set between 950-450
Filling UP/Down is to control the time when the cup starts to come up and drops back to its original position. Generally set between 950-450
Stir is the time to stir the coffee powder in the hopper, which can be ignored.

Note that the above angle parameter settings are based on the value on the machine's encoder, which represents the current machine stop position. Can not be set and changed at will
Generally, after the cup reaches the lower spout, the coffee powder starts to fill, then after the filling is finished, the cup returns to its original position.

2.2- Servo Parameters:

When you click on the servo parameters on the left side of the screen, you will see the above page

There are six parameters on this page: Fill weight, Fill Ratio, Fill Servo speed, Clearing speed, Servo acceleration, and servo deceleration.

Fill weight and Fill Ratio is to set the filling weight parameters. you can check this video to learn how to set these two parameters:

Fill Servo Speed is to adjust servo motor turning speed, normally for K cups, we set 1500-2500, and for Nespresso, we set 1000-1500.

Servo acceleration is to set the parameters to start the auger turning, which means how fast the auger can reach the fastest turning speed, normally set 50-300

Servo deceleration is to set the parameter to stop the auger from turning, which means how fast the auger can stop turning, normally set 50-300

3- Static problem:

We found that the darker the coffee is roasted and the richer the oil is, the more likely it is to generate static electricity during the filling process.
After the generation of static electricity, the coffee powder is more likely to stick to the downstream spout, making the coffee powder transfer to the cup and other parts of the cup during contact with the cup.
Therefore, it is best to configure some electrostatic elimination devices to prevent this type of situation from occurring.
Specific methods of eliminating static electricity can be answered by contacting our sales engineers, who have summarized a set of static electricity elimination solutions based on customer feedback, which substantially helps customers solve many problems of spreading powder.

The above is our summary of the causes and solutions to the problem of spreading powder, there may be other situations that lead to the occurrence of such problems, we welcome feedback from our readers, and we sincerely welcome more comments and suggestions

About the Author

Jeffree Fang - Owner of AFPAK

As one of the first technicians in China to research coffee capsule filling and packaging technology, with more than ten years of front-line sales, design, R&D, and production experience, he has helped hundreds of coffee companies to set up their coffee capsule production lines successfully so far. He has been committed to developing higher-end, more advanced coffee capsule filling and packaging machines and constantly collecting feedback from customers, making AFPAK's machines more and more popular.

The manual of H2 coffee capsule filling sealing machine

What is the main structure of the H2 coffee capsule filling sealing machine.

The structure of the H2 coffee capsule filling sealing machine includes the empty capsules sorter and feeder device, empty capsules conveyor and filling and sealing zone.

1.1 The empty capsules sorter and feeder device and the empty capsules conveyor

With a vibrating plate, the empty capsules sorter and feeder device is used to sort out all disorganized empty cups so they could be put in order one by one on the conveyor. For H2 coffee capsule filling sealing machine, there would be 2 lanes of conveyor. The conveyor will deliver all the sorted empty cups to the filling and sealing zone.

1.2 The filling and sealing zone of H2 coffee capsules filling and sealing machine

The filling sealing zone consists of aluminum capsules feeding device, the coffee powder filling system, the nitrogen flushing system, the anti static system, the coffee powder tamping and capsule edge cleaning system, the roll film cutting and sealing station, the second sealing station and conveyor.

The aluminum capsule feeding device

The capsules are stocked here and delivered to the conveyor. Basically, the function of this device is similar to empty capsules sorter and feeder device, which is delivering the coffee capsules to the capsules conveyor. But the difference is based on the types of coffee capsules, the empty capsules sorter and feeder device are used to sort out those coffee capsules that are not easy to stack by taking advantage of the vibrating device.

The coffee powder filling system

This coffee powder filling system has a conical coffee powder silo which could contain the powder of coffee, cocoa, tea leaves or other type of granules. The coffee powder will be filled into the coffee capsuled in the position of the conveyor.

The nitrogen flushing system

The nitrogen flushing system is used to keep nitrogen flushed during the process of filling and sealing so to ensure the freshness of the coffee powder and extend the shelf life of filled and sealed coffee capsules.

The anti-static system

The static electricity might be generated during the process of filling and sealing, which is harmful to coffee capsule quality and their output, and also the machine itself. Static electricity can cause powder deposition during production to block pipelines. The anti static system will lead to form a conductive layer on the surface of the parts of the machine, thereby reducing its surface resistivity and allowing the static charge that has been generated to leak quickly.

The coffee powder tamping and capsule edge cleaning system

This system is to tamp the coffee powder in the coffee capsules, so to extract the air inside. Also there is edge cleaning function to make sure a complete sealing.

The roll film cutting and sealing station

The roll film cutting system would cut the film into the shape of the lid which match the size of the mouth of the coffee capsules. And the system would deliver it to the sealing station for sealing the film to the coffee capsules.

The second sealing station and conveyor

The second sealing station is to make sure the sealing is tight enough and complete. The conveyor would output the well filled and sealed coffee capsules.

How to connect the empty capsules sorting and feeding device to the H2 coffee capsule filling sealing machine?

In general, the empty capsules sorting and feeding device will be shipped separately. Therefore, after receiving this device and H2 coffee capsule filling sealing machine, customer will need to link them together.

The key thing is put the 2 machine at the right position, so the conveyor of the empty capsules (2 lanes) sorting and feeding device aligns with the conveyor of the H2 coffee capsule filling sealing machine, that the empty capsules can be delivered from the sorting and feeding device smoothly.

After the device is put in the right position, the 2 pipes should be connected.

Further, connect the pipe related the vibration plate. Once it is connected and the switch is on, the device is ready to work.

How the cleaning of the hopper which contains the coffee powder is carried out?

Firstly, find the screw on the side of the hopper. Release the screw a bit. The the cover will be able to be removed.

Take out the down cover. So the whole hopper could move away from the machine.

Put a bin down the nozzle of the hopper to collect the coffee powder residue after cleaning.

The next step is to find the “clean hopper” on the screen and click the “run” button. So the coffee powder residue will be cleaned drop to the bin.

As on the photo there are some connectors. Take off them.

 On the upside of the hopper, there are 4 clamps. Release them. So the whole hopper is ready to open that the auger and other parts could be cleaned.

After cleaning, when putting the hopper back, be careful that the nozzle is in the right position, matching the positions on the conveyor mold.

The system manual for operating the H2 coffee capsules filling sealing machine

Click “auto” button, so the machine will carry out production automatically.

“Sorted cup catch” refers to the bio-degradable capsules from the sorting and feeding device.

“Drop cups” is related to aluminum capsules feeding device.

“Filling” means the process of filling the coffee powder to the empty coffee capsules.

“Feeding” refers to delivery the coffee powder from the coffee powder tank to the hopper.

“Film cutter heating” is related to the filling and sealing area’s temperature of “film cutter 1 temp.” and “film cutter 2 temp.”.

“Sealing head heating” refers to the second sealing head.

“Heat sealing 1 temp.” and “Heat sealing 2 temp.” refers to the second sealing station’ s temperature.

“Vibrating sorter” is for sorting out the empty capsules in the empty coffee capsules sorting and feeding device.

“Sorter air blowing” refers to the empty coffee capsules sorting and feeding device.

“Host speed” means the running speed of the machine.

“Fill ratio” is the amount of coffee powder to be filled.

“Fill 1 ratio” and “Fill 2 ratio” are used to adjust the accuracy of the coffee powder not filled accurately. Big number means more coffee powder is filled and small number means less coffee powder is filled.

On the “Operation scree” page.

The blue gear shape button is for manual running or automatic running.

For auto model, the machine will run itself and the relative button will be green.

For manual mode, control each function and press the Green button“Run”. So this function will work.

On the “Parameter screen”.

The parameters are set and tested already. There are many pages on the “Parameter screen”. In general, only “Servo parameters” should be adjusted.

Before you adjust the parameter on “Servo parameters”, you better screenshot the original data.

“Cylinder debugging” refers to control of each cylinder.

“Language” is for setting the language.

Below yellow button “Jog” refers to run the machine for one time.

Green button “Run” refers to running the machine.

Red button “Stop” refers to stopping the machine. When the alarm is on, use the “Stop” button to stop the alarm.

“Emergency stop” is to stop the machine in emergent situation.

An video introduction is as below.

How the roll film is placed on the H2 coffee capsule filling sealing machine?

The new roll film will be put on the above parts. Press the air gun to make the film flat as on the video.

The film will go through the sealing station and back to the used film collection parts.

How the electricity, air compressor, and nitrogen generator is connected to the H2 coffee capsule filling sealing machine?

This thick cable is 3-meter long which is the electricity cable. Change the plug and connect it to the power.

There is the switch for the machine to run after all are connected.

This is the part to connect the air compressor. The transparent pipe is used to connect the air compressor.After that, change the position of the blue part to get air supply and the meter color will be changed from green to red. The number will be higher on the meter. The air pressure is set to 0.4Mpa in general. Only this 0.4Mpa is met, could the machine work properly. If it is lower than this number, the machine will not work well. And the alarm will be on.

Lift the top part and rotate it so to adjust the air pressure. After the air pressure is adjusted, press the top part down to the original position.

Below the air compressor connection part, there is the nitrogen generator connection part. The red arrow part refers to the input of the nitrogen. To adjust the pressure level of the nitrogen, you just need to make sure it is a little higher than zero. It does not require high pressure for nitrogen flushing.

How the filling weight is adjusted on the H2 coffee capsule filling sealing machine.

Firstly, fill the hopper with coffee powder to make sure the hopper is 80% full. So a constant filling would be ensured. Move the hopper aside to adjust the filling weight with a bin below the nozzles to collect coffee powder.

Find a cup and a scale. Put the cup on the scale and reset the scale to zero.

After, go to the screen. Click the “Filling” and “Stir” and make sure they become green on the “Operation screen”. Press the green “Run” button. So the coffee will start to drop from the nozzles.

If filling weight is set as 5.5, adjust the fill 1 or fill 2 ratio to increase the accuracy.

When filling weight is well set and adjusted, put the hopper back to the right position and lock it.

How the inline weight checker is working on the H2 coffee capsule filling sealing machine?

The inline weight checker is connected to the conveyor (the output part), used to weigh the filled and sealed capsules.