Maintenance & Reliability · SOP

Automated Strapping Machine Coil Change & Jam Clearing

This document provides a structured procedure for changing strapping coils and clearing material jams on automated strapping machines. Proper execution reduces downtime, prevents component damage, and ensures operator safety.

Estimated Time

45 min

Difficulty

Intermediate

Regulation

ANSI/PMMI B155.1

Version

1.0

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Purpose

To provide a standardized, safe, and efficient method for replacing strapping coils and clearing strap jams on automated strapping machines. This SOP minimizes machine downtime, prevents damage to feed rollers, tension heads, and sealing jaws, and reduces the risk of injury from stored strap tension or unexpected machine motion.

Scope

This procedure applies to all automated strapping machines in the facility that use polypropylene (PP) or polyester (PET) strapping with standard coil diameters up to 400 mm. It covers end-of-run coil changes and emergency jam clearing for feed/path obstructions. Machines with servo-driven tension or heated‑seal modules require additional manufacturer-specific steps not detailed here.

Safety Precautions

LOTOLockout/tagout the machine at the main disconnect before any mechanical access or jam intervention. Verify zero energy state by attempting a start cycle while guarding is open.
PPEWear ANSI Z87.1 safety glasses, cut-resistant gloves (minimum ANSI A5 level), and steel-toed boots. Strap edges can cause deep cuts.
PINCHKeep hands and tools away from feed roller nip points, tension wheel, and sealing jaw closure zone. Strap under tension can spring violently.
TENSBefore cutting or removing strap, release stored tension by pulling slack through the feed path. Avoid cutting tensioned strap directly – it can whip.
PNEUFor machines with pneumatic tension/sealing, depressurize the air line and bleed residual pressure before disconnecting any fittings.

Required Tools & Materials

Replacement strapping coil (correct PP/PET type, width, thickness)
Coil lift truck, hoist, or second operator for coils over 20 kg
Strap cutter (ratchet or shear type)
Hex key set (metric and imperial, 2–10 mm)
Flathead and #2 Phillips screwdrivers
Feed wheel removal tool (machine-specific)
Tension wheel removal tool or strap hook
Isopropyl alcohol (99%) and lint-free cloths
Vacuum with crevice tool for strap fragments
Torque wrench (if sealing jaw bolts have specified torque)

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Procedure: Step-by-Step

1 Lockout/tagout. Turn off the machine at the main disconnect, attach a personal LOTO lock and tag. Wait for all motion to stop. Attempt a start cycle to confirm zero energy.

2 Remove remaining strap. Cut the strap at the sealing head using a strap cutter. Pull the tail through the feed rollers and tension head until the coil is free. Remove the old coil from the unwind stand by loosening the retaining nut or quick-release clamp.

3 Install new coil. Using a lift truck or hoist, place the new coil onto the unwind stand. Ensure the strap direction matches the machine feed orientation (usually unwind from the bottom). Secure the retaining nut/clamp – torque to manufacturer spec if available.

4 Thread the strap. Guide the strap through the dancer arm, feed rollers, tension head, and sealing section. Refer to the machine's threading diagram (usually on the inside guard). Avoid twists or sharp bends. Close all guards.

5 Test cycle. Remove LOTO, re-energize, and run a manual test cycle. Check strap tension, seal integrity, and cut-off length. Adjust tension/sealing parameters per coil spec. Document the change.

6 Identify jam location – LOTO. If a jam occurs during operation, immediately press the emergency stop. Lockout/tagout the machine. Open safety guards and visually locate the jam (feed rollers, tension wheel, or sealing head).

7 Clear feed roller jam. Use the feed wheel removal tool to rotate the feed roller manually. If the strap is wedged tightly, remove the feed roller assembly (2–4 hex bolts) and extract the strap fragments. Clean roller surfaces with alcohol.

8 Clear sealing head jam. Remove the sealing jaws by unscrewing the retaining screws. Extract compressed strap material and adhesive residue from the jaw cavity. Clean with isopropyl alcohol. Inspect jaw faces for wear; replace if gapped >0.1 mm.

9 Clear tension wheel jam. Use the tension wheel removal tool to release the wheel. Cut any strap wrapped around the shaft. Remove debris from the wheel grooves. Reinstall tension wheel and adjust air gap per manual.

10 Reassemble and test. Reinstall all removed components, torque bolts to spec. Remove LOTO. Close guards and run a test cycle at slow speed. Monitor strap tracking and seal quality. Run three full cycles before returning to production.

Automated Strapping Machine Coil Change & Jam Clearing

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