The scientific maintenance methods of roof box filling machines: The key to extending service life and ensuring production capacity

(1) Daily Maintenance: A Must-Do Every Day, Building a Solid Foundation for Defense
The core of daily maintenance lies in “cleaning, inspection, and record-keeping”, which must be strictly carried out before and after daily production to prevent the accumulation of problems such as material residue and component wear, ensuring the normal startup of the roof box filling machine the next day.
Comprehensive cleaning and sterile disinfection: Immediately after daily production ends, activate the CIP (Clean-In-Place) automatic cleaning system of the roof box filling machine. Use food-grade cleaning agents to conduct high-temperature sterilization of core components that come into contact with materials, such as filling pipelines, aseptic chambers, filling nozzles, and sealing modules. The entire process should be controlled at a temperature of 85-95℃, with a cleaning duration of no less than 30 minutes, to thoroughly remove residues of milk, juice, and other materials, prevent bacterial growth and pipeline blockages, and ensure that the subsequent aseptic filling environment meets standards. At the same time, wipe the surface of the equipment, operation tables, and feed ports with dust-free cloths to remove dust and debris, maintaining the equipment’s appearance clean and tidy.

Quick inspection of key components: After production ends, focus on checking the ultrasonic sealing module, servo motors, vacuum adsorption devices, and other core components of the roof box filling machine. Observe if there are any abnormal sounds, looseness, or wear marks. Inspect the integrity of vulnerable parts such as sealing rings and sealing gaskets. If any deformation or leakage is found, replace them immediately to avoid affecting the sealing effect of the next day’s filling. Additionally, check if the pressure of the compressed air pipeline is stable at 0.8-1.0m³/min to ensure the normal operation of pneumatic components.

Recording and archiving of operation data: Record the operation parameters of the roof box filling machine every day, including filling accuracy, sealing temperature, cleaning duration, and fault prompts, and establish an equipment operation ledger. Through data tracking, promptly identify abnormal parameter fluctuations, providing a reference basis for subsequent maintenance, and meeting the traceability management requirements of the food industry.

II) Regular Maintenance: Deepen maintenance on a regular basis to avoid potential failures
Regular maintenance should be carried out based on the operating duration of the roof box filling machine and the wear patterns of its components. Plans should be made on a weekly, monthly, and quarterly basis, and targeted lubrication, calibration, and component replacement work should be carried out to enhance the stability of the equipment operation.
Weekly Maintenance: Focus on lubrication and component tightening: Every week, replenish the specified type of food-grade lubricating oil for the servo motors, transmission gears, bearings, ultrasonic sealing modules, etc., of the roof box filling machine, ensuring smooth operation of the components and reducing friction and wear; at the same time, tighten the screws and bolts at each connection point of the equipment, especially the packaging forming mechanism, filling pipeline interfaces, etc., which are prone to frequent vibration, to prevent filling deviations or leakage due to loosening.
Monthly Maintenance: Precise calibration and replacement of wear parts: Every month, use professional instruments to calibrate the filling accuracy of the roof box filling machine, controlling the error within the industry standard range of ±2%-5%, and for scenarios with strict measurement requirements such as dairy products and high-value-added beverages, the calibration frequency can be increased. At the same time, thoroughly inspect the sealing rings, filling nozzles, vacuum suction cups, etc., of the wear parts. If there are signs of aging, cracking, or wear, they should be replaced immediately to avoid affecting the overall production line operation due to a single component failure. In addition, clean the PLC control system, sensors, and interface of the equipment, remove dust to prevent abnormal signal transmission.
Quarterly Maintenance: Deep inspection and system optimization: Every quarter, conduct a comprehensive disassembly and maintenance of the roof box filling machine, focusing on checking the sealing performance of the sterile chamber, the atomization effect of the hydrogen peroxide sterilization system, and the temperature uniformity of the heat-sealing module to ensure that the sterile filling and sealing performance meet the standards; clean the cooling system, filter device of the equipment, replace the filter element to avoid equipment overload due to poor heat dissipation or impurities accumulation. At the same time, debug the PLC and SCADA data acquisition and monitoring system, optimize the operating parameters, update the system firmware, and enhance the intelligent control capability of the equipment.

(III) Special Maintenance: Targeted Breakthrough for Core Systems
The aseptic system, filling system, and sealing system of the roof box filling machine are the core factors ensuring product quality. Special maintenance should be carried out specifically to avoid faults in key sections.
Special Maintenance for Aseptic System: Regularly inspect the sealing performance and concentration of the hydrogen peroxide storage tank to ensure the concentration remains within the standard range. Timely replenish hydrogen peroxide and replace the filter device; clean the sterilization nozzle, clear the blocked channels to ensure uniform atomization and achieve comprehensive disinfection of the inner cavity of the box; check the air pressure and sealing performance of the aseptic chamber to prevent outside air from entering and disrupting the aseptic environment. Conduct aseptic test every six months to verify the sterilization effect.
Special Maintenance for Filling System: For servo-driven filling systems and pneumatic piston filling systems, regularly check the sealing performance of the piston, whether the pipe joints are leaking, calibrate the flow sensor to ensure precise quantitative filling; clean the residual materials inside the filling nozzle, clear the discharge channel to avoid unstable filling volume or material contamination.
Special Maintenance for Sealing System: For ultrasonic heating and hot press sealing modules, regularly calibrate the sealing temperature and pressure parameters, check the wear of the heating tube and sealing gasket; clean the residual stains on the sealing area to avoid affecting the sealing formation effect of the roof box top and prevent leakage and secondary contamination. At the same time, check the date code printing module to ensure clear and accurate printing, and replace the printing consumables in time.

(4) Long-term Maintenance: Implement protective measures to prevent equipment damage
If the roof box filling machine is shut down for a long time (more than 7 days) due to production adjustments, holidays, etc., comprehensive protective measures must be taken to prevent the equipment from getting damp, rusting, or accumulating dust, ensuring a quick return to normal operation after restart.
Thorough cleaning and material discharge: Before shutdown, thoroughly clean all components of the filling pipeline, sterile chamber, sealing module, etc. Empty the residual materials and cleaning solution in the pipeline to avoid spoilage of materials, corrosion of components, or contamination of the cleaning solution affecting the equipment performance.
Component protection and environmental control: Disconnect the main power supply of the roof box filling machine, remove vulnerable parts (such as sealing rings, filling nozzles), clean them, and store them in a dry and ventilated place; apply anti-rust oil to the metal components of the equipment to prevent rust; fully cover the equipment with a dust cover to avoid dust accumulation. At the same time, control the temperature and humidity of the equipment storage environment, keeping the temperature between 5-30℃ and the humidity below 70%, away from corrosive gases and direct sunlight.
Regular startup maintenance: During the long-term shutdown period, start the equipment for 30 minutes every month, activate the CIP cleaning system for a brief cleaning, check the operation status of each component, add lubricating oil, and prevent components from getting stuck or aging due to long-term inactivity, ensuring that the equipment is always ready for startup.

V) Maintenance Precautions: Follow Procedures, Avoid Risks
When maintaining the roof box filling machine, strictly adhere to the equipment operation manual and industry safety standards to avoid operational risks and equipment damage: Before maintenance, ensure that the main power supply and air source are disconnected, and hang a “Equipment Maintenance In Progress” warning sign to prevent accidental startup; When disassembling and installing components, use specialized tools to avoid violent operations that may damage precision components; The replaced parts must be of the original factory-compatible model, especially for core components such as sealing rings and sensors,严禁 using non-standard parts to affect equipment performance and sterility standards； Maintenance personnel must undergo professional training， be familiar with the equipment structure and maintenance procedures， master emergency handling methods， and conduct a trial run after maintenance to verify that the equipment operation status and filling accuracy meet the standards before putting it into production.
Scientific maintenance methods are the core guarantee for the efficient operation of the roof box filling machine， which can not only reduce equipment failure rates and maintenance costs， but also continuously ensure product packaging quality and production efficiency， helping enterprises maintain production capacity and enhance competitiveness in the fierce market competition. Enterprises can combine their own production scale， roof box filling machine models， and product characteristics to formulate personalized maintenance plans， make maintenance work regular and standardized， and maximize the value of the equipment.