5 Ways to Stop Your Autobag® Machine from Jamming: The Operator’s Guide to Roll Handling

You invested in an Autobag® system (like the AB 180™, 500™, or 850S™) for one reason: Speed.

But speed means nothing when your packaging line is down.

There is nothing more frustrating than a "Bag Feed Error" in the middle of a rush shift.The film crinkles, the seal fails, or worse—the bags wrap around the rollers, forcing a 20-minute shutdown to cut them loose.

Here is the truth: It is rarely the machine’s fault, and it’s not always the bag’s fault.

Often, the "invisible killer" of packaging productivity is improper roll handling and loading. As a manufacturer of premium aftermarket bags, Adsure has analyzed thousands of jamming incidents. We found that simple adjustments to how operators handle the rolls can solve 80% of these issues.

Here is your technical guide to keeping your Autobag® running at maximum throughput.

1. The Art of Centering: Precision Loading

Keywords: Autobag loading instructions, core chuck alignment

It sounds basic, but misalignment is the #1 cause of seal wrinkles and jams.

Autobag machines are precision instruments. If your roll is even 3mm off-center, the film will drift as it travels through the dancer rollers. By the time it reaches the loading area, the bag opening will be skewed.

• The Fix: When loading a new roll of Pre-Opened Bags, do not just eyeball it. Use the ruler or guide marks on the supply shaft.

• The Check: Ensure the Core Chucks (the circular holders that go inside the cardboard core) are tightened equally. If the roll wiggles on the shaft, the machine’s tensioner will jerk the film, causing the perforation to break prematurely.

  
  

2. Master the "Dancer Arm" Tension

Keywords: Web tension control, bag feed error

Have you ever seen the film snap suddenly? Or conversely, does the machine error out because it thinks it’s out of bags? This is a tension issue.

The Dancer Arm (that moving bar the film loops around) acts as the machine's shock absorber. It signals the motor when to feed more film.

• Too Tight: The perforation breaks before the bag is in position.

• Too Loose: The film sags, sensors misread the gap, and you get a "Bag Length Error."

• Adsure’s Pro Tip: Ensure the film path is threaded exactly according to the diagram on the machine door. A missed roller increases friction. Also, verify that the dancer arm moves freely up and down—if it’s sticky from old adhesive dust, the machine cannot regulate speed.

  
  

3. Sensor Hygiene: The 10-Second Cleaning Rule

Keywords: Bag edge sensor cleaning, print registration mark

Your Autobag machine uses optical sensors to "see" where one bag ends and the next begins (via the spark gap or registration mark).

In a dusty warehouse, paper dust from cardboard boxes or lint from apparel attaches to the static-charged film. This dust accumulates on the sensor lens.

• The Symptom: The machine cuts through the middle of the bag instead of the perforation.

• The Fix: Make it a standard operating procedure (SOP): "New Roll = Clean Sensor." Every time an operator loads a new roll, use a cotton swab or compressed air to wipe the Bag Edge Sensor and Print Registration Sensor. It takes 10 seconds but saves hours of downtime.

4. Fight the "Invisible Enemy": Static Electricity

Keywords: Static elimination in packaging, bags sticking together

High-speed friction generates static. If you are packing apparel or electronics, static is your enemy. It causes the bag to cling to itself, refusing to open for the product (a "Misfill").

• Check the Ionizer: Most Autobag units have an Active Static Eliminator bar. Check if the green light is on. If the emitter points are dirty/oxidized, they aren't working.

• Environmental Control: Store your bag rolls in a climate-controlled area. Cold, dry air increases static. If possible, bring rolls into the production floor 24 hours before use to acclimate.

• The Adsure Advantage: We engineer our APOP™ bags with a specific slip additive that reduces the coefficient of friction, minimizing static buildup even in dry environments.

  
  

5. Check Your Teflon™ Tape (The PTFE Strip)

Keywords: Sealing bar maintenance, Teflon tape replacement

If the machine feeds fine but jams after the seal, look at your heater bar.

The heating element is covered by a strip of PTFE (Teflon) tape. Over time, this tape burns, tears, or gets covered in melted plastic.

• The Danger: If the tape is worn, the hot wire touches the plastic directly. The bag melts onto the bar and doesn't release. The machine then tries to feed the next bag while the previous one is stuck, creating a massive pile-up.

• The Rule: Inspect the brown tape on the seal bar daily. If it looks black, burnt, or textured, replace it immediately.

Conclusion: Stop Autobag® Machine from Jamming，But Quality Consumables Matter

Following these steps is the best way to stop Autobag® machine from jamming and improve efficiency. You can have the best machine and the best operators, but if your bags have inconsistent perforations or uneven winding tension, you will still face jams.

• Precision Winding: Ensures consistent tension from the first bag to the last.

• Perfect Perfs: "Soft-tear" technology that holds strong during feeding but separates easily after sealing.

• Guaranteed Compatibility: Our rolls fit standard 3-inch cores and run on AB 180, 500, and 850S models without requiring complex recalibration.

  
  

Stop Blaming the Machine. Start Using Better Bags.

[Request a Free "Jam-Free" Test Roll] compatible with your Autobag® machine today. Test the difference yourself—no risk, just smoother production.

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