Agriculture and Nature Conservation Secondary Agriculture

Case Packer And Sealer Unit Maintenance Training

SAQA US 117612 | NQF 4 | Credits 10 | Duration 7 Days
From $1,523 per delegate

Description

This course equips maintenance technicians and operators with the skills to perform routine maintenance, troubleshooting, and repairs on case packer and sealer units. Participants will learn to interpret technical manuals, apply safety protocols, and ensure optimal machine performance, reducing downtime and improving production efficiency.

Learning Outcomes

  • Apply systematic procedures to inspect, clean, and lubricate case packer and sealer unit components.
  • Analyze common mechanical and electrical faults to diagnose root causes and implement corrective actions.
  • Evaluate machine performance data to schedule preventive maintenance and optimize operational efficiency.
  • Demonstrate safe isolation, lock-out/tag-out, and start-up procedures in compliance with workplace safety standards.
  • Implement adjustments to align, tension, and calibrate sealing and packing mechanisms according to manufacturer specifications.
  • Document maintenance activities and report non-conformances using standardised forms and systems.

Target Audience

This course is designed for maintenance technicians, machine operators, and production supervisors responsible for the upkeep and operation of case packing and sealing equipment in manufacturing environments.

Prerequisites

None — open enrollment

Course Outline

Day 1: Introduction to Case Packer and Sealer Units

Objectives:
• Understand the role of case packers and sealers in packaging lines
• Identify key components and their functions
• Recognise safety protocols and hazards
• Explain basic operational principles

Topics:
• Overview of packaging machinery and line integration
• Types of case packers (wrap-around, tray, side-load)
• Types of sealers (hot melt, tape, glue)
• Component identification: infeed, forming, sealing, outfeed
• Safety signs, lockout/tagout, PPE requirements
• Basic mechanical and electrical principles

Day 2: Mechanical Systems and Components

Objectives:
• Describe mechanical drive systems and power transmission
• Identify wear parts and lubrication points
• Perform basic adjustments (guides, belts, chains)
• Troubleshoot common mechanical faults

Topics:
• Conveyor systems: belts, rollers, drives
• Pneumatic systems: cylinders, valves, air preparation
• Guide rails, forming mandrels, and magazine feeders
• Lubrication schedules and types of lubricants
• Adjustment procedures for case size changeovers
• Common mechanical failures and corrective actions

Day 3: Electrical and Control Systems

Objectives:
• Interpret electrical schematics and control diagrams
• Identify sensors, actuators, and PLC components
• Perform basic electrical checks and measurements
• Diagnose simple electrical faults

Topics:
• PLC basics: inputs, outputs, ladder logic overview
• Sensors: photoelectric, proximity, limit switches
• Actuators: motors, solenoids, heaters
• Reading wiring diagrams and component identification
• Using multimeters for voltage, continuity, resistance tests
• Common electrical faults: short circuits, sensor misalignment

Day 4: Sealing Systems and Quality Control

Objectives:
• Understand sealing mechanisms (hot melt, tape, glue)
• Adjust temperature, pressure, and timing settings
• Perform seal quality checks and tests
• Troubleshoot sealing defects

Topics:
• Hot melt systems: tank, hoses, guns, temperature control
• Tape sealing units: tension, cut-off, application
• Cold glue systems: nozzles, pumps, pattern adjustment
• Seal strength tests: peel test, burst test
• Common defects: incomplete seal, adhesive stringing, burn-through
• Adjustment procedures for different case materials

Day 5: Preventive Maintenance and Inspection

Objectives:
• Develop preventive maintenance schedules
• Conduct routine inspections and cleaning procedures
• Identify wear patterns and replace components
• Document maintenance activities

Topics:
• Daily, weekly, monthly maintenance checklists
• Cleaning procedures for glue residue, dust, debris
• Bearing and chain inspection and replacement
• Belt tensioning and tracking adjustments
• Sensor cleaning and alignment checks
• Maintenance logs and reporting

Day 6: Troubleshooting and Fault Finding

Objectives:
• Apply systematic troubleshooting methodology
• Diagnose mechanical, electrical, and sealing faults
• Use diagnostic tools and manuals effectively
• Implement corrective actions safely

Topics:
• Troubleshooting flowcharts and decision trees
• Common jam scenarios: infeed, forming, sealing, outfeed
• Electrical fault isolation: power loss, PLC fault, sensor failure
• Pneumatic system faults: low pressure, leaks, cylinder sticking
• Using manufacturer manuals and spare parts lists
• Case studies and hands-on fault simulation

Day 7: Integration, Optimisation, and Assessment

Objectives:
• Optimise machine settings for efficiency and quality
• Perform complete changeover procedures
• Demonstrate competency in maintenance tasks
• Complete final assessment

Topics:
• Line integration: synchronising case packer with upstream/downstream machines
• Speed adjustments and throughput optimisation
• Complete changeover from one case size to another
• Hands-on practical assessment: preventive maintenance, fault finding, adjustments
• Written assessment covering theory and safety
• Review of key learning points and Q&A

Practicals

No practicals for this training.

This course is made up of exercises and case studies delivered alongside the theory — no separate practical sessions are required to complete it.

Summatives

Each delegate is assessed continuously throughout the course and a final summative test at the end.

Daily Exercises — 30%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 30% to the final total.

Final Test — 70%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 70% to the overall mark.

Final Total
Component Out of Weight
Daily Average (multiple choice) 100% 30%
Final Test (multi-answer multiple choice) 100% 70%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Daily Average 30% + Final Test 70%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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