How to Install & Commission the ZONESUN ZS-ZY300 Filling Sealing Machine
The ZONESUN ZS-ZY300 is an 8-station fully automatic rotary pouch filling and sealing machine designed for mixed granule and liquid products — including beans, millet soup, sauces, and seasonings. This guide walks you through the complete installation and commissioning process to get your machine running safely and at full efficiency.
🎬 Commissioning Video
Watch the full commissioning and operation demo before you begin:
📦 Step 1: Unpacking & Inspection
- Remove all packaging materials and protective foam carefully.
- Inspect the machine frame, conveyor belt, sealing heads, and control panel for any shipping damage.
- Verify all accessories are included: power cable, air hose fittings, spare parts kit, and operation manual.
- Machine dimensions: 2550 × 1900 × 1530 mm | Weight: 1700 kg — use a forklift or pallet jack for positioning.
⚡ Step 2: Electrical & Pneumatic Connection
- Power Supply: AC 380V, 50Hz, 3-phase — connect via a qualified electrician only.
- Ensure the main switch is OFF before making any electrical connections.
- Air Supply: Connect compressed air at 0.8 MPa with a minimum flow of ≥ 0.6 m³/min.
- Check all pneumatic fittings for leaks after connection using soapy water.
- Ground the machine properly to prevent static discharge during operation.
⚖️ Step 3: Weigher Calibration
- Power on the multi-head combination weigher control panel.
- Enter the target weight for your product (e.g., granules, beans, millet).
- Run a dry calibration cycle with no product to zero the load cells.
- Load product into the hoppers and run 10 test cycles — weigh each output bag and adjust parameters until accuracy is within ±1%.
- For liquid filling: set the high-precision pump volume via the touchscreen HMI and verify with a graduated cylinder.
🛠️ Step 4: Pouch & Film Setup
- Compatible pouch material: PET/AL/CPP composite film bags.
- Load pre-made pouches into the bag magazine — align them flat and evenly stacked.
- Adjust the bag gripper width to match your pouch size.
- Set sealing temperature on the HMI according to your film specification (typically 160–200°C for PET/AL/CPP).
- Run 5 test seals and inspect seal integrity before full production.
▶️ Step 5: Trial Run & Speed Adjustment
- Start the machine at the lowest speed setting (8 bags/min) for the initial trial run.
- Observe each of the 8 stations: bag pickup → bag opening → granule filling → liquid filling → sealing → output.
- Gradually increase speed up to your target rate (max 55 bags/min) once all stations are confirmed stable.
- Monitor the output conveyor and ensure finished bags discharge cleanly without jamming.
✅ Step 6: Final Checklist Before Production
- ☑ All guards and safety covers are in place.
- ☑ Emergency stop button is functional.
- ☑ Weigher accuracy confirmed within tolerance.
- ☑ Seal integrity tested — no leaks or weak seals.
- ☑ Air pressure stable at 0.8 MPa.
- ☑ Operator trained on HMI controls and emergency procedures.
🔧 Common Troubleshooting Tips
| Issue | Possible Cause | Solution |
|---|---|---|
| Bag not opening | Low air pressure / suction cup worn | Check air supply; replace suction cups |
| Inaccurate fill weight | Weigher not calibrated / hopper blocked | Recalibrate weigher; clear hopper |
| Poor seal quality | Wrong temperature / film contamination | Adjust sealing temp; clean sealing bars |
| Machine stops unexpectedly | Sensor triggered / E-stop activated | Check error code on HMI; reset sensors |
📞 Need Help?
Our technical support team is ready to assist with installation, commissioning, and after-sales service.
📧 Email: support@zonesunpro.com
🌐 Website: www.zonesunpro.com