Applicable Systems
Pack 301

Symptoms

HMI displays E-201, indicating a film feed fault. The horizontal form-fill-seal machine has detected a film tracking error or film break during the packaging cycle. The machine stops to prevent product waste and film damage.

Possible Causes

  • Film roll installed with incorrect tracking alignment
  • Film tension too high causing film stretch or breakage
  • Film guide rollers misaligned or dirty causing tracking drift
  • Film splice detected or film roll running empty

Troubleshooting Steps

  1. Step 1: Verify film roll is installed correctly and tracking is centered
    Reinstall roll if tracking is off, verify arbor alignment
  2. Step 2: Check and adjust film tension per the film specification
    Reduce tension if film is stretching or breaking
  3. Step 3: Inspect and clean all film guide rollers and tracking sensors
    Clean rollers with isopropyl alcohol, verify free rotation
  4. Step 4: Check for film splices and verify the splice is properly executed
    If roll is empty, install new roll and thread film per procedure

How to Reset

To reset E-201: 1) Re-thread the film if broken or install new roll. 2) On the HMI, acknowledge the film feed fault. 3) Press Reset. 4) The machine runs a film tracking test. 5) If tracking is within tolerance, normal packaging operation resumes.

Common Replacement Parts

  • BP-301-001: Film tracking sensor, ultrasonic (Verify mounting position and gap distance)
  • BP-301-005: Film guide roller, 50mm diameter (Inspect bearings and clean weekly)
  • BP-301-010: Film arbor assembly, 76mm core (Verify friction brake adjustment)

Frequently Asked Questions

  • Q: How do I prevent film tracking problems?

    Ensure film rolls are installed with proper alignment to the machine centerline, maintain correct tension per the film manufacturer specification, clean guide rollers weekly, and verify tracking sensor operation. Always check film specification matches the machine capability.

  • Q: What causes film breakage during packaging?

    Film breakage is commonly caused by excessive tension, misaligned guide rollers, film quality issues (weak spots or gauge variations), incorrect film width for the product format, or sharp edges on the forming collar. Inspect and adjust these factors to prevent breakage.

Related Bosch Packaging Fault Codes

Source: Bosch Packaging Pack 301 HFFS Machine Manual, Edition 2020

Category: Packaging