Filling Leakage and Exposed Filling

Filling leakage and exposed filling look like the same problem, but the causes actually fall into two groups: either the filling itself "can't be contained," or the seal "isn't closed properly." Telling them apart makes troubleshooting much faster.

Why Does the Filling Escape?

The filling can't be contained

• Filling too runny: It flows so easily that it squeezes out through the gap before the seal closes.
• Filling releasing water or oil: When water and oil get on the wrapper at the seal, the wrapper won't stick.
• Too much filling: The wrapper is stretched full, leaving not enough wrapper at the seal to close.

The seal isn't closed properly

• Wrapper too dry or too firm: The seal can't bond.
• Wrapper too thin: There isn't enough wrapper to cover the filling when it's cut.
• Cutting-and-closing timing or speed doesn't match: Most encrusting machines cut the filled dough rope and close it just below the nozzle. RHEON patent US6709256B2 describes this type of mechanism: cutting pieces arranged in a ring close toward the center at the same time, cutting the rope and wrapping it closed, with the closing speed and timing adjustable to the production speed. The patent also notes that when production speed changes greatly, the closing speed of the cutting pieces changes too much, making a clean cut difficult. In other words, if you change the speed setting, the seal condition may change along with it.

How to Adjust the Ratio

The wrapper-to-filling ratio is the most direct thing to adjust. When filling leaks, follow the machine's operating manual to lower the filling ratio a little or raise the wrapper amount a little, then make a few dozen pieces and observe. Once that's stable, gradually move back toward your target ratio to find the balance point of "no leaks and still nicely full."

Handmade products are often "stuffed to the brim," and that habit needs adjusting for machine production. See Do Machine-Made Products Need a Recipe Change?

What If the Cutting Position Is Off?

If leakage is concentrated at the same spot on the seal, or a bit of filling always shows at the top, the cutting-and-closing timing and speed may not be coordinated with the conveyor, or there may be residue stuck at the cutting point or worn parts.

Things you can do first:

1. Return the production speed to the setting that was previously stable and see if it improves.
2. Following the operating manual, check and adjust the settings related to closing the seal, changing only one at a time.
3. Stop the machine, cut the power, and clean the cutting point.

Before checking anything by hand, press stop, turn off the power, and unplug the machine or cut the main switch, and make sure the machine has come to a complete stop. In factories with multiple workers, lock the switch and hang a "Under maintenance, do not energize" tag. Article 57 of Taiwan's Occupational Safety and Health Facilities Rules (職業安全衛生設施規則) requires that when machinery is being cleaned, oiled, inspected, repaired, or adjusted, operation and feeding must be stopped, and measures such as locking out and posting signs must be taken to prevent accidental start-up.

Once the power is confirmed off, remove the detachable contact parts according to the operating manual, clean off dough and filling residue stuck at the cutting point and the outlet, and make sure the parts are reinstalled in their original positions and not loose. Visually check the cutting-related parts for chips, deformation, or wear.

Improving the Ingredients

• Filling consistency and temperature: see Filling Viscosity, Particle Size, and Moisture and Filling Temperature.
• Water release from vegetable fillings: see Dewatering Vegetable Fillings.
• Adding water to meat fillings: see Meat Fillings.

FAQ

Q: Why does my encrusting machine leak filling?
A: Common causes are a filling that is too runny, releases water or oil, or is too generous, or a wrapper that is too dry or thin, or cutting-and-closing timing and speed that don't match.

Q: How should I adjust the wrapper-to-filling ratio?
A: Following the operating manual, first lower the filling ratio or increase the wrapper amount, make a few dozen pieces and observe, then gradually adjust toward your target ratio.

Q: Why does a bit of filling show at the top of every piece?
A: The cutting-and-closing settings and speed may not match, or there may be residue at the cutting point or worn parts. If it's the same after stopping, cutting power, and cleaning, call for service.

Q: What if I can't fix it myself?
A: Don't disassemble internal mechanisms. Note the machine model and the symptoms and contact the manufacturer or a service provider. Dong-Yih Machinery supplies encrusting machine parts and repair; call us at 06-257-4644.