misfeeds

Misfeeds are faults in which material is not fed into a machine as intended, resulting in a misalignment, partial feed, or jam. The term is used across industries to describe feeding problems in devices such as printers and copiers, packaging lines, mail sorters, sewing machines, and other automated feeders. Symptoms include skewed sheets, double feeds, misregistered output, or complete stoppage of a process.

Causes vary by application but commonly include incompatible media or incorrect media size or thickness, moisture or humidity effects, static buildup, paper curl or stiffness, and debris on the feed path. Mechanical wear on rollers and belts, worn guides, misadjusted feeder settings, and poorly calibrated sensors are frequent contributors. In high-speed or complex feeders, small misalignments can propagate into multiple jams or sensor trips.

Impact and remediation: misfeeds can waste stock, damage equipment, and disrupt production. Resolution typically involves clearing the feed path, inspecting and cleaning components, replacing worn rollers or guides, reseating media, and recalibrating feeders or sensors. In some devices, firmware updates or sensor re-alignment may be required.

Prevention and best practices include using media recommended by the manufacturer, maintaining a clean feed path, controlling environmental conditions, and performing regular maintenance. Clear operating procedures for jam clearance and proper training help reduce recurring misfeeds, while automation features such as feed-sensing and interlocks aid early detection.