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SPECIALISTS IN MEDICATION DELIVERY SYSTEMS

Common Issues with Vaccinators and How to Fix Them

Introduction

Reliable vaccination equipment is essential for effective disease prevention and control in livestock. Proper maintenance and troubleshooting ensure accurate dosing, animal safety, and equipment longevity. Over time, issues can arise that hinder performance, but many are simple to identify and resolve. This guide will help educate you on the simple, but sometimes frustrating, process of fixing vaccinators.

Common Problems and Fixes

1. Clogging or Blockages

  • Symptoms: Reduced or erratic flow, increased resistance when squeezing the handle, or no flow at all.
  • Possible Causes:
    • Dried medication, dirt, or debris inside nozzles, hoses, or valves.
    • Poor lubrication of piston o-ring and/or barrel.
    • Fragment of rubber from vaccine bottle trapped inside a valve. This is a very common cause.
  • Fixes:
    • Disassemble equipment parts and soak them in hot soapy water
    • Use a fine brush or pipe cleaner to remove build-up inside nozzles or tubing.
    • Rinse thoroughly with clear water, relubricate and reassemble.
    • Check for cracks or damage and replace parts if necessary (and possible).
  • Tips:
    • Tip #1: Fragments of rubber are easily prevented by piercing the rubber stopper of your vaccine bottle with a clean needle prior to connecting it to your vaccinator.
    • Tip #2: Always disconnect your vaccinator ASAP at the end of a vaccination session and clean it using the steps above.

2. Air Leaks

  • Symptoms: Loss of pressure, inconsistent dosing, or spitting of medication.
  • Possible Causes: Loose fittings, damaged O-rings, or cracked connections.
  • Fixes:
    • Tighten all fittings and connections securely.
    • Inspect O-rings and replace if they show signs of wear or cracking.
    • Apply appropriate lubricants to seals. Virgin olive oil is a good choice.
    • Test the system by pressurizing with water to detect leaks before use.

3. Inconsistent Flow or Dosing Errors

  • Symptoms: Varying doses, over- or under-medication.
  • Possible Causes:
    • Partially blocked valves.
    • Worn or failing springs.
    • Incorrect setting of dose-rate by user.
  • Fixes:
    • Check and calibrate dose rate using a standardized measuring cylinder.
    • Replace worn or damaged valves and/or springs (if possible).
    • Check for debris or blockages that impact flow of medication.
    • Perform test runs with water to verify accurate dosing before medication. Again, this works best with a measuring cylinder.
  • Tips:
    • Tip #1: To maximise the accuracy of any testing/calibration, always deliver a number of shots (no less than 10). Even the best vaccination equipment can have a small variation in dose, so testing with multiple shots will give you a better picture of the overall accuracy.

4. Broken or Worn-Out Parts

  • Symptoms: Equipment not functioning correctly, leaks, or inconsistent dosing.
  • Possible Causes: Wear and tear over time, accidental damage, or improper storage.
  • Fixes:
    • Identify broken parts such as cracked hoses, damaged nozzles, or faulty valves.
    • Replace with original or compatible spare parts.
    • Conduct routine inspections and maintenance to catch issues early.

5. Calibration Issues

  • Symptoms: Dosing volume inconsistent with setting, leading to under- or overdosing.
  • Possible Causes: Mechanical shifts, incorrect initial calibration, or user error.
  • Fixes:
    • Follow the manufacturer’s calibration procedure carefully. (eg. Line up piston head with correct position in barrel).
    • Use test doses (e.g., water) to verify system accuracy.
    • Document calibration results and set a regular maintenance schedule.
  • Tips:
    • Tip #1: Always fit a needle when calibrating a vaccinator, as this will replicate the results as they would be while vaccinating. If you don’t use a needle, you WILL see inaccuracies with any gun.

Preventive Maintenance Tips

  • Disconnect vaccine from vaccinator EVERY time you finish for a day and clean thoroughly.
  • Store equipment in a dry, protected area.
  • Regularly inspect for signs of wear or damage.
  • Replace and/or relubricate O-rings periodically.

When to call Think Livestock

  • Any time you are unable to fix your own problem with the steps listed above, give us a call on (03) 5448 8942 or contact us by email. We’re here to help!

https://www.thinklivestock.com/product-category/injection-and-drenching-equipment/spare-parts

https://www.henkesasswolf.de/en/veterinary/spare-parts

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