Hot Melt News

In manual assembly and packaging applications, the actual hot melt adhesive usage is often twice as much as is required.  Precise manual application of hot melt can be difficult; therefore operators apply additional adhesive to insure a sufficient bond.  Packaging and/or product failures are more expensive than the cost of adhesive overuse, so managers simply accept higher adhesive consumption as a cost of doing business.

With skyrocketing raw material and shipping costs pushing the average cost of hot melt to more than $2.00 per pound, it makes sense to take another look at hot melt consumption.

Tips to Control Hot Melt Adhesive Consumption:

1. TRAINING — Operators have the ultimate control over adhesive usage.  Thorough documentation and training on approved assembly procedures will help operators gauge the correct amount of adhesive usage.
2. EVALUATION — Regular quality control checks should be performed to ensure that the appropriate amount of adhesive is being applied.  If not, additional communication and training with operators might be necessary.
3. EQUIPMENT – There are many options within adhesive application equipment.  Melting, pumping and applying capabilities of equipment should match assembly requirements.  Under-specified hot melt equipment may require operators to overheat the system in order to maintain sufficient melt rates.  This overheating can degrade adhesive and affect subsequent bonds.  In addition, this can lead to increased system maintenance requirements.
4. ADHESIVE – It is critical that the adhesive have the appropriate open time, set time and bond strength for the application.  This can only be accomplished with thorough testing.  If any characteristic of the adhesive does not match the application, consumption will certainly be affected.  Keep in mind that more adhesive does not necessarily mean a better bond; the amount of adhesive affects set times and subsequent bonds.
5. ERGONOMICS – Make it easy for operators to manipulate their tools.  Ease of operation enables operators to apply consistent patterns.
6. ASSEMBLY TIME – Operators need to have sufficient time to focus on the application.  This will allow for correct and standardized adhesive patterning on each package.
7. AUTOMATION – Consider ways to go “Hands Free.”  Benchtop units and XY Tables can provide more consistent and controlled adhesive application.

With proper training, monitoring, supplies and tools operators can produce better products, in less time with less adhesive.  Please visit www.gluemachinery.com/ergo-erector for an example of a system that has produced significant adhesive usage reductions in the case erecting industry.

Be sure to check in next month for information about reducing adhesive consumption in auto glueing applications.

Contact Pierce Covert to discuss your particular process and application needs to find out how we can improve your consumption rates.

Recently, a customer having two identical units was experiencing problems with only one of the units, despite the fact that both were similarly configured and running the same materials. After investigation of his error code (OV-C), we asked him to check his supply voltage. What was discovered was that the voltage source for each unit was from a separate feed. The transformer output that was supplying the roll coater was providing 240v, but was spiking as high as 300V during operation. Relocating the unit to a more stable power source corrected this condition and the customer was able to resume work at full capacity.

Glue Machinery Corporation Hot Coat and Hot Coat Plus industrial hot melt roll coaters have several diagnostic fault codes that may be displayed on the motor speed control (inverter) in case of system error. This feature is one of the many built in benefits and features of Glue Machinery Corporation equipment. Aside from our proven customer service and service department, we also provide superior product documentation with all our products. As always, technical support is just a phone call away. (Ask for Les, Matt, or John in the service and repair department at 1-888-202-2468)

Hot Coat Motor Speed Control Diagnostic Location

A list of fault codes and corrective actions are listed below for your reference.

OC-S Over current during start. Motor is shorted. Check and fix motor or Motor has ground fault - Locate and correct ground fault

OC-A Over current during accel. Accel time is too short - extend accel time

OC-C Over current during constant speed mode. Excessive load changes - check load condition

OC-D Over current during decel. Decel time is too short - increase decel time

OV-C Over voltage during constant speed mode. Input voltage fluctuation - check AC supply to motor/unit, verify that it is constant and not over rated voltage

LV-C Low voltage during constant speed mode. Input voltage drop - verify that the incoming AC supply meets minimum voltage requirements

OH-C Overheat during constant speed mode. Load is too high - investigate load condition

OH-1 Braking resistor overload . Decel time too short - increase decel time -or- frequent starting and stopping of unit - prolong run/stop cycle

OL-1 Motor overload. Load is too high - investigate load on roller, correct if needed

OL-2 Inverter overload. Load is too high - investigate load on roller, correct if needed

OL-3 Over torque. Load is too high - investigate load on roller, correct if needed

Hot melt hoses should be replaced every couple years.  The frequency of replacement depends on amount of time used, temperatures of operation, and adhesive used.

Our experience shows that customers will service their hot melt system and guns regularly and continue to use the same hoses for many years after they should have been replaced.  To protect your investment and insure optimal production standards, Glue Machinery Corporation recommends replacing your old hoses after three years of continuous operation.

Charred hot melt often builds up in hoses and this debris will dislodge and clog filters and nozzles in your adhesive system.

The inside of the hose is Teflon lined but degraded material tends to build up at the ends where fittings are swaged onto the hose.

Recirculating purge through the hose and back to the tank can help extend the life of the hose but can also lead to debris dislodging from the inside of the hose while the system is on line- causing further damage to the previous mentioned filters, nozzles, and guns.

Hot Melt Hose Debris

Contact the Glue Machinery Corporation Service Department to evaluate your particular Hot Melt Hose and how we can be of service to help you maintain optimal performance. 1-888-202-2468 or email:info@gluemachinery.com