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.

Most padded and upholstered seats or seat backs used in the transportation industry are assembled with a solvent based contact adhesive. In this process the fiberglass or steel base of a seat or seatback is bonded to foam, which is then bonded to re-enforced fabrics, and finally covered with cloth. Due to the high traffic of these seats, they typically have a seven + year duty cycle. Given these conditions it is often required that lamination between these substrates be permanent.

Most assembly and recovering companies that perform this service are looking for alternatives to flammable spray products such as contact cement. Along with the need for adhesive alternatives, the need to have easier removal of the foam cushioning from the fiberglass or steel bases has been expressed.

Glue Machinery proposes that PUR reactive hot melt is a good alternative. It is easily sprayed onto one side of each component, it bonds quickly, and it cures to a very strong bond. When it is time for this component to be re-upholstered, the materials can be removed with high heat as the PUR bond is softened at temperatures over 300 F.

PUR Upholstering on YouTube

PUR is also available for smaller jobs or spot welding in 10 ounce cartridges, which are processed by PUR Cartridge Spray guns. For larger volume applications the heated five gallon pail unloader TOF20 Mini with heated swirl hose and handgun is used to dramatically increase output and cut the cost of the PUR hot melt.

Email Pierce Covert (info@gluemachinery.com) at Glue Machinery Corporation to discuss your specific needs and how we can improve or streamline your upholstering process.

Further information:

Champ 5 with GIA1051 Hot Melt

Beads of GIA1051 hot melt applied to different density EPS Foams.

Beads of GIA1051 at 334 F burn very little into substrate.

GIA1051 has a long open time that also gives good initial tack.

Bond between substrates is repositionable.

Bonds between EPS foams are permanent and destructible bonds.