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Do you want to guarantee perfect and secure envelopes to your important customers? If you have not yet considered this, I would suggest starting now. According to the Envelope Manufacturers Association, “Adhesive­‐related issues are the number one cause for customer returns.” Some envelope converters may say, “Our envelopes open and stay closed just fine.” Is this acceptable? An experienced converter will know to ask a customer where the envelopes will travel or how they will be stored to enable the right selection of adhesive. But, in regards to actually applying the glue, what are the right questions to ask? If you are buying envelopes, I’d likely be impressed with any additional knowledge on the subject. This type of expertise could be what helps decide to use one envelope converter over another.

So, what do professionals consider a secure envelope? In technical terms, a secure envelope has at least three folds and two overlapping edges, with seam gumming applied to the overlapping areas. There may be discrepancy on how well the seam is glued.

To ensure a secure envelope, the manufacturer should have systems in place that apply adhesive consistently, with clean cut-off. There are a variety of envelope types that may need glue application, however closed seam envelopes are the strongest form of seam construction and they are also the least vulnerable to breaking or popping during the mailing process. The operator must consider the specific method of application, the machines involved in the process, and equipment speeds to ensure the right applicator style is selected. Paul Chambers, Vice President of Sales and Marketing at Valco Melton explained, “A 0.35mm nozzle is the right choice for side seam gumming, because it applies gum lines consistently, thus eliminating the inherent problems associated with using improper nozzle sizes, such as tailing and clogging.”

In addition to proper gumming, quality inspection will ensure that the adhesive has been accurately applied at high line speeds. Quality inspection will assure an end user that the important documents inside their envelopes are secure, without manual operator intervention. If you have ever had to manually check envelopes for quality, you know that this is a big time-saver. Specifically, quality assurance gum inspection sensors guarantee that envelope side seam flaps are glued flawlessly in volume, start and stop, and overall length.

 

env_524valve_as302e-sensor_6Using an intelligent gluing system with quality assurance will increase business. Here is a quick run-down on how manufacturing a consistent end product will help you:

  • Increase new purchases and repeat business with a repetitive quality product
  • Provide trust and confidence by knowing you have the right equipment in place to do the job best
  • Improve loyalty with a solid track record of superior end-product from the same company
  • Make yourself more marketable by using the very best technology from a global manufacturer that you can depend on to support you whenever you need it

Valco Melton is the world’s leading supplier of envelope gluing systems and quality inspection equipment. Learn more about proper gumming and quality inspection here or by speaking to an expert in envelope adhesive dispensing and quality assurance today.


 

 

 

 

One of the biggest threats to the efficiency and profitability of any production line is unscheduled machine downtime. It can be a sudden production halt, or an intentional machine stop by an operator who has detected defective functioning on the line.

Electric Save Time,Money Blog Post_Image 1

Not only does this cause time loss, but also results in increased over-time to meet production goals, as well as replacing a small part that might be currently out of stock. Such unscheduled machine downtime forces operators to leave their tasks and try to fix the problem, which sometimes requires specific knowledge and can only be fixed by the technical service of your packaging machinery supplier (who, to make matters worse, is located miles away and unable to provide immediate assistance). Simply put: it costs you time and money. Sometimes lots of money.

As a leading manufacturer of adhesive dispensing systems for the packaging industry, we are aware of how distressing this situation can be for our customers. For that reason, we have decided to focus on exactly why a hot melt glue system could cause a packaging line to stop.

We found that the main reason for failure on a hot melt glue gun was typically compressed air.  Luckily, we also identified a solution to fix this problem: electric hot melt glue guns. To dive deeper, in this post, we examine how all-electric hot-melt systems save more time and money than pneumatic hot-melt dispensing machinery by looking closely at long-term issues reported on air quality, solenoid performance, spare parts replacement and adhesive usage.

Air Quality:

How can compressed air have such a big impact on the life and performance of a hot melt applicator? To start off, manufacturing compressed air is expensive, and due to the age of most systems, the quality of the air starts diminishing shortly after installation. This in turn affects the efficiency of the applicator, the accuracy of the pattern and the potential lifespan of the hot melt system. On the other hand, an all-electric valve has a consistent performance throughout its entire life, which can reach up to 300 million cycles.

Solenoid Performance:

Pneumatic hot melt glue guns require air solenoids to activate the module. The combination of heat, debris, oil and air moisture quickly weakens the solenoid performance, resulting in sloppy or inconsistent glue patterns, spitting, or no glue firing at all. While you might think replacing the solenoid would correct the issue, more often than not, it’s hard to tell whether the origin of the problem is the air-activated solenoid valve alone. Therefore, the nozzle, module and the solenoid are all replaced to ensure the problem is resolved, which necessitates an important investment in spare parts, inventory, storage and technical training. Since electric valves don’t require solenoid valves, these associated issues are of no concern.

Spare Parts Replacement:

Seals and moving parts in the valve are subject to wearing out and require regular maintenance and replacement to maintain the valve in good condition. By reducing the number of seals, not only can you diminish the maintenance requirements, but also dramatically reduce chances of failure. Such is the case with an electric valve, which uses a small number of seals and other moving parts, guaranteeing longer life with less maintenance. To help illustrate this point further, we’ve created this infographic comparing the number of seals in both hot-melt systems.

Adhesive Usage:

Electric Save Time,Money Blog Post_Image 2

Last but not least, electric valves reduce adhesive usage up to 75% while continuing to provide perfect bonding and sealing.

Compared to pneumatic hot melt glue guns, an electric valve can be set to work on stitch mode, producing any desired pattern larger than 1/8” (3 mm). The size of the bead and the distance between beads can easily be set and controlled from a Pattern Controller, which is usually provided as an integrated feature of the hot melt unit. All of this translates to great savings, while still allowing you to deliver a more eco-conscious product.

Why take our word for it? Our customer results speak for themselves: Click here to access the adhesive usage comparison at a well-known global beverage manufacturer, before and after they switched to Valco Melton’s EcoStitch™ Electric Valves.

Questions CTA

To contact a hot-melt system specialist today, click here.

Global demand for corrugated boxes is expected to rise 4% annually to 234 billion square meters by 2017, a considerable acceleration from the 2007-2012 period. Largely driven by economic resurgence and growth in manufacturing goods packaging, competition among corrugated box manufacturers has never been greater.

A Message for Corrugated Box Manufacturers: Deliver faster, cheaper and better boxes.

Packaging buyers are increasingly demanding more from corrugated box manufacturers. Not only are you now expected to deliver boxes in record time, but also at unbeatable prices. In conjunction with an increased selection of available adhesive dispensing systems offering the latest technology, the bar for corrugated box manufacturers to deliver 100% defect-free boxes has been raised.

Upgrading Your Flexo Folder Gluer For Maximum Performance

So, how do you ensure your flexo folder gluer is ready for the zero defect challenge? It all starts with selecting the right glue station for your specific application and making the necessary upgrades to ensure it’s equipped for maximum performance. Corrugated Box Manufacturers Demand

Since the advent of faster, direct-electric valves, and advances in adhesive technology, jetting the glue from a distance away from the board has become a valid method for applying adhesives.

This non-contact gluing method has gained in popularity due to its ability to reduce the risk of board marking and skew, as well as the fact that it requires very little “housekeeping,” when compared to contact gluing. As an added bonus, the all-electric, non-contact system does not have the glue pattern applicator, or related wear items typically associated with an air-operated contact system.

Previously, non-contact glue stations could only be used for top-down gluing. In order to produce inside and outside glue lap, machines required glue stations, along with associated fluid handling system components, to be mounted on both the tab-side and 4th panel sides of the machine.

Further research and development efforts have since led to the creation of non-contact glue stations that offer increased configuration flexibility, as well as new glue valve technology, which is capable of operating at higher glue pressure.

By equipping your flexo folder gluer with a glue station that offers both top-down and bottom-up non-contact glue application capabilities, you can really maximize the utility of your machine. Installed on one side of the machine, the operator can quickly set it to run for either inside or outside glued boxes with only the pull of a ring.

Other benefits include:

  • Eliminates the need to invest in gluing equipment for both sides of the machine
  • Avoids potential risks of board marking, board skewing and applicator headwear associated with contact gluing technologies
  • Ideal for machines that can only mount a glue station on one side

Quantity and Quality: The Importance of Quality Assurance Equipment

We can’t stress enough, how important it is for corrugated box manufacturers to select the right glue station in order to maximize flexo folder gluer performance and keep up with demand. Quantity however, is only half of the story.

As advances in adhesive dispensing technology have been made, expectations for supplying perfect boxes have increased. While efficiently delivering boxes in record time and at unbeatable prices is an advantage in and of itself, what if you could also guarantee that every box is 100% defect-free. Would you buy from a company that wasn’t supplying 100% defect-free boxes when they could? No. So why would your customers? This is where the other half comes in: Quality.

Delivering a quality product not only increases client retention, but also helps you stand out from the competition. By equipping your flexo folder gluer with state-of-the-art camera inspection systems and the latest developments in adhesive application technology, you can actually gain control of what you ship.

Don’t wait for an unhappy customer when you can ensure a perfect box before it even leaves your door.

Download Your Guide to the Perfect Box Today

Valco Melton offers a variety of solutions for upgrading your flexo folder gluers including the new 3NCR Non-Contact Glue Station for Top-Down and Bottom-Up Applications, and our ClearVision® Camera Inspection System, an all-in-one quality assurance program that features GlueChek, FoldChek and BundleChek technology to ensure defect-free products from your flexo folder gluer.

To learn more about our entire line of solutions, download our Corrugated e-book today by clicking here.

New India OfficeThe Valco Melton team is pleased to announce the expansion of its business operations in India with a move to a larger office space to accommodate future development plans.

The new office is located at #981, 1st floor of the Ideal Homes Township on Mysore Road in Bangalore.

While the team only recently moved into the space over the summer, they are already enjoying many of its new features including additional customer demonstration and trial areas, as well as increased inventory, and service and repair facilities.

The strategic decision to move offices will enable the company to increase sales and service support of all hot melt and cold glue products for its customers, and meet the demands from rapid business growth in India and surrounding territories.

Since January 2011, Valco Melton India (a wholly-owned subsidiary of our Cincinnati based corporation) has continued to build on its strong team of experienced managers and sales/service technicians. Bangalore will remain the main office in the area, with other regional offices located in Ahmedabad, Chennai, Mumbai, New Delhi and Pune.

Read more about Valco Melton India’s new office and presence at this year’s PackPlus trade show in Packaging South Asia magazine here.

On behalf of the entire Valco Melton India team, we look forward to working with you and welcoming you into our new office.

To speak with someone from Valco Melton India directly, please click here. Complete contact details for the new office can also be found below.

VALCO MELTON INDIANew India Office Location_Map

(Valco Melton Engg. India Pvt Ltd) #981, 1st floor, IDEAL Homes Town Ship, RR Nagar,Mysore Road Bangalore 560098

T: +91 80 28602821
F: +91 80 28606117

Inserting and product attachment are a vital part of Print Finishing. Every day we see mailers with gift cards, credit cards, gas cards, and more. Whether your company is sending out a promotional flyer or attaching a card, coupon or mailer, using an efficient, cost-effective adhesive applicator is an important condition. Obligations to produce excellent print quality, complex folds, special perforations, and the need for speed are growing. It is critical to your brand reputation that this product maintains its integrity even after reaching the end-user. Furthermore, with today’s competitive landscape, producing these materials with a consciousness for sustainability is a requirement.  In our line of business, that means using less adhesive and producing less waste. Here are five ways one hot melt gun can start lowering your adhesive usage today.

diagram of adhesive placement on a mailer
Diagram of adhesive placement on a mailer.

1.“Opt-In” on Options. One of the most critical aspects of adhesive application on a mailer or graphic is the ability to customize the adhesive pattern, so that the system can maintain the flexibility it needs for each customer’s specific requests. Because accuracy and precision are a necessity, it is critical to administer an adhesive application that meets these standards. In a market that is constantly reinventing itself, whether you need micro beads, large beads, are folding or perforating the mailer, or need 30 beads versus 15 beads, the electric valve that provides you with the ability to select an option from a limitless number of bead sizes and pattern lengths is the way to go. Valco Melton’s Ecostitch™ Valve is one of the only valves to provide these options to its customers.

2. Eliminate Stringing.  Another critical aspect to applying a perfect and efficient adhesive pattern on mailers and graphics is the ability to eliminate stringing and provide a clean cut-off. In other words, when the mailer arrives at the end user, it is important that they can open the seal without tearing, ripping, or damaging the mailer. If the end-user tears or damages the mailer that is associated with your company name, it can affect what they think about the quality of your brand.

3. Ensure the Dispensing Valve is Multi-Use. Many mailers are glued with permanent, fugitive, and pressure sensitive adhesive. It is important to have an adhesive applicator that can work with nearly any adhesive to provide the clean finish and quality application you are looking for.

4.  Utilize the “Zipper Stitch. Valco Melton’s Ecostitch™ adhesive applicator applies adhesive in what they have started to call a “Zipper Stitch™.” This adhesive pattern type is truly unique and far superior to the traditional adhesive application method used on mailers. Traditionally, manufacturers would apply a long line or series of lines of adhesive to seal the end piece. More specifically, a large bead of glue is applied to the surface and spread out across the sealing area, which causes the end user to bend, fold, and tear the mailer when opening the seal. The Zipper Stitch is a superior pattern because it provides a perfect, uniform seal across the sealing area. Instead of a thick bead of adhesive stretched across the surface, there is a series of micro beads applied across the surface to provide a seal that can withstand any quality control test. Simultaneously, this allows the “at home” user to open and re-seal the mailer without tearing it. The Zipper Stitch provides a clean opening, while eliminating any tearing or other damage. This increases the integrity of the mailer, which in turn gives the end user a more positive experience.

diagram of integrated product attachment hot melt system
Diagram of integrated product attachment hot melt system.

5.  Long Lives the Clean Valve! With speed and ceramic materials, electric valves are able to produce a tight closure that pushes out and pulverizes any char or debris that comes through the valve. Essentially, the valve cleans itself. By using a top-down adhesive path and electromagnetic coil, low pressure and large orifice size, the valve is able to virtually eliminate nozzle plugging. Additional features support easy change-outs and variable valve configurations with options like a “quick-connect” coil.

As an example of how powerful a little adhesive valve of this kind can really be, Valco Melton’s Ecostitch™ adhesive applicator is built with a ceramic seat and carbide-tipped plunger.  It easily reaches 3000 cycles per minute continuous duty with a lifetime of up to 300,000,000 cycles. This solution has produced every case I’ve seen with instant ROI– Payback has occured in as little as four months.

By selecting a Hot Melt Adhesive Applicator that can achieve these 5 things, your adhesive can be reduced by up to 75%.  Don’t believe me? Check out this case study.

If you’d like to see how an electric valve of this kind works, you can watch that here. To learn more about how this electric valve can start generating savings specific to your requirements today, let us know here. 

 

Assembling sheets and layers during the diaper manufacturing process involves several steps. The bond between each part must be flawless and any interference to the adhesive on the product kept to a minimum.

A common myth amongst manufacturers is that a strong, long-lasting bond means that it is necessary to use higher amounts of adhesive. This is false. By using specific patterns engineered to have higher adherence and locating the pattern in certain key spots, the use of adhesive can be decreased, while the strength of the bond increases. In other words, it’s not the amount of hot melt you use, but how you apply it.

Swirl Spray Technologies in the Nonwovens Industry
Swirl spray hot melt technologies.

Tests at diaper manufacturer facilities have proven that a 50% reduction of adhesive usage is possible by switching from standard spray hot melt dispensing applications to multi-spray adhesive patterns. During spray applications, the surface is covered from side to side with a swirl pattern. With the multi-spray option, the same surface is instead covered by 3 parallel mini-swirls. This application creates a pattern with a high number of adhesive swirl intersections to give additional strength using lower amounts of adhesive.

Aside from adhesive usage reduction, further savings can be attained by using hot melt modules with removable “insert nozzle” technology. This innovative concept permits easier cleaning and pattern configuration processes. The tip of the nozzle features 3 small inserts that provide a highly accurate mini-swirl pattern. A special air output design avoids nozzle clogging, while reducing costly downtime.

nonwovens BAT22 applicator head
PUR being applied onto a nonwoven material.

Additionally, inserts like Valco Melton’s NWV BAT22 Inserts can be easily extracted and replaced, facilitating and reducing the time spent on cleaning and maintenance operations. Inserts can be combined with blanks for additional pattern configurations with minimal spare parts investment and work-change times.

Spare parts inventory can also be reduced as an effect of this hot melt technology. If any malfunction occurs, there is no need to replace the whole nozzle, just the defective insert. By only replacing the inserts, some of the users of our multi-pattern modules with insert-nozzle technology have experienced proven savings of up to 40-60% in their spare parts expenditure.

If you are interested in a deeper technical analysis, here is a white paper detailing the savings a customer achieved at their facility by replacing their swirl spray hot melt systems with multi-spray hot melt technologies. Click here to download it now, or contact one of our experts for additional information.

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Manufacturers have been using compressed air systems for many years. In fact, most adhesive dispensing systems today use pneumatics simply because air has always been available and this was the original design criteria in the development of hot melt system gun technology. Although pneumatic systems will get the job done, there are several known, long-term issues associated with compressed air:

1. Constant and costly replacement of parts gone bad.

2. Diminishing solenoid performance.

3. Pneumatic guns plus solenoid have eleven dynamic seals per set compared to electric guns that have no dynamic seals.

It’s a fact; Pneumatic valve performance starts diminishing shortly after installation. Most modules are replaced because they won’t fire glue, not because they are leaking from the glue seal. This is because the pneumatic portion of the valve module has failed, not because the fluid seal failed. Compressed air is the cause. Many nozzles are replaced because there is no glue coming from the module. Although nozzles do sometimes get plugged, there are just as many issues with the module or air solenoid not performing at full capacity that give the impression that the nozzle is the cause. The nozzles, module and air activation solenoid are all replaced to be sure the problem is resolved.

Air activation solenoids, like valve modules, are constantly pushing air through them. The combination of heat, debris, oil, and moisture in the air will cause the solenoid performance to start diminishing very quickly. A solenoid can still open and close, but it might only be working at 40% of its full capability. This means the volume of air going through the air solenoid is most likely much less than what is shown on the regulator. The symptoms of this issue are sloppy glue patterns, spitting, inconsistent glue patterns and in some cases, no glue at all.

Manufacturing compressed air is expensive and because of the age of most systems, the quality of the air diminishes each year. Compressed air contains debris that enters the piston pump, air solenoids, and glue module with each activation. This problem can be completely avoided by using an all-electric hot melt system. The all-electric hot melt system removes this contamination, resulting in a higher quality and much cleaner product. An all-electric system does not have dynamic seals in the valves, contains a built-in troubleshooting guide, built-in gun filter, and there are no solenoids required. All of these prevent the constant replacement of system parts and diminishing performance; two issues that are common in pneumatic systems.

All-electric systems not only provide a higher quality product, but also decrease downtime caused by diminishing system parts, which simultaneously increases production. Whether you are a folding carton, packaging, or print-finishing manufacturer, all-electric adhesive systems can improve your production rates and increase the quality of your product.

We tested our CHOICE all-electric system over a three-week period with one of our customers that was using a pneumatic valve and a traditional bead of adhesive for their card attaching applications. The customer provided us with sample product of card attachment that was completed with their pneumatic system. Our goal was to run this exact same card attaching application with our all-electric system for three weeks to show the customer the adhesive consumption savings and cost savings they would achieve by using our CHOICE system compared to their previous method.

First, we weighed ten of the products glued with the traditional, pneumatic valve as well as ten products glued with our all-electric system. After obtaining the weight of the glued cards, we subtracted the card weight (6.29 grams) to determine the weight of the adhesive applied to each card. The results determined that there is a 60% reduction in adhesive usage when using the all-electric system compared to the pneumatic system.

We went a step further to discover the financial savings they could attain if 8,000,000 pieces were produced. Now that we had determined the weight of the adhesive applied to each card for the two systems, we calculated how many pounds of adhesive would be used with 8,000,000 pieces of product by the pneumatic system (3,227.57 lbs) versus the all-electric system (1,287.50 lbs).

Using a hypothetical price of $3.00 per pound of adhesive we were able to determine the adhesive cost for the pneumatic system at $9,682.71 and the adhesive cost of the all-electric system at $3,862.50. Bottom line, the customer saves $5,820.21 using the all-electric system.

The test clearly showed the customer that the all-electric system lowers adhesive consumption by 75%, which in turn lowers the adhesive cost. The new systems paid for themselves in less than 4 months.

The great news is that Valco Melton’s CHOICE system can be implemented onto any existing line, but moreover the amount of investment you make today will be in direct correlation with the return you will see tomorrow. You can learn more on how this all-electric system can help your business today by speaking to one of Valco Melton’s specialists. You can contact them directly, here. Don’t forget to mention that you are interested in the CHOICE system you read about in this August blog post

Hard Savings:

  • Adhesive Consumption
  • Removal of Pneumatics
  • Reduction in cost of plant air usage
  • Less spare parts associated with electric system
  • Less degradation to valves because no plant air
  • Less moving seals

Soft Savings:

  • Downtime associated with pneumatics
  • Less stoppage to change out solenoids and seals
  • Nozzle Plugging
  • Larger nozzle orifice and lower operating pressures
  • Also helps with machine safety
  • Faster Production Speeds
  • Gives you the ability to stitch at higher production rates with clean, crisp patterns

image of corrugated boxes in bundlesThe corrugated box manufacturing industry has long been focused on reducing waste as one of the key drivers of efficiencies. Like most box makers, you are probably focused on reducing waste in your facility. However, most people fail to realize the complex interdependent relationships that exist between quality, waste, product price, cost and production volume. What if “increasing” waste built value for your customers or increased your revenue and “decreasing” waste actually increased the cost of the box or even lowered sales? With so much at stake, it pays to take some time to more closely examine the tipping point between quality and waste.

What is Waste Anyway?

image of corrugated box waste
corrugated box waste

There are actually two separate types of waste – internal and external. Internal waste is typically what the corrugated box industry refers to as “waste.” Internal waste represents any defective sheet or box that is produced and not shipped to the customer. However, if you don’t catch the defective product and it ends up in the hands of the customer, it is considered external waste. External waste is rarely, if ever, discussed unless brought up by the customer. The cost is only accounted for in the form of credits for defects returned. Some customers do not return many defective or problem products to the corrugated box maker, resulting in an inefficient and distorted feedback loop.

Misleading Numbers

Through our investigations, we have found that the costs tracked for external waste are more often larger than the internal waste figures. Furthermore, customer complaints, credits and feedback are a minority of the actual rate of defective product that customers are receiving. What this means is that some customers are bearing much of the direct costs (downtime, lost productivity, wasted products) associated with external scrap rates, while box makers are bearing much of the direct costs associated with internal scrap rates.

image of unsatisfied option check-markedIf customer complaints were, in fact, true indicators of the external scrap rates, this model would be useful for making operational decisions. However, discussions with end-users have shown that customers are not complaining about the vast majority of problems. Similarly, many box plants don’t complain about every hiccup in their machines or every minor issue with their paper – that’s the norm and they are used to it. Because this feedback loop is broken, many corrugated box makers have a warped view (literally) of how much scrap they’re actually sending their customers.

Options

Two clear options are available to box makers for handling waste. First, do a better job of finding all defects before shipment and remove them from the production stream, increasing internal scrap rate and improving quality. Alternatively, send defects to customers in an effort to reduce internal waste, but increasing external scrap rates and decreasing quality. What are box makers expected to do? Is sacrificing quality worth the savings of reducing internal waste? What impact will this have on your business?

Possible Solution

The secret to improving both internal and external waste is not only to identify the defective products and remove them from the production stream, but also to identify the root causes of the scrap production and address them. Investment in quality assurance systems for box inspection, operator training, as well as PM discipline and keeping equipment current can both identify scrap and reduce its root causes. If management is committed to solving problems on the floor that are causing waste, not only will less defective product be produced internally (internal waste) but also less defective product will be shipped to customers (external waste). In addition, profits will improve and customer retention will increase, which directly improves the bottom line. Finding the problem quickly through quality assurance devices and not having them occur from the other improvement measures will decrease internal and external scrap rates and improve the ROI performance of the business.

End Result

If investment in quality assurance systems, operator training, improvement in preventative maintenance programs and an upgrade program for production machinery can reduce the internal scrap rate, then the external scrap rate will be significantly reduced. Box makers will improve profits and keep happy customers who shouldn’t need to complain about the products they receive.

Why pay the price of the traditional corrugated box manufacturing industry’s approach for quality, counting pennies and losing dollars.

Download or request a free infographic depicting the difference in cost and value from decreasing scrap versus increasing quality here.

Having worked in supplying adhesive dispensing equipment and packaging machinery to people all over the world since 1952, we have heard quite a few horror stories from customers using hot melt glue systems. They mostly stem from the same common mistakes. Unfortunately for them, if they had known what we are about to tell you, these issues could have been easily avoided and the risk of downtime dramatically reduced.  In an effort to make sure you don’t become another one of the characters in these legendary stories, we suggest following these 5 easy tips: 

  1. Never start the unit before it has reached working temperature.  We know time is money and waiting for the system to reach working temperature everyday can feel
    image of hot melt pattern control system
    hot melt pattern control system

    like you are wasting valuable minutes that should be spent doing other things. However, it is necessary for the unit to reach working temperature to ensure that the adhesive has the required viscosity. Failing to do this can create problems with the pump and other internal parts that will result in unstable working conditions and downtime. So, count this daily ritual in as an important one.

  2. Stop “overfilling”. When the hot melt glue system runs out of adhesive, it can make the entire packaging line come to a screeching halt, resulting in expensive downtime. Although overfilling the melter to ensure the adhesive supply will last longer seems like it could be a brilliant idea, once the adhesive is actually melted, it can result in unwanted spillages. This can create serious safety hazards for yourself or other operators, as well as damage your packaging equipment.
  3. Get rid of risky maintenance practices. Regular maintenance processes should always include cleaning your hot melt glue systems. Rushing through this task can sometimes lead operators into manipulating the melter without getting rid of the high pressure first. Given the risk that the combination of hot adhesive and high pressure involves, eliminating the pressure from the system is a necessity to ensure a safe cleaning process.
  4. There is no universal configuration. Although it would be ideal, unfortunately, one configuration does not work for all applications. It is important to know the exact parameters, such as line speed, pattern type or applicator cycle speed that each application requires to avoid defective bonding or stringing caused by either an excess or a lack of hot melt adhesive.
  5. image of valcomeltons high-speed EcoStitch Applicator
    High-speed EcoStitch Applicator.

    Always use the adequate type of adhesive. It is important to be aware of the type of adhesive your application needs. Take into account the product that is being sealed and the hot melt glue system being used. Using the wrong type of hot melt for your products may create defective bonding or even damage the material. If the adhesive is not suitable for the hot melt glue system, common problems can include an unstable pumping rate due to incorrect viscosity, clogged nozzles due to debris formed by burnt adhesive, or a complete stop of the system if the melting requirements are higher than the system’s melting rate. If you are not sure, ask!  There is nothing more glorious than a perfectly glued product.

Start seeing instant improvement in your production processes today by implementing these simple changes into your day-to-day operations. Reach out to our Packaging Machinery Experts anytime by emailing us here. They will be happy to assist you with any additional questions you may have.

Learn how our hot melt glue systems can help you avoid these and many other common mistakes, by instantly downloading this informative literature series on Hot Melt Glue Systems for Packaging Lines today.

download more reading material by clicking here

If you’re in the market of using pressure sensitive adhesive with a deferred use seal machine for corrugated box products, folding cartons or envelopes with conventional paper converting machinery, it’s important to consider production speeds and volume when making the decision between a double sided transfer tape applicator system or a system that applies pressure sensitive adhesive followed by a covering release liner. Both double-sided transfer tape and pressure sensitive adhesive sealing systems with release liner get the job done, but which method completes the task most efficiently, while giving the highest quality product and the most cost-effective solution? I’d say it depends largely on a few things.

The pressure sensitive adhesive applied in ribbon, bead, or spray form during the converting process on the converting machine is deposited evenly onto the substrate surface. This process produces a much stronger bond than adhesive transfer tape systems. The release liner overlay can be customized for length and width coverage to off set the adhesive pattern thus providing the easy peel and seal feature that is not possible with transfer tape.

 

an image of valcomeltons sealtak system for adhesive sealing
Valco Melton’s Sealtak System for Adhesive Sealing.

By eliminating the need for excessive transfer tape roll changes, production significantly increases, while simultaneously decreasing down time and reducing material costs by 40% or more. The cost of buying bulk adhesive and bulk silicone paper is far less than the cost of transfer tape and is easier to inventory and store.

If you are looking for a more efficient process, a stronger bond, to reduce material cost, increase production, and decrease downtime, I’d suggest using the Valco Melton SealTak® deferred-use sealing equipment method. Just do the math and decide what makes the most sense for your company.

Learn more about how deferred-use sealing can help your business today by clicking here.


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