There is a difference in approach between establishing a new application and troubleshooting an existing production issue. A new application is defined as a freshly installed production line or an existing line where an application has been changed from one technology to another -for example slot coating to spray coating or changing between two different types of spray applications. A new application requires establishing an operating window based on the key process elements.

An established application was previously optimized upon installation. The performance has diminished significantly over a period of time.  The key process variables of an established application should never be adjusted.  The established settings that worked for the previous weeks, months or years should not need changing. Instead, a root cause should be identified. This could include:

Unauthorized change to a key process variable-pump speed, temperature or something else.

Damage or failure of a process component.

If the process variable has changed, then returning it to a known good run setting will remedy the issue. If the issue is a malfunctioning component, the first step is cleaning and inspection are the minimum requirement, while in some cases replacement will be necessary. Keep in mind, a faulty component can be anything within the hot melt adhesive system (e.g., hot melt pump) or an external input (e.g., air supply line). It is not isolated to the spray applicator, module and nozzle.

In extreme cases, process issues can warrant a significant change. This could be the type of application technology – from spray to slot coating – or the specific adhesive product to incorporate different performance properties. While extremely uncommon in new applications, a mismatch between hardware, adhesive selection and process requirements can be the cause of any persistent issues. For established applications, a different set of factors should be considered such as changes to substrates, machine settings or the plant environment.

Operating a hot melt adhesive production line has a variety of challenges. To establish a robust spray adhesive process, a strong understanding of the relationship between several factors is required. This includes understanding the key process variables required to create and maintain a stable application. It also involves learning how to implement new applications and troubleshoot existing applications. For nonwoven applications, manufacturers rely on the effectiveness of hot melt adhesives to assure a strong seal or bond. Brand owners need to understand the working relationship between the equipment and adhesive to maximize both uptime and finished good performance. 

To gain more insights on ways to increase efficiency of hot melt adhesive, contact us and learn more best practices about improving the operating life of adhesive.