lower the weight of your film and nonwoven materials through adhesive application management: systems can save on raw material and non-material costs alike.
Film and non-woven material.
Manufacturers can save not only the use of raw materials, but also the overall transportation cost, which can make up for 60-70% of the non-
Cost of material products.
However, many manufacturers have neglected the strategic approach to achieving this goal, thus greatly saving costs. -
Many times, the limiting factor that prevents manufacturers from using materials with lower weight, including polypropylene and polyethylene, is the adhesive application that the film must withstand.
An opportunity to reduce the weight is to change the adhesive itself: Some adhesives can reduce the application temperature or provide better adhesive strength, thereby reducing the addition of the adhesiveons to be used.
Another key and often overlooked opportunity that can mitigate the weight ---and costs--
Reviewing your adhesive application device can provide an instant and efficient opportunity for film weight reduction.
Two main strategies for adhesive application audit are adding-
Optimization of variable management and application technology.
Change management: save money in unexpected ways by managing changes, producers minimize burns
Film and bleeding issues-
Through a problem with non-woven materials, thus allowing the use of lowercost, lower-
Weight materials, these materials are very sustainable and eco-friendly
Often, when manufacturers consider managing adhesive applications, they focus only on the use of the adhesive.
However, diapers are an example that reveals the truth about this strategy: the use of adhesives only affects 3-
Accounting for 7% of the total cost of diapers.
But the cost of film and non-woven materials accounted for 30-
Diapers cost 40% of the total.
Therefore, by using the adhesive application device to reduce the weight of the film, you can greatly reduce the total cost of baby diapers. [
The picture above illustrates the concept behind variation management.
The orange line indicates the amount of adhesive required-
On, or the minimum amount of adhesive required to achieve the required function, usually the adhesive strength or creep resistance.
If the producer has a high degree of variation (blue line)
, They have to set their average output so that none of their valleys will be below the Orange Line.
Due to the large amplitude, the additional setting point of the average adhesive must be higher.
Peak value represents maximum added value
It can also represent the minimum bonding temperature and opening time that the web material must withstand.
When changes are small, producers can create a situation with effective change management, and they can set a much lower average added value
Your network material has to endure a lower peak. Less add-
On allows you to use lowcost, lower-
Weight of film or non-woven material.
There are two sources of change: Slope-up and steady-State change. Ramp-
When the adhesive application system has to catch up with the speed of the production line, an upward change occurs
Slowly rising from the queue-downor stop.
This is usually the overriding change that has to be addressed through higher add-on features
In order to ensure the minimum amount of glue, on the price.
Not only the extra adhesive
About the duration of the ramp that causes the manufacturer to use materials of higher weight-
Upward change also brings a lot of waste.
In order to ensure that the pressure of the adhesive application is restored to stability-
At the national level, manufacturers generally maintain a certain amount of their own \"elimination\" after slow
Stop or stop.
During this period, imperfect products were thrown away.
To illustrate the waste caused by this, on the production line that produces 1000 diapers per minute, remove
20 seconds means throwing away 333 diapers.
Now, multiply by the number of times the producer has to slow down or stop queuing every day.
A person can spend more than $100,000 a year cleaning up garbage. Steady-
Change of state refers to the change of adhesion agent
When a line runs at full speed.
This is usually due to cross
Network Distribution of adhesives assigned from multi-module applicator, or pressure fluctuations due to adhesive pressure of single-module adhesive applicator and hose scalability. [
Change management application device options for different adhesive application sets-
Ups, you have different coverage scenarios.
Usually on the disposable hygiene line-
It can expand and shrink with a compression-able adhesive inside-
Connect the adhesive melter to the applicator.
The most important or important change in this setting is the ramp-
Upward change, usually running at plus or minus 30%-compared to the average stability value-
State Change, 10-15%. [
The first solution is to build with pressure-
The up function in Hotmelter can keep the minimum glue pressure in the adhesive applicator when shutting down or slowing down.
During normal shutdown, all equipment including pumps and motors will be turned off. In this set-
Up, the pressure in the adhesive system is associated with the speed of the whole system, and sometimes the pressure may be zero if the line stops.
This is when the pressure begins to return to the Hot Melt melt. [
The line speed can rise faster than the pressure in the viscous system and can reach a stable-state.
Therefore, keeping the adhesive pressure stable will bring the adhesive slope
Duration consistent with the rest of the web ramp-up.
Typical savings for this option tend to be 5-10%.
While this option is the lowest cost of implementation, this feature is not included in all hot device control systems.
Another option for the remote metering station to manage changes is to install the remote metering station--
Variable speed motor-
Drive the gear pump outside the hot melter, close to the adhesive applicator.
Because the remote station is much smaller than melter, it can be closer to the application point and overcome the problem of longmelterto-
Apply hose length.
Remote metering stations can help overcome problems with ramps
Therefore, it is no longer an overriding source of variables that must be addressed, reducing your average additionon by 10-20%.
These savings are fully realized using a single-module application without cross-network distribution changes. In multi-
Modular applications where producers can take their changes to a level that is usually below the crossoverweb, or steady-
Because extra equipment is needed--
The solution represents an increase in investment.
But with such a huge waste and the potential to reduce costs, it is an investment that can be recovered quickly.
The first two options for managing the ramp are the metering applicator
This is a more traditional system of overriding changes.
But the third option is not just to get the gear pump close to the app, but inside the app.
Each module has a meter with a separate gear pump and optimized the temperature control, reducing the slope
Change and crossover
Changes in Web distribution are usually below 5%.
This solution causes about 25% reduction in the amount of adhesive addedon.
Upgrading to a metering applicator is a step towards further strengthening health and investment;
However, this solution justified the maximum cost savings.
As the cost of raw materials increases and the speed of the production line accelerates, the need to achieve better process control through the management of adhesive changes will continue to grow.
This is not the last word for variable management, just the latest one.
More change management technologies have been developed.
For most cuts, producers should check with their adhesive application technology providers-edge solutions. [
Optimized application technology provides another opportunity to reduce the weight of film and non-woven substrates.
Some notes can help you get started: peak bonding strength.
Standard deviation: peak adhesion strength is not the best measure of adhesion effect;
In order to achieve this goal, the change of binding strength and the peak of binding strength must be considered.
Some techniques can obtain higher peak bonding strength, but just because they have higher peak bonding strength does not mean that they have enough peak bonding to maintain the required bonding strength.
If producers need to use more adhesives to maintain the required adhesive strength, they do not achieve savings in adhesive use or film weight.
Precautions for breathable lamination: contact and non-contact
Contacttechnologies can provide breathability, but some technologies require higher Additional features
Heavier than others.
Some people use repetitive spray techniques to achieve breathability, which affects the feel and often requires higher added valueon rates.
On the contrary, considering industry standards, the technology of random pattern of content that allows lower adhesives to be added
A more comfortable product.
During the line stop, the contact applicator can be easily recovered. Their add-
After the reduction, the substrate with lower weight than the spraying application can be used.
Elastic considerations: the elastic coating is a key part of the diaper manufacturing process, because the elastic features largely determine the suitability of the product to the user. Too-tight or too-
Looseelastic can compromise product performance and customer satisfaction. Multi-
The Strand elastic coating can accommodate all types of elastic configurations, but it also uses the most adhesive and can lead to elastic creep.
Personalized spraying technology-
Especially those that use the overall elastic guide rail in the applicator nozzle to ensure that each chain is fully coated with a minimum adhesive ---are a cost-saving option.
General system: in order to position the production line as continuous, maximum change management efficiency, consider migrating the general platform to other platforms.
As part of a good preventive maintenance plan, the universal system not only simplifies the process of changing nozzles, but also means that manufacturers can upgrade easily-
And without the entire applicator. -
With the advent of new technologies.
Many people ignore the opportunity to increase profits even if material costs continue to rise.
From a strategic point of view * adhesive selection * Change Management * optimization of application technology starts because each line is unique and it may be a challenge to determine what strategy works best for each operation.
A good way to start is to use a tool that analyzes savings that producers can achieve by moving to a substrate with lower base weight based on material usage.
Here\'s a tool like this: go to this calculator and insert the parameters of youroperation to see your potential savings.
Then consult your adhesive equipment supplier to help you assess how low your cango is.
For more information about the Nordson Adhesive System, visit contactwww. nordson. com.