A Range of Metallocene Hot-Melt Options Available

Metallocene-based hot-melt adhesives not only offer superior performance properties, but also provide manufacturers with a range of product options and capabilities:

Mettalocene

  • High-melt metallocene: Applied at 350 degrees Fahrenheit, this gives production operators a smooth-flowing, consistent, and trouble-free adhesive solution for a wide variety of product operating requirements;
  • Low-melt metallocene: Applied at 250 degrees Fahrenheit, this melts to a lower viscosity, so the same amount can be applied at lower pressure, increasing mileage. Low-melt also offers machine operators the added safety feature of working with adhesive at a safer, lower application temperature
  • Packaging-specific metallocene: Formulated for a wide variety of specialized box, carton, tray, and packaging materials, including corrugated plain and inked, coated and uncoated stocks, paper bag stocks, trays, frozen food and ready-made meals packages, and other packaging stocks and configurations.

Next Time: A new Metallocene option

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

Comparing Costs: Metallocene vs. EVA Hot Melt Adhesive

Previous posts outlined the advantages of metallocene-based adhesives compared to traditional EVA-based hot-melt adhesives.

But what about cost?

Metallocene-based hot-melt adhesive may initially cost more than EVA-based hot melt adhesive. However, the costs associated with problems from char-prone EVA can erase any initial cost savings you may have received.

Costs from problems with char buildup can include:

  • Production downtime expense: Usually the highest cost, which can be calculated from hundreds to thousands of dollars per hour, depending on the operator’s production environment
  • Product defect costs: Packaging defects due to poor carton adhesion, which lead to pop-opens and other package failures throughout the distribution chain, can be a significant ongoing expense, leading to additional negative impacts from lost and damaged products, negative effects on customer goodwill, and potential liability cost

Replacement adhesive applicator parts and service cost: When charring conditions reach the point where the adhesive application system can no longer be cleared, hoses, nozzles, and other affected parts of the system must be replaced, usually at a significant cost in new applicator components and additional costs per hour of service expense.

CharvsClear

Next Time: Choosing the right Metallocene

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

Key Benefits of Metallocene-Based Adhesives (Part 2)

The previous post covered several key advantages of metallocene-based adhesives compared to traditional EVA-based hot-melt adhesives.

Metallocene Benefits 2

Here are several more metallocene advantages:

  • Can be used with a wide variety of coated and uncoated package stocks: The superior adhesion performance of metallocene-based hot melt makes it versatile for application to a wide variety of coated and uncoated paper packaging and corrugated stock. Because of this versatility, metallocene is especially suited for application to coated stock used in frozen food products.
  • Better penetration over heavy ink surfaces: Compared to EVA-based adhesive, metallocene adhesive provides deeper penetration of packaging surfaces which have heavy ink coverage. This deeper adhesive penetration provides greater package and carton sealing assurance and reliability.

Next Time:  Cost Advantages of Metallocene

 

Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

Key Benefits of Metallocene-Based Adhesives (Part 1)

Metallocene-based hot melt adhesives offer several key advantages compared to traditional EVA-based hot-melt Metallocene Benefits 1adhesives:

  • Improved mileage: Because metallocene-based adhesives have a lower density than EVA-based adhesives, they can be applied at lower flow rates, often yielding up to 40% reduction in adhesive use compared to EVA.
  • Precision application: Since viscosity of metallocene hot-melt does not increase during its pot life, it gives operators more precise control over flow, bead size, and bead quality, so adhesive application can be continuously optimized for maximum economy.
  • High and low-temperature performance: Metallocene-based adhesive provides superior bonding strength across a wide range of temperature variations, offering resistance to both high temperatures and freezing cold. This performance makes metallocene a strong choice for frozen food packaging applications, as well as for many packaging, carton, and box applications requiring resistance to wide temperature fluctuations

Next Time:  More Key Benefits of Metallocene-based Adhesives.

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

One Solution to the Problem Of Char: Metallocene-Based Adhesives

Clear with MetalloceneIn the past few years metallocene-based polymer hot-melt adhesives have become more widely available in the marketplace, and more affordable for use in the packaging field.

Metallocene-based hot melt offers superior performance and char-free operation, because the chemical composition means they are not subject to carbon buildup, gelling, or any other changes over extended high temperature storage and use.

As a result, metallocene-based adhesives can be stored indefinitely in glue tanks at high temperatures. The glue will flow clearly at all times through the application cycle, without char buildup or any other material change. Also, unlike EVA-based adhesive, metallocene-based adhesives won’t cause poor or blocked adhesive flow through pumps, hoses, or nozzles.

Next Time: Key Benefits of Metallocene-based Adhesives.

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

Preventive Maintenance Can’t Solve Char Buildup

Preventive maintenance, which involves systematic monitoring and periodic flushing of the adhesive application system, can substantially reduce the incidence of charring and gelling and extend the life of applicator hoses and extrusion nozzles.

However, the unfortunate fact is that charring is an inherent problem with EVA-based adhesives (see previous posts). No matter how diligent the preventive maintenance program, charring will eventually occur in any hot melt system using EVA-based adhesive kept at an operating temperature above 350º for prolonged periods. Since prolonged high temperature operation naturally occurs in any production environment, char resulting from EVA will eventually pose a problem, regardless of the steps taken to prevent it. (Read more about the impact of char.)

In some cases, the maintenance required when using EVA is considered part of the cost of choosing this type of adhesive. However, in other cases, finding an alternate adhesive may address some of the drawbacks inherent with EVA-based adhesive.

Next Time:  One Solution to the Problem of Char.

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

The Problem of Char: Negative Effects

Before char is apparent oChar Clogs Hoses and Nozzlesr clogging occurs, char creates a thermal barrier in hose linings. This lowers the optimal operating temperature of the adhesive, causing poor flow performance. When your system applies more heat to compensate, even more char build up results.

When char buildup occurs, pieces break loose in your application system. These pieces clog applicator hoses and nozzles, causing uneven adhesive application and eventually, production stoppages. (Read more about Common Causes of Char.)

Even when charring isn’t immediately visible, hidden char deposits contribute to poor adhesive application due to clogged or char-degraded tanks, hoses, or nozzles. This leads to improperly and insufficiently glued packages, plus unsightly char deposits on packaged products.

Next Time:  Can char build-up be prevented?.

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

The Problem of Char: Common Causes

Ethylene vinyl acetate (EVA) adhesive is widely used for packaging hot melt applications. However, because of its chemical composition, EVA tends to develop carbon buildup, or char, inside of adhesive application tanks, lines, hoses, and nozzles.

Char — carbon buildup — occurs when EVA oxidizes at prolonged high temperatures above 350º. This heat and oxidation reaction creates carbon buildup during idle periods when adhesive is not flowing through the system, due to degradation of the EVA.

During packaging operations, Char Clogs Applicatorsince adhesive which flows closer to the walls of a hot melt applicator hose moves more slowly than the adhesive flowing in the center of the hose, adhesive nearer to the outer wall of the hose wall tends to degrade more readily, becoming thicker and sticking to the inner walls of the hoses, and eventually forming char on the inside of the hoses, adhesive tank, and nozzles of your hot melt adhesive application system.

 

Next Time: What happens when char is present.

(Excerpted from “No More Char”, a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

Dextrin vs. Resin Part 2: With Hybrid Adhesives, You Don’t Have to Make a Choice

Hybrid adhesives combine the flexibility of resin-based adhesive with the lay-flat attributes of dextrin-based adhesives to solve many of your moisture-related production problems. (Read more here.)

One such hybrid — Evans Adhesive’s ResDex™ — is suitable for the majority of litho lamination jobs, and provides key advantages compared to resin-based adhesive.

  • ResDex hybrid adhesive benefitsProduction speeds are equal to those for resin-based adhesives, so production rates will be unaffected by the changeover.
  • Hybrid adhesives can be applied at a lower thickness (as low as 6 lbs. per M.S.F compared to 8-9 lbs. per M.S.F for dextrin-based adhesive), lowering material costs for each job.
  • Hybrids are approximately 10-20% less expensive than resin-based adhesives.
  • Unlike resin-based adhesives, hybrid adhesives do not cause early deterioration of neoprene bands in your Automatän machine; this saves repair cost and downtime in your production flow

With hybrid adhesives, you no longer have to make tradeoffs between the speed of resin and the easier workability of dextrin: This is one instance where you can truly have the best of both for the majority of your litho lamination projects.

(Excerpted from “Fighting Warp,” a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

Dextrin vs. Resin Part 1: With Hybrid Adhesives, You Don’t Have to Make a Choice

Benefits of Hybrid AdhesivesUsing dextrin-based adhesive potentially increases the risk of warping. Fortunately, there is a workable adhesive solution for most of your litho lamination projects that also greatly reduces the risk of warp and other moisture-induced problems.

Hybrid adhesives, which contain a mix of both dextrin and resin emulsion, combine the flexibility of resin-based adhesives with the lay-flat attributes of dextrin-based adhesives. These formulations have been problem solvers in many litho lamination jobs.

Hybrid adhesives, such as Evans Adhesive’s ResDex™, are suitable for most litho lamination jobs, and provide key advantages compared to resin-based adhesive.

With hybrid adhesives, you have the advantages of both for your litho lamination projects.

(Excerpted from “Fighting Warp,” a recent issue of Evans Adhesive Solution Advisor. Download entire issue here.)

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