Contamination in the production environment during the adhesive process.
Context of the problem.
AKAB came straight to BIT Hotmelt Technology when they encountered issues in their production process. As a family-owned company specializing in custom-made interior doors, AKAB has perfected an efficient manufacturing process through high levels of automation and robotics, ensuring top quality without compromise.
However, during production, the company faced a significant challenge related to the adhesive application process. The use of PU Hotmelt adhesive caused excessive contamination in the production environment, leading to frequent and intensive cleaning. This resulted in high adhesive waste and production downtime, requiring up to two hours per day just for cleaning the equipment and production area.
Additionally, AKAB experienced frequent malfunctions and inconsistent adhesive coverage, affecting overall efficiency. To increase production capacity and reduce cleaning time, optimizing the adhesive process became a top priority.
Case-Specific Challenges.
Contamination of the production environment
The adhesive head is not properly adjusted, causing overspray and leaving significant contamination after use. This excess adhesive accumulates on the equipment, requiring additional cleaning.
Adhesive loss and waste
The adhesive head cannot adjust to the size of the door, resulting in significant adhesive waste during production. This is not only costly but also leads to a less sustainable manufacturing process.
Malfunctions and downtime during production
Without a continuous flow in the adhesive process, especially during drum changes, production can be delayed, reducing overall productivity.
Solutions BIT Hotmelt Technology.
AKAB enlisted BIT Hotmelt Technology to jointly improve the adhesive process and reduce adhesive waste. The solutions provided by BIT Hotmelt Technology include:
- New adhesive head for reduced contamination & more efficient adhesive application
The advanced adhesive head eliminates contamination in the production environment and ensures precise, even adhesive application on the doors. It automatically adjusts to different door sizes, preventing adhesive waste and optimizing efficiency. - Upgraded Hotmelt unit – Macro 50-4 PUR
By installing a new Hotmelt unit between the existing drum melter and the new adhesive head, the adhesive process can continue uninterrupted during drum changes. The tank of the Hotmelt unit maintains a sufficient supply of molten adhesive, allowing drum changes to take place without production downtime. Additionally, the high-capacity pump ensures a consistent adhesive flow, guaranteeing a stable adhesive application from start to finish. - Swirl modules for a maintenance-free process
By integrating swirl modules with needle shut-off technology and precisely programmed adhesive and air control, the adhesive process becomes fully maintenance-free, ensuring continuous availability of the equipment.
Our achievements.
- Contamination in the production environment reduced to zero.
- Savings of 2 hours of cleaning per day.
- No adhesive waste due to the new adhesive head.
- Continuous adhesive process enabled by the new Hotmelt unit.
- Fully maintenance-free adhesive process.
”Thanks to BIT Hotmelt Technology, we can operate smoothly without issues. We highly recommend BIT Hotmelt Technology to solve problems in your production process!
MichelOwner - CEO
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