State-of-the-art hot melt adhesive combined with auto-feed system for safe and efficient delivery.
Keeping up with changing consumer demand requires products and systems with the ability to adapt to changing manufacturing needs. Fast-moving consumer goods use hot melt adhesives to keep production lines running at higher speeds for a variety of bonding needs. The challenge is keeping a steady flow of adhesive to the production lines without increasing manpower or experiencing changes in adhesive temperature or overfilling hot melt tanks.
Some of the most challenging consumer products are related to personal hygiene applications. The product construction includes multiple substrates, from non-woven materials to plastic barriers, and it can be challenging to find the right mix of products. In addition, consumers demand absorbency, softness, low odour and discreetness, which adds another layer of complexity. Both large and small brand owners agree that the top priority for personal hygiene applications is quality and safety.
Henkel offers customers Easyflow® to solve their production challenges. Built around an innovative hot melt adhesive formulation, Easyflow® sets a new standard in process performance and efficiency.
Easyflow® is a patented adhesive delivered in small, non-sticky, and easy-to-handle mini chubs. The protective coating does not compromise application or end-performance and is 100% compatible with the adhesive. The unique form enables automatic feeding into hot melt tanks, improving production line efficiency while minimizing downtime and material handling.
The Easyflow® mini chubs are conveyed by air from a reusable bag into hot melt tanks and applied onto the nonwoven substrate. The adhesive is designed to be stored away from the line, avoiding manual handling. Easyflow® offers a complete solution with flexible equipment configurations to meet the unique requirements and space constaints of each manufacturer.
Jeremy NOEL, Adhesive Manager, Celluloses de Brocéliande
Production line operators have many tasks to accomplish during each shift. Troubleshooting common hot melt adhesive challenges—from char formation and tank levels to poor substrate coverage and adhesive bleed-through—should not be consuming excessive amounts of time. Production efficiency is a balance of good processes and well-suited materials. For personal hygiene applications, understanding the hot melt adhesive characteristics and performance is important to eliminate common process challenges. Easyflow® is designed to work efficiently and avoid these issues.
Easyflow® brings three main benefits for consumer goods manufacturers to keep productions lines moving and reduce downtime. The unique product form helps establish a robust production line to support improved efficiency, resolve application issues and make it easier for line operators.
Eliminating manual handling of hot melt adhesive tank filling in personal hygiene applications is an easy way to increase efficiency and offer a cleaner and safer work environment for employees.
Improving how the hot melt adhesive equipment operates keeps production moving and results in less maintenance. Easyflow® preserves the heat history and doesn't experience the temperature fluctuations of other hot melt adhesives.
External pollutants can impact the performance of the hot melt adhesive and associated equipment. The Easyflow® closed system requires less maintenance and reduced downtime.
Knowing the basic safety precautions when working with hot melt adhesives is important to keep line operators safe. Changes in shifts and the arrival of new employees leaves room for errors or omissions. An important part of safety is keeping the equipment well maintained and the production area clear of debris and melted adhesive. The fast production lines for personal hygiene applications require the equipment to be maintained and the adhesive closely monitored to avoid contamination in the hot melt adhesive tanks.
Easyflow® is designed to integrate into a hot melt adhesive auto-feed system which is closed to eliminate contaminants. The auto-feed feature improves the safety of production line operators by eliminating manual handling of hot melt adhesive and exposure to the high temperatures. When manufacturing personal hygiene products, it supports a cleaner and safer working environment. Additionally, the closed system avoids contaminants in the system and reduces maintenance on the equipment with improved uptime for production.
Easyflow® combines three unique features to increase operational efficiency for personal hygiene applications. The new melt-on-demand adhesive form enables auto-feeding within a closed system and results in:
- Reduced risks and manual product handling for operators
- Decreased operating costs
- Improved quality and output
Our mini chubs set a new standard in performance and efficiency. Learn how our mini chubs can make a big difference in your production lines.
Adhesive-related downtime is often caused by viscosity drift, char formation, nozzle clogging, inconsistent adhesive supply, and manual handling processes. At line speeds of more than 700 products per minute, even short interruptions can have a significant impact on output and efficiency.
Manufacturers can reduce downtime by stabilizing the adhesive process window, minimizing thermal degradation, and reducing operator-dependent interventions. Automated adhesive feeding and melt-on-demand systems can help maintain more consistent adhesive conditions, reduce contamination risks, and support more reliable production performance.
The purchase price of an adhesive is only one part of its total economic impact. Downtime, scrap, maintenance requirements, energy consumption, adhesive usage, and product quality can contribute significantly more to overall manufacturing costs than the adhesive price itself.
For this reason, many manufacturers evaluate adhesive solutions based on total cost of ownership (TCO). A stable adhesive process that supports higher uptime, lower waste, and consistent quality can generate greater value than a lower-priced adhesive that introduces variability into production.
Maintaining a consistent adhesive application process requires viscosity stability. Excessive viscosity fluctuations can lead to poor spray patterns, inconsistent bonding, increased clogging, and even visible defects to consumers.
When viscosity remains stable across the operating temperature range, manufacturers can achieve more reliable bonding, fewer production interruptions, and improved product quality. As a result, viscosity stability can directly support the three key components of OEE: availability, performance, and quality.
Common causes of adhesive application failures include temperature instability, viscosity drift, char formation, nozzle contamination, inconsistent adhesive add-on, and excessive thermal exposure. These issues can lead to weak bonds, delamination, leakage risks, or product quality inconsistencies.
Many of these challenges are linked not only to adhesive formulation but also to how the adhesive is stored, melted, supplied, and applied. A stable adhesive delivery process can help minimize variability and improve overall production reliability.
Consumer sensitivity to odor continues to increase, particularly for products that remain in close contact with the skin. Adhesives can influence odor performance through their raw material composition, VOC profile, thermal stability, and processing conditions.
Reducing thermal exposure during processing can help limit the formation of odor-causing degradation by-products. Combining low-odor adhesive technologies with controlled adhesive handling can support more consistent product quality and reduce the risk of odor-related complaints.
Low-VOC adhesives help manufacturers address growing expectations regarding consumer safety, product quality, sustainability, and regulatory compliance. VOC performance is increasingly considered during audits, supplier evaluations, and product qualification processes.
Adhesives with low-VOC and low-odor characteristics can support compliance requirements, reduce complaint risks, and contribute to a more controlled and predictable production environment.
Melt-on-demand systems heat only the adhesive required for production rather than maintaining large adhesive volumes at elevated temperatures for extended periods. This can reduce thermal stress on the adhesive and help preserve its performance characteristics.
Potential benefits include improved viscosity stability, lower char formation, reduced maintenance requirements, more consistent adhesive application, and lower energy consumption. For high-speed hygiene production, melt-on-demand technology can be an effective way to support process stability and operational efficiency.
Automated adhesive feeding systems can help reduce manual handling, maintain a more consistent adhesive supply, and decrease process variability. By eliminating many of the interruptions associated with manual loading, manufacturers can improve process stability and reduce the likelihood of operator-related inconsistencies.
Automated feeding can also support higher uptime, lower maintenance requirements, and more predictable production performance by helping ensure a continuous and controlled adhesive supply.
Traditional adhesive handling methods often require large volumes of adhesive to remain at elevated temperatures for long periods. Automated handling and melt-on-demand concepts can increase the melting speed, reduce the amount of adhesive held under heat and help avoid unnecessary energy use.
In addition, controlled adhesive supply can help reduce material waste, limit thermal degradation, decrease packaging waste, and improve adhesive usage efficiency throughout the manufacturing process.
Consistent adhesive performance depends on maintaining stable process conditions. Variations in temperature, adhesive supply, thermal exposure, and manual handling can all contribute to process instability and inconsistent bonding results.
Automated adhesive systems are designed to provide a more controlled adhesive supply and reduce process variability. By supporting stable operating conditions, they can help manufacturers achieve more predictable adhesive application, improved product quality, and more consistent production performance over time.
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