“Bookbinding Adhesives Challenges”

Presented by Tom RolandoWisdom AdhesivesHBI/LBI 2010 Fall Conference – Springfield, ILOctober 23-26, 2010

Everybody Hates Their Glue “I don’t like my salesperson”

“The adhesive smells”

“The labels on the adhesive container aren’t displayed correctly”

“Pricing is too high”

“The product isn’t running like we are used to and nothing has changed!”

“The truck-driver was rude”

“We don’t like the payment terms”

Everybody Hates Their Glue “The adhesive isn’t melting fast

enough”

“The adhesive is drying too slow or the adhesive is drying too fast”

“I’m not getting the proper adhesion”

“The adhesives is too thin or the adhesive is too thick”

“Can I get the adhesive in a different container”

“I don’t like the color of the adhesive, can we get the adhesive made in a different color”

Proper use of the Adhesive by Technology

Warping Coated Stock Adhesion Case Making Adhesion in General Set Time

Most Common Adhesives Challenges

Main Adhesive Technologies◦ Protein Adhesives

Finicky to run, susceptible to swings in the environment (summer/winter versions), moderate adhesion capabilities.

◦ Waterborne PVAc Adhesives Removal of water, set times.

◦ Hot Melt Adhesives Runnability (degradation, charring), adhesion to

difficult surfaces, brittleness.◦ PUR Adhesives

Runnability, Reaction to moisture.

Use of the Adhesive (Simple as )

Use of the Adhesive (Simple as )

Main Attributes◦ Selection◦ Runnability◦ Adhesion

Main Properties◦ Handling of the Adhesive◦ Determining Success of the Adhesive

Main Goal◦ Zero Defects

Likely the single biggest issue for binders involving the use of adhesives.

Many factors involved including:

board process adhesive cover material

Warping

Warping Knowledge is out

there, but comparisons are general, specifics are limited.

Warping can be very costly involving re-working and/or re-binding of product.

Binder is having difficulty with warping in the late winter months.

Resolution: Summit meeting called with Binder, Board Supplier, Equipment Supplier Adhesive Supplier and Cover Material Supplier.◦ Specify the moisture content and density of

board. Specify Cover Material.◦ Apply consistent and near minimum amount of

adhesive for both case-making and casing-in.◦ Control entire process for repeatability –

conditions, speeds, application weights

Warping - real life example

Adhesion to coated stock can be difficult.

Gloss, matte and plastic films (mainly PP, Nylon, PET) is difficult with all types of adhesive technologies (protein adhesives, waterborne PVAc adhesives, hot melts and PURs).

Binding to Coated Stock

Many factors to consider including:

◦ type of coating◦ surface tension of

coating◦ application

equipment

Binding to Coated Stock

Binder having difficulty with coated stock adhesion with hot melt spine adhesive.

Same coated stock, same hot melt adhesive as always used.

Resolution: Lab testing demonstrated that the coated stock had varied from previously used stock. Alternate hot melt used in the interim until stock depleted. Pre-testing saved the day.

Long-Term Solution – Binder putting in waterbased priming station (or additional hot melt priming station) as well as “roughing” station.

Binding to Coated Stock - Example

Protein Adhesives predominately used on case making.

Viscosity and adhesion are keys to success.

Case Making

Binder ordered new casing making equipment. Case making adhesive was not performing (runnability and poor adhesion) on the new equipment.

•Case Making - Example

Resolution: On-site meeting with OEM, Adhesive Manufacturer and Binder to map out plan. Adhesive change to faster set and lower viscosity resolved runnability and adhesion issues.

•Case Making - Example

Difficult to adhere to surfaces.

Adhesion Issues

Waterbased adhesive not

adhering to new coated stock.

Adhesion Issues - example

Resolution: Know the surfaces you are bonding to.◦ Pre-testing the new

surface for adhesion to ensure current adhesive will work (it didn’t).

◦ Ask for help (supplier intervention).

◦ New product suggestion made, pre-test successful, scale-up on product.

Adhesion Issues - example

Set Time Issues

Binder having difficulty with line speeds on casing-in line during summer months. The adhesive appears to be setting slow.

Set Time Issues - example

Resolution: Conference call with the board and adhesive suppliers.◦ Higher humidity

environment means a change in conditions.

◦ Options are change environment, board moisture/density content or use summer & winter month adhesive. The later chosen.

Set Time Issues - example

An ounce of prevention◦ Can’t be emphasized

enough. Not much can be done once the book is made.

Advanced testing◦ A must for any new items

or for troubleshooting existing ones.

Co-Supplier Meetings◦ Best approach to resolution

of issues, prevention – making advanced testing a must.

Keys to Success

Consistency is the key, know what variables in the process and materials that can be controlled and those that will vary.

Selection of Adhesive Key to the Process. Match Performance with Expectation Based

on Ever-Changing Environments. Change Mentality from Hating Adhesives to

Loving Adhesives.

Wrap Up

Looking for a Greener Adhesive?

Looking for a Greener Adhesive?

Address each challenge from a new perspective.

Gather all applicable information:◦ Bonding what to what (determines adhesive technology)◦ Type of application equipment (determines physical property

of adhesive)◦ Expectation (determines performance properties like rate of

set, open time, application weight, etc.., economic impact)

Do it right the first time, however, be ready for ever-changing parameters.

The Wisdom Way

Thank You