Bookbinding Adhesives Challenges

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This presentation by Tom Rolando, Chief Technical Officer at Wisdom Adhesives, covers challenges with bookbinding adhesives. It includes information on different types of adhesives used in bookbinding as well as outlines challenges and solutions for warping, adhesion including coated stock adhesion, case making and set time.

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Bookbinding Adhesives Challenges

  1. 1. Presented by Tom Rolando Wisdom Adhesives HBI/LBI 2010 Fall Conference – Springfield, IL October 23-26, 2010
  2. 2.  “I don’t like my salesperson”  “The adhesive smells”  “The labels aren’t on correctly”  “Pricing is too high”  “The product isn’t running like the last batch”  “The truck-driver was rude”  “We don’t pay on time”
  3. 3.  “The adhesive isn’t melting”  “The adhesive is drying too slow or too fast”  “I’m not getting the adhesion I need”  “The adhesives is too thin or too thick”  “Can I get this in a different container”  “Can the adhesive be made a different color”
  4. 4.  Use of the Adhesive  Protein Adhesive  Waterbased PVAc  Hot Melt  PUR  Warping  Coated Stock Adhesion  Case Making  Adhesion in General  Set Time
  5. 5.  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.
  6. 6.  Main Attributes ◦ Selection ◦ Runnability ◦ Adhesion  Main Properties ◦ Handling of the Adhesive ◦ Determining Success of the Adhesive  Main Goal ◦ Zero Defects
  7. 7.  Likely the single biggest issue for binders involving the use of adhesives.  Many factors involved including:  board  process  adhesive
  8. 8.  Much written, comparisons are general, specifics are limited.  Warping can be very costly involved re-working and/or re-binding of product.
  9. 9.  Binder is having difficulty with warping in the late winter months.  Resolution: Summit meeting called with Binder, Board Supplier, Equipment Supplier and Adhesive Supplier. ◦ Specify the moisture content of board and density. ◦ Apply consistent and minimal amount of adhesive for both case-making and casing-in. ◦ Control entire process for repeatability – conditions, speeds, application weights
  10. 10.  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).
  11. 11.  Many factors to consider including: ◦ type of coating ◦ surface tension of coating ◦ application equipment
  12. 12.  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.
  13. 13.  Protein Adhesives predominately used on case making.  Viscosity and adhesion are keys to success.
  14. 14.  Binder ordered new casing making equipment. Case making adhesive was not performing (runnability and poor adhesion) on the new equipment.
  15. 15.  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.
  16. 16.  Difficult to adhere to surfaces.
  17. 17.  Case-making adhesive not adhering to new coated stock.
  18. 18.  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.
  19. 19.  Binder having difficulty with line speeds on casing-in line during summer months. The adhesive appears to be setting slow.
  20. 20.  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.
  21. 21.  An ounce of prevention ◦ Can’t be emphasized enough. Nothing can be done once the product 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 and advanced testing a must.
  22. 22.  Selection of Adhesive Key to the Process.  Match Performance with Expectation Based on Ever-Changing Environments.  Change Mentality from Hating Adhesives to Loving Adhesives.
  23. 23.  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.

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