Streamline Supply Chain with Hot Melt Adhesive

In today’s crowded market coupled with high consumer demand, speed is everything when it comes to order fulfillment. The more a company can shorten the time between when a customer orders their product and when the customer receives it, the more competitive that company will be. Depending on the size of your own company, you might find it more difficult to compete when space and budget limitations require you to manufacture products on demand. In situations like these, using hot melt adhesive systems for product assembly can greatly streamline your supply chain, helping you stay toe to toe even with your larger competitors.

Challenges with Smaller-Scale Manufacturing

For many companies, the problem with their supply chain boils down to a cascading set of events that essentially “clogs up the works” can cause a backlog. To illustrate, consider the following scenario:

Suppose your startup company makes and sells affordable modular furniture targeted to college-age and young adult buyers. Due to a combination of budget constraints, space limitations and a desire to manufacture your products here in the U.S., you opt for an on-demand manufacturing model. Suppose your launch goes quite well and you get a large number of orders at once. Now you have a problem: Your water-based adhesives take at least a day to cure, and you don’t have the storage space for more than a few pieces at a time. Suddenly, you’re faced with having to tell half your customers that their products will be delayed—and since they’re sitting on the floor of their empty apartments waiting for their furniture, they’re not likely to be pleased. They cancel their order and go to your competitor, who guarantees delivery in two days.

Hot Melt Adhesives Provide the Solution

What could have prevented the backlog in your supply chain as described above? Simple: Shorten the drying time of your adhesives. This is where hot melt adhesives can help.

Unlike water-based adhesives which take a day or longer to dry, hot melt adhesives cure within minutes — and they are every bit as strong and durable as their water-based alternatives. By installing a high-quality, well-designed hot melt system, you can greatly shorten the amount of time it takes to make your products, and depending on what you’re manufacturing, you may be able to fulfill orders within hours, rather than days. As you might imagine, this streamlined approach typically results in much greater customer satisfaction and customer loyalty.

If space and workflow limitations are hindering your ability to compete in a high-demand market, it might be time to streamline your supply chain with a hot melt adhesive system. Sure Tack Systems can help you configure a system perfect for your manufacturing needs, and we provide stellar customer support, technical support and training to ensure that you’re getting the most benefit from your system. To learn more, call us today at 800-580-2803.


How Bed-in-a-Box Mattresses Are Produced

Over the past decade, bed-in-a-box mattresses have been taking the world by storm. With all the typical headaches involved in mattress shopping — from visiting the showroom and choosing a mattress to expensive delivery and setup costs — the idea of receiving a compressed foam mattress shipped to one’s home in an easy-to-handle box appeals to millions of consumers. From the original Bed-in-a-Box created in 2007, we now have close to 200 companies now following the same model — and demand continues to increase.

Obviously, with all these companies now contending for market share, the field has become quite competitive, and manufacturers are now under increased pressure to get their mattresses built and shipped more quickly than ever. For a business model that essentially builds mattresses on demand, this presents some unique challenges, causing some to re-think how their bed-in-a-box mattresses are produced. Many have discovered that using hot melt systems for product assembly can greatly shorten the amount of time it takes to build and ship a mattress. Let’s take a look at how these mattresses are made and how hot melt systems can reduce production time.

The Manufacturing Process

For many bed-in-a-box companies, if not most, their mattresses are made to order, and construction doesn’t begin until the customer places an order online. The reasons for this range from customization options to logistical space (many of these boutique companies don’t have room to store large amounts of inventory). Each mattress is constructed of state-of-the-art memory foam which has the ability to be highly compressed and rolled for shipping. The biggest delay in the manufacturing process is in applying the adhesives to build the mattress itself — water-based adhesives require 24 hours or more for curing. When a company has limited space, they can only cure so many mattresses at a time, which can cause even more delays in the supply chain. Before long, customers get impatient. Needless to say, a company that can overcome these delays and streamline the manufacturing process can be highly competitive.

Some companies have overcome this challenge by using hot melt adhesives in place of the standard water-based adhesives. Hot melt adhesives are just as effective and enable the same level of quality in bed-in-a-box mattresses — they just cure much more quickly. Using a hot melt system, a manufacturer can produce, compress, roll and ship a bed in a box within hours, rather than days, greatly streamlining their workflow and keeping customers happy in the process.

Sure Tack offers an array of hot melt systems that are perfect for companies looking to streamline their production. If you’re a bed-in-a-box company or another manufacturer looking to shorten your turnaround time, a hot melt adhesive system can greatly accelerate your manufacturing process without impacting quality control. To learn more about whether a hot melt system is right for you, call us today at 800-580-2803.


Why Choose Hot Melt Adhesive for On-Demand Manufacturing?

These days, more and more companies are moving away from stock production and instead gravitating toward on-demand manufacturing. This comes from a need to improve the efficiency and cost-effectiveness of supply chains in an economy increasingly dominated by online retail. This shift is a stark contrast to the days when large quantities of a product used to be constructed on assembly lines and then kept in storage facilities for weeks or even months until they are ready to be shipped to a customer. Hot melt adhesive systems are a critical component of much on-demand manufacturing, but before we get into why, let’s dive a bit deeper into the benefits of on-demand manufacturing for product assembly operations.

  • Ensures a speedy, responsive turnaround. Depending on the type of item, products can often be constructed on-site and shipped off to a store (or in some cases, a direct customer) on the same day an order is placed.
  • Reduces overhead costs by saving on storage space. There’s no need to store large quantities of products for multiple weeks or months since everything is shipped soon after they come off the production line.
  • Cuts down on product markdowns and waste. With on-demand manufacturing, you never need to produce more product than you need. That means you can reduce the amount of product you must discount or throw away.

The Role of Hot Melt Adhesive in On-Demand Manufacturing

With on-demand manufacturing, speed is the name of the game. Once an order is received, the goal is to build the item, package it, and ship it out within the same day. Having a hot melt adhesive system on your assembly line for constructing products makes this possible. Hot melt adhesive is simple and easy to apply to a variety of materials, and best of all, it cures incredibly fast (it’s dry to the touch within seconds). This represents a stark contrast to other methods for adhering products on an assembly line. For example, a water-based adhesive can take 24 hours or more to fully cure, which can really bog down the process and cause logistical storage headaches. After all, where are you going to store all this product while you wait for the water-based adhesive to cure?

Mattress manufacturers are one industry that relies on the speedy qualities of hot melt adhesive to fulfill on-demand production goals. Both traditional mattress companies and newer bed-in-a-box online mattress retailers benefit from hot melt adhesive’s ability to speed up production and fulfill orders quickly. Mattresses can be constructed and then loaded directly from production lines onto trucks that ship them out the same day the order was received.

Ready to streamline your company’s manufacturing process? A hot melt adhesive system is ideal for constructing products in an on-demand manufacturing setting. As an industry leader in hot melt adhesive application equipment, Sure Tack Systems’ hot melt glue systems are reliable, simple to operate, and easy to maintain. Contact us to learn more about how a hot melt adhesive system can improve the bottom line of your company’s manufacturing process.


Hot Melt Adhesive Revolutionizes Bed-in-a-Box Mattress Manufacturing

Bed-in-a-box mattresses are becoming more popular than ever as customer purchasing behaviors shift from brick and mortar mattress stores in ecommerce-based mattress retailers. Instead of worrying about physically driving to a mattress store, enduring sales pitches, wondering if you’re getting a good deal, and then dealing with transporting your mattress, these bed-in-a-box companies are simplifying the process for all parties involved.

The bed-in-a-box mattress industry has exploded over the past five years, but the concept actually dates back to 2007 when a Nashville-based entrepreneur named Bill Bradley built the first machine designed to compress and tightly roll foam mattresses for simple shipping. This piece of equipment was key in the founding of Bradley’s mattress business, Bed in a Box, and it was long before other major bed-in-a-box companies — like Casper and Tuft & Needle — threw their hat in the ring.

Fast forward to 2019 — there are now nearly 200 online mattress manufacturers that follow the bed-in-a-box model for compressing, rolling, and shipping foam mattresses direct to customers. These companies represent about 12 percent of the mattress market (it was only 6 percent in 2014). As this niche market grows in dominance, bed-in-a-box mattress businesses are looking for new ways to innovate their product assembly and improve the experience of customers.

One way bed-in-a-box companies are streamlining their manufacturing process is by switching from water-based adhesive to hot melt adhesive for adhering the mattress’ multiple foam layers. How? Well, it all comes down to curing time.

Bed-in-a-box mattresses are often built to order, which means that when a customer orders a mattress, the company immediately gets to work on constructing the mattress before compressing, rolling, and boxing it up to be shipped. If a company is using water-based adhesive during the construction phase, they must wait a minimum of 24 hours for the adhesive to fully cure before it can be compressed and rolled. This poses two problems. First, water-based adhesive slows down foam mattress production. Second, water-based adhesive requires a bed-in-a-box manufacturer to have enough space to store multiple mattresses while they undergo curing process. Given how large mattresses are, that’s a lot of space if you’re flooded with hundreds of customer orders per week.

That’s where hot melt adhesives come in to save the day. Unlike water-based adhesives, hot melt adhesives cure incredibly fast. When applied to mattresses, hot melt adhesive will dry within a few seconds, as opposed to a day or more. This means bed-in-a-box mattress companies are able to construct, compress, roll, and ship a mattress within several hours of receiving a customer’s order.

Ready to maximize the efficiency of your bed-in-a-box mattress manufacturing process? A hot melt adhesive system is the way to go. Sure Tack Systems is an industry leader in hot melt adhesive application equipment. Our hot melt glue systems are reliable, simple to operate, and easy to maintain. Contact Sure Tack Systems to learn more about implementing hot melt adhesive into your bed-in-a-box manufacturing process.


Hot Melt Adhesive System Training by Sure Tack Systems

From the moment you install a Sure Tack hot melt adhesive system in your facility, it’s understood that machine is going to be put under constant strain. You have products to make, orders to fulfill, clients to satisfy, a business to grow.

The good news is that our adhesive systems are built to withstand the demands of your business. The bad news is that even the best-made equipment can experience problems. Parts wear out over time and under stress, an employee might use the machine incorrectly, or any of a hundred other factors might throw a wrench into the works—metaphorically speaking. That’s why, in addition to creating products built to endure 24-7 wear-and-tear, we also provide an extensive support system for your Sure Tack hot melt adhesive system, including one-on-one training and ongoing technical support.

Benefits of Training

Time is money, and when your manufacturing goes down, you’re losing potential revenue every minute. With our hot melt adhesive systems, proper training on the equipment can actually help prevent breakdowns or stop them before they start. Sure Tack stands apart by providing one-on-one training, free of charge, over the life of your system. This training helps you and your team understand how the machinery works, not only so it gets used effectively, but also so if something goes wrong, you’ll know where to look for the source of the problem.

What are some of the benefits of our hot melt adhesive training schools? Let’s look at a few:

  • Combined team and one-on-one instruction. Our instructors can train your team on the equipment, but also one-on-one. This ensures no question goes unanswered and that each employee using the system fully understands how the system works.
  • Customized training. No generic, cookie-cutter curriculum here. Our training is not geared specifically to the equipment you have purchased and installed, ensuring that you’re not wasting time and brain space on the information you don’t need.
  • Learn preventative maintenance. We don’t just teach you how to use the equipment; we also teach you how to take care of it. Preventative maintenance is important for your hot melt equipment because it extends the life span of your system and helps you stop problems before they start. (This benefit alone can save you thousands in maintenance costs.)
  • Ongoing training support. Our training benefit is free for the life of your machine. That means if you hire someone new after we’ve finished the training, we’ll come back out and train them. For free. For as long as you own the system.

Additional Technical Support

Hot melt adhesive systems are complex machines with many moving parts. Even with the level of training we provide, every so often you may encounter a problem you don’t know how to solve. Since moments count when it comes to downtime, we back up your training with 24-7 technical support for your hot melt adhesive system. No matter what time of day or night you encounter a problem, our experts are available to help.

Providing Sure Tack hot melt adhesive system training is just one of the ways Sure Tack Systems stand out in customer service. To learn more about our systems and the training we provide, contact Sure Tack Systems today.


FAQs About Hot Melt Adhesive Systems

Trying to figure out the right hot melt adhesive system for your needs? Have questions you need to be answered? Here are some common questions asked about our industry and products:

What are hot melt adhesives?

Hot melt adhesive, sometimes referred to as “hot glue,” is a thermoplastic material that is solid in normal conditions yet moldable under heat. In industrial settings, they are popular adhesive choice for product assembly because they can bond materials together quickly. Want to learn more about hot melt adhesives? Read our article, “What Are Hot Melt Adhesives?”

What is a hot melt glue system?

A hot melt glue system is used to dispense thermoplastic adhesive for use in a variety of product assembly industries, including the manufacturing of mattress, carpeting, cars, cardboard boxes, textiles, and more. Want to learn more about hot melt glue systems? Read our article, “What is a Hot Melt Glue System?”

Do I need a manual or automated adhesive spray system?

Trying to decide if your business needs a manual or automated spray system? There are several things to consider. How big is your operation? What is your budget? What kind of demands are you dealing with? Learn more in our article, “Do I Need a Manual or Automated Adhesive Spray System?

Can I customize my hot melt adhesive system?

At Sure Tack Systems, we offer a range of hot melt adhesive systems, including extrusion, slot coating, and wide web spray All of these can be partially or fully automated to help meet the assembly line needs of any operation. Learn more in our article, “Can I Customize My Hot Melt Adhesive System?

What is a slot coating applicator and how does it work?

A slot coating applicator offers a fast and efficient application of adhesives to anything from mattresses to cardboard packaging to cars. Learn more about sloat coating applicators in our article, “What is a Slot Coating Applicator and How Does It Work?

Why should I use an in-line spray handgun for hot melt adhesives?

An in-line spray handgun connects to an overhead mount, which can be adjusted to suit your requirements. This type of hot melt handgun has many advantages, which you can learn more about in our article, “Why Should I Use An In-Line Spray Handgun For Hot Melt Adhesives?

Why do I have to change the seals on my hot melt glue equipment?

Hot melt adhesive equipment, like seals, needs regular maintenance to keep them running longer and more cost effectively. Learn more about seal maintenance in our article, “Why Do I Have To Change The Seals On My Hot Melt Glue Equipment?

Why water-based adhesives are a thing of the past?

There are four types of water-based adhesives: animal or protein glues, resin cements, latex cements, and vegetable glues. Water-based glues have a long history, but for industrial use, their popularity is declining as hot melt glues grow in popularity. Learn more in our article, “Why Water Based Adhesives are a Thing of The Past?

How bad are solvent-based adhesives for the environment?”

Despite the versatility of solvent-based adhesives is that they can adversely affect the ecosystem and human health in numerous ways. Learn more in our article, “How Bad Are Solvent-Based Adhesives for The Environment?

Why is it important to have a flow adjustment lockout for your hot melt system?

If you’ve been researching adhesive application systems, you’ve probably come across the term “flow adjustment lockout”, but perhaps you’re unsure what it refers to. Learn more about these mechanisms in our article, “Why is it Important to Have a Flow Adjustment Lockout for your Hot Melt System?

Have questions about hot melt adhesive systems that aren’t answered here? Contact Sure Tack Systems today!


What Are Non-Woven Fabrics?

Hot melt adhesives play a key role in the manufacture of many products, including non-woven fabrics. But what, exactly, are non-woven fabrics, and how does the right hot melt adhesive system help to streamline product assembly for these fabrics?

In the broadest sense, non-woven fabrics are engineered fabrics consists of fibrous materials bonded through some method other than weaving. In most cases, these fibers are bonded in a sheet or web form through mechanical, chemical adhesive or thermal bonding processes. Of these three processes, thermal bonding (using a hot melt adhesive) is often considered the least expensive and safest option when possible.

Benefits of Non-Wovens

Non-woven fabrics provide a wide range of versatility across a number of applications compared to their woven counterparts. For example, non-wovens can be designed to be single-use or biodegradable, limited in scope or highly durable, depending on the need. They can be designed to resist tearing under piercing or high pressure; they can also be flame retardant, temperature-resilient, water absorbent or water repellent, stretchable, washable, anti-bacterial and so much more. Effectively, non-woven fabrics give us much more control over what we need these fabrics to do.

Examples of Non-Woven Fabrics

Non-woven fabrics can be found in nearly every aspect of our lives, from industrial applications to home-use products. Examples of non-woven products include:

  • Disposable diapers
  • Carpeting
  • Upholstery
  • Jacket lining
  • Household wipes
  • Insulation
  • Automotive coverings
  • Roofing
  • Laundry aids
  • Hygiene products
  • Medical use products
  • Fiber envelopes

How Hot Melt Adhesives Help with Product Assembly for Non-Woven Fabrics

Hot melt adhesives are made up of thermoplastic resins that become pliable under heat and pressure, yet are also able to cool quickly after application. These properties make hot melt adhesives an excellent option for manufacturing non-wovens because:

  • They create the necessary bonding without affecting the properties of the material itself (e.g., the product retains its softness, flexibility, etc.).
  • They accelerate the manufacturing process because there no drying, curing or cooling stage is necessary.
  • They are more economical than other bonding options.
  • They are safer and more eco-friendly than other bonding options.

Whatever your non-woven manufacturing needs, Sure Tack hot melt adhesive systems are designed for the fast, efficient and uniform application of just the right amount of adhesive to help you maximize productivity with minimal downtime. Contact Sure Tack Systems to learn more about which our systems and tools are right for you.


Team Training For Hot Melt Adhesive Systems

Sure Tack Systems are designed for efficiency, smooth operation and extensive use — but that doesn’t mean everyone uses them correctly. Many system failures and breakdowns can be easily prevented simply by knowing how to operate and maintain the equipment properly. This is why we include team training for our hot melt adhesive systems as part of our wide-reaching customer support policy.

How the Team Training Works

When your Sure Tack hot melt adhesive system is installed and ready to go, we’ll schedule a time for one of our experts to provide comprehensive training to your entire team, including anyone who will be operating the equipment as well as anyone else who needs to understand how it works. Our team training includes the following:

  • Proper daily operation of each part of the system.
  • System-specific training. We customize the training specifically to the equipment you have installed, so you’re not wasting time learning about components you don’t need or won’t use.
  • Preventative maintenance protocols — to ensure optimal productivity, prevent many breakdowns and extend the life of your products.
  • One-on-one training and support. Even when training an entire team, we don’t treat it like a “class.” We provide one-on-one training as needed to make sure every person on your team has their questions answered and has a good working knowledge of the system.

Ongoing Lifetime Support

One of the greatest benefits of Sure Tack team training for our hot melt adhesive systems is not just that it’s free, but that it’s ongoing — for as long as you own the equipment. We understand that as you grow, expand or experience turnover, you may have new employees who need to learn the equipment. You may also install updates and expansions to the system itself. Sure Tack understands that training is an ongoing need with our clients, so we’ll come back and train your new people, or provide refresher courses, as often as needed, for the life of your Sure Tack system.

At Sure Tack, we want your hot melt adhesive system to help your company be as productive and profitable as possible. Team training for hot melt adhesive systems is just one way we help meet this goal. To learn more about our systems, training options and support, contact Sure Tack Systems today.


Hot Melt Adhesive Systems 101

The manufacturing sector has relied on various adhesives for decades, but in recent years, the advancement of high-quality hot melt adhesive systems has revolutionized many of these processes. These days, a large number of industries have turned to hot melt adhesives as opposed to solvent-based adhesives, including a few industries you probably didn’t realize. Hot melt adhesives are preferable to solvent-based adhesives for a number of reasons, including the fact that they are safer, “greener” and generally easier to apply. If you’re considering implementing a hot melt adhesive system for your manufacturing process, here are the basics you need to know.

Choosing a Hot Melt Adhesive System

Selecting the right hot melt adhesive system for you will depend on a number of different factors. To start, you’ll need to evaluate your process to decide on what kind of glue equipment you’ll need for your particular application. For example, would your assembly process benefit more from an automated spray application or an extrusion system? Which types of hot melt adhesives would be best suited to your needs? Would your company work best with a manual application system or an automated system, and in case of the latter, what should you look for in an automated hot melt adhesive dispensing system? Sure Tack can help guide you through these decisions according to your specific processes, needs, and budget.

Using Your Hot Melt Adhesive System

Once you have selected the right hot melt adhesive system for your needs, understanding how a hot melt system works can go a long way toward helping you make the most of it. Take some time to learn the equipment and educate yourself and your team on the best ways to utilize it most efficiently. For instance, setting up individual workstations often works best for manual applications, and learning the best dispensing techniques for each piece of equipment will help improve productivity while reducing costs. Learning the correct way to support your hose will also prevent costly, dangerous wear-and-tear to the equipment.  Read here for additional useful tips and tricks for getting the most from your system.

Maintenance and Troubleshooting

As with any piece of complex equipment, your hot melt adhesive system requires regular maintenance, and even with a consistent maintenance plan in place, occasionally you may experience some common problems with your adhesives. Cold temperatures can affect the performance of pressure sensitive adhesives, for example. Incorporating a glue pressure gauge can help you monitor your dispenser’s performance and detect signs of trouble. Proper preventative maintenance will greatly improve your hot melt adhesive efficiency. If you’re experiencing performance issues, our troubleshooting guide can help. Click here for additional maintenance tips.

Sure Tack Systems is committed to helping you learn all you need to know about how to choose, use and maintain the right hot melt adhesive system to elevate your business. Contact us to learn more.


The Definitive Guide to Hot Melt Adhesive Products

Adhesives have played a key role in modern product assembly for quite some time, but in recent years, hot melt adhesive technology has taken great strides forward, making adhesive applications both safer and more cost-efficient. That said, choosing the best hot melt adhesive system for your company’s needs can be challenging. For instance, what is the best hot melt dispenser to use? Which adhesives are best for foam bonding? Which high-temperature adhesive applicators do you need?

While there are certainly certain pieces of hot melt glue equipment everyone should have, each company has unique needs that may require certain types of equipment for custom applications. As an industry leader in hot melt adhesive systems, Sure Tack has put together the following guide to serve as a starting point for companies looking to install hot melt adhesive equipment for product assembly.

Manual Inline vs Wide Web Spray

One of the first questions you’ll need to ask yourself is whether to go with a manual inline spray gun or an automated wide web spray system. Generally speaking, for larger-scale manufacturing operations, a wide web spray system saves a lot of money in the long run by increasing productivity and reducing labor costs. Automated systems used to be primarily allocated for solvent or water-based adhesives, but most industries today prefer hot melt wide web spray systems over water-based applications.

For smaller operations or more precise tasks, a manual inline extrusion system is typically the most effective and economic solution — and Sure Tack offers some of the most efficient and advanced inline handgun products available on the market. Between the versatility and high yield of wide web spray and the precision of inline handguns, some industries actually benefit from both systems — the wide web spray for primary assembly and inline extrusion workstations for finer applications and finishing.

Adhesives

In addition to choosing the right equipment, you’ll have to decide on the right type of hot melt adhesives for your application. Wood bonding adhesives will differ considerably from the finer adhesives required for package sealing, for example. Sure Tack can offer sound advice on the best type of adhesive to use for your application and your hot melt system.

Accessories

If your hot melt system is the engine, the accessories are like the turbo boost. Choosing the right hot melt adhesive accessories and add-ons can greatly streamline your product manufacturing and make your workflow many times easier. There are many decisions to make here, such as:

As you can see, there are many choices to make when configuring a hot melt adhesive system for your particular application. Hopefully, this guide has given you a good place to start asking the right questions. The experts at Sure Tack can help you with more specific decisions as to the right products for your needs. Contact us to learn more.