Adhesive Char = Higher Downtime,

Rejects and Operational Costs

Get more productivity and lower TCO

Time + Temp + 0² = Adhesive Char

• Every hot melt adhesive has a pot life — a point in time at which the heat and oxygen cause it to degrade.

• Heating elements in hot melt hoses are used to keep adhesive flowing at the right viscosity and temperature.

• Char forms during idle periods when your system is on/heated and no adhesive is flowing.
• Adhesive near the heated walls of the hose moves slower than adhesive in the center of the hose.
  This hotter, slower adhesive degrades faster and sticks to the hose wall — forming char.

• Char inside the hose breaks loose and clogs filters, guns and nozzles.
• Lower-grade hot melt adhesives degrade and form char more quickly.Changing adhesive and bending or flexing a hose makes char to break off easier/faster.

Why should I replace my hose? It looks fine.

• Even if you can’t see it, char cuts your productivity and increases your operating costs.
• Char restricts the adhesive flow and requires more system pressure to force adhesive through the hose.

• Char build-up creates a thermal barrier in the hose. When the adhesive isn’t hot enough, it doesn’t flow correctly.

• Slow, restricted flow then increases the melter’s “heater-on” cycle. Problems multiply as more heat produces even more char.n More heat and char increase your energy use and production costs.

• Char causes uneven adhesive beads, missed beads and clogged nozzles. You lose time and productivity long before your line shuts down.

• Flaking and loose char results in poorly glued packages, pop-opens and char on your products.

Why can’t I just clean my hot melt hose?

• Flushing your melter can remove some char and prevent it from entering your hose. Flushing hoses with solvents is not recommended. Solvent can begin to break down hardened char but will not remove it entirely. Char will break off during system operation, clogging guns and nozzles.

 Adhesive char is present in your hot melt hose…
even if the adhesive in your tank is clear.

 How can I lower char and hose replacement costs?

• A good preventive maintenance program, smart operating procedures and common sense can all help. For example:

• Flush your adhesive melter regularly and whenever you change adhesives. Do-it-yourself flushing kits contain everything you need to get the job done. Or, call Astro Packaging we can schedule inspection, maintenance or a design program to fit your specific needs.

• Replace melter filters. Newer adhesive melters have disposable, basket filters that take less than one minute to replace.

• Install in-line filters between your hose and gun to trap char before it reaches your guns and nozzles.

• Use hose straps to support the hose and minimize hot spots. Don’t use wire or other tie wraps.

• Avoid bending, flexing and moving your hose whenever possible.
• Keep hoses off the floor. Stepping on a hose, running it over with a forklift, getting it wet or
• having it covered in dirt will shorten its life.n Don’t leave your adhesive system on when it is not in use. Using the 7-day clock or system standby will reduce char and allow the system to be ready when you need it.

 
When should I replace my hot melt hose?

• At least every 3 years
• If your new nozzles clog in less than 3 months
• If the hose shows external damage
• If the (non-waterwash) hose has ever been wet
• If hose fittings are leaking

 
Don’t wait. With today’s tight production schedules, smaller maintenance teams and the need to reduce expenses, downtime can be a major factor in your total costs.
Invest a little and save a lot! Astro Packaging hoses will start paying for themselves right away, and for years to come.

Contact your local Astro Packaging service representative. Call (800) 642-7876 today!