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TOPCORE has a long-standing commitment to innovation and continuous improvement of its products and processes. Our latest innovation, the implementation of dextrin glue in our customer’s paper honeycomb production, represents a significant step forward. Our dextrin adhesive has enabled our customer not only to increase production efficiency, but also to improve the quality of its products and reduce material costs. So here is a summary – a sort of case study of the impact that replacing traditional PVA adhesives with dextrin adhesives can have, and we invite you to join us in the production of paper honeycomb. We have decided to structure the article in such a way that under each point (i.e. the advantages of using dextrin glue) you will always find a comment from our real customer (marking Z before the text) and his observations from the production.
Why replace PVA adhesives with dextrin adhesives?
Traditionally, polyvinyl acetate (PVA) adhesives have been used in the production of paper honeycombs, which of course have their advantages (strong adhesion, ease of application, flexibility, etc.) but also several limitations. The idea of replacing PVA adhesives with dextrin adhesives in the production of paper honeycomb was based on several key factors:
Variability in adhesive form:
Dextrin adhesive offers variability in both liquid and bulk solutions, allowing fresh adhesive to be prepared on site. This not only simplifies logistics and reduces transportation costs, but also improves production efficiency by having the adhesive ready to use whenever it is needed. Special TOPCORE BLENDECO additives can also be added to the adhesive, allowing us to adjust the final properties of the adhesive and thus the final product!
Z: The ability to supply glue in bulk form is absolutely crucial for our company, as we can save a considerable amount of money on transport and at the same time have fresh glue available in the quantities we need at the time.
Economic benefits:
Dextrin adhesive contains up to 30% more dry matter than PVA adhesive, which means the products are not as wet and dry significantly faster. This reduces the energy costs associated with the drying process – especially in these days of rising energy prices, this is certainly one of the key features. In addition, the higher strength that dextrin glue provides allows the use of lower quality paper without compromising the strength and quality of the final product.
Z: Although the cost of dextrin glue is slightly higher (5%), this additional cost is more than offset by the savings from lower glue consumption and increased production efficiency. So this is one example where it is definitely worth paying extra for a more expensive solution, but ultimately saves many times more money.
Production optimization:
Higher strength and faster drying mean that products can be passed on for further processing more quickly. This not only improves overall quality but also increases production efficiency.
Z: While the strength of our products has not changed significantly, the main advantage is that panels made with dextrin glue have lower moisture content. As a result, they can be used immediately for further processing, which shortens the overall production cycle and increases productivity.
Speeding up the production process:
A key factor that enables dextrin adhesives to speed up production is the ability to adjust the “open time” – the time during which the adhesive remains workable and sticky before it dries. This setting can be adjusted to the customer’s specific needs and requirements. The flexibility in open time settings means that production lines can be more efficient, with less delay and higher productivity, resulting in a significant speed up in the overall production process.
Z: Thanks to the faster drying time of the dextrin glue, we achieved a 7% increase in overall production speed. This increase in efficiency allows us to respond more quickly to our customers’ needs and increases our competitive advantage in the marketplace.
Environmental benefits:
Dextrin glue is made from potato (or e.g. corn) starch, which is a renewable resource. This is in line with the growing emphasis on environmental sustainability, which TOPCORE also promotes. Using more environmentally friendly materials can also improve brand reputation among consumers or buyers of our customers’ products.
Z: The use of dextrin glue has led to a significant reduction in glue consumption of 15-20%. This not only reduces material costs but also contributes to a greener operation due to less waste.
Easier machine maintenance:
Dextrin adhesive is water soluble, making it easier to remove and clean from production equipment, saving time and maintenance costs. Simply rinse with lukewarm water instead of spending hours cleaning as is often necessary with PVA adhesives.
Z: Dextrin adhesive does not leave as much residue on production line knives, reducing the need for frequent sanding. This not only extends the life of the knives, but also increases the overall efficiency of the production line.
TOPCORE quality and service:
Our dextrin adhesive offers consistent quality with every delivery. If you encounter any problems, the TOPCORE team is ready to provide fast and efficient service to ensure your production is not affected.
Z: We are extremely satisfied with TOPCORE’s service. We have had periods of testing adhesives and putting the process into “sharp” and their team has always been fully available to us, whether online or in person. Any uncertainties were immediately resolved and together we have come to a complete switch to dextrin adhesives, which are already making our production more efficient without the need for further intervention.
The implementation of dextrin adhesives represents a significant step forward in the production of not only paper tubes and edges, but now also in the production of paper honeycomb. Increased efficiency, reduced costs and improved product quality for our customers are evidence of our continuous innovation. We look forward to working with the experts and innovators who will help us take the paper honeycomb industry to the next level. Contact us and join our journey of innovation and sustainability.
