Project Background

This customer is a well-known large flexible packaging enterprise in China, primarily producing high-end flexible packaging products for food, pharmaceutical, and daily chemical industries. The company owns 3 imported Bobst dry lamination production lines with an annual capacity of 50,000 tons. As market competition intensified and customer quality requirements increased, traditional manual adhesive mixing could no longer meet the company's development needs.

Customer Challenges

• Large Mixing Ratio Errors: Manual mixing relied entirely on worker experience, with ratio errors frequently exceeding 5%, leading to unstable peel strength and a defect rate as high as 3%.
• Severe Adhesive Waste: Manual mixing used large batches, often resulting in premature adhesive curing, wasting approximately 50kg of adhesive daily.
• High Labor Costs: Each production line required 2 mixing workers, totaling 6 workers for 3 lines — high labor costs and management complexity.
• Missing Production Data: No data recording during the mixing process, making quality issue traceability impossible.
• Significant Safety Risks: Workers were exposed to organic solvents long-term, posing occupational health and safety concerns.

Solution

After thorough on-site investigation and technical discussions, Gluexpert provided 3 sets of GB-DL-500 dry lamination automatic adhesive mixers, each paired with one Bobst dry lamination production line. The system employs gear pump + load cell dual metering technology, achieving ±2% ratio accuracy, fully meeting the customer's precision requirements.

Solution Features

• Dual Metering Technology: Gear pump metering + load cell feedback correction for consistently reliable ratio accuracy.
• Small Batch Continuous Mode: Automatically adjusts mixing volume based on line speed, use immediately after mixing to avoid waste.
• Seamless Integration: Signal interlock with Bobst laminators — automatic adhesive supply on startup, automatic stop on shutdown.
• Data Recording: Automatically records mixing parameters and adhesive consumption for every batch, supporting USB export and printing.
• Smart Alarms: Automatic alarm and shutdown when ratio errors exceed set thresholds or raw materials run low.

Implementation Process

The entire project — from contract signing to equipment installation and commissioning — took only 20 days. Gluexpert's technical team completed the installation and commissioning of all 3 units in batches without disrupting the customer's normal production. Comprehensive training was also provided to operators and technicians to ensure proficiency in equipment operation and maintenance.

Results

After deployment, the equipment has been running stably and reliably, with all indicators meeting or exceeding customer expectations, delivering significant economic and social benefits.

Economic Benefits

• Adhesive Cost Reduced by 32%: Precise mixing reduced adhesive waste, saving approximately ¥1.5 million annually.
• Labor Cost Reduced: Only 0.5 person per line for inspection, saving 6 workers and approximately ¥600,000 annually.
• Defect Rate Reduced: Product yield improved from 97% to 99.8%, reducing defect losses by approximately ¥800,000 annually.
• Fast ROI: Total equipment investment of approximately ¥2.4 million recovered in just 10 months.

Management Benefits

• Consistent Product Quality: Stable mixing accuracy, peel strength variation narrowed from ±15% to ±3%.
• Production Traceability: All mixing data automatically recorded, enabling rapid root cause analysis for quality issues.
• Management Efficiency: Achieved automated and intelligent mixing process, reducing management complexity.
• Safety & Environmental: Reduced worker exposure to organic solvents and improved working environment.

Follow-up Cooperation

Based on high recognition of Gluexpert's products and services, the customer placed an additional order for 2 solvent-free two-component mixers in October 2025 for newly commissioned solvent-free lamination lines. Both parties have established a long-term, stable strategic partnership.