Gluing in the textile industry: mattresses, nonwovens, hygiene products
Precise application onto delicate material – hot melt for the textile industry and mattresses
Robatech application systems for mattress production, nonwovens lamination, hygiene products and technical filters – precise hot melt dosing that keeps pace with the line speed and does not damage the sensitive material.
- ExclusiveRobatech partner for the Czech Republic
- 50+ yearsin the industry
- Our owntesting centre
- 24/7service and SOS line
Selected customers from the industry
Where we help in the textile industry
Mattress production – bonding layers and padding
Dot, bead or spiral spray application of hot melt for bonding side padding, foam layers and pocket spring core components. A programmable application pattern and a fast mattress format change happen automatically with no line downtime.
Lamination of nonwovens
Spiral spray or coating application of hot melt for laminating layers of nonwovens (PP, PE, PET), films and foam. An even layer of adhesive with no bleed-through of the material – the basis of hygiene products, filters and technical textiles.
Hygiene and medical products
Precise hot melt dosing for fixing elastic, laminating absorbent layers and attaching cover layers in hygiene products and medical textiles. A repeatable application that is gentle on delicate materials.
Filter textiles and technical filters
Bonding the filter layer to the structural frame or laminating the filter textile with hot melt. A strong and airtight bond that does not compromise the filtration properties of the material.
Technical textiles and laminating
Laminating of technical fabrics, lamination of reflective or functional layers onto technical textiles for industrial, construction and protective applications.
What you're dealing with
- Hot melt must not penetrate thin or porous materials (nonwovens, foam, filter textiles) – bleed-through of the adhesive damages the product and leads to complaints. The key is the right choice of application technology and adhesive viscosity.
- Production lines for hygiene products and nonwovens lamination run at high speed – the application system must maintain a constant and even application even when the speed fluctuates, otherwise rejects invisible to the naked eye arise.
- Mattress and hygiene product manufacturing involves many sizes and types – the system must allow a fast change of the application pattern or format with no lengthy retooling and line downtime.
How Kaletech solves it
For laminating nonwovens and manufacturing hygiene products we use spiral spray application with Aero technology – the hot melt is applied as a fine spiral filament (a non-contact application method) that evenly covers the surface of the textile with no bleed-through of the thin material. The result is a strong lamination with minimal adhesive consumption and no damage to the textile.
In mattress production, Robatech systems enable programmable application patterns with individual nozzle control – each nozzle starts and stops independently. A fast format change when switching to a different mattress type happens automatically, with no lengthy machine retooling.
The Robatech Control System (RCS) control platform, or direct integration via a PLC, synchronises the application with the movement of the material along the line.
We always verify the technology on your materials before deployment into operation. At the Kaletech testing and manufacturing centre we have our own laminating line – we run a test on your nonwovens or textiles, record the parameters, and the result is a specific configuration verified on your material, not just on paper.
How it works and what technology is used
Robatech technology for the textile industry integrates a melter, a heated Performa hose and an application head into a single controlled unit synchronised with the production line. For nonwovens and lamination, a spiral spray (the Aero head) is most often chosen, where the hot melt leaves the nozzle as a fine filament and evenly covers the surface even at low base pressure. For dot or bead applications (mattresses, fixing elastic), the electric Volta heads with precise cut-off are suitable. For large-area lamination – laminating technical textiles, films and flat materials on calenders or flat-bed lines – coating heads for coating application (slot coating FKV) are available; they apply an even layer across the full width of the material with precise thickness control. The choice of a specific configuration depends on the material, the line speed and the requirements for the bond – we always assess it during the application analysis.
Choosing the technology for the material
Spiral spray (the Aero head) for laminating nonwovens, hygiene products and surface laminating – the hot melt is applied as a fine spiral filament that covers the surface with no bleed-through of the material. For dot or bead application (mattresses, fixing elastic), the electric Volta heads with precise cut-off are suitable.
Melting the adhesive and a stable supply
The melter (for example JumboFlex for high-output lines) melts the hot melt granules to the working viscosity. The heated Performa hose maintains a stable temperature and adhesive pressure from the unit all the way to the application head – a prerequisite for a repeatable application, product after product, even during a long production shift.
Application and control of the application pattern
The application head applies the hot melt in the chosen pattern – spiral, dot or bead. In mattress production, individual nozzle control enables a programmable pattern adapted to the mattress format. A fast format change happens automatically from the control system.
Integration with the line and process monitoring
The control system (PLC or RCS) synchronises the start and stop of application with the movement of the material along the line. Real-time monitoring of adhesive consumption makes it possible to detect a deviation from the set pattern in time – before a faulty product leaves the line.
Technology used
Aero spray head
The Aero spray application head guarantees high-quality, repeatable coating application of adhesive in the form of a spi…
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Volta application head
Thanks to its design, it is durable and protected against external influences with IP55 protection. With Volta you save…
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Robatech JumboFlex Melter
JumboFlex is a powerful Robatech melter with a capacity of 50 or 100 litres. Flexible use as a buffer, pre-melter or mel…
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Performa – heated hose for highly precise applications
Heated hoses for hot melt adhesives have a significant influence on how reliably and precisely products are glued.
More informationReal-world results
Laminating the upper boot board of a car
Full-surface spray adhesive application on composite material and textile.
Show case study
Application of spray gluing on medical material
The universal solution of the technology allows the production of a large number of product variants.
Show case studyCustomer references
„The aim was to replace the manual gluing of ironing boards with a faster and more economical solution – and that succeeded. Robatech supplied complete gluing equipment thanks to which we saved a quarter of the costs on both adhesive and production staff. I believe the cooperation will continue on further Leifheit projects."
Why solve your gluing challenge with Kaletech
50+ years of industry experience
We build on the development of Swiss Robatech (since 1975) and our own practice on the Czech market since 2004.
Authorised Robatech partner
The exclusive supplier of Robatech technologies for industrial gluing.
In-house service and parts
A service team, spare parts in stock and an SOS line.
Free consultation
We will design a tailored solution and fine-tune it directly in your operation.
How the collaboration works
Inquiry and consultation
Get in touch and tell us what and where you glue. We will discuss your operation and goals with no obligation.
Application analysis
We assess the materials, the line speed and the requirements for the bond. We recommend a suitable technology and adhesive.
Design and test
We design the configuration and verify it with a test on your materials – often in our testing centre.
Installation and training
We install the system, integrate it into the line and train the operators and maintenance staff.
Service and support
We provide spare parts, preventive service and an SOS line throughout the entire operation.
Frequently asked questions
The key is spiral spray technology (the Aero head) – the hot melt comes out as a fine spiral filament and evenly covers the surface of the material without the need for high base pressure. The adhesive does not soak into the material because it is gently distributed on the surface. The second factor is choosing the right type of hot melt (viscosity, processing temperature) for the material – we always verify this with a test in our testing centre.
Interested in a solution for the textile industry?
Get in touch – we will assess your application (material type, line speed, application pattern) and design an application system precisely for your operation. With no obligation.
- +420 732 469 082
- info@kaletech.cz
- SOS service: +420 736 443 247