Case study: Automated gluing of carton packaging for Fatra

Fatra, a major global plastics processor (PVC, PE and PET) based in Napajedla, has commissioned a new fully automated production and packaging line designed for processing and packaging LVT floor coverings. A key part of the line is the automatic closing of carton boxes using hot melt gluing, supplied and integrated by KALETECH using Robatech technology.

The aim of the project was to replace a number of manual and discontinuous operations with a single, seamless process, to increase productivity, ensure 100% gluing reliability and stabilise operation over the long term.

Solution design and involvement of KALETECH

After market research, Deprox was chosen as the main integrator of the entire line, and it brought in KALETECH as a specialist in industrial gluing technology. Fatra had already worked with KALETECH in the past, but this time it was a project with significantly higher demands on performance and reliability.

“For such a complex and fast line, we needed a partner who understands not only gluing but also the real-world operation of a production line. In this respect, KALETECH delivered exactly what we expected,” says Martin Čech, R&D Project Manager at Fatra, of the collaboration.

The solution design also included cooperation with KALEP, which supplied the hot melt adhesive for the project. Choosing the right adhesive was crucial given the high line cycle rate, the requirement for immediate bond strength and long-term operational stability. The chosen APAO hot melt adhesive Kalep Perform 100 made it possible to reliably glue carton packaging with low consumption and without any negative impact on operator comfort.

Technological gluing solution

On the line, LVT floor panels are packed into carton boxes made of corrugated cardboard. The boxes are closed using hot melt gluing in the form of a bead application.

Technology used:

• melter Robatech Vision S,
• Performa heated hoses Performa,
• three SX 1S application heads,
• granulate hopper with pneumatic conveying,
• APAO hot melt adhesive Kalep Perform 100.

The adhesive is characterised by high thermal stability, low consumption and is odourless, which is important from both an operational and an ergonomic point of view.

Operational and reliability requirements

The performance of the line is very high and the gluing technology must not limit it in any way. At the same time, it was necessary to ensure that the system worked without any need for operator intervention.

“Once we had the parameters set correctly, the system runs. The operators essentially don’t have to worry about the gluing, which was exactly our goal,” confirms Marek Novák, floor covering technologist at Fatra.

Alongside the technical parameters, the economics and environmental aspects of operation also played a role. Hot melt gluing proved to be a significantly more economical solution than the original adhesive tape.

Integration into production and technical challenges

During the design and implementation, a number of specific challenges had to be addressed, including:

• the above-standard distance of the granulate hopper from the melter,
• correct positioning of the application heads,
• vibrations at high speeds, which affected the accuracy of some operations.

Thanks to close cooperation between Fatra, Deprox and KALETECH, all these aspects were resolved both structurally and technologically. The local availability of all partners also played a significant role, enabling rapid in-person interventions and fine-tuning.

Commissioning and results

The technology was commissioned according to plan and production got under way without any major complications. The delivery also included operator training, after which Fatra took over routine maintenance itself.

“From the point of view of the gluing technology, today we only deal with refilling the granulate. Reliability is 100% and matches the results of the guarantee tests,” summarises the current situation Marek Novák.

Project results

The new packaging line has brought Fatra a number of concrete benefits:

• fully automated and stable packaging,
• a significant reduction in the need for manual labour (saving approx. 16 employees across the chain of operations),
• 100% gluing reliability,
• greater workplace safety and ergonomics,
• lower operating costs compared to taping,
• smooth operation without unplanned interventions.

The line has now been in operation for a considerable time and the results confirm both the expectations and the data from the guarantee tests.

Long-term cooperation and further development

Cooperation with KALETECH continues even after the line was commissioned. Further optimisation options are regularly explored, for example testing new hot melt adhesives with a lower operating temperature.

“We appreciate that KALETECH does not approach the project with a ‘delivered – done’ attitude, but actively comes up with suggestions for further improvements,” concludes Martin Čech.

Conclusion

The Fatra case study confirms that a properly designed hot melt gluing technology is a key element of modern automated lines. Thanks to the close cooperation of Fatra, Deprox and KALETECH, a solution was created that combines high performance, operational certainty and long-term sustainability.