A request from a leading car seat manufacturer involved the delivery of adhesive application technology capable of collaborating with an industrial robot in order to make the production automatic.
The application head applies a spray coating of hot-melt adhesive. Depending on the movement and position of the industrial robot, it deliberately omits the places above holes.
The result is a fully automated work station with the precise application of the desired layer of adhesive in the desired locations.
A leading automotive upholstery manufacturer contacted Kaletech with a request for automated measurement of adhesive application for upholstery for car door panels. The customer's main requirement was to keep the adhesive deposit between two layers of upholstery materials constant.
The solution consisted of the use of a travelling thermal camera which scans and measures the adhesive coating thickness. It evaluates and gives a warning if the layer breaches the limits or indicates future irregularities and produces a report for quality control. The device has the possibility to change the gluing parameters on-line.
The new solution is more efficient from the point of view of adhesive consumption and thanks to the automated measurement system, the quality of uniformity of its application is monitored continuously. Our customer saves €27,000 per year on rejects and €8,500 on adhesive consumption.
The customer's requirement was to deliver gluing technology which would allow them to change the parameters and gluing width according to the needs of individual products.
The solution was to design a unique application head with 78 modules and a blade that allows intermittent adhesive application.
The customer can set the parameters and width of gluing for individual products without stopping production for complicated adjustment of the machine.
A furniture manufacturer contacted Kaletech with the requirement to deliver technology for the application of a cold adhesive for anchoring construction bolts. This operation had been made manually so far.
The solution consisted of an automatic application system for a dispersion adhesive using an industrial robot. The gluing device control unit communicates with the robot and applies the adhesive precisely in the required amount depending on its movement.
Thanks to this solution, the customer acquired a work station operating with sustainable quality and higher production. They saved 6 workers, who can now be utilised for other production activities.
The customer's requirement was to upgrade a 50-year-old formwork machine. Compared to standard production, the edges had to be banded to avoid penetration of moisture in the formwork.
Kaletech managed to synchronise the operation of the machine with a modern adhesive application system, thus making the original obsolete machine competitive again.
Thanks to the retrofit, the customer can continue using their production technology. In this way, the need to make a considerable investment in a new production line is avoided.
The customer's request was to deliver gluing technology for bottle labelling. They required versatility and the possibility to use the technology for multiple product types, each with a different number of joins.
The solution was the use of seven application modules for sprayed adhesive application and connection of the control unit with a PLC production program.
The modules apply adhesive at the desired height according to the specific product. Everything is controlled automatically and it is not necessary to adjust the machine settings.
The customer's request was to deliver gluing technology for the production of packaging with different heights depending on the volume of packaging.
The solution was the use of an adhesive bead application using a head which automatically changes its height according to the given product.
The modules apply adhesive at the desired height, according to the specific product. Everything is controlled automatically, production can take place even for a large quantity of packages, and there is no need to adjust the machine settings.
One of the largest Czech manufacturers of building materials presented Kaletech with the requirement to glue sound insulation wool between two parts of acoustic bricks. This was an improvement of already existing production.
Kaletech offered a solution in the form of replacing the PUR foam with a hot-melt adhesive and process optimisation. In terms of functionality, the hot-melt adhesive was as suitable as the PUR foam.
The result was rapid acceleration of production of one piece, thanks to faster drying of the adhesive. In addition to the time for production of one piece, the customer also saved an area in the production hall thanks to the removal of several dozen metres of belt for drying.
VA manufacturer of medical material for operating rooms contacted Kaletech requiring a solution for the gluing of impermeable membranes and non-woven fabric.
The solution consisted of the use of a spray adhesive application. It was necessary to set an appropriate layer of adhesive, which is applied to the patient's skin with optimal force, while guaranteeing the impermeability of the material. Fixed application heads are switched on depending on the desired quantity of the product.
On a complex production line it is possible to produce up to 86 different products using the same equipment.