Hot melt is one of the leading forms of industrial glue for manufacturers. The global hot melt market is worth 7.5 million and is estimated to reach 11.7 million by 2025. Hot melt adhesive, which may be colloquially called hot glue, is a thermoplastic adhesive. It is available in different forms. Hot melt is sometimes applied with a hot glue gun, but usually it requires a melt tank and hoses, depending on the packaging and the industry. Once applied to a surface, hot melt can solidify in a few seconds to a minute. In some cases, hot melt may be applied via spraying or dipping.

Why Hot Melt for Appliances?

Hot melts are one of the most popular glues for manufacturers for several reasons. However, estimating hot melt coverage costs can be tricky. Too little hot melt could create unstable packaging and liability concerns; using too much could create business waste that affects profitability. Knowing how to estimate hot melt coverage for your appliance boxes is essential for consumer and distributor safety, packaging and product integrity, and more.

A thermoplastic bond is advantageous over solvent-based adhesives, particularly for the appliance industry. Here are a few reasons why.

• With the use of hot melt, there is little to no concern over volatile organic compounds, which is important in the food and beverage industry.
• Unlike solvent-based adhesives, there is no need for curing or long drying times. Technomelt 8990 is especially effective when fast drying situations are required.
• Expired hot melt adhesives do not require special disposal requirements.
• Hot melt has a long shelf life and will remain stable as long as temperatures remain consistent in the warehouse.
• Hot melt adhesives do not lose thickness when drying or solidifying. Some solvents can lose up to 70% of their layer thickness upon drying. Since thickness can affect the integrity of the bond, this can be especially important for packaging heavy-duty items such as appliances.
• In general, hot melt adhesives are resistant to weathering, so packaged items can sit for longer in warehouses, as long as temperatures remain relatively stable.

In general, hot melt adhesive provides a high-quality bond at an affordable price. Manufacturers can rest assured that their bond will hold steady, even under the weight of heavy-duty appliances. Technomelt Supra 106M is a great product for heavy weight applications.

Saving Direct and Indirect Costs with Hot Melt

When looking at the hard numbers, hot melt adhesive makes the most financial sense for businesses who need industrial glue. Across the available options (such as packaging tape), costs and quantities of hot melt adhesive allow manufacturers to get the most for their investment. At the same time, there are also softer numbers that give hot melt adhesive the advantage:

• Even at large scale industrial sizes, pellets and slats will take up less space than other forms of adhesive.
• Application of hot melt adhesive is less dangerous to workers than solvent-based glues.
• Adhesive create a quality, professional-looking seal, which can affect a customer’s first impression.
• The adhesive process is faster and ultimately improves business efficiency.

Determining Quantities of Hot Melt Adhesive for Your Business

Hot melt adhesive comes in several different forms. Businesses have the option of ordering it as a stick, a block, a cylinder, a rope, a flat block, pellet forms, and even in 55-gallon drums. One of the most important considerations a business will make, after deciding to use a hot melt adhesive, is deciding how much to order for their application. The benefits of ordering the correct amount are numerous:

• Applying too little adhesive could prove to be a liability issue. Thought hot melt adhesive can create a strong bond, it is still essential to correctly estimate how much adhesive each box will need. A break in the packaging can lead to injuries for either the consumer or the distributor. Correctly estimating how much adhesive is required per package can help mitigate risk.
• You avoid wasting resources. Though hot melt is relatively shelf stable, it can also be vulnerable to fluctuations in temperature, particularly high levels of heat. If the air conditioning goes out in your warehouse, you could be forced to discard what’s left of your hot melt. . On the other hand, ordering too little could cost you more on shipping costs in the long run, as you place more orders.

How to Estimate Hot Melt Coverage for Your Appliance Boxes

Deciding to use hot melt adhesive for your appliance boxes is only one part of the equation. At Premier Packaging, we understand it can be difficult to estimate how much hot melt coverage you’ll need and what it will cost your organization. That’s why we’re laying out some simple tips to guide your ordering process.

Using a Dot Reference Formula

Dispensing your hot melt adhesive in dots can make it simpler for you to do the math and find out how much hot melt adhesive you’ll need to fulfill orders. Though dot size will vary depending on the packaging, here is a rough guide that will help you determine order size:

• If using 1/4 inch dots, you will get around 9,500 dots per pound, or .10 pounds of hot melt per 1,00 dots.
• If using 1/2 dots, you will get roughly 2,300 dots per pound, or .42 pounds for each 1,000 dots.

If you use automated machinery to apply dots, apply this rough formula to determine how much hot melt you need:

Glue Pounds per Hour=Dots per hour/Dots per pound

Linear Application Formula

The other main method of application is the linear method, where a person or machine applies glues in lines. To determine how much hot melt you need, determine your approximate line size. Generally, your line size is determined by the size of your linear bead applicator. A rough outline:

• A linear bead 1/4” in size will provide 180 feet per pound of hot melt, or you can get 1000 linear feet with 5.4 pounds.
• A linear bead of 1/8” will provide 425 feet per pound of hot melt, or you can get 1000 linear feet with approximately 2.3 pounds.

For more questions about how much hot melt to order, talk to our team. Premier Packaging Solutions is here to help. Contact us to learn more.