Adhesive Applications
Choosing the right adhesive format for your packaging line
Alex Zulewski, commercial manager at Power Adhesives explains the best approach to choosing the right adhesive.
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s the packaging industry embraces more sustainable materials, biodegradable adhesives are gaining momentum. For converters exploring more
environmentally responsible adhesive technologies, a key question is emerging: shaped or bulk? Biodegradable hot melt adhesives are now available in both formats after Power Adhesives launched the fi rst ever biodegradable hot melt adhesives range earlier this year. This off ers manufacturers a practical way to align their bonding operations with environmental targets. But choosing the right format isn’t just about sustainability, it’s about matching adhesive performance to operational needs, run sizes, substrates and equipment.
UNDERSTANDING THE FORMATS Shaped adhesives are typically supplied as sticks or slugs, designed for use in glue guns or compact applicators. They are ideal for small to medium- scale production, manual assembly tasks and prototyping. Because they require less setup and storage, shaped formats are often the preferred option for lower volume runs or fl exible operations. Bulk adhesives, in contrast, come in pillow, block, or prill form and are used with high capacity melters and automated dispensing systems. They off er lower unit cost at scale, are more suitable for high-throughput lines and reduce downtime by minimising adhesive reloads.
VOLUME AND PRODUCTION SCALE One of the clearest distinctions between the two formats is scale. For converters running high-speed carton sealers or case erectors, bulk adhesives are generally more effi cient. They integrate easily with automated lines, provide consistent application and allow larger volumes of adhesive to be loaded and applied with minimal operator input.
On the other hand, for converters producing short runs or operating manual workstations, such as in POS display assembly or bespoke packaging, then shaped formats are often the more fl exible and cost-eff ective choice. They enable quick setup, reduced waste and easy switching between adhesive types or colours.
12 July/August 2025
are optimised for specifi c applications, such as bonding specifi c coated or laminated boards, fi bre- based trays, or corrugated cases. Shaped adhesives off er greater control during manual application, which can be benefi cial when bonding areas that require greater manoeuvrability from the operator, or varying amounts of adhesive to be applied. Bulk adhesives however, are preferred where speed and volume matter, for example in continuous carton sealing, where uniformity and throughput are critical.
WASTE, STORAGE, AND SUSTAINABILITY Both formats now off er biodegradable options certifi ed to international standards such as ASTM D6400 and EN 13432. However, bulk adhesives may off er greater advantages in terms of packaging waste and energy effi ciency. They typically require less packaging per kilo of adhesive, and modern systems support lower application temperatures, reducing energy consumption.
Shaped adhesives though, can help reduce waste in other ways as they make it easier to use exact quantities, limit over-application and support agile production schedules with minimal excess inventory.
MAKING THE RIGHT CHOICE
EQUIPMENT COMPATIBILITY Another key consideration is existing machinery. Bulk adhesives require melting tanks, hoses and application systems designed to handle higher volumes. For operations already equipped with folder gluers or automated sealers, the transition to biodegradable bulk formats can often be seamless. In contrast, shaped adhesives can be deployed without major investment. For converters using handheld glue guns or benchtop systems, shaped sticks provide immediate access to biodegradable bonding with little to no modifi cation. They are also well suited for fi eld applications or facilities with limited production space.
SUBSTRATE TYPE AND APPLICATION METHOD
The choice of format can also depend on the packaging material. Some biodegradable adhesives
Ultimately, the choice between shaped and bulk comes down to matching the adhesive format to the realities of your production line. Converters should consider:
• Run length and production speed • Equipment setup and available infrastructure • Flexibility needs and frequency of adhesive changeovers
• Storage space and adhesive consumption rates • Environmental and sustainability goals As the demand for more sustainable packaging continues to grow, the availability of biodegradable adhesives in both shaped and bulk formats ensures that converters of all sizes can adopt more environmentally responsible practices without compromising performance. By assessing their specifi c operational requirements, converters can determine the best-fi t adhesive format and take another step toward a more sustainable packaging future.
www.convertermag.com
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