Case Study: Precise PET Die-Cuts for Automated Assembly Success
We supported on a critical battery pack component project involving the high-speed automated applica…
Case Study: High-Volume Precision Die-Cuts for the Food Industry
Delivering Components Engineered for Compatibility with a Demanding Automated Process
"Manufacturing adhesive die-cuts for automated application processes is one of our strengths and in this project the skills of our operators and technical team really got to shine. We were delighted to be able to deliver the extreme volumes that were required whilst ensuring component compatibility with the customer's automated process"
Alan Bryan, Key Account Manager
High-Precision Components for Automation at Scale
1. The Challenge
A leading manufacturer in the food and retail industries required the development and manufacture of die-cut adhesive parts for the sealing of paper delivery bags. The project involved extreme volumes and required complete compatibility with the customer's high-speed automated application process.
The die-cut Pressure Sensitive Adhesive (PSA) component had to seal the bag, when required by the end user, whilst avoiding any operational issues for the customer's automated process, which ranged from:
- Machine Jams: Very minor deviations in part dimensions or alignment could halt the entire line.
- High Scrap Rates: Poor release levels or delamination during the automated process would lead to excessive material waste.
- Costly Downtime: Any incompatibility with the application process would result in expensive delays in a low-margin, fast-moving supply chain.
Material Optimisation & Process Compatibility
2. Solution
We initiated the project with a thorough discovery stage, visiting the customer’s facility and observing their automated process first-hand.
- Managing Premature Delamination: We observed that the multiple path rollers, in the automated process, presented a major delamination risk as the parts traveled around the sharp angled corners at speed. We therefore selected a backing liner that ensured survival through the automated application process, and a light enough release level for effortless application by the end-user.
- Adhesive Selection: After extensive testing on the bag’s coated paper, we selected an adhesive that gave an instant bond while remaining stable under the mechanical stress of the customer’s automation process.
- Fine-Tuned Manufacturing Process: Through experienced led process engineering we developed a manufacturing process that guaranteed:
- Zero missing and misaligned parts
- Splice-free rolls to reduce the number of stops on the customer’s production line.
Seamless Integration and Evolution
3. Outcome
We successfully scaled production to meet the extreme volume demands, without compromising the strict tolerances and format requirements of the high-speed assembly line.
- Continuous Part Evolution: Following the successful rollout, we continued to innovate, proposing a "finger-lift" feature on the liner. To significantly improved the end-user experience by making the manual sealing stage faster and more ergonomic—without hindering the automated application process.
Results of the Project:
Why did the customer choose Tecman?
Faced with integrating a die-cut PSA part into their high-speed automated process, the customer needed a technical partner that understood the application and the finer details of automated processes.
They chose Tecman because of our solution-driven approach and ability to bridge the gap between material science and mechanical application. Our technical expertise allowed us to engineer a part that balanced the conflicting requirements of the automated process and the end-user ease of use. We ensured the customer achieved their volume targets without the hidden costs of machine issues or high scrap rates.
Discuss your project with Tecman
We can support our customers through every stage, from material selection and design to choosing the right manufacturing processes. This ensures the delivery of an optimised, cost-effective solution designed to effectively overcome challenges and deliver tangible benefits.
If your application could benefit from cost savings, process improvements, material enhancements, and product advancements, reach out to our experts to discover how we can support your application.
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