Cut Down 20% of Material Wastage

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Manual mixing & dispensing is widely known as a low-cost & convenient method for many manufacturers. However, this method actually increases material wastage costs, which are hidden and mostly unaccounted for.

Manufacturers can apply the most suitable solutions when they identify the correct error in their process. Therefore, according to our customers’ cost-cutting cases, Gluditec has summarized four key reasons for the wastage of material.

1. Rejection due to improper mix

This error is most familiar in the manual method as the materials are not appropriately weighed before mixing or an inexperienced worker performs the task. Moreover, the manual mixing method also leads to the air bubbles phenomenon in the mixed material. These bubbles create tiny gaps in electronic components, which break the insulating cover and diminish or even ruin high-voltage resistivity.

As a result, unpreserved properties of the adhesives increase the number of substandard products. If these products are rejected at the Customer’s end, companies may face the loss of reputation.

2. Handling

The wastage that occurs in handling goes largely unaccounted for, which includes: The material that remains stuck inside the syringe units, tanks, or mixing vessels, Materials dropped off from the syringe units between the dispensing shots, etc. More noticeable, although being the factor that increases the wastage cost, it’s taken as a standard wastage norm without effort to eliminate this wastage.

3. Leftover Mix

With fluctuating manufacturing schedules, the amount of mix needed for dispensing changes each time depending on different applications. Workers generally mix a ‘little more’ material than required to avoid running out at the last minute. Most of the time, this ‘little bit more’ turns out to be a lot for current mass manufacturing. Due to the short pot life, this mixed material has to be disposed of.

4. Overfilling

The lack of control over the accuracy of the shot size means an uncontrolled possibility of wastage. When dispensed manually with a syringe, the chances of distributing more material than required are very high. When manually dispensing adhesives, it is difficult for workers to remove excess material due to residual compressed air or force.

According to our observation, it is common for workers to dispense 1-3 gms of the extra during the process using a syringe to dispense 100 gms of materials. Ultimately, these extra amounts contribute to a significant proportion of the total material wastage.

Recommendation

Material wastage in manual mixing & dispensing could be as high as 20%. It also directly affects profitability & cost competitiveness for SMEs, who typically work on thinner margins and higher volumes. Therefore, finding methods to cut down material wastage is essential.

Gluditec recommends Fully Automated 2K Mixing & Dispensing Systems due to its:

Flexibility with mixing ratio ranging from 1:1 – 10:1
Meter-mixing module with advanced functions
High precision and repeatability dispensing module to avoid rejects

We also provide Semi-Automated 2K Mixing & Dispensing Systems with:

High precise mixture ratio with Piston Pump
High precision valve ensures no glue dripping
Time and cost efficiency