How do I troubleshoot packaging adhesive problems, such as bond failures or equipment issues?


Packaging is a critical stage in any manufacturing or distribution process. It’s where products are sealed, protected, and made ready for delivery. To ensure the packaging process runs smoothly and efficiently, adhesive plays a pivotal role. However, like any other component in the production line, packaging adhesives can sometimes present challenges. Bond failures, equipment issues, and downtime can be frustrating and costly. In this article, we’ll guide you through common adhesive problems encountered during the manufacturing packaging process and how to troubleshoot them effectively.

Packaging glue application for case and carton sealing


Common Bond Failures

Poor Adhesion: One of the most common adhesive problems is poor adhesion. This can lead to packaging that doesn’t hold together, resulting in damaged products, returned pallets, fines from Big Box Retailers, and unhappy customers.

Possible Causes:

Corrugate changes (coatings, more recycled content, etc.).

Incorrect adhesive type for the materials.

Bead placement / equipment settings.


Verify that the adhesive chosen is suitable for the specific packaging materials.

Verify that the adhesive can handle the temperature conditions your packaged products will experience (hot, cold, freezing, etc.).

Contact BC Adhesives for recommended PM procedure, or to help troubleshoot any potential issues with your set up or equipment.Poor Adhesion: One of the most common adhesive problems is poor adhesion. This can lead to packaging that doesn’t hold together, resulting in damaged products, pop-opens, pallet rejects from Big Box Retailers, and unhappy customers.


Equipment Issues

Uneven Adhesive Application: Inconsistent adhesive application can result in packaging that doesn’t hold properly.

Possible Causes:

Irregular adhesive pressure.

Clogged nozzles or applicator heads.

Malfunctioning adhesive application equipment.

Pattern misfiring.

Charring in the pots.


Regularly inspect and maintain adhesive application equipment.

Ensure nozzles and applicator heads are clean and unobstructed.

Adjust adhesive pressure settings for even application.

Contact BC Adhesives to do a free line audit to see what the potential issue is.


Adhesive Buildup: Accumulation of adhesive residue on equipment components can lead to malfunctions and uneven adhesive application.

Possible Causes:

Insufficient equipment cleaning and maintenance.

Incorrect adhesive application settings.

BC Adhesives can provide free on-site audits, training, and perform your PM’s so you don’t have to think about glue, and focus on more important aspects of your business.


Establish a regular cleaning and maintenance schedule for adhesive application equipment. BC Adhesives has a simple 3 page guide that goes over everything you need to do.

Verify that adhesive application settings are correct for the application.


Tips for Effective Troubleshooting

  1. Root Cause Analysis: To effectively troubleshoot adhesive problems, identify the root cause of the issue. This may involve process mapping, equipment inspection, and material testing.
  2. Adhesive Selection: Ensure you are using the correct adhesive for the materials you are bonding. Consult with BC Adhesives for guidance, and visit
  3. Equipment Maintenance: Regularly clean and maintain adhesive application equipment to prevent buildup and malfunctions. Follow BC Adhesives free PM program, or check out
  4. Training and Education: Rely on BC Adhesives for free training and education to new operators so everyone fully understands the adhesive application and equipment operation.



Packaging adhesive problems can disrupt your production process and impact the quality of your products. By understanding the common causes of bond failures and equipment issues, and following effective troubleshooting steps, you can minimize downtime, reduce waste, and ensure that your packaging is secure and reliable. Remember that proactive maintenance and continuous improvement are key to preventing adhesive problems in the first place. With the right approach, you can keep your packaging process running smoothly and your customers satisfied.

As always BC Adhesives is here to help. You can call, or email and should expect a response within an hour.

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