In today’s fast-paced industrial landscape, sustainability has become a major driving force behind innovation. Adhesive technology is no exception, as companies look for eco-friendly solutions that reduce environmental impact, particularly where solvent-based PSAs are used, without compromising performance.
One area where sustainability is gaining traction is in pressure-sensitive adhesives (PSAs). Traditionally, solvent-based PSAs have been widely used in industries such as packaging, automotive, textiles and electronics. However, with growing concerns over volatile organic compound (VOC) emissions and high energy consumption, industries are turning to UV hot melt adhesives, where the desired properties can be achieved, as a more sustainable, cost-effective alternative.
This article explores why UV hot melt adhesives are becoming a popular alternative to solvent-based PSAs. Here are three key reasons why making the switch to UV hot melt is a step toward a more sustainable future.
1. Zero solvent emissions: A cleaner production process and meeting sustainability targets
One of the most pressing issues with solvent-based PSAs is their reliance on chemical solvents. Solvents serve as a necessary carrier that dissolves the adhesive compound making it easier to apply, but due to their nature, they present some environmental, safety and health-related hazards.
The problem with Solvent-Based PSAs
Solvent-based PSAs contain VOCs that evaporate into the air during application. These emissions contribute to air pollution which can pose health risks to workers, albeit most western manufacturing facilities now have safeguards in place to keep workers protected when running solvent processes.
When VOCs are released, they react with nitrogen oxides (NOx) in the atmosphere, leading to the formation of ground-level ozone and smog, which have harmful effects on both human health and the environment. Regulations often require evaporated solvents to be incinerated in an after-burner / oxidiser prior to release. This adds another cost and another step to converting.
Governments and environmental agencies worldwide are tightening regulations on VOC emissions to reduce their impact on the environment. While this has been common practice in western manufacturing, it is now being addressed in the east as well. Emissions permits are becoming more difficult to obtain and come with increasingly tighter limits on what can be released to the atmosphere. Manufacturers using solvent-based adhesives are required to invest in air purification and waste disposal systems and periodically measure and report the quality of the emitted air. Both increase operational expenses, although both are costs that many converters already bear.
Why UV Hot Melt is becoming an alternative
Unlike solvent-based PSAs, UV hot melt adhesives are 100% solvent-free. This means that they do not release harmful VOCs into the air, making them a cleaner and safer option for manufacturers and workers.
Since UV hot melt adhesives do not emit VOCs, they eliminate the need for air purification systems, saving businesses costs on compliance with environmental regulations. This also means companies can avoid fines and penalties for exceeding emission limits.
Using UV hot melt adhesives contributes to a lower carbon footprint as the production process does not involve the release of solvent-based pollutants. This makes it an eco-friendly alternative that aligns with sustainability initiatives across various industries.
2. Lower energy consumption: A more efficient process
Another major sustainability challenge with solvent-based PSAs is their energy-intensive manufacturing process. This not only drives up operational costs but also increases carbon footprint.
The high energy demand of solvent-based PSAs
Solvent-based adhesives require long, thermally intensive, drying ovens to evaporate solvents and set the adhesive properly. These dryers consume large amounts of energy to speed up solvent evaporation. These ovens must be operated continuously during production, leading to an increase in electricity or fuel consumption.
Extended processing times further add to energy waste. Since solvent-based adhesives need additional drying time, manufacturers must keep production lines running for longer periods, using up more power and reducing overall efficiency.
Cooling systems are another hidden energy drain in the solvent-based PSA process. After being exposed to high heat, materials must be cooled down before they can be handled or packaged, requiring even more energy consumption in the form of cooling tunnels, chilled rollers or refrigeration units.
How UV Hot Melt saves energy
UV hot melt adhesives offer a more energy-efficient solution because they cure instantly when exposed to UV light, eliminating the need for heat-intensive drying processes. Without the requirement for large-scale ovens, manufacturers can significantly reduce energy consumption, leading to lower operational costs and a smaller carbon footprint.
Since UV hot melt adhesives set faster, the production process becomes more efficient. This increases output and enables manufacturers to complete more adhesive applications in less time, improving overall productivity.
By switching to UV hot melt adhesives, companies can also reduce their carbon emissions as less energy consumption means fewer greenhouse gases released into the atmosphere. This aligns with global sustainability efforts and helps businesses meet carbon reduction targets.
To learn more about the sustainability benefits on offer from UV hot melt, read our case study with Nu-Coat, here.
3. Safer working environment: protecting workers’ health
While converters using solvent-based adhesives should always use necessary safeguards to protect workers, eliminating risks entirely is always best. Fortunately, UV hot melt offers an immediate opportunity to eliminate solvent related risks at the converter.
Health hazards of Solvent-Based PSAs
Solvent-based adhesives contain toxic chemicals that can be harmful to workers when inhaled. Fumes released by these adhesives contain VOCs, which can cause dizziness, headaches, nausea, and respiratory problems. Long-term exposure can lead to chronic health issues, including lung damage and nervous system disorders.
Direct contact with solvent-based PSAs can cause skin irritation, burns, and allergic reactions. Workers handling these adhesives should always wear protective gloves and clothing to avoid exposure, adding additional safety costs and discomfort in the workplace.
Another major risk of solvent-based PSAs is their high flammability. Many solvent-based adhesives are highly flammable, meaning they must be stored and handled with extreme caution to prevent workplace fires and explosions. This increases hazards in production facilities, requiring additional safety measures and fire prevention systems.
UV Hot Melt: A safer alternative
UV hot melt adhesives eliminate the risk of toxic fumes as they are completely solvent-free. This means workers do not have to worry about inhaling dangerous chemicals, creating a healthier work environment.
Unlike solvent-based adhesives, UV hot melt adhesives are non-flammable, removing the need for costly fire prevention systems. This makes production areas much safer and significantly reduces the risk of accidents or workplace fires.
Conclusion: The future of sustainable adhesives
As industries move towards more sustainable solutions, UV hot melt adhesives are becoming a viable alternative to solvent-based PSAs for many converters who want to reduce energy costs and meet sustainability targets. At present, there are still many applications where solvent-based adhesives must be used to achieve the necessary properties, albeit UV hot melt is catching up in this regard.
However, in the applications where UV hot melt is a viable alternative, the switch from solvent-based PSAs to UV hot melt can offer converters several benefits, such as reduced energy consumption, ensuring a safer, greener working environment, and ensuring sustainability criteria is met by eliminating solvent emissions.
Speak to our team about switching to UV hot melt by clicking on their details below:
Region, Americas:
Jennifer Heathcote
Vice President, Business Development
Email Jennifer directly
