Adhesive Processing Challenges and the RingExtruder Advantage

Adhesive production is increasingly challenged by complex formulations, tightening environmental requirements, and the need for stable, cost-efficient operation. Sensitive polymers, tackifiers, fillers, additives, and volatile components must be processed within a narrow operating window. Even small deviations in temperature, shear, or residence time can affect bonding performance, causing degradation, discoloration, instability, scrap, and avoidable cost.

At the same time, regulations such as REACH, CLP, TSCA, OSHA are driving higher expectations for ingredients and safety, emissions control and solvent or monomer removal. Effective devolatilization is therefore critical, but difficult in batch production and even with conventional extrusion systems because sufficient residence time must be achieved without damaging shear- or heat-sensitive materials. A continuous devolatilization concept helps reduce interruptions, limit solvent carryover, and maintain consistent product quality.

Producers also face more frequent formulation changes and raw-material variability. Materials from different suppliers may behave differently under identical processing conditions, making stable quality and predictable output harder to maintain. As a result, equipment with suitable screw configuration is required that can be adjusted quickly through torque, speed, temperature profile, and vacuum settings while keeping the process continuous.

Traditional batch processing can further exacerbate these challenges, as it leads to variations between individual batches, rework, production interruptions, and higher operating costs. For this reason, many adhesive producers are moving toward continuous processing technologies that provide more stable quality, greater flexibility, higher throughput, and measurable savings.

The RingExtruder RE offers a strong advantage for continuous adhesive production. It combines devolatilization, mixing, dispersion, and temperature control in one continuous manufacturing step. This, along with an automated material-handling and dosing system, can reduce the need for multiple machines, simplify process management, improve stability, and support cost reduction without compromising bonding performance.

Its design with twelve co-rotating screws and helical melt-flow movement creates a smooth, low-shear processing environment. This enables efficient dispersion and mixing while protecting sensitive materials from excessive mechanical or thermal stress. Tight temperature control supports demanding adhesive formulations and helps maintain reliable bonding performance.

Customers using the RingExtruder have reported stable continuous operation at high throughput rates while maintaining excellent product quality and cost control. The system also offers high flexibility: screw configuration, vacuum systems, and process parameters can be adapted to changing formulations and raw-material behavior. This helps minimize changeover-related interruptions, reduce scrap and off-spec material, and keep formulation performance stable.

Beyond the equipment itself, CPM supports adhesive producers through collaborative process development focused on product quality, cost reduction, and environmental compliance. Together with customers, CPM analyzes production challenges, conducts laboratory trials, generates comparative data, and optimizes process conditions before implementation. This approach reduces scale-up risk and supports confident technology decisions.

As adhesive formulations become more complex and economic pressure increases, manufacturers need continuous production technologies that deliver flexibility, consistent quality, efficiency, environmental compliance, and measurable cost benefits. The RingExtruder was designed to meet these requirements, supporting reliable bonding performance and sustainable adhesive production.

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