Inline Glue Viscosity Measurement for Optimized Industrial Automation

Optimal viscosity ensures even application and strong adhesion, while inconsistencies lead to defects, waste, and increased costs. Inline viscometers, such as Lonnmeter’s advanced instruments, provide real-time monitoring and control, offering significant advantages over traditional offline methods like efflux cups.

Definition of Glue Viscosity

Glue viscosity refers to a glue’s resistance to flow, a critical property that determines how it behaves during application in industrial processes. Two viscosity unit centipoise (cP) and milliPascal-seconds (mPa·s) are used to specify internal friction of adhesives.

Low-viscosity glue is suitable for coating or spraying due to high fluidity; high-viscosity glue is ideal in gap-filling or bonding uneven surfaces.

Low-viscosity glues flow easily, ideal for coating or spraying, while high-viscosity glues are thicker, suitable for gap-filling or bonding uneven surfaces. In industrial automation, precise glue viscosity measurement ensures consistent application, impacting bond strength, curing time, and product quality. Factors like temperature, shear rate, and material composition influence viscosity, making real-time glue viscosity control essential for reliable production outcomes.

Application of Glue in Automated Industrial Processes

Glue plays a pivotal role in automated industrial processes across sectors like packaging, automotive, electronics, and construction. In automated systems, adhesives are applied through spraying, coating, or dispensing to bond components efficiently.

Automated viscosity measurement enables precise application by ensuring glues maintain optimal flow characteristics, preventing issues like clogging or uneven distribution. In general, automation demands consistent viscosity to minimize waste, reduce downtime, and enhance throughput. Therefore, it’s necessary to integrate robust viscosity measurement instruments into pipelines or tanks for continuous monitoring and control.

Common Glues Used in Industrial Automation Production

Various glues are employed in industrial automation, selected based on application needs, bonding strength, and environmental conditions. Key types include:

• Starch-Based Adhesives: Derived from natural sources like corn or wheat, these are widely used in corrugated cardboard production due to their eco-friendliness, low cost, and biodegradability. Additives like borax enhance viscosity and tack.
• Polyvinyl Acetate (PVA): Water-based, cost-effective, and versatile, PVA is used in paper bonding, packaging, and woodworking, offering good adhesion at room temperature.
• Hot Melt Adhesives: Thermoplastic glues applied at high temperatures, ideal for packaging and product assembly due to adjustable viscosity via temperature control.
• Epoxies and Polyurethanes: Synthetic adhesives for high-strength bonding in automotive and aerospace, offering resistance to heat and chemicals but requiring precise glue viscosity control due to their sensitivity to environmental factors.
• Cyanoacrylates: Fast-curing adhesives for small components in electronics, requiring low viscosity for precision dispensing.

These adhesives vary in viscosity, necessitating viscosity measurement instruments to ensure consistent performance in automated systems.

Application of Starch Glue in the Production of Corrugated Cardboard

Starch glue is essential in corrugated cardboard production, which bonds fluted paper layers between flat liners to create strong, sustainable packaging. The glue is prepared by cooking starch in water at around 90°C, with additives like borax or sodium hydroxide adjusting glue viscosity for optimal tack and cohesiveness.

Starch glue is applied to flute tips in automated corrugating lines. Consistent and precise glue viscosity control is beneficial to manufacturers to keep even spreading and strong adhesion without excess waste. Its pseudoplastic and thixotropic behavior demands real-time monitoring to maintain consistent application.

How Viscosity Affects Glue Performance and Quality of Corrugated Cardboard

Viscosity directly impacts glue performance and the quality of corrugated cardboard. Optimal glue viscosity ensures proper impregnation of paper layers, enhancing bond strength, flexibility, and durability.

If viscosity is too high, the glue may not spread evenly, leading to weak bonds or clumping, which compromises cardboard strength and increases waste. Conversely, low viscosity can cause over-penetration, reducing adhesion and causing warping or delamination. For starch glue, maintaining viscosity within a specific range (typically 30–60,000 mPa·s) is critical to achieve uniform coating and prevent defects like pinholes or uneven layers. Fluctuations due to temperature, shear, or improper mixing can degrade quality, making glue viscosity measurement essential for consistent production.

Instrument Used to Measure Viscosity

The instrument used to measure viscosity in industrial settings is a viscometer, with inline viscometers being the gold standard for automated processes. These devices, such as rotational, vibrational, or resonance frequency viscometers, measure viscosity directly in the process stream. These viscosity measuring instruments offer continuous, real-time data, unlike traditional efflux cups, which are less accurate for dynamic processes.

Benefits of Viscosity Automation in Corrugating Process

Viscosity automation in the corrugating process transforms production efficiency and product quality. Key benefits include:

• Consistent Quality: Automated viscosity measurement ensures glue viscosity remains within optimal ranges, reducing defects like weak bonds or uneven layers, enhancing cardboard strength and usability.
• Reduced Waste: Real-time adjustments minimize over-application or rejects, lowering material costs and supporting sustainability goals.
• Energy Efficiency: Precise control reduces energy consumption by optimizing glue application and curing processes.
• Process Optimization: Continuous monitoring allows fine-tuning of parameters like temperature and mixing, improving throughput and batch consistency.
• Anomaly Detection: Inline systems detect viscosity deviations instantly, preventing downtime and maintenance issues.
• Regulatory Compliance: Automation ensures adherence to environmental standards by minimizing solvent use and waste.

These advantages make instrument for viscosity measurement indispensable for modern corrugating lines.

Lonnmeter Viscosity Measurement Instruments

i. Main Function and Parameters

Lonnmeter viscosity measurement instruments are designed for real-time glue viscosity measurement in industrial applications like corrugated cardboard production. Their main function is to monitor and control viscosity in pipelines, tanks, or mixing systems, ensuring consistent adhesive performance. Key parameters include a viscosity range of 1-1,000,000 cP, temperature tolerance up to 450°C, and compatibility with non-Newtonian fluids like starch glue. Equipped with advanced vibrational sensors, it oscillates at a certain frequency along its axial direction, providing accurate, continuous readings and can measure density alongside viscosity. They feature user-friendly interfaces for easy integration into automated systems, with options for wall-mounted or inline installations.

ii. Advantages Over Traditional Offline Viscosity Monitoring

Compared to traditional offline viscosity monitoring, Lonnmeter viscosity measuring instruments offer significant advantages.

Offline methods rely on periodic sampling, leading to delays and inaccuracies due to temperature or shear variations. Lonnmeter’s inline systems provide real-time data, eliminating sampling errors and enabling immediate adjustments.

They handle complex fluids like pseudoplastic starch glue with precision, unlike offline tools that struggle with non-Newtonian behavior. Additionally, their robust design reduces maintenance needs, and automation minimizes human error, enhancing process reliability over traditional methods.

iii. Benefits in Viscosity Automation

Lonnmeter instrument for viscosity measurement delivers transformative benefits in viscosity automation for corrugating processes. These include superior product quality through consistent glue viscosity control, ensuring defect-free bonding and uniform cardboard strength. They reduce operational costs by minimizing glue waste, rework, and energy use, aligning with sustainability goals.

Automated adjustments enhance efficiency, reducing downtime and boosting throughput. The instruments’ ability to detect anomalies in real-time prevents production issues, while their integration into control systems streamlines operations. Overall, Lonnmeter’s solutions drive precision, cost savings, and environmental compliance in automated glue applications.

Optimize Automated Viscosity Measurement with Lonnmeter Viscometers

Discover how Lonnmeter’s viscosity measurement instruments can optimize your production, reduce waste, and ensure top-quality results. Contact us today for a personalized quote and take the first step toward seamless automation! Request your quote now and transform your adhesive performance!