Correlation Between Nozzle Size and Consumption of Hot Melt Adhesives
Choice of nozzle size is obviously important in ensuring the correct amount of adhesive is applied. Too little and the bond will fail; too much and you’re wasting product, increasing the risk of overspray, build-up, and maintenance downtime.
In our latest whitepaper, we explore how much impact nozzle size really has on adhesive consumption — and whether there’s a reliable way to calculate the correct nozzle for your application.
The Factors That Influence Bead Weight
Bead size is influenced by several interrelated variables — primarily viscosity and temperature.
As temperature increases, the adhesive becomes less viscous (more “runny”), allowing it to flow more easily through the nozzle. This in turn increases the amount dispensed — and therefore raises consumption.
However, from a manufacturing standpoint, running at higher temperatures isn’t always a good idea. Higher tank temperatures can cause thermal degradation and charring, increasing maintenance issues and reducing adhesive performance.
The goal, therefore, is to find the balance — the lowest practical temperature that still provides the required flow and bond strength, without wasting material.
Five Key Factors Affecting Bead Weight
In summary, there are five primary variables that result in an increased adhesive bead weight:
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Increased pump speed or pressure
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Increased temperature
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Slower line speed
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Use of a lower-viscosity adhesive
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Use of a larger nozzle size
Of these, the first three are typically constrained by existing line optimisation — meaning that nozzle selection and adhesive viscosity become the most practical levers for controlling consumption.
Why Nozzle Size Matters
A larger nozzle will deliver a higher adhesive volume per trigger cycle. Over time, even a small difference in orifice diameter can result in significant increases in total adhesive usage — and therefore in production cost.
Our whitepaper provides a quantitative look at this relationship. Through controlled testing, we measured adhesive flow rates using a series of nozzles with varying diameters, all under consistent pressure, temperature, and line speed conditions.
The results are illustrated in a detailed chart showing adhesive consumption as a function of nozzle size — giving production teams a clear picture of how much more (or less) adhesive is applied when switching from one nozzle size to another.
Get the Full Whitepaper
For packaging engineers and maintenance teams focused on reducing adhesive consumption, improving line efficiency, and cutting costs, this whitepaper provides valuable insights and actionable data.
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Understanding Nozzle Size and Hot Melt Adhesive Consumption — and discover how small changes in nozzle diameter can make a big impact on your bottom line.