Hot Melt Troubleshooting: Bond Failures

Bond failures can bring even the most efficient packaging line to a halt. From pop-opens to weak seals and costly rework, the root causes are often subtle… but the impact is anything but. That’s why understanding why bonds fail — and what you can do to correct them — is essential for keeping production moving smoothly.

In this edition of our Hot Melt Troubleshooting series, we take a closer look at three of the most common bond-failure scenarios our technical team encounters on site. If any of these sound familiar, make sure you download the full Hints & Tips Sheet using the form — it’s packed with practical fixes and proven actions you can take today.

1. Adhesive on One Side of the Board (Constantly)

When adhesive consistently appears only on one surface, it’s a sign that something in the setup is fundamentally off. Only one flap gets coated, the other doesn’t bond and cases pop open under the slightest pressure.

Our tips sheet explains the specific checks you need to make, the adjustments required, and how to verify the fix.

2. Adhesive on One Side of the Board (Intermittently)

Intermittent bonding problems can be some of the trickiest to diagnose. One moment the glue pattern looks fine… the next, there’s nothing on the flap at all. The downloadable guide outlines how to identify the cause and the step-by-step actions to resolve it.

3. Adhesive on Both Sides of the Board (But Still Failing)

When the glue is clearly present on both flaps but the bond still doesn’t hold, something deeper is going wrong. The hints and tips sheet walks through the diagnostic questions our technicians use on site, helping you pinpoint exactly where the bond is breaking down.

Want the Full Troubleshooting Guide?

The blog only scratches the surface. Our Hot Melt Bond Failure Hints & Tips Sheet gives you:

• A deeper breakdown of the three major failure modes

• The root causes behind each issue

• Corrective actions and preventative measures

• Operator-friendly checks you can print out and keep at the line

• Practical advice from Alphabond’s technical specialists

If you’re facing pop-opens, weak bonds, or unexplained failures, this guide will save you hours of downtime.

👉 Download it now using the form on this page.