The Hidden Cost of Adhesive Spray Booths & Extraction in Industry

Adhesive spray booths and fume hoods are crucial for reducing health risks during spray contact adhesive applications, ensuring compliance with safety standards. However, they can also bring financial strain, time-consuming processes, and increased labour demands. Often, businesses accept these costs as necessary and unavoidable, but what if there was room for improvement? 

At Adkwik, we’re committed to helping your adhesive operations run safer, faster, and more cost-effectively. In this article, we’ll illuminate the hidden costs of booths and ventilation systems and share strategies for optimising operations without sacrificing safety. 

Industry Use of Spray Adhesive Booths & Fume Hoods  

Thanks to its convenient and reliable bonding properties, sprayable glue is vital in many industries. However, like many adhesives, the glue can contain harmful solvents or volatile organic compounds (VOCs). These elements pose health and environmental risks, particularly with frequent exposure. Employers must implement protective measures according to the UK Government’s Control of Substances Hazardous to Health Regulations 2002 (COSHH) legislation. 

Spray contact adhesives exacerbate health risks as they disperse into the air upon application, making particles easy to inhale and challenging to manage. Typically, employers turn to spray booths and extraction systems. This equipment is tried and tested, useful for creating controlled environments, containing overspray, and redirecting airborne contaminants. Since it’s the go-to solution, many don’t realise that there are alternatives that can improve safety, productivity, and profitability.

The Hidden Costs of a Spray Glue Booth and Extraction System

This equipment is beneficial, yet there are a few areas where it could cost your business. Below are a few instances.

Spray Adhesive Booth and Fume Hood Cost: 

Usually, spray booths and extraction systems carry a hefty upfront cost, plus installation, transportation, and assembly fees. Further outgoing expenses include:  

• Ongoing energy costs
• Extra infrastructure (e.g. sprinkler systems in case of emergencies)
• Personal Protective Equipment (PPE)

Maintenance Demands:

Spray booths and ventilation systems are complex, requiring time-consuming upkeep, checks and paperwork to prevent breakdowns, liabilities and costly repairs. Key maintenance tasks include the following:

• Daily to monthly in-house tasks and inspections – cleaning down overspray and inspecting fume hoods, ducts, lights, fans, alarms and filters for wear, damage or blockages.

• Measuring the airflow and monitoring contaminated levels regularly.

• Performing routine examinations and tests at least once every 14 months. Some systems require more frequent, monthly or six-monthly reviews. Employers must source and hire qualified contractors to conduct tests.

• Keeping comprehensive records of all tests, inspections, and repairs. The information must be available for at least five years and is crucial for compliance and future reference.

Training:

Staff must undergo training to use equipment properly and meet ever-evolving health, safety, and environmental regulations. This process demands investment in time, resources, and potentially external expertise. 

Failing to comply has severe consequences, including fines, legal liabilities and reputational damage. Improper training and misuse of equipment can also cause fire and explosion hazards, costly property damage and danger to employee safety.

Restricted Work Space:

Spray booths and extraction systems occupy considerable space in the workshop, which can constrain the working environment and prevent expansion opportunities. Exploring safe and practical alternatives could free up valuable space. You could bring in new machinery and explore new avenues to boost your business, giving you a competitive edge and profitability. 

Disruptions: 

Any issues or breakdowns cause delays and downtime, resulting in lost revenue and missed deadlines. Sometimes, these disruptions are entirely out of your control. 

For example, changes in HSE guidelines can render your current adhesive unsuitable for your existing extraction system overnight, meaning you must rethink your entire process. Adkwik has helped a client deal with this exact challenge – read about how we resolved the issue in our case study here. 

Reducing reliance on equipment can help mitigate the impact of breakdowns and regulatory changes, giving you more control over your operations.

Is there an Alternative? 

Explore our alternative adhesives and application methods below, some of which may be better suited to your production.

Switch to a Safer Sprayable Adhesive  

If you appreciate the ease and uniformity of spray contact glue, opt for a safer alternative, such as Timbond Professional NC Sprayable Contact Adhesive. This glue contains much safer solvents and is non-chlorinated and dichloromethane-free. 

You may still want to use booths and ventilation systems with this adhesive. However, the safer components significantly decrease hazardous residue and buildup within extraction filters. This process will improve employee health plus cut maintenance time and costs.

The NC sprayable glue is versatile and useful for bonding plastic laminates to MDF, chipboard, plywood and other materials. It also has tacky, pressure-sensitive properties and is excellent for foam, fabrics, and carpets. Use the canister with a portable spray gun and a stainless steel hose, ideally using a web spray tip. 

Choose a Different Type of Glue 

You can also eliminate the need for booths and ventilation systems by overhauling your adhesive process. 

1. Hot Melt Adhesive 

One alternative is to use a hot melt adhesive and apply it with an efficient Meler B4 Melter Machine Kit. Hot melt glue is applied directly to the substrate, eliminating concerns about the adhesive becoming airborne. This factor also helps save money by reducing product wastage.

We recommend using a zero-emission, solvent-free glue such as Timbond H509 to eliminate the need for spray booths, extraction and PPE. This glue is especially beneficial for upholstery industries as it bonds foam, insulation and carpet to most sheet materials.

Hire a Meler B4 Machine Today

If you don’t have the budget or resources to purchase and install a new machine, why not hire a machine from Adkwik? Whether you need the Meler B4 for a one-off project or long-term use, our flexible plan can accommodate your needs. Head to the Meler B4 product page and hit the ‘Enquire Now’ button to speak with our experts. 

2. Resin Adhesive 

For tasks such as veneering and laminating, you could swap your spray adhesive for a resin. While Urea Formaldehyde (UF) resin is popular thanks to its performance and cost-effectiveness, there are several concerns about the potential health effects of formaldehyde.

To have full confidence in the safety of your glue, opt for new product developments such as Ubabond U30. This rapid-bonding resin is free of formaldehyde, solvents, and VOC emissions, making it much safer to work with and reducing the need for spray booths and fume hoods. 

Optimise your Adhesive Process with Adkwik 

If you’re dealing with a specific adhesive issue, our team of experts can help. From identifying the correct glue to reviewing your process, we can learn about your business and your requirements. 

Get in touch and benefit from our expertise by filling out our online contact form or calling 01223 412373. We look forward to hearing from you!