Reducing CO₂ emissions through optimized adhesive application

09. September 2026 4 min.

Rolf Gräser, Industry Manager Packaging

Measures to improve sustainability in production processes are often considered costly. However, in industrial adhesive application, targeted optimization of adhesive consumption offers both environmental and economic benefits. In the packaging industry in particular, this can reduce CO₂ emissions while simultaneously lowering production costs. We’ll show you how to achieve this.

Icon for CO2 reduction: the Volta hot melt adhesive stitching application head, the Performa heated hose, and the Vision adhesive melter—Robatech’s best solution for sustainable adhesive application.

Where does the largest carbon footprint occur in adhesive application?

A closer look at the carbon footprint of an adhesive application system with a melt rate of up to 8 kg/h reveals that the operational phase accounts for the largest share of the environmental impact. Over a ten-year life cycle, the hot melt adhesive throughput accounts for 429 metric tons of CO₂-eq., followed by electricity consumption at 13.7 t CO2eq. Excluding the operational phase, the environmental impact of an adhesive application system amounts to only 1.55 t CO2eq.

Graph showing the environmental impact of an adhesive application system over its entire life cycle.

Consequently, approximately 99% of CO₂ emissions from industrial adhesive application occur during adhesive production and the melting of the adhesive. The greatest and most direct way to reduce CO₂ is therefore through economical adhesive application. Particularly in the packaging industry, which primarily uses bead application, Scope 3 emissions can be significantly reduced by optimizing adhesive application quantities.

How much adhesive do you really need?

For secure bonding, a sufficient amount of adhesive must be applied to the correct location. But what does “sufficient” mean? More adhesive does not automatically mean stronger adhesion. To verify adhesion, the transverse tear strength can be used as a performance indicator. It describes the force required to tear or separate a bonding or a material across the intended direction of force. This provides a reliable answer to:

whether functional reliability is maintained despite material savings,
whether the seam strength is sufficient for transport and handling stresses.

Tests show that shorter beads or dot applications require a greater tear-off force than longer beads. This is exactly where hot melt stitching comes into play: Instead of applying the adhesive as a long bead, the application is divided into short beads or dots. This allows the amount of adhesive to be reduced while maintaining a secure bonding.

How much adhesive does hot melt stitching save?

The following real-world example demonstrates how optimizing adhesive application can positively impact glue consumption.

On a carton sealer with a throughput of 40 cartons per minute, the two pneumatic jetting heads used for gluing the lid flaps were replaced with electric jetting heads. This step was necessary because the application of many small beads or dots requires a high switching frequency and a large number of operating cycles.

Table comparing the parameters—application head type, application nozzle, heated hose, adhesive melter, pump pressure, and adhesive consumption—before and after the optimization of the adhesive application system.

Cardboard flap gluing: Reduction in adhesive consumption through hot melt stitching and subsequent process optimization

Originally, 18 g of adhesive was applied per carton. The introduction of hot melt stitching resulted in glue savings of 8.2 g. The subsequent optimization of the application process led to a further savings of 2.6 g per carton. This results in a total adhesive savings of 60%.

Savings at a glance

Projected over a full year of operation, optimizing adhesive application yields benefits on multiple levels. The example of the carton sealer mentioned above demonstrates that using a smaller amount of adhesive significantly reduces CO₂ emissions and adhesive costs. Additional savings on maintenance and replacement parts result from the use of electric application heads. These operate without compressed air and therefore do not require a dynamic seal or solenoid valve. Furthermore, the service life of Volta, the hot melt stitching head from our example, is up to two billion operating cycles. Although stitching results in a switching frequency up to four times higher than that of bead application with a pneumatic jetting head, the lifetime is ten to forty times longer, depending on the comparable pneumatic model. In summary, the following savings result:

CO2 reduction: 24,42 t per year
Savings on adhesive costs: 12,285 euros per year for gluing lids and bottoms
Savings on maintenance and replacement parts: 4,040 euros per year
Return on Investment (ROI): 9,4 months

Less CO₂, lower costs, secure bonding

The use of an electric application head with a hot melt stitching function, as well as the targeted optimization of the application process, directly reduces CO₂ emissions. By reducing the amount of hot melt adhesive applied, production costs are lowered and the reliability of the bonding actually increases. In industrial adhesive application, sustainability is therefore not a cost factor—but rather a driver of efficiency with measurable economic benefits.

Are you curious about how you can specifically improve your metrics for CO₂ emissions and adhesive consumption? We’d be happy to analyze your gluing process and, if desired, calculate your ROI.

Rolf Gräser, Industry Manager Packaging

Rolf Gräser has worked in the packaging industry for 30 years. As Industry Manager Packaging at Robatech in Muri, Switzerland, he uses his in-depth expertise to incorporate the environmental and economic needs of the market when developing new adhesive application systems and components.

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Where does the largest carbon footprint occur in adhesive application?

How much adhesive do you really need?

How much adhesive does hot melt stitching save?

Savings at a glance

Less CO₂, lower costs, secure bonding

Rolf Gräser, Industry Manager Packaging

COMMENTS

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