News release | August 2026

ZRAY has introduced glue-saving stitch patterns for its hot-melt case former range — a software-driven adhesive application method that reduces hot-melt glue consumption by 25–35% while maintaining or improving bottom-seal strength. The feature is now standard on all new hot-melt machines and available as a software upgrade for existing ones.

The Math Behind Glue Consumption

Conventional bottom sealing applies a continuous glue bead along each bottom flap edge. For a typical case, that means a bead running the full length of the box — even though the seal only needs to resist the stresses concentrated at specific points.

A continuous bead on a 450 mm case edge uses about 2.2 g of glue per case at a standard 1.0 mm bead. But sealing stress is not uniform along the edge. With stitch (intermittent) application, the same edge can be sealed with 1.4–1.6 g — the difference is pure saving on every case.

At typical hot-melt pricing (USD 3.5–5.0/kg), a plant producing 1 million cases per year saves USD 2,800–4,400 annually — before counting the reduced tank energy, less char, and fewer adhesive stringing problems.

How Stitch Patterns Work

The glue-saving system is implemented entirely in the machine control:

• Programmed stitch geometry: the PLC controls the glue gun’s open/close timing, producing a pattern of glue segments with controlled gaps. The standard library includes 12 stitch patterns (continuous, 40/60, 50/50, 30/70 segment/gap ratios, edge-tight variants, etc.).
• Edge-reinforced stitching: segments are denser at case corners, where sealing stress concentrates, and sparser along the middle of the edge.
• Speed-compensated timing: the stitch frequency is synchronized to belt speed via an encoder, so the pattern stays geometrically identical from 8 to 40 CPM.
• Per-recipe selection: the pattern is stored per case recipe, so a light E-flute case can run a lighter stitch pattern while a heavy BC-flute case runs the denser variant.

Seal Strength: Tested, Not Assumed

Some packaging engineers worry that intermittent glue means weaker seals. The ZRAY test data says otherwise — if anything, the edge-reinforced pattern distributes stress better than a uniform bead:

The corner segments carry the load where it matters; the middle gaps simply remove glue that was not contributing to seal integrity.

Additional Green Benefits

• Less adhesive char: lower tank throughput means less thermal degradation and fewer char particles blocking nozzles.
• Lower tank energy: less glue melted per hour reduces the hot-melt tank heating load by an estimated 10–15%.
• Cleaner running: fewer glue strings and less adhesive bleed on the case surface improves the appearance of retail-ready packaging.
• Recyclability: less adhesive per case makes the board easier to repulp — a point that matters for brands with recyclability commitments.

Compatibility

The stitch pattern feature is standard on all new double-head high-speed case formers and hot-melt versions of the single-piece case erector and three-piece case erector. For existing machines with ZRAY’s current glue control system, it is a software upgrade — no new hardware required for machines with servo-controlled glue guns.

Availability

Glue-saving stitch patterns are available immediately on new orders and as a field upgrade for installed machines. Send us your case sizes, glue type, and annual volume, and we will calculate your exact annual glue savings with the stitch pattern applied.

Request a glue-saving calculation or message us on WhatsApp at +86 13681839278.