Hot melt spray adhesives have become a key bonding solution for modern mattress production thanks to their eco-friendly, solvent-free nature, strong bonding performance, and stable quality. Among them, pressure-sensitive hot melt spray adhesives are widely used for laminating materials such as foam, non-woven fabrics, and textile layers in mattresses.
This guide summarizes recommended machine settings, common issues, and practical troubleshooting tips to help manufacturers achieve stable, high-quality bonding results.
1️⃣ Recommended Application Parameters
To ensure optimal bonding, set your spray equipment as follows:
Tank temperature: 145–175 °C
Hose temperature: 150–175 °C
Nozzle temperature: 155–180 °C
Adhesive output: 20–40% of max flow
Air pressure: 2–4 kg/cm²
Spray distance: 20–40 cm
🔹 Spray pattern:
For most mattress applications, a spiral spray pattern gives the best bonding effect. Some manufacturers prefer a more atomized pattern similar to traditional solvent-based sprays; if so, make sure the atomization is not too fine (avoid a “spider web” effect), which can lead to false bonding and weak adhesion.
🔹 Material preparation:
The foam, non-woven fabrics, and other substrates must be clean and dry — free from dust, oil, or moisture.
⚠️ Current hot melt spray products are not recommended for plasticizer-rich materials. If unsure about the material’s formulation, always test the adhesive first.
🔹 Open time:
Our spray adhesives are designed with an open time of 5–10 minutes. Complete lamination within this window to ensure proper adhesion strength.
2️⃣ Common Bonding Issues & Solutions
Q1: Poor Initial Tack — Adhesive doesn’t stick well?
Possible causes:
Ambient temperature is too low
Adhesive layer is too thin
Tank/nozzle temperature is too low
Solutions:
Use a winter-grade formula or an adhesive with better low-temperature performance
Increase adhesive output to recommended levels
Adjust tank/nozzle temperature upward following operating guidelines
Q2: Adhesive won’t spray out
Possible causes:
Filter or nozzle blockage
Melt temperature too low
Spray gun air pressure too low
Air trapped in delivery hose
Adhesive viscosity too high
Solutions:
Clean filters and nozzles regularly
Increase melt temperature to recommended range
Increase spray gun air pressure
Bleed air from the delivery hose
Switch to a more suitable viscosity adhesive
Q3: Partial bonding or delamination after pressing
Possible causes:
Uneven spray (too much or too little glue in areas)
Uneven pressing pressure
Unstable production conditions
Solutions:
Recalibrate spray pattern and output
Apply even pressure during lamination
Ensure consistent operating conditions or switch to an adhesive with wider process tolerance
Q4: Excessive smoke or strong odor during spraying
Possible causes:
Melt temperature set too high
Equipment malfunction
Contamination or excessive moisture in raw materials
Poor-quality adhesive
Solutions:
Lower melt temperature to the recommended range
Inspect and repair equipment if necessary
Keep the working area and glue tank clean
Switch to high-quality, low-VOC adhesives
Q5: Delamination — glue only sticks to one side
Possible causes:
Temperature, air pressure, or output too low
Lamination done outside the open time window
Material not compatible with adhesive
Solutions:
Adjust temperature, air pressure, and spray output to optimal settings
Complete lamination within the 5–10 min open time
Replace substrate or select a better-matched adhesive
✅ Final Tips
Stable temperature control and proper material preparation are critical to avoid bonding failures.
Regularly clean filters and nozzles to maintain smooth adhesive flow.
Always test new materials or suppliers before mass production.
HUJUMP provides a full range of pressure-sensitive hot melt spray adhesives designed for mattress production — offering strong initial tack, eco-friendly formulations, and low VOC emissions. Our technical team can help you fine-tune parameters and choose the best adhesive grade for your production line.
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