Adhesives and sealants: Production route
Water-borne, hot melt or reactive: how adhesives set
What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.Adhesives are classed by how they set. Water-borne dispersions dry by losing water. Hot melts are solid thermoplastics applied molten that set on cooling. Solvent-borne systems dry by solvent loss and are being squeezed by VOC rules. Reactive adhesives (epoxy, polyurethane, cyanoacrylate, silicone, MS polymer, acrylic) cure by chemical reaction and give the strongest bonds. Pressure-sensitive adhesives stay tacky and bond under light pressure. Each relies on a different monomer chain: VAM and acrylates, EVA and polyolefins, isocyanates and epoxies, silicones.
Routes compared
| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| Water-borne dispersions (PVAc, VAE, acrylic, starch and dextrin) | the largest technology by volume, roughly 40-45% (indicative) | about 400-550 kg polymer solids (largely from VAM or acrylates) and 450-600 kg water per t (indicative) | emulsion reactors of 10-100 kt/yr | near 100% | wash water | VAM is the swing cost; PVAc dispersion about 1.0 t CO2e per t (Omya) |
| Hot melts (EVA, polyolefin, styrenic block copolymers, reactive PU hot melts) | about 20% of volume (indicative) | about 30-40% polymer, 30-40% tackifier, 20-30% wax or oil (indicative) | 1-50 kt/yr extrusion and mixing | near 100% | little | polymer and tackifier prices; energy to melt at the user |
| Reactive adhesives and sealants (epoxy, PU, cyanoacrylate, silicone, MS polymer, acrylic) | about 20% of volume and a higher share of value (indicative) | epoxy resin and amine hardener, or isocyanate and polyol, or silicone polymer plus fillers (indicative) | small to mid-size batch plants | near 100% | isocyanate and amine handling residues | high value per kg; feedstocks from the epoxy, polyurethanes and silicones tiles |
| Solvent-borne adhesives (polychloroprene, SBS, nitrile, PU contact) | about 10% of volume and falling (indicative) | about 600-800 kg solvent per t (indicative) | small batch plants | near 100% | VOC emissions on use | solvent and rubber prices |
How each route works
Water-borne dispersions (PVAc, VAE, acrylic, starch and dextrin)Polymer particles dispersed in water. Bonds form as water soaks into porous substrates such as wood and paper. White glue, carton sealing, wallpaper paste and many PSAs.
cheap, safe, low VOC; slow on non-porous surfaces, poor water resistance unless cross-linked
Omya sustainability toolkit; indicative Hot melts (EVA, polyolefin, styrenic block copolymers, reactive PU hot melts)100% solids thermoplastic blends melted at about 120-180 C and applied as beads or sprays; set in seconds. Used in packaging lines, bookbinding, hygiene nonwovens and woodworking edge-banding.
fast, no solvent; limited heat resistance
indicative Reactive adhesives and sealants (epoxy, PU, cyanoacrylate, silicone, MS polymer, acrylic)One- or two-part systems that cure by moisture, heat, mixing or UV. Structural bonding in cars, aircraft, wind blades and electronics; sealants for glazing and construction joints.
strongest bonds and durability; more toxic precursors and harder to debond and recycle
indicative Solvent-borne adhesives (polychloroprene, SBS, nitrile, PU contact)Rubber or resin dissolved in toluene, acetone, hexane or esters; contact adhesives for footwear, furniture laminates and rubber.
instant grab; flammable, VOC-heavy, health risks to workers
indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.