Situation:

A low voltage transformer manufacturer in India was using a heat curable epoxy for lamination stacking and was experiencing very high energy costs and limited production line output. They were looking for an alternative solution that would increase production output and reduce energy costs.

Challenges:

The manufacturer was facing multiple challenges due to their current solution:

• The heat curing process of epoxies requires a lot of electrical energy to heat parts to 125^oC. for 90 minutes
• Process time of 6 hours created WIP, required more floor space, and led to limited line output

Both rising electrical costs and reduced productivity increased end product price and reduced market share for them.

Solution:

Post understanding manufacturer’s requirement of faster, room temperature curing adhesive that reduces energy costs and increases production output, the Henkel solutions expert suggested LOCTITE EA E-30HV epoxy structural bonder for stacking mild steel laminations in transformer.

LOCTITE EA E-30HV was manually mixed and applied to laminations using a metal spatula. This then cured at room temperature and attained handling strength in 3 hours.

Results:

Bonding with LOCTITE EA E-30HV:

• Cut down high energy costs by eliminating of the need for an oven curing process
• Doubled productivity by eliminating the 3 hour additional cool down period
• Stabilized production costs allowing more flexibility with market pricing