The adhesive volume is now electronically controlled with the new equipment using 24V signals to activate the electric valves, instead of adjusting the volume using nozzles and pneumatic pressure.
Mundo EXPO PACK
Topo Chico is a mineral water brand with 130 years of history in U.S. and Mexican markets, but more recently in 2017 was purchased by Coca-Cola. Today, Arca Continental, the Topo Chico bottling plant in Monterrey, Mexico has six production lines, where the processes of bottling, filling, capping, and assembling boxes and trays with bottles are carried out, in configurations of 4, 6, 12, 18, and 24 units, according to market demand.
Recently, the company introduced a what it says is a major technological innovation that aligns both with its environmental commitment and its drive for operational optimization. In 2024, the company installed two Valco Melton's EcoStitch electric hot melt adhesive application systems to enhance efficiency in box gluing and sealing, deliver significant cost savings, and reduce waste.
Stakeholders say that the systems enabled Topo Chico to optimize adhesive dosing and application on boxes, cutting consumption by 55% and enhancing precision in the gluing process. In addition to operational savings and greater overall plant efficiency, the company has also reinforced its commitment to environmental sustainability by minimizing waste and reducing its carbon footprint.
“Valco Melton’s EcoStitch equipment allows process stability, economic benefits, and achieving high-quality packaging that meets North American consumer expectations. Now we prioritize solid packaging, functional for transport and visually attractive, adapted to market demands,” says Federico Arámbula, production manager at Topo Chico’s plant.
This innovation positions the Monterrey plant as a pioneer in Mexico, becoming the first in the beverage production sector to adopt Valco Melton’s technology, and further consolidates its leadership in both the industry and sustainable practices
Improving secondary packaging efficiency and quality
Topo Chico says its main objective with this change was to address complaints from the North American market about delaminated corrugated cases in 18-pack, 500-mL packages across three flavors. The issue was particularly critical in packs containing heavy, high-volume glass bottles (averaging 15 kg), which compromised safety and caused losses for customers. A second key goal was to cut the high costs linked to excessive glue consumption in the previous system, which relied on pneumatic guns and offered no way to optimize usage without affecting packaging quality.
“By implementing the EcoStitch system, we eliminated complaints about poorly glued boxes, significantly boosting line efficiency. Its electronic dosing ensures consistent adhesive application, unlike the old pneumatic system, which was prone to clogging,” says Roberto Iván Ontiveros, corporate manager of Manufacturing Strategy, Maintenance, and Digitalization at Arca Continental.
At the plant, the shortcomings of the previous adhesive application system were evident, making it necessary to seek a solution that would not only lower operating costs but also enhance precision and reliability in the box assembly and sealing process.
To meet these objectives, the acquisition of two Valco Melton EcoStitch systems was decisive. The first piece of equipment, installed in March 2023, is a gun conversion system for wrapping, with six valves and four firing modules controlled by VD2, used to apply hot melt in the assembly and sealing of boxes for 12- and 18-unit glass bottles.
The second equipment also features a gun conversion configuration, with two single-module firing valves, and is installed on a tray former machine for 600-mL bottles.
“The gun conversion technology allows maintaining the original melter tank and only changing the guns and adding firing controllers; furthermore, the EcoStitch valves are compatible with tanks from other brands,” explains Salvador Rodríguez, hot melt packaging specialist at Valco Melton.Electric valves have played a decisive role in the equipment, since they can fire up to ten times faster than pneumatic valves and do not require O-rings to keep the air compressed.Mundo EXPO PACK
Successful implementation
The first step in the implementation was an adhesive audit conducted in January 2023 to assess the performance of Line 4 at the OCME case former, which was still operating with the previous pneumatic gluing system.
“That system offered no upgrade options to optimize adhesive use without compromising box sealing quality,” explains Arámbula.
This evaluation enabled the Topo Chico and Valco Melton teams to align and make the necessary technical adjustments to the new system in advance.
To measure the precise weight of the adhesive, masking tape was used in the application area on 18-bottle cases so that the adhesive could be removed without cardboard. This method facilitated comparison between the pneumatic valves of the previous system and Valco Melton’s electric valves.
In tests carried out on the Line 4 OCME case former, which operates at a speed of 18 cases/min (1,080 cases/hour), the pneumatic valves consumed an average of 1.65 grams of adhesive per valve, totaling 9.9 grams per case with six valves. In contrast, Valco Melton’s EcoStitch electric valves averaged 0.85 grams/valve, reducing total consumption to 4.95 grams/case, demonstrating significant adhesive optimization.
The test analysis highlighted that the EcoStitch system offered significant functional and aesthetic advantages thanks to its precision and flexibility in adhesive applications. Unlike the pneumatic system, which generated waste and large amounts of adhesive stringing, EcoStitch eliminated this problem through independent valve module control, which reduced glue tank pressure and achieved more precise applications. Additionally, the electric design of the Valco Melton system allowed adjustment of the size and spacing of adhesive dots, optimizing consumption and reducing hot melt waste.
In March 2023, a second installation was completed that included the full conversion of six valves (four side and two top) to improve the first installation limited to only two valves. During this implementation, key information was collected, such as the total adhesive weight applied in 12- and 18-bottle cases and the reduction in downtime due to adjustments in the pneumatic system.
Challenges overcome
The main challenge during installation was not only proving that replacing pneumatic applicators with the EcoStitch system improved box sealing but also showing that the savings achieved would deliver a full return on investment in under six months.
Achieving this goal was largely thanks to the electric valves, which fire up to ten times faster than pneumatic ones and eliminate the need for O-rings to maintain compressed air. This allows for continuous cycles and greater durability. With electronic control of adhesive flow, the system applies small, precise amounts of glue, reducing material use without compromising seal quality and ensuring consistent, reliable placement. Additionally, EcoStitch delivers stronger bonds than traditional bead patterns, enhancing box integrity and flexibility while shortening drying times.A special feature of the EcoStitch system is that it dispenses the glue in dots, which prevents the runoff common with the previous system. This reduces waste in conveyor systems and in the machine.Mundo EXPO PACK
Technical considerations for implementation
In May 2023, several tests were conducted with nozzle sizes in pneumatic valves to optimize adhesive use. Initially, nozzles of .016, .018, and .020 inches recommended by Valco Melton were tested, and it was confirmed that 0.020-inch nozzles offered the best results in terms of performance and consistency in adhesive firing. “Downtime due to nozzle clogging decreased by 80–85%,” explained Engineer Ontiveros.
At the same time, adjustments were made to valve temperatures, setting them uniformly at 170°C (330°F) after detecting variations that affected adhesive performance. Likewise, a 45-day trial with the EcoStitch system was completed, which confirmed advantages in adhesive savings, elimination of off-box firing, and reduction of stoppages due to pneumatic valve adjustments.
The installation process, carried out in mid-2023, also included the integration of a stainless-steel cabinet with digital control, which allows efficient management of the EcoStitch electric gun systems. The initial tests, conducted over a 60-day period, allowed adjustments in pressure, nozzle, and temperature parameters and confirmed that the electric gun system was compatible with different hot melt adhesives.
Clear benefits
From a broad perspective, the EcoStitch system has improved the overall equipment efficiency (OEE) at the Topo Chico plant, reduced total cost of ownership (TCO), and minimized machine stoppages by eliminating the need for electro-pneumatic adjustments in the adhesive system, thus optimizing process productivity and reliability.
By migrating to this system, valve repair kits were eliminated, which reduced maintenance costs. As explained by Engineer Salvador Rodríguez, Hot Melt Packaging Specialist at Valco Melton, the EcoStitch system has improved efficiency by eliminating compressed air, spare parts, nozzle clogging, downtime, poor adhesive issues, and routine maintenance.
With the new equipment, adhesive volume is electronically controlled via 24V signals that activate the electric valves. Instead of relying on nozzle adjustments and pneumatic pressure, the system enables dot size changes (ranging from 2 mm to 9 mm) at the press of a button. A dedicated controller, linked to the PLC, regulates both adhesive volume and application patterns—whether continuous beads, dots, dot spacing, or uniform dot counts—according to the received input signal.
A distinctive feature of the EcoStitch system is its ability to apply glue in precise dots, preventing the dripping issues common with the previous system. This not only reduces waste in transport lines and packaging formers but also eliminates the extra cleaning time previously required, explained Engineer Arámbula, Production Manager at Topo Chico. Engineer Ontiveros added that the lower adhesive consumption also had a direct positive impact on packaging quality.
Environmental impact
Beyond the operational and economic advantages, the transition to the EcoStitch system also delivered clear environmental benefits. By reducing the use of chemical adhesives and eliminating waste, Topo Chico not only lessened its environmental footprint but also advanced its carbon reduction targets and improved resource efficiency.
“Since implementing the system, we have significantly reduced adhesive consumption and, consequently, the amount of waste generated. This reinforces our commitment to sustainability,” explained Engineer Arámbula.
This technological shift is part of Topo Chico’s broader strategy to align with leading sustainability practices, as reflected in its plan to extend hot melt adhesive systems to additional Arca Continental production lines.
Training and technical support
The integration of the new technology, in addition to involving changes in equipment, also required a comprehensive training approach. Valco Melton offered extensive training for operational and mechanical staff, ensuring that the use of the EcoStitch system was efficient and optimized. “Both theoretical and practical training allowed us to quickly adapt to the new systems, which was key to the success of the project,” comments engineer Roberto Ontiveros.
Valco Melton also provided ongoing technical support, including periodic preventive maintenance visits and recommendations for storing critical spare parts, which has guaranteed the operational continuity of the plant’s operations.
Looking ahead
Building on the success of the first implementation, the Topo Chico plant now plans to expand the use of EcoStitch systems to additional packaging lines, including those operating at higher speeds of up to 1,000 bottle/min.
“We are considering implementing these systems in our higher-speed lines, which will allow us to further enhance efficiency and reduce costs,” concludes Arámbula. PW
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Electric valves have played a decisive role in the equipment, since they can fire up to ten times faster than pneumatic valves and do not require O-rings to keep the air compressed.Mundo EXPO PACK
