Standard Features:��High Shear Oakes Stainless Steel Mixing Head��Power: 230/460 3PH 60Hz��A-B™ Operator Interface with on-screen glue usage display��Bladder Tank for immediate “on demand” glue delivery��Fully adjustable Density/Pump controls��Precision Flowmeter for Controlled Air Injection��Multiple Feed Capability��Low maintenance Eccentric Seal-less Pump��Double Mechanical Pressurized Seal��Stainless Steel frame with easy access doors��Automatic Purge Valve for simplified shut down��High Visibility LED Stack Light

Optional Equipment:��Automatic Bypass System to switch between foaming and non-foaming applications�� Injection System for cross linking��Ethernet Grace Port��Level Sensor control package��Color Touch Screen��Other power voltages available

Save up to 40% on your adhesive useage!

E.T. Oakes Corporation686 Old Willets Path Hauppauge, NY 11788tel: (631) 232-0002 fax: (631) 232-0170e-mail: info@oakes.com www.ad-foam.com

Ad-Foam

™ A

DF Series

Ad-Foam™ ADF adhesive foamers produce a continuous, precisely homogenized mix of adhesive and air. Mixing air into adhesive allows users to save up to 40% on adhesive consumption without effecting bond quality. A reduction in adhesive usage also means that the amount of water in the process is reduced proportionately, resolving a myriad of troublesome moisture related problems.

Ad-Foam™ improves lay-flat while minimizing grain rise, washboarding and buildup on knives. Setting speeds are faster, VOC’s are reduced and there is excellent holdout on recycled or highly absorbent substrates due to higher foam viscosity. This system works with most process methods and does not require reformulation.

Ad-Foam™ is compatible with:

��PVA��PVOH��Dextrin��Latex��Acrylic��Coatings��Starch��UF Resins

Advantages of foamed adhesive include:

��Use up to 40% less adhesive��Better Lay-flat��Less Moisture��Faster Speed of Set�� Increased Tack��Lower VOC Emissions�� Improved Rheology

This unit can accommodate continuous production or multiple lines. Average installation and set up takes just one day. Once production parameters are set, the opera-tor simply presses the start button and the machine will automatically run your daily production.

For further information, or for quantity discounts, please contact an Oakes Sales Engineer at: 631-232-0002.

ADF-2

E.T. Oakescorporation

www.ad-foam.com

PVA

PHOV

Dextrin

Latex

Acrylic

Use with:

Coatings

Starch

UF Resins

2M-ADF 4M-ADF 8M-ADF Rated Capacity in Pounds Per Hour

ADF shown below w/upgraded A-B PanelView™ & Ethernet port

up to 300 lbs/hr

up to 700 lbs/hr

up to 1200 lbs/hr

AD-FOAM, the adhesive foaming system from E.T. Oakes Corp., Hauppauge, N.Y., is continuing to slash costs for users of water-based PVAc adhesives in litho-laminating,

bulk box laminating, panel laminating ( paper or vinyl), and paper laminating. This continuous foaming system is designed to address the major problem with all water-based systems: the water itself. The Ad-Foam system produces a continuous, precisely homogenized mix of adhesive and air. Mixing air into adhesive allows users to maintain bond integrity using the same volume of bonding material with 25 to 40 percent less adhesive. The amount of water in the process is reduced proportionately, resolving a myriad of troublesome moisture related problems. Ad-Foam improves lay-flat while minimizing grain rise and buildup on knives. Setting speeds are faster and there is excellent holdout on recycled and highly ab-sorbent substrates due to higher foam viscosity. This system will work with most process methods and does not require reformulation. Within two years, the Ad-Foam system has been successfully inte-grated into many large scale adhesive applications. Customers across the country are saving between 25 and 40 percent in adhesive costs while enjoying waste reduction, lowered VOC emissions and more efficient glue lines. Ad-Foam’s success is attributed to a powerful combination of modern computer controls and the mixing head technology originally patented by E.T. Oakes in 1946. Quality foam-ing requires an understanding and tight control of five dependent vari-ables: residence time, rate of shear, back pressure, temperature, and air flow. The control program is based on years of hands-on practical experience with aerating equipment. Ad-Foam combines an Oakes Foamer with precision controls to meet the needs of the adhesives end user. The heart of Ad-Foam is a compact mixing head consisting of three parts: front stator, rotor and rear stator. Each internal surface is covered with concentric rows of teeth. As the rotor re-volves between the two stators, the rows of concentric teeth mesh perfectly without contacting. All mixing takes place between the teeth of the rotor and the two stators. Adhesive and compressed air enter the mixing head through

the center of the rear stator. Any material passing through the head is first forced in a radial path through rows of teeth, from the center to the outer edges of the stator. Product travels up, over the revolving rotor and into the front stator, again flowing radi-ally between the teeth and exiting through the center of the front stator. The high shear Oakes Mixing Head produces a continuous stream of very fine and uniform cell structure. Foam is discharged under pressure and piped through a flexible hose di-rectly to the point of use, eliminating manual handling. Ad-Foam is completely automated via the “Oakes-Touch”

Mixer Controller. This touch screen interface puts several features at your fingertips: automatic density con-trol, multi product demand tracking, activity log of process line history, and password security. Multi-level touch screens guide the user through complete diagnostic checks as the system automatically monitors and compensates for wear over the life of the machinery. The Ad-Foam package features: AC variable frequency drives, digi-tal tachometers for pump and rotor, in-line strainer for mixing head pro-tection, double mechanical seals, and solenoid air shut-off valve. Back pressure is regulated by the “Smart Accumulator,” which is capable of automatically supplying foamed adhesive to more than one roller location. Foamers are mounted on stainless steel frames with swivel lock and brake casters. Optional equipment includes: thru-stator injection ports and pre-cision metering pumps for injecting

liquid catalyst directly into the mixing head. Catalysts enable cross-linking adhesives and in-line formulating while foaming, reducing labor costs & waste while improving catalyst dispersion. Ad-Foam systems are available in several sizes suitable for lab, pilot and production requirements. Each machine is engineered to customer specifications and fabricated in 300 series stainless steel. Reconditioning and retrofitting services are available over the lifetime of the equipment. All parts are made in the U.S. Simple to install, Ad-Foam quickly ties into the existing system with its own delivery process and level controls. Installa-tions and start-ups are typically completed in one day. For further information, visit the E.T. Oakes web site at www.ad-foam.com. Or call 631/232-0002..

Product of the Month

Ad-Foam is E.T. Oakes’ newest foaming system devel-oped specifically for the adhesives end user. The con-tinuous foaming system is designed to address the major problem with all water-based systems-the water itself.

Reprinted from PAPERBOARD PACKAGING, October 1999 AN ADVANSTAR PUBLICATION Printed in U.S.A

PAPERB ARDPACKAGING

Ad-Foam Assures Bond Integrity With Less Adhesive

E.T. Oakes Ad-Foam™ System

Reduce adhesive usage up to 40% without reduction in bond characteristics

Easy to operate

Precisely controlled foamHomogeneous cell structure

Cross Linking Capability

Remote Diagnostics

Ad-Foam™ CLX:

www.ad-foam.com

E.T. Oakes Corporation686 Old Willets Path Hauppauge, NY 11788tel: (631) 232-0002 fax: (631) 232-0170e-mail: info@oakes.com

F E A T U R E S B E N E F I T S

The Ad-Foam™ CLX adhesive foaming system allows you to reduce your adhesive usage (and associated moisture) up to 40%, while improving glue line appearance and cutting down on waste. Built to Oakes’ exacting standards, the CLX is the most accurate foaming and cross linking system available.

The Ad-Foam™ system couldn’t be easier to use. A simple Touch Screen guides you through the entire process. Powerful software automatically manages the glue puddle level while maintaining foam density regardless of line speed changes. If you decide to shut down the entire line, you can restart without any changes to foam density.

The CLX continuously calculates, tallys and displays glue usage in pounds/1000sq’. Even installation is easy - taking less than one day.

Ad-Foam™ systems are available in several configurations. Machines can be custom built to suit any application, requirement or budget.

Foamed adhesive can be applied via:

J Roll Coater J Extrusion J Gravure CoaterJ Slot Nozzle J Spray

toll free: 1-(877)-foamers

E.T. Oakescorporation

Just Add Foam

High-Shear Mixing Head (pictured left) vs. Low Shear Mixing Head (pictured right)

BENEFITS OF FOAMINGFoaming brings the following benefits tothe end user.

• Better lay flat: less glue means lesswater

• Better bond: more adhesive at theinterface of the substrates

• Better hold out on absorbent substrates• Improved open times• Faster setting• Increased wet tack• Improved filming characteristics• Reduced adhesive usage, up to 50%

APPLICATIONS FOR FOAMINGFoaming was reintroduced to the convertingmarket several years ago, first in single-facelaminating and later into both the converting and product assembly markets. The single-face application lent itself very well tofoaming due to the need for reduced warp,cost reduction pressures and the large volume of adhesive used.

Following are the only limiting factorsto foaming.

• The ability of the adhesive companies to formulate a foam-friendlyversion of their adhesive brand

• A low coat weight limit, usually 1 mil.• An application method not suitable

for foaming, e.g., recirculating adhesive system, spray, etc.

Below is a growing list of applicationsand markets where foaming is currentlyin use.

CONVERTING:Single-face laminatingBulk-box laminatingTube windingPaper-to-paper laminatingArtist mat boardCeiling tilesFoam-to-paper and -boardMulti-wall bags

PRODUCT ASSEMBLY:HPL laminatingDoor manufacturingPaper and vinyl to particle board, MDF,

Lauan and gypsumDrawer wrapFSK to OSBPanel manufacturingVeneering

FORMULATION CONSIDERATIONSFoaming is compatible with most water-based adhesives, including: PVA, VAE,Dextrin, starch based, acrylics, UF resins,casein, and polyvinyl alcohol. As statedearlier, it is paramount to good foamingthat the defoamer be removed from theadhesive manufacturing process. A typical adhesive with defoamer will onlyaccept about 15% air and the foam willbe very unstable, resulting in very little,if any, actual benefits.

When formulating a foam-able adhesive for an application, these basic fundamentals need to be kept in mind.

• Let the foamer do the foaming. Inorder to achieve the desired densityreduction and to keep the adhesivestable, the foam needs to be produced by the foamer only. If theadhesive continues to foam uponintroduct ion to the appl icat ionpoint, the adhesive will become"overfoamed" and will not perform.The addition of foaming agents to aformulation is usually not needed.

• The application method will determine formulation. Considerationsmust include the type of roller beingused, the amount of shear thefoamed adhesive will be subjected toon the roller, and whether or not itis an extrusion application.

• The adhesive must perform bothfoamed and un-foamed. An adhesive must not be formulated in sucha way so it will only work for a customer when it is foamed.

• If a customer could use a filled

product, they would be using itnow. Foaming will not change thebasic bonding characteristics of anadhesive. Trying to recover lostmargin dollars by filling a productwith clay or calcium carbonate willonly result in adhesive failures.

• In almost al l cases, the onlydefoamer that can be in the adhesive is the defoamer that is in theraw polymer itself. Even a very

Reprinted with permission from Adhesives & Sealants Industry magazine, BNP Media

small amount of defoamer added to an adhesive to aid in the adhesive manufacturing process will dramatically decrease the foama-bility of the adhesive and its effectiveness for an application.

• Highly plasticized PVAs (10%+) will not foam as well.The addition of a surfactant may be needed.

• Foaming increases viscosity. Foamable adhesives are usually lower in viscosity. Determine the lowest possible viscosity for an application and then formulate the adhesive.

• Foaming changes the rheology of an adhesive. The flowcharacteristic of an adhesive will change as the amount ofair increases. This change allows a foamed adhesive to actas a void filler and to stay where it is applied, keeping moreof the adhesive at the substrate interface.

• Upper limit to density reduction. When an adhesive isfoamed, the density is reduced by the amount of air that isincorporated into the adhesive, usually in the 10-45%range. It is usually not recommended to reduce the densityby more than 50%. At this point, the foamed adhesivebegins to act like a solid rather than a liquid, and problemscan occur with the application.

MARKETING STRATEGIESWith the continual expansion of foaming into a wider range ofmarkets and applications, adhesive manufacturers are presentedwith a new set of challenges. In a market that is static, at best,for water-based adhesives, manufacturers are struggling to maintain market share and margins, let alone trying to increase sales.To adhesive sales managers, adhesive foaming is a new opportunity as well as a nightmare. Ignoring this technology will lead tolost sales dollars and reduced market share. Addressing foamingonly when forced to by a customer who expresses an interest infoaming will send the wrong message to that customer.Adhesive manufacturers that proactively develop foamableadhesives as well as a viable market strategy will benefit fromthe expansion of foaming into the marketplace.

Some adhesive companies have entered into exclusiveagreements with foaming equipment manufacturers and areoffering foaming as a package. Here's the deal: if the customeruses their adhesive they get access to a foamer. If thecustomer wants to use a different adhesive supplier, thefoamer is removed. While this approach may be advantageousto the adhesive company in the short run, the "captivemarket" is not in the best interests of the end user. Bydeveloping a line of foam-able adhesives for a range ofapplications and offering the latest information regardingfoaming equipment, adhesive suppliers can positionthemselves to not just "survive foaming" but to actuallyincrease sales and provide better customer service.

One possible strategy would be to develop primarily foamableadhesives regardless of whether the customer plans to foam ornot. Remember, the adhesive needs to work both foamed andunfoamed. By using this strategy, a manufacturer can avoid adual product line and keep costs down. The advantage to asingle product line would be that if a customer is using afoamable product but not foaming and then wishes to foam theiradhesive, they can use the same product, eliminating down timewith prolonged testing procedures and any necessary approvalsor certifications.

Producing foamable adhesive may result in adhesive manufacturing issues that need to be addressed. Static in-line mixers can

Unfoamed Adhesive

be used in the manufacturing process to eliminate air incorporation and to allow cup weight specifications to be met. Largeadhesive companies that polymerize both PVA and VAE canformulate products right out of the reactor and thereby eliminate some of the issues presented to a formulator of adhesives.

CONCLUSIONFoaming is here to stay. The benefits that can be gained byfoaming water-based adhesives are significant and will continueto drive the expansion of this technology into more markets andapplications. The adhesive manufacturer that recognizes thisand can develop a market strategy designed to protect currentsales (as well as address new opportunities) will be the companyto prosper.

For more information on foaming, contact Don Berlin. E.T. Oakes Corp., 686 Old WilletsPath. Hauppauge. NY 11788: phone (631) 232-0002: fax (631) 232-0170: or visitwww.oakes.com.

Reprinted with permission from Adhesives & Sealants Industry magazine, BNP Media