The Company
One of the largest full-service direct mail producers in the U.S., this company operates high-volume printing and inserting lines across multiple divisions. They handle a wide variety of substrates, formats, and glue applications daily—at speed, with no room for failure.
When their Director of Manufacturing joined, they inherited a persistent problem: the company was relying on three different adhesive suppliers to manage fugitive hot melt glue applications. Each adhesive worked for certain substrates but failed on others.
It was confusing, inconsistent, and caused downstream problems.
“When I came on board, we were buying from three different suppliers. And it was a nightmare.”
The Challenge
Adhesive failures were costing time, damaging customer relationships, and making quality control unpredictable. Some adhesives stained the product, others caused tearing. No one could reliably track which glue worked for which job, leading to frequent mix-ups and unnecessary waste.
The Director of Manufacturing led a full-scale effort to consolidate all adhesives into a single product that could meet every requirement across all applications.
The solution had to deliver:
-
No staining
-
No tearing
-
Full compatibility with existing glue systems
-
A clean, manageable form factor for operators
Three suppliers entered the intensive 18-month testing process; one dropped out early, and another lost interest. Capital Adhesives stayed engaged from start to finish, working through every substrate, test batch, and failure analysis until performance was fully dialed in.
“Capital stayed 100 percent engaged. They were fully committed from day one.”
The Solution
Capital delivered more than just adhesive samples. They delivered a partnership.
Every sample arrived with purge material to ensure clean testing. When a formula didn’t perform, Capital reformulated, retested, and restarted the process. Their chemist worked directly with the production team to analyze failures and guide next steps.
The plant created a detailed matrix to track testing across every substrate and configuration. Capital remained responsive throughout, sending updated formulations, reviewing failed samples, and staying committed—even when the process grew tedious.
Once the adhesive passed every test, Capital went one step further: transitioning from messy pellets to clean, pillow-shaped chubs, making it easier and safer for operators to handle on the floor.
“They wanted feedback. They asked for failed samples to guide the next iteration. It was smooth on their end. Very smooth.”
The Results
Consolidating from three suppliers to one simplified purchasing, reduced waste, and eliminated production errors. For the first time in years, the plant had a single adhesive that worked across every product line and substrate.
Capital not only delivered consistent performance—they improved day-to-day operations. By transitioning from messy pellets to clean, pillow-shaped chubs, they made handling easier for operators and reduced maintenance issues on the floor.
“We moved from messy pellets to chubs—little pillow-shaped blocks that don’t get stuck in the pots or jam things up. That was another big win.”
Most importantly, quality complaints disappeared. No staining. No tearing. No uncertainty on the floor. Just a product that performed as promised, every time.
But what made the biggest difference wasn’t just the adhesive—it was the trust built through clear communication, responsive support, and a long-term commitment to partnership.
“We haven’t had a tear or stain complaint since. And it’s been seven years.”
“If someone asked me to change adhesives, it would be a very quick and affirmative no.”