Innovation

Companies in the same business sector as Lohmann GmbH und Co. KG, rely on multiple different machines to manufacture adhesive tapes, based on what kind of tape they are trying to produce. Two common types are acrylic systems and rubber systems. (Domanski, 2023) The adhesive itself is typically a polymer, dissolved in an organic solvent like gasoline, ketones and esters, to facilitate easier application onto the respective surfaces and subsequently cold-curing through solvent evaporation (Bundesinstitut für Bau, Stadt und Raumforschung, n.d.). The utilization of solvents in this process results in the emission of volatile organic compounds (VOC’s) released during the tape's curing, which have hazardous potential to human health and negatively impact earth’s climate (Umweltbundesamt, 2016).

The TwinMelt-Technology that Lohmann developed tackles these issues by enabling the production of both rubber and acrylic systems on the same machine, hence the ‘twin’ in TwinMelt, without the need for solvent utilization. Furthermore, TwinMelt not only has the capability to produce diverse adhesive systems using the same machine but also allows for their flexible combination, a feature not achievable with conventional systems or by competitors.

The transition to solvent-free tape production has been a substantial achievement, but Lohmann also managed to reduce the energy consumption by 66% per square meter of tape. This remarkable feat happened concurrently with a doubling in production speed, all while ensuring that 100% of the utilized electricity was harnessed by sustainable practices. Additionally, both the rubber and the acrylic systems are biocompatible as well as the applied adhesive itself being composed of 50% biocompatible compounds, aligning with evolving environmental standards.

Lohmann GmbH und Co. KG has a long history of adhesive inventions with over 1440 patents since the company’s founding (Lohmann, n.d.). The business is equipped with several departments that are responsible for researching and developing new technologies, such as the TEC-Center and the Innovations-Hub.

The TwinMelt-Technology stemmed from the aspiration to expand upon the existing product lineup of solvent based adhesives with a manufacturing facility that renounces the use of said solvents, while simultaneously not compromising on performance and quality.

The facilities development began by weighing up, whether the implementation of the machine was generally possible, due to the fact that the used materials, that are processed on the manufacturing plant, have different physical characteristics like melting points and material-induced tensions. However, these initial issues were resolved through the utilization of specialized, highly precise cooling systems, effectively clearing the path for Lohmann’s engineers to fully design the machine and ultimately its construction.

The adhesive applied by the TwinMelt system to the carrier material is also manufactured in Neuwied at the TEC-Center, inaugurated in 2016.

The process of developing and designing highly complex and technological systems like TwinMelt undoubtedly demands a lot from everyone involved. To ensure that the system operates effectively and achieves the expected results, it requires a qualified team and adept leadership.

In the case of TwinMelt the leadership role was occupied by Reinhold Domanski, who took the position of project manager. The graduate chemical engineer started his career at Lohmann more than thirty years ago and has since undergone several departments before taking on the responsibility for the TwinMelt-Technology.

A further important participant that contributed to the completion of the production plant is the machine supplier, who implemented Lohmann’s engineering and design and equipped the company with the individual parts of the facility.

Although not explicitly mentioned in the interview, it is likely justified to assume that the two managing directors, Chief Executive Officer (CEO) Dr. Jörg Pohlman and Chief Technology Officer (CTO) Dr. Carsten Herzhoff, also contributed to the development of the TwinMelt technology, just like the employed engineers and workers in Reinhold Domanski's team.

Sustainability is something that Lohmann GmbH und Co. KG has always taken into account since its founding over 170 years ago, when it comes to developing new ideas and innovations. The company’s mission statement for sustainability emphasizes the importance of sustainable energy utilization, morally procured raw materials and recycling. ‘We make it green’ is the statement that underlines Lohmann’s climate roadmap, that initially had a focus on achieving climate neutrality by 2050, but has now been revised to 2035, overshadowing the old plan.

The three strategic pillars the roadmap is built on are ‘Beyond Innovation’, ‘Beyond Excellence’ and ‘Beyond Sustainability’, and the TwinMelt-Technology is the embodiment of all three.

‘So I think it would quite well cover the pillar Beyond Innovation, which, procedurally, I believe there is no other facility in the world that can do it like our facility’ (Domanski, 2023)

Additionally, the TwinMelt facility aligns with the second pillar, 'Beyond Excellence', as it can achieve double the production speed, offering extensive design flexibility for the adhesive tape, all while effectively reducing costs.

Lastly it succeeds at matching the third pillar ‘Beyond Sustainability’ because of its utilization of 100% green electricity and drastically lower carbon emissions through 66% lower energy consumption per square meter produced adhesive tape.

Inspiration

Every industrial sector is overseen by a certain governing body and must follow specific guidelines and technical directives. In the case of the adhesive industry, one of those technical directives is the Industrial Emissions Directive. The Industrial Emissions Directive tries to minimize harmful emissions by providing guidelines that companies, operating in those fields, have to obey. One of those policies is called Best Available Techniques (BAT) which refers to the most effective methods and techniques recognized within a specific industry for preventing or reducing environmental impacts. BAT constitutes general guidelines and principles, the Best Available Technique Reference Documents (BREF), that guide the industry on minimizing environmental impacts.(European Commission, n.d.)

‘The philosophy behind it was that we said, we have an extremely strong portfolio with solvent-based adhesives. And solvent based means these are organic solvents. Essentially, sometimes it is also water, but in most cases, it is an organic solvent. However, there are technologies that completely forego this technology. So that brings us to the topic of TwinMelt’ (Domanski, 2023) [translated by the author].

In the case of Lohmann it states that the best available technique is to renunciate the use of solvents in tape production. These factors have to be considered in the development of new inventions and the techniques have to be applied wherever possible.

TwinMelt meets those regulations and because Lohmann follows its strategic pillars, the idea for the facility does not only produce solvent free, but it inherently does so in a much more efficient and sustainable way.

TwinMelts purpose is primarily to help Lohmann to achieve its goal to reach climate neutrality by 2035 regarding scope one and two. The production plant contributes to said goal in a major way by lowering carbon emissions, using biocompatible resources and utilizing green energy.

Another motivating factor was taking on the technical challenge of combining two fundamental adhesive technologies, rubber based hot melts and UV-acrylates that were previously deemed incompatible and achieving a breakthrough by enabling their seamless integration within a single process.

Furthermore, the clients that purchase Lohmann’s product now more than ever have an interest in knowing if their bought goods were manufactured in a sustainable manner.

‘I do believe that customers are interested today in technologies that are more sustainable than what we have done so far. They also want evidence from us. ( . . . ) what are you saving in terms of fossil resources? In the CO2 footprint?’ (Domanski, 2023) [translated by the author].

In essence, the motivation for TwinMelt was rooted in environmental sustainability, the desire to offer a diverse product range and the aspiration to overcome traditional limitations in adhesive technology.

Overall impact

The TwinMelt facility has proven to be a groundbreaking innovation for Lohmann, especially impacting the efficiency and cost area of the business. By eliminating redundancies in the tape production, it can conserve 66% more energy, while simultaneously reducing the production time to only half compared to previous machines.

Furthermore, since TwinMelt allows for rubber and acrylic systems to be produced on the same line, it provides a high level of design flexibility, that enables new product combinations. This capability combined with symmetrical and asymmetrical stripe coatings, not only contributes to material savings but also leads to a reduction in overall production costs for the company. (Lohmann, n.d.; Domanski, 2023)

Additionally, the innovation helped Lohmann gain recognition as the business was rewarded the ‘Rhineland-Palatinate Innovation Award 2023’ in the category ‘CO2 Reduction’ (Lohmann, n.d.).

Besides those short-term effects, Lohmann’s future plans involve leveraging the new technology to its fullest potential.

‘This is, of course, not something that happens overnight ( . . . ) it takes time. However, our intention is always to increase the utilization of this facility by transitioning other technologies to this one. (...) All of this takes time. But that is the long-term goal: to utilize the facility more extensively than solvent-based facilities and gradually phase out solvent-based systems’ (Domanski, 2023) [translated by the author].

Because of how specific the end product and the TwinMelt-Technology itself is, the impact and benefit it provides for society and the environment largely overlap, as only a few of us are direct consumers of high-tech adhesive tapes but mostly purchase products that utilize them. Therefore, in the case of TwinMelt, society primarily benefits from the effects it has on the environment.

The impact the technology has on the environment is significant as it reduces Lohmann’s carbon footprint through reduced energy consumption, the renunciation of solvents, recyclable materials as well as the utilization of 100% green electricity. In the long term TwinMelt will be a big part of Lohmann’s goal to reach climate neutrality by 2035. (Lohmann, n.d.; Domanski, 2023)

‘The primary benefit for society, if you mean all of us in this context, is, of course, the matter of improving our CO2 footprint and (...) wanting and needing to become carbon-neutral at some point, with the notion of wanting no longer being up for discussion’ (Domanski, 2023) [translated by the author].

The social impact of TwinMelt is evident in its contribution to improving the overall CO2 footprint. As society collectively strives for carbon neutrality, TwinMelt becomes a crucial element in this endeavor, emphasizing the necessity of reducing environmental impact.

Business benefit

The TwinMelt technology not only provides Lohmann with a distinctive competitive advantage in the adhesive industry but also offers significant benefits. By presenting solvent-free adhesive solutions, Lohmann positions itself as an innovator, not only attracting environmentally conscious customers but also staying ahead of competitors relying on traditional solvent-based methods.

The remarkable flexibility of TwinMelt empowers Lohmann to craft a diverse array of adhesive products. This newfound flexibility, coupled with design freedom, not only expands the range of adhesive solutions but also opens up exciting possibilities for creating customized products tailored to specific customer needs. This adaptability enhances Lohmann's capability to cater to a broader customer base seeking personalized adhesive applications.

In the context of a growing global emphasis on sustainability, Lohmann's adoption of TwinMelt goes beyond mere innovation; it aligns seamlessly with evolving market trends. This strategic choice positions the company as environmentally responsible, effectively meeting the demands of an increasingly eco-conscious consumer base. The environmental benefits derived from TwinMelt reflect Lohmann's commitment to sustainable practices and contribute to a positive impact on both the industry and the planet.

Social and environmental benefit

At a social level, TwinMelt technology helps to protect the health of employees. The elimination of organic solvents significantly reduces potential health risks in the workplace. This not only promotes the well-being of Lohmann's employees, but also demonstrates the company's social responsibility towards its employees. TwinMelt technology also has significant environmental benefits. Avoiding organic solvents and using only green electricity helps to reduce CO2 emissions and minimize the ecological footprint. This is particularly important in the context of global efforts to mitigate climate change and achieve the Sustainable Development Goals (SDG 13). The switch to environmentally friendly technologies such as TwinMelt shows that Lohmann takes its social and environmental responsibility seriously and is actively committed to a sustainable future. This has a positive impact on the company's image and can help to raise awareness of environmentally friendly practices in the industry.

Interviews

Reinhold Domanski, Project Manager for the TwinMelt-Technology

Katharina Candia, Head of Sustainability