Converting Ideas into Solutions ®

Case Studies

Case Study Adaptation

After not having any success with vendor solutions, this customer contacted Budnick to design a nontraditional solution for their metal pan sealing needs:

  • Adapted a product designed for sealing roofs and metal enclosures
  • Withstood all customer application's demanding needs
  • Saved customer from recalling over 30,000 units

Case Study Oven Door Assembly

Using an expensive multi-layered double coated foam for gap filling in their oven doors was creating problems for a major appliance manufacturer.

  • Developed a better solution with a custom product that fully fit their needs
  • Improved the customer's application methods in the process
  • Helped both the customer's bottom line and their production line workers

Case Study Small Changes

A customer was using a high tack adhesive for numerous applications throughout their process - but there were issues with some having exposed adhesive.

  • Multi-use tape was used for several applications and redundant on use
  • After the tape was applied, adhesive was exposed in some areas
  • Customer continued with a single product that would fit all the existing applications

Case Study Improved Process

Inconsistencies in tape usage and scrapping a significant amount of product were becoming a serious issue for a well-known appliance manufacturer.

  • Foam-in-place insulation application was failing – 30% of the refrigerator doors were scrapped
  • Converted product designed to hold foam insulation in and allow more air and water to escape
  • The customer’s amount of discarded doors dropped from 30% all the way down to 5%

Case Study Quick Response

A local automotive supplier came to Budnick in the hope of finding material to be cut for use as steering wheel cowling cover.

  • A vinyl cloth material was sourced and converted with detailed holes and edges
  • To save the customer tooling costs, the material was cut with Budnick’s waterjet
  • Changes in part dimensions were able to be made during the project’s initial stages

Case Study Vendor Value

A customer was seeking a less expensive, alternative that would have to bond to a wide variety of veneer backings.

  • The large veneer and edge banding manufacturer had been using an acrylic transfer
  • A double coated acrylic tape with a paper liner was chosen and slit to size
  • The anti-slip liner gave the customer an opportunity to brand their product

Case Study Efficiency

Working in tandem with our distribution customer, we were able to identify an ideal solution for the end user, improving both production efficiency and the bottom line.

  • Distributor approached Budnick regarding their customer, a vinyl window manufacturer
  • By modifying the final format we were able to reduce machine stoppage dramatically
  • Several options were presented to consider and implement in their processes

Case Study Improved Process

Too much wasted product and stoppages during production brought this architectural window manufacturer to Budnick.

  • Tape was inconsistent when being applied to window muntin bars
  • Workers were applying the tape by hand, resulting in too much wasted material
  • Budnick’s production manager worked directly with customer on the application issue

Case Study Environmental

A building materials manufacturer came to Budnick after experiencing failure with a tape they were using on their fiberglass insulation line.

  • Used in a flying splice application, it needed to perform in extreme temperatures
  • A double coated PET tape was found to work well in both winter and summer months
  • A die-cut tab was supplied to the customer to better support the splice

Case Study Quick Response

A commercial refrigeration manufacturer needed to protect commercial coolers from the time they were on the production floor to installation.

  • Customer was looking for a product to act as a bumper on the commercial coolers
  • Bumpers needed to withstand high temperatures while being transported in train cars
  • The bumpers would be applied to metal surfaces and needed clean removability

Case Study Improved Process

Production was in the process of moving from Arizona and Ohio and finding a supplier who could meet stocking and delivery requirements was critical.

  • Needed tape stocked in a temperature controlled environment and delivered weekly
  • Customer had issues with splices and roll tolerance standards not being met
  • Budnick worked with vendors to negotiate competitive pricing and fix splicing issues

Case Study Reposition Thermal Interface

Finding a repositionable tape that bonds to silicone without interfering with thermal conductivity put Budnick’s tape experts to the test.

  • Typically, silicone only bonds to silicone, but silicone tapes affected thermal conductivity
  • Sufficient amount of testing took place before finding an acrylic transfer
  • The acrylic adhesive did not prevent the heat transferring through the interface

Case Study Process Review

This customer was spending far too much time masking cabinets before wash and baking cycles, having to use different tapes for each step.

  • Process review was performed with a trusted tape manufacturer
  • Implemented a tape that withstood both the painting and powder coating processes
  • Converted products saved the customer valuable production time

Case Study Aesthetics

A customer was struggling to mount retail signage in the end user’s retail location with the use of magnets, only to experience waves and wrinkles.

  • Magnets were being used to install thirty-foot panels
  • A reclosable fastener was suggested to replace the magnets
  • Ability to adjust the panels creates a much more aesthetically pleasing finish

Case Study Efficiency

An interior sign manufacturer came to Budnick looking to solve several issues within their applications, products, and production processes.

  • Budnick's in-depth process audit was performed to analyze current systems
  • Suggested alternative tapes that outperformed previously used tapes and liquids
  • Working directly with the customer’s team led to optimal efficiency implementations

Case Study Converting Experts

Unable to obtain them directly from the manufacturer, a distributor turned to Budnick to supply and convert hook and loop dots.

  • Hook and loop dots would be used for promotional displays in a cell phone retailer
  • 3/8’’ diameter hook and loop dots were processed after laborious trial and error
  • Budnick provided the dots to the customer in pancake rolls as well as spools

Case Study Small Changes

A display manufacturer needed to increase the speed in which its finishing department was using tape, while the end user required decreased assembly time.

  • Budnick recommended reducing the roll width and adding an extended liner
  • Budnick expected the customer to balk at a price increase due to increased machining
  • Customer realized the justification for the changes after seeing the extended liner’s easy removability

Case Study Enhanced Production

Lacking in production efficiency and healthy hands, this aerospace came to Budnick in search of solutions for a complex masking application.

  • Workers were cutting tape by hand and often cutting themselves
  • Tape was being cut for various sizes of metal parts to mask during shot peening
  • After working with Budnick, the customer was able to double production

Case Study Converting Experts

Exposed adhesive on a die-cut acting as a hole cover was causing issues on the production floor for this major appliance manufacturer.

  • Die-cut was used for whole covering on a refrigerator
  • Exposed adhesive was causing plant rollers to become gummed up
  • Bullnose die-cutting capabilities allowed Budnick to design an entire new die-cut

Case Study Vendor Partners

A transfer tape was causing plywood to delaminate from various other materials, including, magnetic materials, styrene, and other plywood.

  • Needed a durable tape that would bond to multiple materials
  • The materials would be part of pre-school toys – no room for error
  • Consulted with a trusted supplier to source a product that met cost and application needs

Case Study Consulting

A POP/graphics manufacturer tried using cheaper material from a competitor, only to come back to Budnick after experiencing mass product returns

  • Customer previously used a double coated UPVC tape to bond a hanger to a frame
  • Budnick consulted with a vendor to find a cost saving alternative to the original
  • New alternative saves the customer money, production time, and improves the product

Case Study Converting Experts

An automotive supplier could only purchase rolled product, but the application called for short pieces

  • Sheets containing four individual pieces met the customer's need
  • A custom die was made to cut parts to length with a minimum amount of bevel on the product
  • The material maintained its cord, and the presentation saved production time

Case Study Adhesive Tab

This customer came to Budnick requesting our help in creating an adhesive tab matrix with easy application onto a film.

  • The tab needed to stick quickly in a temperature range from 0 – 150°F
  • Tab required bondability to both sides of the film
  • The tab would be part of a product used to collect crops while in the fields

Case Study Improving Efficiency

We were brought into this account to help improve the efficiency, with downtime and material waste becoming a problem.

  • Customer had to change out pancake rolls far too frequently
  • Budnick application engineers collaborated with a tape manufacturer to find an optimal solution
  • Introduced the possibility of using traverse round rolls and an unwind stand/dispenser

Case Study Custom Printing

Budnick's flexographic printing capabilities were put to the test to create custom printed container seals for a leading packaging manufacturer.

  • The seals feature Budnick’s ability to combine static flexo printed images with variable printed data
  • Lot numbers were printed in both barcode and human readable for on four labels
  • The labels’ adhesive system sticks to multiple surfaces and includes a tamper evident security feature

Case Study Extrusion Mounting

Unable to meet production goals due to an extrusion that failed to bond to a medical sink, this medical equipment manufacturer turned to Budnick to develop a solution.

  • Customer was using an extruder’s failing foam to attach an extrusion to a sink base
  • A new acrylic foam with quick-stick properties was tested and implemented
  • Budnick worked with a new extruder to develop a properly fitting extrusion

Case Study Reengineering

A medical equipment manufacturer turned to Budnick to implement process improvements related to their medical cabinets.

  • Customer also wanted to reduce their number of vendors
  • Customer needed a solution to mount brackets and secure a medical hose
  • Both gaskets needed to be FDA approved due to cleaning and sterilization

Case Study Mounting a Fuel Tank Emblem

A fuel tank manufacturer was spending excessive time hand cutting tape to the dimensions of their logo, only to see it fail to bond to the tank.

  • Customer was using a film tape that was not a long-term emblem mounting solution
  • Hand-cutting the tape was no longer a feasible option for the customer either
  • Customer needed a tape that could withstand environmental elements

Security Panel Cover Attachment & Protection

Budnick's die-cutting capabilities and expertise with extended liners helped create user-friendly solutions for a major electronic automation and controls manufacturer.

  • High bond 3M™ VHB™ Tape was die cut to the customer's exact specifications
  • Added a 12 point liner that is stiff enough for easy release & and a finger-lift tab to simplify product assembly
  • Designed packaging that would prevent shipping damage & also act as a dispenser unit for the parts

Case Study Die-Cut Protective Film for RV Wheel

A custom die-cut surface protection film reduced time, labor, and quality concerns for an RV manufacturer

  • Custom cut to 39.5’’ diameter sheets
  • Added paper liner for easy removal
  • Only one worker is now needed to apply the film

Case Study Heads-up Display

An automotive electronics manufacturer turned to Budnick to find a surface protection solution for a heads-up display (HUD).

  • Linered and perforated for easy installation
  • Locator holes for accurate placement
  • Pull tabs for easy removability

Laminating Decorative Signage to Foam Board

Budnick's adhesive laminating capabilities helped a sign manufacturer enhance their process of bonding decorative sheets to foam board prior to router cutting

  • Eliminated dangerous workspace conditions created by the liquid adhesive
  • High bond double sided tape eliminated lengthy cure times
  • Evenly laminated panels improved product quality

Foam Gaskets for Cooler Doors

Long lead times and quality concerns lead to a cooler and freezer door manufacturer looking for a new, US based supplier

  • Long lead times from China were slowing production
  • Too much cold air was escaping from the cooler doors
  • Budnick sourced and converted a polyurethane/polyester gasket

Projector Screen Reflection Reduction & Window Shade Extrusion Mounting

A projection screen and window shade manufacturer needed an adhesive tape laminated to flock material and a tape that would bond extrusions to window shades.

  • Customer’s previous supplier sent unusable, wrinkled material
  • Needed an adhesive tape to laminate to flocked material
  • Budnick laminates a double coated tape to the flock and slits it into rolls with zero quality issues

Conductive Die Cut Gasket for Electrical Grounding

A major appliance OEM needed an electrical grounding solution due to quality issues with wiring/lighting.

  • Worked with 3M™ to provide products for testing
  • Provided a die-cut gasket with electrically conductive properties
  • Quick and easy to apply

Case Study Attaching Stiffener Bars to Computer Enclosures

An electronics manufacturer needed a more efficient method to attach stiffener bars to computer boxes.

  • The customer had previously been using spot welds to attach the stiffener bars
  • Budnick die cut a high bond foam that would adhere to powder coated paint
  • Budnick developed a jig that holds parts in place in order to to ease assembly

Foam Injection Venting Solution

An appliance customer came to Budnick in search of an alternative to a Permagum sealing compound-masking tape combination that was being used to seal metal casing gaps in a refrigerator during the PU foam injection process.

  • Adhesive stripes laminated to a non-woven fabric and covered with a release liner
  • Striped adhesive pattern ensures proper venting
  • Virtually eliminates foam leaks and re-work time

Electronic Device Repair Die Cuts

Budnick's narrow width slitting and die-cutting capabilities enhanced this electronic device repair company's efficiencies when repairing Apple Watches

  • Customer's previous converter could not consistently slit to narrow widths
  • Budnick recommended switching to a tape that is much more ideal for bonding applications within electronic devices
  • Various die-cut shapes and sizes presented on a single pad sped up production time and eliminated the use of unsafe cutting tools