Production and reduction – a balancing act

A major step: By the end of 2023, solvent-based manufacturing was completely phased out and replaced with solvent-free extrusion at tesa Site Sparta. The patented process developed by tesa allows for the solvent-free production of adhesive tapes. Embedded in a holistic concept, it ensures a reduction in fossil fuel consumption during the production process, thereby significantly reducing CO₂ emissions. To put this in perspective: Beginning in 2024, 52 truckloads of solvents (or about 1,100 tons) will no longer be annually transported to Sparta.  A major step towards a more sustainable adhesive tape production process.

And not the only one. Over the next five years, the site’s 11 forklifts will be powered by lithium-ion batteries. Unlike the lead batteries currently in use, lithium-ion batteries can be charged up to 50% in just 25 minutes, require less maintenance, and last four to five times longer. Conclusion: They save resources and electricity. Speaking of which, as part of the ambitious renovation and expansion projects,  15% of the electricity in Sparta will come from the on-site photovoltaic system that is currently under construction. This corresponds to the total amount of electricity required to currently run the new solvent-free production line. The remaining 85% of the power needed for the site to operate will be purchased and sourced from renewable sources.

With a total area of 16,000 m², the Sparta site is now six times larger than when it was founded over 40 years ago. Most recently, the technology and production laboratory was expanded by 2,500 m² to a total of 10,000 m², and a Customer Solution Center was built to develop customized solutions with North American customers.

"Through these expansion measures, we are closer to our customers and can significantly increase production capacity," says plant manager Armin Hagenloch. "At the same time, we are reducing our CO₂ emissions by 38%. The special properties of tesa® S^FX technology demonstrate the potential of innovation, especially when it comes to sustainability. By switching to solvent-free production and decommissioning the post-combustion system, approximately 1100 tons of CO₂ are saved annually. Paired with the many other measures, this is a significant contribution to sustainability. Each of these projects is a massive undertaking and requires extensive planning as well as regional and global teamwork."

Extrusion is a process in which material in a viscous state is pressed through a shaping opening under high pressure and high temperature. This results in a body with a continuous profile in any desired length, which can then be further processed into a finished end product.