By Valco Melton On 2026-01-14
The Church & Dwight facility in Old Fort, Ohio has successfully transformed its packaging operations by implementing Valco Melton's EcoStitch adhesive application system, achieving remarkable improvements in uptime, cost savings, and production efficiency.
Taking On a Challenge
Church & Dwight's Old Fort location produces baking soda and cat litter. For years, the facility struggled with an aging pneumatic glue application system that was creating significant operational challenges. Sam Failor, Packaging Mechanics Supervisor at Church & Dwight, recalls the situation: "We were experiencing tremendous amounts of downtime and maintenance costs because of our old pneumatic system," with production lines shutting down for five to six hours per day for glue head maintenance.
The turning point came approximately three years ago when Failor discovered Valco Melton in a trade publication. After initial inquiries, Valco Melton visited the plant to tackle an innovative challenge for its all-electric EcoStitch technology. "They had never done an (electric) sift proof application for anyone before, so we were kind of the first to do that," Failor recalls.
Impressive Results
The implementation of the EcoStitch system delivered exceptional results. Spare parts costs dropped dramatically from $80,000 annually per glue head to below $5,000. Production efficiency, measured by Overall Equipment Effectiveness (OEE), improved by 10% once both systems were operational. Additionally, adhesive consumption decreased significantly compared to the old pneumatic heads.
The system's design advantages include a reduction from 46 modules down to 23, with nozzle bar changes now taking just 3-4 minutes instead of an hour. Daily maintenance requirements are minimal, requiring cleaning only twice per shift.
Church & Dwight also transitioned from cold glue to hot melt adhesive application for their baking soda line. "The ease of application with the hot melt compared to what we had to go through with the cold glue is phenomenal," Failor explains. The new system provides precise pattern control and consistent application quality throughout each shift.
More Than Technology
Beyond the technology, Failor praises Valco Melton's support: "They've been great to work with all the way. A service call and somebody is here either that day or the next day."
When asked what advice he would give to others considering Valco Melton technology, Failor's response is direct: "Don't wait. Call their engineers now. Get on the list."
Watch the full interview HERE with Sam Feiler to learn more about Church & Dwight's experience with Valco Melton's EcoStitch technology.