Why We Had to Rethink Cartridges
When COVID hit and supply chains seized up, cartridges suddenly became the bottleneck. Big Dog Adhesives could still make MMA and epoxy, but one factory in Eastern Europe going offline meant no one could get enough plastic shells.
So, we started doing what we could …
2017-2019
Founding of Big Dog Adhesives
Big Dog Adhesives was established in Elkhart, Indiana. Initial growth came from serving local manufacturing customers with direct delivery. As volumes increased, the challenge of cartridge disposal became evident. A large plastic recycling facility is located adjacent to our plant. After thorough evaluation, technicians determined that the mixed plastics and residual adhesive in standard cartridges render them non-recyclable.
2020–2022
Launch of “Recycle My Tube” Program
Prior to the COVID-19 pandemic, we introduced the “Recycle My Tube” initiative. Customers returned spent cartridges, which were refilled through the nozzle in exchange for a $1 credit per unit. This program reduced costs for customers, minimized waste and ensured supply continuity during widespread cartridge shortages. A single cartridge achieved an average of seven to nine reuse cycles.
2022–2024
Development of Foil Packaging
We pursued alternative packaging formats for resins and activators. SeamKing, our bulk countertop resin, became the first product filled into foil pouches. Extensive material and dimensional testing followed. Building on this success, a complete two-part foil system was engineered for methacrylate and epoxy adhesives, paired with dedicated battery-powered and pneumatic dispensers. Performance met expectations for high-volume users, yet market adoption remained limited. The requirement for new dispensing equipment and processes proved to be a significant barrier for most customers.
2024–Present
Introduction of the ReLoad System
To achieve broader adoption, sustainability needed to integrate seamlessly with existing equipment. The solution was a durable, reloadable two-part cartridge that functions as a reusable outer shell for standard dispensers. After numerous prototypes and multiple mold iterations, the ReLoad system was finalized. It combines fresh foil packs with optimized adhesive formulations while maintaining compatibility with industry-standard guns. This design substantially reduces the environmental impact of single-use cartridges.
Looking Ahead
Routine Advancement in Adhesives
At Big Dog Adhesives, continuous improvement and responsible innovation remain core principles as we look ahead. The ReLoad system represents a practical advancement in performance, cost efficiency and sustainability for the adhesives industry.