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Manual application is consistent only in how inconsistently it performs.
Hand spraying, brushing, dipping, and wiping all share the same problem: the result depends on who’s doing it, how long they’ve been doing it that shift, and how carefully they’re working under production pressure. Coverage varies between operators, between shifts, and between the first hour and the eighth.
Automated fluid application removes that variable. The same volume goes to the same place at the same rate, every cycle, for the life of the equipment — which for Spraymation systems is measured in decades. We’ve been building automated fluid dispensing systems since 1958.
Consistency. Application becomes a machine setting rather than a technique. Variation between operators and shifts disappears, which is usually the first thing quality notices.
Material consumption. Manual methods overapply as a matter of course — it’s the only way to guarantee coverage when you can’t meter. Metered application typically cuts consumption substantially.
Labor. The hours spent applying, and the hours spent cleaning up afterward, both come back.
Throughput. Application stops being the step the line waits on.
Safety and housekeeping. Less airborne material means less mist in the air, less residue on floors, and less operator exposure. In bakeries, oil mist is a slip hazard before it’s a cost problem.
Scrap. Application defects caught downstream stop being a routine category of loss.
Converting a manual application step is a smaller project than most people expect, and it usually doesn't require replacing the line.
[01]
What’s being applied, how much, where, and what happens when it’s wrong. The current consumption rate is worth measuring before anything changes — it’s the baseline the ROI is calculated against.
[02]
Air atomizing, airless, air-dispersed, extrusion, slot coating, or non-contact — driven by viscosity, target geometry, and how much overspray the process can tolerate.
[03]
Electromatic™ heads sized for the application, with triggering tied to line speed or part position so application follows the line rather than running on a timer.
[04]
Many conversions are applicator heads and controls added to equipment already in place, not a new machine.
[05]
Application is verified at your conditions before it’s your responsibility.
Hand spraying → automated spray application. The most common conversion, and usually the one with the fastest payback.
Brushing and rolling → extrusion dispensing or automated spray. Replaces a slow, operator-dependent step with a metered one.
Dipping and flooding → metered application. Where the substrate takes whatever the bath transfers, most of the material is never needed. Metering it is often the single largest material saving available.
Aerosol cans → automated application. Consistent coverage, no propellant cost, no overspray in the work area.
Heads, controls, and fluid handling are engineered together and manufactured in Fort Lauderdale, Florida.
Adding Electromatic™ heads and controls to equipment you already run is frequently the whole project.
If your application doesn’t have an off-the-shelf answer, that’s normal work here.
Spraymation systems are still in production service 40 years after installation — the automation you install now is likely to outlast the product line that justified it.
Documented quality processes, including for one-off builds.
Spare parts, consumables, remote technical support, and factory rebuilds.
A Fortune 100 tissue manufacturer needed consistent adhesive across three application points running simultaneously at over 2,000 ft/min. Spraymation’s unified multi-station system cut adhesive consumption 40%, delivered a 99.7% tail-seal first-pass rate, and paid back in under a year.
A medical device manufacturer couldn’t validate its siliconization process for GMP, with coating-weight variability above 25% and recurring glide-force failures. Spraymation’s Electromatic™ 29 system cut variability to below 8% CV, reduced silicone use 35%, and reached 0.25 mg dispensing precision.
A major OSB manufacturer’s drip bars over-applied wax and fouled the blender drum, and catalog nozzles couldn’t handle the high-viscosity emulsion. Spraymation’s custom air-atomizing spray headers cut wax consumption 30%, shortened the press cycle 15%, and saved over $150,000 a year.
Usually, yes. A large share of conversions are applicator heads and controls integrated into existing equipment.
It depends on your current consumption and labor, but material savings alone often carry the project — manual methods overapply because they have no way to meter.
Triggering tied to part position or line speed handles variation in spacing and rate. Variation in the part itself is a design question — send us the details.
Then it’s a good fit. Difficult, low-volume, and unusual applications are a core part of our business.
Get Started
Tell us what you’re applying and how you’re applying it now. We’ll tell you what automating it would involve.
Or call us directly +1 954 484 9700