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The line got faster. The application step usually doesn’t come along for free.
Almost every application method works at low speed. What separates equipment built for production is what happens as the rate climbs: whether the pattern holds its shape, whether cut-off stays crisp, whether the volume stays constant, and whether the timing still lands on the target when there are milliseconds to work with instead of seconds.
Spraymation builds high-speed production spraying systems for lines where application can’t be the bottleneck — including the tissue and hygiene converting lines that run some of the fastest webs in manufacturing.
Line speed problems are usually one of four things, and they have different fixes.
Cut-off response. As cycles shorten, the time an applicator takes to open and close stops being negligible and becomes a large fraction of the cycle. Slow cut-off produces trailing at the end of every application and inconsistent starts at the beginning — visible as tails, drips, and ragged pattern edges that get worse as the line accelerates.
Trigger timing. Application triggered on a fixed timer drifts the moment line speed changes. Tying triggering to an encoder means position, not elapsed time, determines when material is applied — so the pattern lands correctly through ramps, slowdowns, and speed changes.
Pattern stability. Some patterns hold their geometry at speed and some don’t. Air-assisted patterns behave differently against a fast-moving web than a stationary one, and the pattern that was set at commissioning may not be the pattern running at rate.
Flow following. If volume doesn’t scale with speed, coverage thins as the line accelerates. Tying flow to line speed keeps add-on constant regardless of rate.
Electromatic™ applicator heads engineered to start and stop cleanly at production cycle rates.
Triggering and flow tied to line position and speed rather than a timer.
Air cap and nozzle geometry selected for stability at your actual line speed, not at bench conditions. See air-dispersed spray → for wide-web pattern work.
Heated systems have to hold setpoint while material is moving quickly through them — a hose that keeps up at low flow can lose temperature at high flow.
An applicator cycling thousands of times per shift accumulates cycles fast. Service life at that duty is a design requirement, not a warranty question.
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Ply bonding and tail-tie adhesive on some of the fastest webs in manufacturing. Spraymation equipment is used in producing a large share of the world’s paper towel and tissue products.
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Adhesive and treatment application across high-speed webs.
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Carton, case, and closure application at full line rate.
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Application onto product moving at production speed.
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Marking and treatment on continuously moving material.
Tissue and hygiene lines are where our equipment has run for decades, and they set a speed bar most industries never approach.
Most speed limitations trace back to how quickly an applicator can stop cleanly, and that’s a design property of the head.
If nothing off the shelf keeps up with your line, that’s the work we do.
Spraymation systems are still running 40 years after installation — in continuous, high-cycle service.
Documented quality processes.
Spare parts, consumables, remote technical support, and factory rebuilds — because on a fast line, an hour down is a lot of product.
Encoder integration and line-following control
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 cut-off timing rather than the pattern itself. As cycle time shortens, the fixed time an applicator takes to open and close becomes a larger share of each cycle, so trailing and ragged starts that were invisible at low speed become obvious at rate.
Tie flow and triggering to an encoder rather than a timer, so both follow line position. Coverage then stays constant through ramps and speed changes.
Sometimes, with control changes rather than new applicators. Worth asking before assuming a replacement is needed — send us your current setup and target speed.
Get Started
Tell us your line speed, the material, and what’s failing at rate. Our engineers will tell you whether it’s a control problem or an applicator problem.
Or call us directly +1 954 484 9700