Spraying Barriers on Paper & 3D Fiber Forms - My FachPack Keynote

If you work in paper, fiber-based packaging, or converting, you already know: spraying is everywhere. In my FachPack keynote, I dive into what really determines coating success on paper webs and complex molded fiber parts - and why the shape (and how we reach every surface) matters more than whether a barrier can be sprayed at all.

Below you’ll find the story behind my talk, the key lessons, and a link to watch the full recording.

Why this topic matters now

Brands and converters are racing to deliver recyclable, fiber-based solutions with reliable barrier performance. You can atomize almost any modern barrier. The real challenge is achieving uniform, right-thickness coverage - especially on 3D geometries with corners, undercuts, and variable porosity - while keeping overspray and waste in check.

What you’ll learn in the recording

• Spray fundamentals: flat spray vs. full cone vs. hollow cone and where they shine on paper machines (e.g., felt cleaning, re-moisturizing, additive application).

• Atomization choices: liquid-only vs. air-assisted - how medium viscosity and target finish guide the choice and help you assess overspray risk.

• 3D reality check: why static, top-down spray paths miss recesses, and how trajectory limits coverage.

• Robots + vision as an enabler: when object recognition and path planning deliver clean edges and minimal overspray.

• Economics that matter: throughput, and unit count - not just “can we spray it?”

The big takeaway

The bottleneck isn’t whether the barrier can be sprayed - it can.
The bottleneck is getting consistent coverage everywhere on complex shapes, with minimal overspray, using the right atomization method and, in many cases, robot/vision-guided application.

Inside our lab: coating the inside of a molded-fiber bottle

In a recent test, we colored the coating medium (to make results visible) and delivered a sub-second interior spray pass. The result looked great - but the lesson was bigger:

• Substrate rules performance. Fiber compression and surface hardness change how a barrier penetrates and anchors.

• The nozzle applies; the material decides. Application quality and barrier efficacy both matter - optimize them together.

• Visibility accelerates decisions. Simple visualization (ie coloring media for trials) reveals gaps before scale-up.

3D shapes: when robots make sense (and when they don’t)

• When they shine: complex geometries, variable parts, tight functional specs, and high material-savings potential from overspray control.

• What to consider: cycle time, line speed, and unit volumes. You may need many coordinated axes to meet throughput - plan the economics early.

• Static set-ups still win for flat goods and repeatable passes - don’t over-engineer where a fixed set-up does the job.

Practical pointers you can use today

• Match atomization to the medium. High-viscosity barriers may need more energy; very aqueous systems can succeed without compressed air.

• Engineer the spray path, not just the spray. Corners, rims, undercuts: design trajectories to reach them - or you’ll never hit your target.

• Design to eliminate overspray. It’s wasted material and cleanup time. Split-paths and masking helps.

• Prove it small. Quick lab trials (visible media, short sprays) reveal coverage limits before you invest in hardware.

• Measure the result that matters. Don’t stop at “wet look.” Validate thickness uniformity and functional performance at critical points.

Who should watch this

• Process engineers in paper and converting

• Packaging developers working on molded-fiber parts

• Operations leaders chasing material savings and line stability

• Sustainability teams validating functional barriers on fiber

Watch the full keynote

Grab a coffee and join me for a practical, no-nonsense walkthrough - from spray basics to robot-assisted application on complex shapes.

Special thanks to Pacoon for the invitation to speak about this important subject.

Let’s talk about your application

Have a project or a coverage challenge you’d like to discuss? Get in touch with our team to explore feasibility and application options tailored to your line speed, targets, and geometry.