Case study

Installation of Automated Spray System Saves Materials Manufacturer


A prominent high-purity fiber producer needed to optimize the spray system used to manufacture fluff pulp. During processing, a surfactant mixture is applied to the fiber-based material used in diapers and personal hygiene products. The system oversaturated sections of the fluff pulp during start-up and slow-down and continued to spray during sheet breaks. These inefficiencies wasted costly surfactant, created a dangerous work environment and caused maintenance issues.

Header spray application


The fiber producer now uses an AutoJet® PLC-based spray system. A spray header, equipped with eight PulsaJet® nozzles, applies the surfactant mixture to the top side of the fluff pulp rolls. The controller automatically adjusts the application rate with line speed increases or decreases to ensure the proper volume of surfactant is applied. The controller also turns the nozzles off when sheet breaks are detected.


The system, which includes four spray headers and treats two rolls simultaneously, has dramatically reduced operating costs and waste for the fiber producer. Surfactant use per roll has decreased by 15% since system installation. The savings on chemicals alone are US$1.4 million annually. In addition, the producer has reduced fluff pulp scrap due to over-saturation. The system cost was recouped in just two months.  

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PulsaJet Nozzle

PulsaJet® Nozzles

Provide high-transfer efficiency to minimize waste and messy overspray. Cycle speeds up to 25,000 cycles per minute are possible to keep pace with fast line speeds. 

autojet pulsajet modular spray system controller

AutoJet®  PLC-based Spray System

Provides easy control of spray nozzles and makes automatic flow rate adjustments based on operating conditions.

Precision Spray Control Savings

Precision Spray Control

Involves turning nozzles on and off very quickly to control flow rate. This cycling is so fast that the flow often appears to be constant.