Industrial WideTrack Dual Jet Ultrasonic System for Wide-Area and Web Coating

The Industrial WideTrack Dual Jet is Sono-Tek’s most advanced ultrasonic web coating system, engineered to deposit thin, uniform films and nano-material coatings on moving substrates and wide-area panels with exceptional control and repeatability.

Each WideTrack Dual Jet nozzle assembly, paired with its dual air-jet head, produces a uniform spray pattern up to 24 inches wide. Multiple assemblies can be positioned side-by-side to create unlimited coating widths, ensuring seamless coverage for even the largest continuous web, glass sheet, or other large-area substrates.

Using dual synchronized air jets, the system forms a precisely shaped fan pattern with up to 90% less overspray compared to conventional pressure or air atomizing methods. This efficient design delivers consistent coating uniformity across webs, films, or sheets. Ideal for roll-to-roll, inline, or wide-area substrate coating processes, the Dual Jet enables high-performance thin-film production with excellent efficiency and process control. Sono-Tek also designs complete custom roll-to-roll and web coating systems that integrate seamlessly with WideTrack Dual Jet coating heads for fully automated production.

Unlike contact-based methods such as gravure coating, Sono-Tek’s ultrasonic process is completely non-contact, eliminating mechanical wear and preventing damage to delicate substrates while maintaining highly uniform film thickness.

Precision Web Coating System with Advanced Control

Every Dual Jet web coating machine features Sono-Tek’s HMI touchscreen control tower, providing full recipe management, data logging, and automated parameter control for repeatable production.

Ultrasonic atomization creates micron-sized droplets that form uniform thin films on glass, textiles, and polymer substrates. The programmable coating process includes RS232 communication and multi-recipe storage. Integrated flow control ensures a stable deposition rate across all coating zones and is fully compatible with inline coating equipment featuring unwind and rewind stations for roll-fed substrates.

Sono-Tek systems are typically supplied with a standard, user-friendly control interface but can also be built using customer-specified PLCs when preferred. This flexibility allows seamless integration into existing plant control architectures, supporting the use of Allen-Bradley, Beckhoff, Siemens, or other PLC platforms as requested.

Key Advantages

• Drip-free, non-clogging operation ideal for 24/7 industrial use
• Up to 80% reduction in coating material consumption versus conventional spray
• Full temperature control of liquids for consistent material behavior
• Titanium and chemically resistant construction (Teflon, Ryton, stainless steel)
• Flexible single- or dual-sided coating configurations
• Low maintenance and designed for extended service life in continuous manufacturing

Thin-Film and Nano-Material Coating Applications

The Dual Jet’s precision control and gentle atomization make it ideal for coating functional thin films and nano-dispersions in high-value applications, including:
• Anti-reflective and protective coatings on glass or films
• CNTs, graphene, and silver nanowires for conductive or optical layers
• Antimicrobial coatings for medical textiles and protective films
• Oleophobic and hydrophobic coatings for polymer or glass substrates
• Barrier or functional coatings in web coating and roll-to-roll processes

Designed for Thin-Film Innovation

The WideTrack Dual Jet merges ultrasonic precision with controllable air shaping, creating a uniform coating film thickness across the substrate width. Its programmable control system, non-clogging ultrasonic nozzles, and flexible width options make it the ideal wide-area and web coating system for advanced manufacturing environments seeking repeatable, high-yield thin-film deposition.

Example System Configurations

Each WideTrack Dual Jet nozzle and air shaping head produces a coating pattern up to 24 inches wide. Systems are commonly configured with multiple nozzles arranged across the coating width to cover large-area substrates or full web spans.
Typical specifications per nozzle assembly:
• Coating width: 2–24 inches per assembly (expandable to unlimited width with multiple heads)
• Typical flow rate range: 2–200 mL/min depending on pump system
• Deposition uniformity: ±10%; repeatability: ±2%
• Power requirements: 110–240 VAC, single phase
• Air supply: clean, oil-free air, 70–150 psi

Energy-Efficient and Environmentally Responsible

Sono-Tek’s ultrasonic spray technology minimizes waste and VOC emissions, supporting manufacturers focused on sustainability and process efficiency. By using low-velocity air shaping and precise fluid control, the Dual Jet reduces chemical usage and eliminates the need for costly overspray collection or scrubbing systems.

Request a Custom Configuration

Every WideTrack Dual Jet system is tailored for your coating material, substrate width, and line speed. Sono-Tek also offers fully integrated roll-to-roll and web coating systems that include unwind and rewind stations, drive controls, tension management, and inline drying, creating complete turnkey solutions for thin-film coating production.

Contact Sono-Tek today to discuss custom configurations, inline integration, or complete roll-to-roll system designs that incorporate WideTrack Dual Jet technology.