Henniker Launches ‘Altus A Multi-Nozzle Atmospheric Plasma System
October 2026 – Henniker, UK.
Henniker Plasma, a leading manufacturer of plasma treatment systems, has announced the launch of Altus, a multi-nozzle atmospheric plasma system designed to integrate directly into existing production lines. An array of four to eight individually controllable nozzles, fed from a single controller, treats widths of up to 100mm in a single pass.
Solving the Throughput Challenge
On a wide web, a large moulded panel or a row of parts on an indexing line, a single plasma nozzle must make multiple sequential passes or follow a slow robot raster. Both approaches add cycle time and eat into the limited window before bonding or painting.
Altus arrays its nozzles side by side to treat the whole area in one parallel operation. Because every nozzle is individually controllable, the same system treats small localised areas, intricate components with tight radii, or up to eight separate parts at the same time..
“Altus was developed for manufacturers whose parts and lines have outgrown single- and dual-nozzle treatment.” said Lee Brown, Managing Director at Henniker Plasma. "By placing up to eight individually controllable nozzles under the control of customer's own PLC, Altus turns plasma surface treatment into another controlled station on the line, with wide-area activation in a single pass."
Built for Integration
Altus is a component system rather than a stand-alone cell. The controller mounts alongside the line, the nozzle array sits over the moving substrate or indexing parts, and the line’s own PLC drives the system through a defined I/O set: a 9-pin DIN error output, an 8-pin DIN plasma on/off input and a 15-pin D-Sub interlock trigger. This level of process control enables Altus to start, stop and report in step with conveyor motion, part indexing or web speed. Henniker’s proprietary high-stability plasma generator drives every nozzle consistently, delivering uniform coverage from the first nozzle to the last.
Benefits at a Glance
- Wide-area coverage in a single pass across widths of up to 100mm
- Individually controllable nozzles for small areas, tight radii or up to eight parts at once
- Direct line integration via PLC and external input, with error, on/off and interlock signals
- Compressed-air operation, a clean, low-running-cost step that replaces solvents and chemical primers
- Multi-material treatment of polymers, metals, composites, glass and ceramics on the same line
Proof in Practice
Most common engineering polymers have inherently low surface energy, which leads to poor adhesion. In Henniker’s surface testing laboratory, atmospheric plasma treatment reduced the water contact angle on PET from 83.8° to 20.6° and raised surface energy from 43.2 mN/m to 74.5 mN/m. The result is a remarkable and immediate increase in wettability and adhesion performance.
Applications Include:
- Battery, EV and energy structural bonding
- Aerospace and composites mould-release removal
- Automative bonding, sealing and coating lines
- Medical device assembly and bonding
- Extrusion products uPVC window/door panels and lamination lines
Click here to download the press release
Please contact us today If you’d like to discuss how Altus could fit into your production environment, our team is ready to help.
