How to Use a Spoolerator: Automated Spool Winding for Kelp Nurseries
Learn how to operate a spoolerator, an automated spool winding machine designed specifically for kelp nurseries. Presented by Dave Bailey at the Alaska Nursery Operators Workshop in August 2025, this demonstration covers the mechanics of the electric motor-powered system, including how to adjust spool diameter using standard PVC drain caps, set proper gear ratios for different twine types, and achieve tight, consistent winding for optimal out-planting results.
The system features automatic stop switches, accommodates spools up to 16 inches in length, and tracks exact footage per spool (approximately 400 feet at standard settings). Key techniques include proper spool cutting to ensure straight alignment, loading procedures, and creating bowline knots for easier farm handling. The machine’s torque-focused design enables tight winding which is particularly important for gametophyte seeding methods where gaps in twine can result in material loss. Designed for holdfast twine specifications, the system can be customized for different twine diameters through gear ratio adjustments.
Special thanks to Alaska Sea Grant for their support in co-hosting the Alaska Nursery Operators Workshop.
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Video Transcript
PVC Spool System Components [00:00:04]
These are our PVC drain caps here. They make them in different diameters – five inch and you can get them up to like six inch, but six inch pipes all the way down to like one inch, something like that. So this system, as long as you’re using the same twine size, you can change the diameter of the spool by just going to the hardware store and buying different diameter lids. We tried to match these with the diameter or with the spool size that you guys are using.
Electric Motor and Gear Ratio [00:00:31]
The system works with an electric motor in here. The electric motor is powering this sprocket here, and so this sprocket has a specific gear ratio to that one and it moves down at a set rate based on the thickness of twine. This version is designed for old fast twine. If you’re using a different type of twine that might have a different diameter, we need to talk about how we can gear this ratio to make it work for you.
Operating the Winder [00:01:02]
If the system’s plugged in right now, all we do is put it on run and we crank it up. So it’s going this way right now. At the end there, these are stop switches. So when it gets to the end, it just automatically stops. If I want to say my spool’s loaded up there, we’ll just go down there. And so that’s full speed right now.
Winding Speed and Torque [00:01:31]
We initially designed this to be slow because it’s based on torque. So we want a more torquey motor so you can actually get these spools really tight. If you see that spool that Maddie has, we actually use something metal to sort of push the spools really tight. The reason we keep our spools really tight is because it makes it better for outplanting.
The tighter twine will make it more consistent for outplanting, but also because we use gametophyte seeding. And so if you guys ever move to gametophyte seeding, you’re going to paint on or spray on. If you have gaps in that twine, you’re going to lose material.
Revolution Counting and Spool Length [00:02:14]
By knowing the number of revolutions, we know exactly how many feet go on each spool. So this one is set to 340. So 340 is just about 400, I think it’s a little over 400 feet. So we know it’s getting 400 feet.
You guys are going to get one of these. I want you to test it out, put it through the ringer and work with us to try to make it better, because we know it’s not perfect. And we know that once you start winding hundreds of spools, problems are going to come up that we need to address.
Spool Preparation and Cutting [00:02:47]
This is a spool that’s 16 inches. This system can accommodate different lengths that are 16 inches or shorter spools. Cutting the spools is really important and it takes a while to get good. What you want to make sure is that the spools are standing up straight. If you cut your spools a little wonky, the system’s going to be hard to work with because it’s going to just spin in a weird way. So you want to make sure you’re cutting your spools well.
Spool Design Features [00:03:19]
Here they use these slits. These slits are nice because you can just put the seed string in. We actually, like Tamson does, we rip them down that way too and put a notch so you can remove the spools without detensioning your line. Some farmers like that, some farmers don’t. It’s all preference.
End Caps and Assembly [00:03:37]
There are two end caps here. There’s an end cap with a wing nut – the wing nut end goes on the drive side. And then there’s this other end which is just laid down. A bolt will go on that other end. So I’m starting from that side, so I’d put on the wing nut one first.
Loading Tips and Techniques [00:03:58]
I like to tie a bowline in the lines just because it makes it a lot easier when you’re out on the farm to grab the line. So you grab it with your glove finger and you can tie a knot pretty easily. Just expect there’s a learning curve.
Winding Speed and Efficiency [00:04:19]
How long did it take you to do a spool now with the machine? I can wind four spools in 42 seconds. If I let it go too far without pushing it, that needle will catch up and it’ll backlash, which you don’t want. I spend more time tying the line and tying the knot and hooking it on the other end.
System Benefits [00:05:01]
There are spool winders out there and I think it’s a great thing to have because it’s going to reduce the amount of time you’re spending on a monotonous task that you think could be standardized.