Apparatus and method for minimizing waste and improving quality and production in web processing operations by automated threading and re-threading of web materials

An apparatus for threading a material layer through a machine path, the apparatus comprising a forwarding series of blowing air mechanisms aimed at said material layer in a machine direction to guide said material layer in said machine direction forwards through said machine path until an acceptable material state is achieved;

• a sensor;
• and a reversing series of blowing air mechanisms aimed at said material layer in a reverse machine direction to guide said material layer in said reverse direction;
• said sensor operatively coupled with said forwarding series of blowing air mechanisms and operatively coupled with said reversing series of blowing air mechanisms;
• at most one of said forwarding series of blowing air mechanisms and said reversing series of blowing air mechanisms instantaneously operative upon said material layer.