What Makes Things Easier Than An EXAIR Static Eliminator? Another EXAIR Static Eliminator!

A contract manufacturer, servicing the medical and biotechnology markets, is a long time user of our Ion Air Guns. They’ve had great success with them in keeping their products free from static & dust for years. These are mainly small, hand-held parts, so, when they need to get them clean and static-free during assembly and packaging, EXAIR’s Ion Air Gun is ideal, because it, too, is small and hand-held.

A new process, though, involves the operator needing both hands for assembly. This would mean picking up the Ion Air Gun, blowing off the part, putting it down, and then using both hands to complete the operation. They thought there had to be a better way. And they were right!

The Model 8910 Instant Static Elimination Station offers hands-free control of ionized air flow – a foot pedal turns an Ion Air Jet (whose performance is identical to the Ion Air Gun) on and off with…well, the press of a foot. The Magnetic Base and Stay Set Hose make it easy to install, and even easier to position.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

Hand held convenience of the Ion Air Gun (easy) or no-hands convenience of the Ion Air Jet Station (easier.) Your call.

For an even more automated approach, they are considering an EFC Electronic Flow Control. They’re ready to go, right out of the box…the photoelectric sensor will open and close a solenoid valve (installed in the compressed air supply line) based on the setting of the programmable timer unit. With a simple wave of the part in front of the sensor, the operator could activate a preset blow of a few seconds, which would be easy to determine, even easier to set, and…easiest of all…reliably repeat all day long. They’re going to try out the foot pedal first, and that’s just fine by me.  Perhaps there’s such as thing as “too easy,” but man, I hope not.

Even if you’re already using EXAIR products to make things easy, you can call me to see how much easier it might get.

Russ Bowman
Application Engineer
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Speaking of easy...get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Speaking of easy…get a FREE AC Sensor with a Static Eliminator order. Promotion ends 1/31/2017!

Solving a Printing Problem with EXAIR Static Eliminators

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Unrolling plastic into this machine created a static charge throughout the process

One of the most common sources of static electricity in automated processes is friction.  As two (or more) materials move against each other, static is produced due to the triboelectric effect.  By definition, the triboelectric effect is a type of contact electrification in which certain materials become electrically charged after they come into frictional contact with a different material.  If these materials are non-conductive, or if they are not grounded, the static charge will remain.  This was the case for the machine shown above.

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Multiple stations of this machine, all experiencing static problems

This machine is a Chesnut 150 Gravure Print Station.  It is used for printing, coating, laminating, and sometimes die cutting of paper, light paperboard, films, polyester, flexible packaging and aluminum foil.

In this application, a roll of plastic is dispensed, but a static charge is preventing proper printing on the plastic as it travels from roll to roll.  As the film is separated from the roll, a static charge is produced, and this charge is carried through the process at values ranging from 3,000 – 20,000 volts.  The manager for this production area contacted EXAIR to see if there’s a viable EXAIR solution to remove this static charge.  They were interested in a solution that could eliminate static on the full width of the plastic, could be mounted 200-300mm away from the rollers, and could be replicated at multiple places along the machine.

With this in mind, the best solution was to use a series of 18” Super Ion Air Knives installed periodically along the path of plastic within the machine.  Operating at a low pressure of 1-2 BARG (14.5 – 29 PSIG), the Super Ion Air Knives create an evenly dispersed, quiet airflow of static eliminating ions with a low compressed air consumption.  Using the laminar, static eliminating airflow from the Super Ion Air Knife, this solution can be mounted away from the static charge, allowing the ions to “rain” down on the affected areas.

For this application finding a solution meant finding a method to keep production on schedule.  Without static elimination this machine faced defects, downtime, and decreased efficiency.  Using EXAIR Super Ion Air Knives brought this application back up to optimal operating speeds, keeping the revenue generating process of this manufacturer ongoing.

Colder weather is here and static comes along with it.  If you’re experiencing a static related problem in your facility, contact one of our Application Engineers.  We’d love to help you find a solution.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Ion Bars Eliminate Jam In Fiberglass Production

Last week I worked with a specialty glass manufacturer who was experiencing a static issue in their fiberglass mat production. Their particular production cycle consists of a rotary spinning process where molten glass exits a furnace and goes into a cylinder with several holes that rotates at high speed, causing the glass to be “pushed” through the holes. Upon exiting the cylinder, the fibers are blown down on to a conveyor belt underneath, treated with a binder and pressed together, then sent to an oven to cure. After the sheets exit the oven, they are air cooled, cut to the desired length, then sent to a sorter that directs the material to collection bins, based on thickness and length. It is at this point that they were seeing the parts start to “bunch” up, which caused the system to be shut down so an operator could manually clear the jam and sort the mats. The customer has experienced static issues before in other parts of their plant and took some readings and were seeing a 4 kV charge on the surface of the mats.

After discussing the details of the application, I recommended they use our 24″ Ionizing Bar, the width of their widest mat. The Ionizing Bars produce a high concentration of positive and negative ions to eliminate the surface static of an object when mounted within 2″ of the surface of the material. At 2″ away, the units are capable of dissipating a 5kV charge in less than half a second. By placing a unit above and below the exit point of the sorter, they would effectively remove the surface charge and eliminate the potential jam.

Ionizing Bars Work

Ionizing Bars are effective up to 2″ away and require no compressed air to operate.

Our Ionizing Bars are available in lengths from 3″ up to 108″ for a variety of small or wide surface treatment applications. For assistance selecting the best product for your specific requirements, please contact one of our application engineers at 800-903-9247.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Solving Static Problems with EXAIR Ion Bars

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This plastic film stretching machine needed a viable static elimination solution.

The relationship between humidity and static is something we’re very familiar with at EXAIR.  As temperatures drop and humidity decreases, the reduction in moisture content within the air translates to an increase in static .  This is because higher moisture content in the air creates a surface layer of moisture that dissipates accumulated static charges.  When this surface layer disappears, static forms quickly and easily.

Fortunately, we have a full line of static eliminating equipment suitable for use in removing static related process disturbances.  For example, the photo above shows a plastic stretch wrapping machine at its dispensing point.  As the plastic is pulled from the roll static builds up quickly and this customer needed an easy, reliable solution to remove the static.  Ideally, they wanted something that would not require compressed air, but could still mount closely to the machine and remove the static charge.

The solution for this application was a series of two 24” Ion Bars mounted on each side of the film.  As the plastic is unrolled it passes through the opening created by the Ion Bars, eliminating the static charge.  The machine required no significant downtime to install this solution, and nothing within the machine setup had to be modified.

This type of setup was ideal because it treated the static at the proper point within the process, used no compressed air (as requested by the customer), and it provided a simple installation to solve the problem.

Plastic sheets and films that are being separated after full contact can generate significant static charge.  If you have a film/sheet application, or another static related need, contact an EXAIR Application Engineer.  We’d love to help you find a solution.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Removing Debris from Jars Prior To Filling

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These PET jars needed a way to remove static dust prior to filling with product

Back in the spring of this year I had some interaction with a customer in India about a Vortex Tube application.  At the time, they were facing an overheating condition and needed some guidance as to which model would provide the best solution.

Fast forward to this week and this same customer reached out to me again, this time for a static problem.  The application in question was plagued with difficulty in removing small dust particles from the inside of PET jars (shown above).  The jars range from 220-260mm in height (8.6”-10.25”), 80-100mm (3.1”-4”) in diameter, and travel through the process at a speed of ~40 units per minute.

Due to static charge, the dust in this application would adhere to the inside of the jars, presenting a problem with filling during the next stage of the process.  What this customer needed was a way to remove the static, blow away the dust, and then pull a slight vacuum on the jars as a safeguard against any remaining dust.

The solution was to use the Stay Set Ion Air Jet to blow into the jars, removing the static and blowing away the dust, followed by a Super Air Amplifier to remove any dust particles which were not removed by the Ion Air Jet.

The customer was happy with this solution, but there was a bit of hesitation as to whether the Air Amplifier would be able to truly remove debris from the jars.  In an effort to visualize the effects of an Air Amplifier on this type of application I made the short video below.

This video shows paper pieces inside of a cylinder of comparable height to the jars in this application.  After the paper is placed in the cylinder the model 120021 Super Air Amplifier is used to pull the paper out of the cylinder, mimicking the effect it will have on residual dust in the customer’s application.  After seeing the video the customer was confident in the application solution.

Providing this type of assistance for our customers is nothing new for us at EXAIR.  We’re available via phone, online chat, or email for all of our customers, and commit to taking the time needed to really provide the assistance needed.  If you find yourself in need of solid engineering support for an application in your facility, contact an EXAIR Application Engineer.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Stretch Wrap Static Solution

Recently a customer called in to EXAIR to discuss a static issue in a stretch wrap process in the plant. Stretch wrap is a highly stretchable plastic film.  The elastic recovery keeps the wrapped load tightly bound. The most common stretch wrap material is a linear low-density polyethylene or LLDPE.  The combination of the stretching of the plastic film and the sliding of the film on the cardboard boxes as it is being wrapped causes a build up of static. This static can cause serious havoc and issues in the process including personnel shocks, zapping counters and other sensors causing failures, and preventing marking systems from delivering good information on to the stratch wrap.

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Stretch Wrap Operation

The discussion started with minimum and maximum load sizes and how to design a system that would work with all configurations and be as flexible as possible.  We spoke of dimensions and where we could we could mount on 3 sides, and so forth.

Then came the question that we invariably get to and that is ‘what issue does the static cause and how does it affect the rest of the process?’  The answer here simple, ‘an operator has to write a code number on the side and affix a label, and in doing so, receives a shock.’ When it was determined that only a small section of one side of the load needed to be treated, the solution was simple.  We proposed an 18″ Ionizing Bar and Power Supply. Because the machine had a fixed datum, all loads would pass within 1-2″ of a vertically installed Ionizing Bar, so no adjustment is needed for different load sizes.

Ion Bar

Ionizing Bars Treating Top and Bottom Surfaces

The Ionizing Bar quickly dissipates a strong static charge as shown in the chart below.

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EXAIR offers many systems for total static control. When static is a problem on moving webs, sheet stock, three dimensional parts, extrusions or packaging, EXAIR has a solution.

To discuss your application and how an EXAIR Static Eliminator would help out, feel free to contact EXAIR and one our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Static Can Become A Big Issue With Winter Approaching

Many automotive parts are made of plastic, and with nonconductive materials, static electricity can become a big problem, especially in cooler climates.

A customer with whom I spoke recently assembles instrumentation clusters for vehicles.  The assembly process started by using a regular compressed air gun to blow the surfaces clean before assembly.  The operator would place a polycarbonate applique onto a lighting fixture.  Then a clear polycarbonate cover would go over both parts.  To complete the cluster assembly, an ultrasonic welder would weld the plastic studs around the outside edge and seal the parts together.  This completed the assembly process.  However, during inspection, they started to notice more visual defects after the welding process.  The cause was debris that became lodged between the applique and the clear cover. The debris was still present even after blowing.  If the debris wasn’t cleared prior to welding, the entire assembly would have to be scrapped due to the visual defect. The customer knew about EXAIR from previous projects and so decided to get help from us again to solve this expensive reject situation.

Initially, blowing the plastic components with regular compressed air before assembling and welding  worked well, but then they started seeing an increase in the reject rate.  I came to find out that they were located in Michigan. So I asked the customer about the weather there recently. They indicated that was getting cooler as we begin to head into Fall and Winter. As cooler weather is among us, static can be generated much easier because cool air cannot hold as much moisture. And with less moisture, which aids to eliminate a static charge, the likelihood that static will generate goes up.  Once static is generated on plastic components, dust and debris likes to stick to the surface.  Static charges are very strong, and even with blowing compressed air, the debris can still cling to edges or even “jump” to another location.  This was a manual operation and they needed to remove the static from the surface in order to eliminate the debris from the assembly.

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I recommended the model 8493 Ion Air Gun Kit. It combines static removal capability with a blowing force that one would normally associate with a compressed air blowgun.  The kit includes the Ion Air Gun, power supply, filter and regulator.  The Ion Air Gun is designed with a 5:1 amplification ratio; minimizing compressed air usage and maximizing ionized airflow.  With the regulator, you can control the force from a “blast” to a “breeze”.  The ionized airflow eliminates the static from the plastic surfaces, allowing the airstream to remove any dirt and debris.  They replaced their current air gun with the EXAIR Ion Air Gun, and the rejection rate decreased to the acceptable levels that they were seeing in the summer months.

Being that the winter months are approaching, you may want to re-evaluate your processes.  If you are working with non-conductive materials like plastic, wood, glass, or textiles, EXAIR has a variety of Static Eliminators that can save you from getting headaches, losing money, and saving time.  With our customer above, they weren’t able to get ahead of the static issue, and it created many problems until they investigated using EXAIR Static Eliminators. Get rid of your static headaches by using an EXAIR Static Eliminator today.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

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