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

EXAIR Air Nozzle Provides Non-Marring Solution For Rotary Die Cutting

Die Cutting is a highly efficient means to produce large volumes of uniquely shaped parts while creating a low volume of wasted materials. There are several different ways to produce die cut parts with one of the more common being Rotary Die Cutting. A Rotary Die Cutter typically incorporates the material passing between a roller die cutter and a heavy roller anvil to cut the specific shape  then passes the material down a conveyor or feed line while retrieving the waste material in another collection device.

I recently worked with a customer who was starting to see a large volume of scrap in their vinyl and rubber parts die cutting process as the die cut parts themselves were getting stuck onto the rolling die cutter and weren’t getting grabbed by the conveyor rollers. To try and get the parts to eject from the cutter they installed a few 1/4″ open copper tube air lines running across the roller but were concerned with amount of air they were wasting and the high pitch noise levels of close to 100 dBA. They were also seeing some damage to the parts they were able to get loosened from the die as some of the parts would make contact with the pipe, causing a “blemish” on the part, ultimately failing inspection.

I recommend the customer use our Model # 1100-PEEK Super Air Nozzle. The Model # 1100 consumes only 14 SCFM of compressed air (at 80 PSIG), much less than a 1/4″ open pipe, tested at close to 140 SCFM @ 80 PSIG. This nozzle produces a low sound level of only 74 dBA falling well within the allowable noise exposure levels set forth by OSHA. In addition, the PEEK plastic construction provides a non-marring solution in the event one of the parts did make contact with the nozzle.

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1100-specs Model # 1100-PEEK Super Air Nozzle with Performance Specs

EXAIR offers a large selection of engineered air nozzles with varying airflow patterns, force, sound levels and materials of construction to meet a wide variety of application requirements. With help selecting the best solution or to discuss your particular application, please give us a call.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN