Super Ion Air Knife Stops Material Jamming During Unwinding

gen4-static

Static electricity is something that we talk about often here at EXAIR. When an atom gains or loses an electron from its outer shell, it becomes electrically imbalanced. A material’s propensity to either gain or lose an electron is “ranked” on a list known as the Triboelectric Series. Static Electricity is generated in a few different ways: contact static build up, detachment static buildup, and frictional static build up.

Detachment static build up occurs when a material is in contact with another and these two surfaces separate from one another. During the separation, not all of the electrons are able to get back to their original molecule. This results in an instantaneous static charge as the electrons are transferred from one object to another in accordance with the Triboelectric Series. Due to the large surface area in most detachment static buildup scenarios, the amount of static generated is typically far greater than contact static buildup.

One of the most common types of detachment static buildup occurs as material separates from a roll. This typically occurs at a high rate of speed and the large surface area across the width of the roll presents an ideal situation for static buildup. This charge can cause the material to stick to itself and not come off the roll properly, creating issues down the line. It can also result in painful shocks to operators, which not only presents a safety hazard but also negatively impacts productivity and morale.

I recently worked with a customer that needed a solution for removing this static from a roll as it was placed onto their work table. The customer manufactures a variety of clothing and equipment used by the military. One of the materials used in their combat clothing provides protection against heat transfer should the wearer be exposed to fire, explosions, etc. that are common on the battlefield. The material is lightweight, but a coating on the surface allows for a significant amount of static to generate as it is unrolled. This presents two separate issues for them. The machine must be stopped to fix the roll as it jams. When fixing the jam, the operator must grab a hold of the material and manually feed it back onto the roll. When doing so, they’re occasionally met with a very unpleasant jolt in addition to the time wasted stopping and restarting the process.

The solution was to install a 42” Gen4 Super Ion Air Knife blowing onto the roll as it unwinds. The positive and negative ions from the knife neutralized the charge on the surface of the material and stopped it from jamming. The customer estimated an increase in production of nearly 20% as they weren’t stopping to fix the jam. The shocks that resulted from having to fix the subsequent jams also stopped. If static is causing production problems in any of your processes EXAIR has the solution ready to ship from stock. Give us a call today and an Application Engineer will be happy to help prescribe the solution to all of your static woes.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Solving Static and Increasing Print Quality on Food Packaging

Gen4 Static Eliminators

A yogurt company printed bar codes on every cup that they produced. This was necessary for registering and tracing their product. After failing a bar code reader quality test, they started noticing some print issues during batch runs. They would have to stop their system, clean the inkjet printer head, and scrap product that would not register with the bar code reader.

This affects production rates, scrap rates, and overall cost. They stated that they threw away 30 to 40 cases per batch of yogurt due to this problem. They had an EXAIR catalog where they found a similar application within our Gen4 Static Eliminator product line. They contacted us to see if we could find a solution.

With non-conductive material like plastic, static is easily generated; especially during cooler weather. Static can be in a negative state or a positive state dependent on the material. For opposite charges, things are attracted to each other and will “stick” like magnets. For similar charges, they will repel each other. The higher the static charge, the stronger the force.

For the company above, the yogurt cups moved along a 7” (178mm) wide conveyor before they reached the bar code printer. This movement causes static to be generated on the surface of the cups. But, what about the inkjet printer? The function of the printer charges the ink droplets for direction and positioning. Since the ink droplets and the cup surfaces have the same charge, the droplets were being “pushed” back toward the printing head (reference photo below). Thus, the ink would dry on the surface and affect the quality of the bar code.

Bar Code Printer

When it comes to removing static, EXAIR is a leader in this market. We have a large product line of different types of Static Eliminators. Our design generates both positive and negative ions to remove any type of static charge. Since we only had to remove the static from the surface of the cup, I recommended a Gen4 Ionizing Bar. With a quick static decay rate, we can remove the static right before the bar code printer with only one Gen4 Ionizing Bar. For this application, I recommended the model 8003 3” Gen4 Ionizing Bar and a model 7960 Gen4 Power Supply. Together, it was very easy to mount and start using. EXAIR stocks lengths from 3” (76mm) up to 108” (2743mm), and we can ship a solution the same day. When you are losing 30 to 40 cases, time matters. And for this company, they received the items the next day to correct the misprints and short printing runs.

Gen4 Ionizing Bar w/ power supply

When problems occur, time can be of the essence. This is why EXAIR stocks our cataloged items for fast delivery.  For the company above, they had an EXAIR catalog which helped them to find a solution. If you would like to have an EXAIR catalog, you can click here to get one.   After they started using the Ionization Bar, the static was removed, the bar code was clean, and the operation ran smoothly. If static is causing issues for you, you can contact EXAIR and speak to one of our Application Engineers. We will be happy to assist you.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

Gen4 Static Eliminators: Cleaning as a Preventative Maintenance

The Gen4 Static Eliminators have been successful for EXAIR because of our robust design and great performance. They are rugged enough to be used in many industrial areas. EXAIR manufactures two styles; with and without compressed air assistance. For both types, preventative maintenance is still required to keep the Gen4 product line functioning optimally. In this blog, I will describe how to clean the points for years of hassle-free operations.

There are two common ways that an anti-static product will start to drift; contamination buildup and emitter point degradation. The degree of buildup is dependent on the environment. To create an ion, we have to apply a high voltage to a fine point. The high voltage is supplied by our Gen4 Power Supplies which generate 5,000 volts from a selectable 115Vac or 230Vac input. As the high voltage is pushed into a fine point; the energy creates a corona field.

Any contamination near or around that point can collect on its tip. The more contamination in the surrounding area, the faster the buildup will occur. Once the point gets coated, the ion production begins to decrease. Before this happens, the points should be cleaned with a soft-bristled brush as a preventative maintenance. Make sure that the power is turned off to the power supply and please do not use any liquid or cleaners on the points.

The second way is caused when the ionizing tips start to lose its sharpness caused by the cycle rate of ion production. Like a wick in a candle, a bit of material is lost over time. To mitigate this, our resistor-based line has replaceable ion points. This feature makes a cost-effective way to keep the points sharp, and the Static Eliminators like new. The video below shows how to clean and replace the ion points.

For any analysis with the Static Eliminators, EXAIR offers a model 7905 Static Meter. The Static Meter can help to find problem areas for best placement for the Gen4 Static Eliminators. It can also help to diagnose any static issues when cleaning is required and to help decide a preventative maintenance schedule. Whether is it a single point or multiple point product, the video above will help you to keep your machines running smoothly.

“An ounce of prevention is worth a pound of cure.”   With a maintenance schedule and a soft-bristled brush, you can protect your equipment from many issues with static. This would include machines jamming, difficult alignments, collection of debris, and hazardous shocks. EXAIR has a large line of Gen4 Static Eliminators to remove these static nuisances, and with the cleaning instructions above, you will have years of effective static removal. If static is affecting your operation, you can contact an Application Engineer at EXAIR to help select the correct solution.

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

Ion Air Jet Applications

While writing my blog last week on all of the features & benefits of the Gen4 Ion Air Jet, I couldn’t help but think of some of the very interesting and successful uses I’ve seen in my nine years (as of this past Monday) as an Application Engineer at EXAIR Corporation.  In honor of my workaversary, this week’s edition is Russ’ Top 9 Ion Air Jet applications:

  1. A medical device manufacturer uses Ion Air Jets to remove dust from plastic extrusion as it goes through a puller belt.  The small diameter (0.05″ to 0.10″) made the Ion Air Jet a more efficient fit than the Super Ion Air Wipe, which is commonly used for extrusions like this, but is most effective for larger diameters.
  2. A maker of large scale automated machinery has provided Ion Air Jets (as well as other EXAIR quiet, efficient, and safe compressed air products) on machines they’ve been selling their customers for years.  When they started machining their own plastic parts, the Ion Air Jet was their first thought for a solution when plastic chips started sticking to their drill bits.
  3. A commercial printer makes displays, signs, etc. from a variety of static-prone materials such as acrylic, polycarbonate, and styrene.  They use CNC routers to cut them to size & shape, form the edges, and add dimensional detail.  Ion Air Jets blow the dust & shavings away, and keep them away, greatly reducing the prep time between routing and assembly.
  4. A weather sealing/stripping manufacturer uses Ion Air Jets to remove statically charged dust from their rubber & foam product extrusions, allowing for increased line speeds and better cuts for the products they cut for specific seal packages for the residential & commercial door and automotive industries, among others.
  5. A major provider of electrical and electronic contactors uses Ion Air Jets to blow off contact strip as it rolls off large reels to remove protective film and static.
  6. A manufacturer of wire marking machinery installs Ion Air Jets on their machines that are used to print on products with especially static-prone jackets, to ensure clean and crisp markings
  7. A cable manufacturer that caters to the computer & electronic industries uses Ion Air Jets to remove static & dust as foil is applied to PVC coated wire.  This eliminates the static charge that was causing inconsistencies when the adhesive was heated to activate.
  8. A wholesale food equipment distributor uses Ion Air Jets to blow out bottles during the sterilization process, prior to filling.
  9. A maker of specialty polymers uses Ion Air Jets to keep fine powders from accumulating in the entries into their hoppers.
Some applications call for a fixed-in-place solution, like the (above, from left) Super Ion Air Knife, Super Ion Air Wipe, Ion Air Jet, and Ion Air Cannon.) Others are best suited to the hand-held convenience of the Ion Air Gun.  Whatever your static problem is, though, EXAIR has a solution for you!

If you have a problem with static, the Ion Air Jet is just one of the solutions EXAIR Corporation can provide.  If you’d like to find out more about how we can help, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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