Promotional Item: Gen4 Static Eliminators and a free AC Sensor

As the weather gets colder and the air gets dryer, static electricity can become a real nuisance in a production plant.  Machines will start jamming, alignments will be difficult, debris will collect on surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a large line of Gen4 Static Eliminators to remove this static nuisance.  And beginning January 1st, 2019; EXAIR will be giving away a free AC Sensor, a $57.00 value, with a purchase of any of the Gen4 Static Eliminators.

EXAIR stocks eight different product lines in two different styles, Gen4 Static Eliminators with Air and Gen4 Static Eliminators without Air.  In conjunction with a power supply, these ionizers can create both negative ions and positive ions to remove any type of static charge that is on the surface.  The Gen4 Power Supplies come in either a 2 port or 4 port configuration; so that, you can power multiple Gen4 Static Eliminators at once.  From the power supply to the ionizer, an armored and electromagnetic shielded cable is used in a single wire design. This helps to protect the cable from abrasions, cuts and splits in industrial areas.   The Gen4 Static Eliminators have a shockless design, and are UL Component Recognized and CE compliant.  I will give a brief description of each product that utilizes this rugged industrial design for optimal static neutralization.

Gen4 Static Eliminators with Air:

Gen4 Super Ion Air Knife
  1. Gen4 Super Ion Air Knife: This product has the best compressed air efficiency in removing static by combining the Super Air Knife with an Ionizing Bar.  The Gen4 Super Ion Air Knife has a 40:1 amplification ratio and uses the laminar air flow to carry the positive and negative ions to the surface up to 20 feet (6.1 meters) away.  The laminar air flow also allows for a quick static discharge in applications with fast conveyance speeds.  EXAIR manufactures stock lengths from 3” (76mm) to 108” (2.74 meters).  Some typical applications for the Gen4 Super Ion Air Knife are found in web cleaning, sheeters, pre-paint dust removal, and shrink wrappers.

    Gen4 Standard Ion Air Knife
  2. Gen4 Standard Ion Air Knife: Similar to the Gen4 Super Ion Air Knife, the Gen4 Standard Air Knife has a good efficiency at 30:1 amplification ratio.  It utilizes the Coanda effect to draw in ambient air, and they come in stocked lengths from 3” (76mm) to 48” (1.22 meters).  The Gen4 Standard Ion Air Knife are used in similar applications as well as mold releasing, package cleaning, label applications and plastic bag opening.

    Gen4 Super Ion Air Wipe
  3. Gen4 Super Ion Air Wipe: This product blows ionized air in a 360-degree pattern.  They are engineered to remove static and debris from the outside of hoses, plastic pipes, extrusions, and coated wires.  With the split design, the Gen4 Super Ion Air Wipe can easily mount around the product without having to rethread.  They come in two different sizes with a 2” (51mm) and 4” (102mm) inner diameter. The ionized air has a fast decay in removing static for speedy transfers.

    Gen4 Ion Air Cannon
  4. Gen4 Ion Air Cannon: Just like the name, this product will shower an area with ions to remove static. It can reach distances up to 15 feet (4.6 meters).  They are used in multiple areas including pre-paint car bodies, containers, shrink packaging, lenses, etc.  As an Air Amplifier, a small amount of compressed air will draw in a large amount of ambient air.  The ions are carried to the surface by the Gen4 Ion Air Cannon in a laminar air steam.   Once the ions coat the surface area, the air flow can gently remove any debris held by static forces.

    Gen4 Ion Air Gun
  5. Gen4 Ion Air Gun: For manual static removal to target specific areas, the Gen4 Ion Air Gun will work great.  This product comes standard with 10 feet (3 meters) of shielded cable for maximum reach.  An ergonomic air gun is attached to a Gen4 Ion Air Jet to manually remove static in difficult areas and to pre-treat within “shock” zones.  The Ion Air Guns work great for small batch processes used for quality checks or label applications.

    Gen4 Ion Air Jet
  6. Gen4 Ion Air Jet: Similar to the Ion Air Gun, this product is used for “hands-free” operations. They use a small amount of compressed air to “shoot” the ions onto a target area.  They can be operated with a solenoid valve or foot pedal to blow ions during specific times and situations.  They can easily be attached to a Stay Set Hose and Magnetic Base for best “hands-free” positioning for optimal cleaning.  They work well on small targets for automated systems or inspections areas prior to packaging.

Gen4 Static Eliminators without Air:

Gen4 Ionizing Bar
  1. Gen4 Ionizing Bar: This rugged design is for industrial use to remove static cling from flat surfaces. They range in length from 3” (76mm) to 108” (2.74 meters).  Without the assistance of air, the product has to be within 2 inches (51 mm) from the surface to remove static charges.  The Gen4 Ionizing Bar is compact, shockless and works well in applications where blowing air could be a detriment.  The applications would include screen printing, labeling, and large printing processes.

    Gen4 Ionizing Point
  2. Gen4 Ionizing Point: This single point design is manufactured to remove static on small targets in tight spots.  Utilizing the same rugged design, this product can remove static in spot areas and help to stop jams from slitting operations. They can also be panel mounted to neutralize areas using ducted air.
Model 7929 EXAIR AC Sensor – FREE to end user customers when purchasing ANY EXAIR Gen4 Static Eliminator through March 31st, 2019

Now how about that free promotional item, the AC Sensor, with a purchase of any of the Gen4 Static Eliminators above?  This device, as mentioned above, has a $57.00 value which you can get for free.  This sensor provides a non-contact way to verify if voltage is present.  A red light at the tip will glow, and an audible tone is sounded when voltage is detected.  The model 7929 AC Sensor is an ideal tool to quickly verify that power is going to your ionizer.  This instrument will also work for finding power in receptacles, junction boxes, switches and breaks in power cords.  Batteries will be included, so you can start using it right after receiving the robust Gen4 Static Eliminators.

If you are an end-user and located within the United States or Canada, you can take advantage of this offer until March 31st, 2019.  An Application Engineer at EXAIR will be happy to assist you with your application and a solution with the Static Eliminators.  And if you qualify, a free AC Sensor.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

What Causes Static Electricity?

We’ve all been shocked before. And no, I’m not talking about the feeling we all here in Cincinnati felt when the Cincinnati Bengals finally fired Marvin Lewis… I’m referring to the discharge you’ve likely felt on a cold winter day after walking across a carpeted surface and touching a door knob. This electrostatic discharge is a result of static electricity. To understand how this static electricity is generated, let’s first go back to basic chemistry class and talk about the atomic structure of an atom.

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An atom consists of three basic particles: protons, neutrons, and electrons. The protons (positively charged) and neutrons (neutral charge) form the nucleus. Outside of the nucleus, electrons (negatively charged) are quickly zipping around in orbits at specific distances from the nucleus. These electrons are bound to the nucleus due to electromagnetic force. Opposite charges attract, since the protons in the nucleus carry a positive charge this acts on the negative charge of the electrons and keeps them in orbit. The closer the electron to the nucleus, the stronger the bond and the more energy required to break that electron from its original orbit.

When an atom gains or loses an electron, it affects the balance that occurs within an atom. If an atom gains an electron, it now has more electrons than protons. This results in a negatively charged atom. The opposite can be said if an atom loses an electron, it now carries a positive charge. This charge imbalance is where static electricity comes from. Both positive and negative charges will remain static until contacted by or in close proximity to a conductive or grounded surface.

The strength of this charge will depend on a few different factors: the types of materials, surface area, environmental conditions, etc. will all play a role in the generation of a static charge. The triboelectric series is a scale, listing various different materials and their tendency to become positive or negative. Those at the far end of the spectrum have an increased propensity to gain or lose an electron, while those in the center are more likely to remain balanced. When two materials on opposite ends of the spectrum come into contact with one another, it poses the greatest risk of generating high levels of static electricity. The chart below shows some common materials and where they fall on the tribolectric series.

triboelectric

When materials carry a static charge, a variety of problems can ensue during manufacturing. These can manifest in the form of painful shocks to operators, materials jamming or tearing, sheet feeding problems, discharges causing imperfections in the material appearance, etc. To remove the charge, we need to introduce static eliminating ions to balance it out. EXAIR’s full line of Static Eliminators create an equal number of both positive and negative ions to saturate the surface of the material and neutralize any charge present.

With a wide range of different solutions all available from stock, EXAIR has the solution to your static problems this winter. Give us a call and we’ll be happy to discuss the application and help to identify the best method to mitigating any static issues in your processes. Take advantage of EXAIR’s current promotion (now through the end of March) and receive a free AC Sensor with your Static Eliminator purchase!

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

 

Atom photo courtesy of janjf93 via Pixabay Creative Commons License

Super Ion Air Knife Removes Static from Flour Packaging Process

Static Eliminators
Static Eliminators

Recently I had the pleasure of working on an application with one of our South American distributors, AYRFUL. Their customer is an OEM manufacturer of packaging machines that deals with a variety of different industries in the region. They had a machine in the field operating in Argentina that was posing some issues for a company that processes flour.

Static was building up on the packaging material and was causing flour particles to stick to the outside of the package. If there was any residual flour stuck at the top of the bag after filling, it wouldn’t allow the package to seal properly. This would result in bags of flour that would be improperly sealed, this caused housekeeping issues as some would spill out, but also some of these bags have to be thrown out due to potential contamination.

SIAK web

They reached out to our distributor who was able to go see the application and confirmed that the static was causing the problem with a Model 7905 Static Meter. The web was 27” wide, making our Model 112030 30” Gen4 Super Ion Air Knife a near perfect fit. By placing the Super Ion Air Knife just prior to the filling operation, we were able to remove the static charge on the material and blow off any residual flour that was still stuck to the outside of the packaging. This immediately mitigated the static on the material and allowed for the packages to seal properly, resulting in a production improvement of almost 20%!!

We’re smack in the middle of winter here in the US with drier air causing an uptick in static problems across a wide variety of industrial processes. With a wide range of Static Eliminator solutions available from stock, EXAIR has the ability to solve your problem QUICKLY!

Get in touch with us via phone, chat, or e-mail and an Application Engineer will be happy to assist you in selecting the most suitable Static Eliminator based on the application.

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

EXAIR Webinar 11/7/18 2pm EDT: Understanding Static Electricity

Halloween has passed, temperatures are dropping, and you’ve had enough of constantly raking up leaves. It’s clear to everyone that summer is over (much to my dismay). As temperatures decline, so too does the amount of moisture in the air. As this happens, issues related to static electricity begin to increase. If you’ve ever walked across a carpeted surface, only to be shocked as soon as you touch a doorknob, you’re familiar with the effects of static electricity. In addition to painful shocks, static can contribute to a variety of problems within industrial processes.

We’ve talked here on the EXAIR blog about several of these different applications. Some examples include: removing static on plastic packaging, stopping dust from clinging to product, or aiding in part removal in an injection molding application. These types of applications can certainly occur year-round, but the absence of humid conditions dramatically increases the potential for them to occur.

summer static
In this photo, a static charge present causes the plastic particles to cling to the end of a suction wand.

They key to combating static electricity is first understanding how it it’s generated and how to test for it. To help you gain some more knowledge about static electricity and the problems it can cause, EXAIR is hosting a FREE webinar this week. Within this webinar you’ll learn how to identify a static charge, the series of events that are causing the charge, as well as various ways to eliminate this nuisance.

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Brian Farno, EXAIR’s Application Engineering Manager, will be conducting the webinar at 2:00 ET on 11/7/18. Immediately following the presentation will also be a brief Q&A. If you can’t attend, don’t let that stop you from registering! A link to view a recorded version of the webinar will go out to all registered participants whether you’re able to attend live or not.

Click here to register and view details on this upcoming webinar. Make sure you’re educated on the issues associated with static electricity before it’s too late!

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

Gen4 Super Ion Air Knives Remove Pesky Dust from Crepe Paper Manufacturing Process

Paper Measuring Equipment

A paper manufacturer was having issues with their measuring equipment (reference photo above).  They were producing 6” (152mm) wide crepe paper which is very thin and dusty.  As it would pass through the machine, a real-time measurement of basis weight and moisture content was being performed.  The basis weight of the sheet was around 14g/m2 which is like facial tissue.  The machine was giving false errors in the basis weight measurement.  As they opened the device, they noticed dust particles on the optical lens.  Because the basis weight was so small, any dust would cause a false reading.  They contacted EXAIR to see if we could help with their problem.

With a dry fibrous material like crepe paper, static can be a big issue.  Static has a strong force that can cause small fragments to “stick” to surfaces.  As you can see in the photo, the paper material is sticking to the sides and lens of the measuring device.  For this application,  I recommended two pieces of the model 112206 Gen4 Super Ion Air Knife Kits.  The Gen4 Super Ion Air Knife is uniquely designed to have two functions; remove static and blow off dust.  The Gen4 Ionizing Bar creates both positive and negative ions to remove any type of static charge.  The Super Air Knife creates a laminar air stream to carry the ions and also generate an even blowing force to remove the dust particles from the surface.  With this combination, it becomes a very effective non-contact way to remove the contamination.  This was an important requirement as the crepe paper is very thin and could break very easily.  They were able to mount one Super Ion Air Knife above and below the paper in order to blow the dust particles in a counter-flow direction.  This would keep the particles from entering the measurement device.

Super Ion Air Knife Kit

The Super Ion Air Knife Kit includes the Super Air Knife with a Gen4 Ionizing Bar attached.  The kit also includes a power supply, filter, regulator, and a shim set.  The power supply is specifically designed for the Gen4 Static Eliminators.  The Gen4 Super Ion Air Knives use the high voltage from the power supply to generate enough ions to remove static from the paper at a running speed of 49.5 ft/sec (15m/sec).  The filter will remove any contamination and liquid water from the compressed air system before it enters the Super Ion Air Knife.  This is important to keep the product clean.  The shim set is a set of three different shims with a thickness of 0.001” (0.025mm), 0.003” (0.076mm), and 0.004” (0.1mm).  They are used to dramatically change the blowing force from the stock shim at 0.002” (0.05mm) thick.  Being that the paper was extremely thin, they opted to put the 0.001 (0.025m) thick shim inside the Super Ion Air Knife.  With the regulator in the kit, the customer could “dial” in the correct amount of force to keep the machine running optimally without breaking the delicate paper.

When the customer installed the Gen4 Super Ion Air Knives just before the entrance into the measuring device, the air stream was able to carry the ions to neutralize the static and to remove the dust from the paper surface.  The system was now able to make accurate measurements without disruptions.

For this customer above, the Gen4 Super Ion Air Knives made their system run accurately and consistently by removing any pesky dust particles.  If you have an optical device that needs to stay clean, you can contact an Application Engineer to review your application.

John Ball

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

NFL is Back! But So is Static……

bengals
View of Paul Brown Stadium

I awoke on Sunday with a bit more pep in my step. It’s been a long and dreary past 7 months (8 or more months for unlucky fans like me), but this day marked another early season NFL Sunday. Wives across the U.S. were collectively rolling their eyes as their husbands perched themselves comfortably on the couch, cold beer in hand, glued to the television screen from dawn ‘til dusk. It’s an exciting time for many, especially us Bengals fans, as the season is ripe with hope and cautious optimism. Fantasy leagues are in full swing, and my apologies to any of you who elected to draft Le’Veon Bell with your 1st pick this year….. However, with the arrival of football season, there is  an unwelcome guest that begins to rear its ugly head: static electricity.

As summer ends and moves towards fall and winter, the air becomes much drier. And because moisture in the air can mitigate some static charge, the dry air allows more static to be present. You may be familiar with the unpleasant shock you get from the door knob after walking across a carpeted surface. While this type of shock doesn’t generally cause any sort of problems, in many industrial processes this static electricity can cause a wide range of different issues. These may manifest simply as nuisance shocks to the operator similar to the door knob example, but it can also cause problems with finish quality, materials jamming/tearing, sheet feeding problems, product clinging to itself or rollers, and dust clinging to product.

In many painting applications, particularly in the automotive industry, dust and debris from the ambient environment can settle on the part prior to painting. Just blowing them off with a standard air gun won’t remove all of the particles if they’re statically charged. The static must be removed in order to remove it or it’ll cause imperfections in the finish after painting. This often results in a high amount of rejected parts that must be scrapped out. I recently visited with a company who handles the painting of small interior automotive parts. The parts are housed on shelves in a dusty environment. This dust settles on the parts while they’re waiting to be painted and just using an air gun alone wasn’t taking care of the problem. In this setup, they were rejecting nearly 60% of all painted parts after inspection.

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Automotive parts after painting

We brought with us a Model 8193 Gen4 Ion Air Gun to replace their regular compressed air gun. The Ion Air Gun is an ergonomic handheld gun that combines low air consumption along with an incredibly fast static decay rate. After taking a reading both before and after with a Model 7905 Static Meter, it was clear that the Ion Air Gun was the right tool for the job. The static eliminating ions were carried to the surface of the part which not only removed the static charge, but also the dust particles clinging to the surface. By replacing their two standard guns with Ion Air Guns, the reject rate was reduced to just under 10% after painting!!

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Model 8193 Gen4 Ion Air Gun

Break out your favorite football team’s gear and enjoy the cooler weather and activities that accompany the coming of Fall, but don’t let static wreak havoc in your processes. EXAIR has a wide range of solutions available that are designed to solve these problems. Give an Application Engineer a call and we’ll be happy to help recommend the best solution. And to all of my fellow Bengals fans out there, WHO DEY!

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

 

Bengals photo courtesy of  Nunya Biz via Flickr Creative Commons License

Eliminating Static On An Automatic Stretch Film Machine

Another recent application I’ve worked with from our Peruvian Distributor involved mitigating static on the outside of plastic shrink wrap. The customer manufactures a variety of different containers which after produced are then palletized for shipment to the end-users. They must ensure that the containers are adequately wrapped so that any dust/debris from the environment doesn’t come into contact with them and pose a contamination issue. This static charge would also at times cause the roll to jam up in the machine, and if left unnoticed for any length of time created quite a mess to untangle and fix. In addition, that static build-up that was occurring also manifested into painful shocks to the operators.

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Automatic Packaging Machine

To wrap them, they’re using an automatic plastic wrapping machine. They wanted some type of a solution that could be permanently affixed to the machine and eliminate the static on the film as it was unrolled. As two non-conductive layers of material are separated (in this case two layers of plastic wrap), a strong static charge is produced. Mounting an Ion Bar on the outside of the stretch film provided an excellent solution for them as they didn’t have to have an operator standing by keeping an eye on it. They weren’t concerned about static on the underside of the material as much as this also allowed for the plastic to adhere better to itself as its wrapped around the pallet. Typically, we’d recommend an Ion Bar or other Static Eliminator on either side of the material, but in this case the static charge there was wanted.

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Gen4 Ion Bars without compressed air requirement

Since we were able to mount the bar within 2” (50mm), it didn’t require a supply of compressed air to carry the ions to the surface of the plastic. As an extra layer of precaution, they also purchased an Ion Air Gun that was used to treat the outsides of the pallets again as they’re removed from the machine. Doing so has now prevented them from having to inspect and re-wrap pallets as needed. Since some runs may span over several days, there were times that they had to re-wrap products more than once as the dust build up was not acceptable to their customer. They estimated that 40-50% of the pallets had to be re-wrapped at least once, taking anywhere from 5-10 mins each after accounting for removing the old wrap, placing it back into the machine and re-wrapping.

With a wide variety of Static Eliminators available from stock, both with and without a compressed air requirement, EXAIR has a solution for your static problems. As we move into the cooler and dryer months of the year (If this hot summer ever ends), static becomes much more of an issue. Don’t wait until it becomes a serious problem and get in touch with an Application Engineer today!

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