Eliminating Static in Industrial Processes

Ever wonder what causes that annoying shock you get when you go to grab a plastic or metal piece. That is a phenomenon caused by static electricity. This static is an electrical surface charge that is generated and when two surfaces come in contact with each other and generate an electrical charge from friction, separation, or simple contact. If the material in question is not grounded properly the electrical charge will continue to accumulate until it comes in contact with a proper ground or the path of least resistance to discharge the built up static and return to a neutral state.

Static

Static is generated on the atomic level from the exchange of valance electrons on each surface. The energy produced from the friction, separation or contact cause those valance electrons to enter an excited state; when in this excited state they begin to jump back and forth from atom to atom. When this happens, the atoms begin to accumulate either a positive charge if the atom lost electrons or a negative charge if the atom gained electrons. As the charge accumulates on the surface were the friction occurs if a ground source (i.e. piece of metal or a person) comes in close proximity to the charged surface an arc is generated between the two surfaces returning the originally charged surface to a neutral state.

Static can be harmful to both employees and product in an industrial environment. If a static arc is generated in the presence of either flammable, combustible, or explosive liquids or gasses the arc can cause an ignition of the material. Static can also cause the charged object to stick or cling to various surfaces causing clogs in pipes and issues when trying to separate the material one at a time. This phenomenon is called static cling.

Even though static is very easy to generate it can just as easily be dissipated; EXAIR’s line of static eliminating devices use a high voltage emitter point to generate a small zone of ions which consists of both positive and negative charges to dissipate the static build up on the surface. Also, when the various emitter points and ion bars are coupled with our compressed air products, the air carries the ions much farther and can dissipate static up to 20’ away. The best part is that about the line of our line of static eliminators is that they are shockless; this means that if somebody bumps into it, they won’t get shocked.

Gen 4 Super Ion Air Knife Eliminating Static with Ions

For more information on EXAIR’s Static Eliminators and any of EXAIR‘s Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Cody Biehle
Application Engineer
EXAIR Corporation
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Super Ion Air Wipes – Eliminate Static on Wire, Cable, Extrusions

Gen4 Super Ion Air Wipe

As the colder dryer months are upon us, static electricity will be more frequent and will become a real nuisance.  Machines will start jamming, alignments will be difficult, dirt will collect to surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a line of Gen4 Static Eliminators to remove this nuisance.

EXAIR manufactures eight different product lines in two different styles within our Gen4 Static Eliminators.  In this blog, I will be covering the 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 pipe, extrusions, and coated wires.  With a split design, the Gen4 Super Ion Air Wipe can easily mount around the product without having to re-thread.  EXAIR stocks two different sizes with a 2” (51mm) and 4” (102mm) inside diameter. The Super Ion Air Wipes give a fast static-decay, a shockless and non-radioactive design, variable flow and force, low air consumption and no moving parts.

8462 Super Ion Air Wipe Kit

The Gen4 Super Ion Air Wipe can be purchased as a kit which will include the power supply (required for ionization), a filter separator (to clean contamination from the compressed air), and a pressure regulator (to control the blowing force).  The filter and regulator are properly sized to avoid any air flow restrictions or loss of performance which can occur when using components which are not suited for the application.

Static

Generally speaking, static is generated from non-conductive surfaces being “rubbed”.  This could be from going over rollers on a conveyor, stacking product onto each other, sheet feeding, and even peeling away a backing material.  When non-conductive surfaces, or insulators, are moved or separated, electrons are “stripped” and redistribute on to different areas of the surface.  Static charges are typically measured in kilovolts (kV), or 1,000 volts, and they can be either positive or negative.  The higher the charge, the stronger the static force.  In reference, at 10 kilovolts, a spark can jump one inch (25 mm) from the surface.   EXAIR offers a Digital Static Meter, model 7905, to measure the amount of static voltage on a surface.  It is a great tool for finding problem areas in your process as well as determining the effectiveness of the treatment.

All EXAIR Gen4 Static Eliminators use one of two Power Supplies – your choice of the 2-port Model 7960, or the 4-port Model 7961.

These ionizers are powered by a 5,000V AC power supply.  The alternating current, AC, will create both negative ions and positive ions.  So, no matter the polarity of charge on the surface, the Gen4 Static Eliminators will be able to remove it.  The power supplies come in either a 2 port or 4 port design so you can power multiple Gen4 Static Eliminators with one power supply.  The input power is selectable from either 115VAC or 230VAC in both 50/60 Hz.   Two armored and electromagnetic shielded cables connect the Super Ion Air Wipe to the power supply. This will help to protect the cable from abrasions, cuts and splits which can be common in rugged industrial areas.

Static can be a real nuisance with shocking operators, “sticking” debris, and jamming processes.  If you run into these issues in your application, no matter the shape, EXAIR has a Gen4 Static Eliminator for you.  Even if you have cylindrical objects like tubes, pipes, hoses and extrusions; EXAIR can provide the Gen4 Super Ion Air Wipes in stock.  For more information, you can contact one of our Application Engineers at EXAIR.

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

EXAIR Eliminates Static – Public Enemy Number one in the Printing Industry

Static electricity is the enemy of the printing industry. Downtime and inefficiency caused by static means longer lead times and angry customers! EXAIR can remove static electricity in the many printing applications across wide and narrow webs.  With our rugged line of EXAIR Super Ion Air Knives and Ionizing Bars, EXAIR can improve your efficiency and printing quality.

Digital printing dries out the printed substrate, creating high static charge that can cause printing defects, ink overspray, and even print head clogging and print head shorting issues. If a press is printing on non-porous substrates like plastic, metallics and highly coated glossy papers, a device called a corona treater is used to increase the surface energy of the substrate to ensure the ink droplets adhere and do not spread too much on the substrate. A byproduct of the corona treatment is static charge, which must be removed. This can be achieved by installing an EXAIR Ion Bar after the corona treatment device across the web.

Static is also created anywhere in the printing or finishing operations where sheets are moved over each  other.   Sheet-fed presses, for example, create friction in the stacking of individual sheets on top of each other.  This friction induced static creates misfeeds, print registration issues, multiple sheet pickups and equipment jams.

Folding operations cause static issues too. Like a sheet-fed press, static is created by folded pieces being dragged across each other.

In both cases, installing an EXAIR Super Ion  Air Knife or Ion Air Cannon that can direct a stream of ions between the stack and the top sheet can eliminate the static that causes misfeeds and jams.

The typical easy fix printers employ is what’s called a tinsel bar. Also called garland, it looks just like what you drape on a Christmas tree, except that it’s made of highly conductive copper that needs to be grounded to the printing press.The problem with tinsel bars is that although they are cheap initially, they don’t last long. They’re not a set-it-and-forget-it solution. The sharp strands work on induction and interact with the static field on the substrate creating a neutralizing cloud that surrounds the area, reducing both positive and negative ions. Printing operations are usually dusty environments and when the tinsel becomes dusty, oxidized, or matted and crumpled, they don’t work as effectively.

Static is also created in unwinding and rewinding operations, when rolls are slit to needed widths of various presses. The removal of the web from the roll creates static charge that attracts dust to the substrate surface and can cause major problems in downstream printing operations. Installing an EXAIR Ion Bar on top of the web can eliminate this static.

EXAIR Super Ion Air Knives don’t need to be placed close to the surface like a tinsel bar. Static dissipation of 5 KV can occur in less than a half second up to 20 feet away and can be adjusted from a blast to a breeze, depending on static level.

If you are a printer, finisher or labeler, EXAIR has a static elimination product that can improve your operations. For more help you can contact one of our EXAIR application engineers to talk you through a solution.

Dann Woellert
Application Engineer
dannwoellert@EXAIR.com
@EXAIR_dw                    

 

 

 

Video Blog: How To Clean & Replace Emitter Points for the Ion Air Gun & Ion Air Jet

This video will give a thorough walk-through on how to clean the emitter point on EXAIR Ion Air Jets model 8194 and Ion Air Guns model 8193.  This is the same procedure for replacing a damaged emitter point.  This procedure is for new style Static Eliminators with integrated grounded terminals, released on February 1, 2016.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

A “Static Season”-al Affective Disorder Blog

One of the more popular inquiries we get this time of year is for Static Eliminator Product selection assistance. EXAIR offers a variety of Static Eliminators, to accommodate a wide range of applications.

Static charge can be caused by contact or friction between non-conductive surfaces…and you don’t need a lot of contact, or motion, to produce a decent charge. We keep some clear plastic Lexan plates in our Efficiency Lab, and can get a few hundred volts just by putting one on top of the other, and picking it up. To generate several thousand volts (or more), we’ll rub a plate on the carpet for a few seconds.

This makes for a great all-purpose set up – from here, we can easily and effective demonstrate any of our Static Eliminators (or do an Efficiency Lab test on anyone else’s…just so you know). Not every situation or application involving static dissipation presents itself that simply, though. That’s where the diversity of our Ionizer Products line comes in:

Are you getting zapped by packages coming fresh off your shrink wrapper? Do you need to remove dust from – and keep it off of – parts prior to painting? Are your rolls of fiber, web, paper, film, etc., jamming or mis-feeding? EXAIR Super Ion Air Knives could be the efficient, quiet solution you’re looking for. They produce a high volume, extremely adjustable, laminar curtain of ionized air flow, perfect for large surface area and/or high speed applications. They’re available in lengths from 3” to 96”. If space is tight, our Standard Ion Air Knives, while not quite as efficient or quiet, do provide a smaller profile “footprint,” and are just as effective and fast in eliminating static.

Perhaps your application is smaller, and you need a tighter, focused stream of ionized air. The Ion Air Jet is compact, easy to install (even easier with a Stay Set Hose and Mag Base), and just the right size for table or counter top situations. If this is your size & scale, but you want the convenience and flexibility of a hand-held device, our Ion Air Gun is just the thing.

For jobs that are a bit larger, but still with a need for a compact installation, the Ion Air Cannon provides a high volume, but still concentrated, flow of ionized air. It’s effective over long distances, and very efficient, using a small amount of compressed air to entrain “free” air from the surrounding environment at a rate of 25:1. In dusty or dirty areas, you can even duct clean air in from elsewhere, so you’re not impinging that dust or dirt on your parts’ surfaces.

To remove static from a continuous run of cable, hose, extruded shapes, etc., the Super Ion Air Wipe comes with a 2” or 4” ID. Its split design makes for quick and easy installation, and means you’ll never have to “thread” it if product feed is changed or interrupted.

No compressed air? No problem. If you can mount it within 2” of the part, the Ionizing Point can dissipate up to 5 kilovolts of static charge in under a third of a second. For wider surfaces, our Ionizing Bars offer the same rapid performance, and can be provided in lengths of up to 120”.

All of our Static Eliminators are shockless, UL Listed, low maintenance, and available for same day shipment…except for a couple of our longer Super Ion Air Knives, which we need a day or so to put together.

If you have questions about which Static Eliminator is right for you, give us a call. We’re eager to help!

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
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