Static Electricity: What Is It And The Products To Solve Industrial Process Problems

The lower relative humidity associated with the cold, dry air of winter results in a significant increase in customers  with problems related to static. Luckily, EXAIR has a wide-range of Static Eliminators that are designed specifically to address static issues in a wide variety of industries. So, what exactly is static and how is it generated? Let’s take a quick trip down memory lane to elementary school science class….

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. Materials such as paper, plastic, or textiles will normally contain an equal number of both positive and negative ions. When subjected to friction, this balance can be disturbed if the atoms gain or lose an electron.

The static charge will then exert a force on nearby charged objects or grounded conductors (including personnel). These issues can also manifest in the form of dust clinging to product, product clinging to itself, rollers, machine beds or frames, materials jamming, and sheet feeding problems.

To eliminate these charges, EXAIR’s Static Eliminators produce an equal amount of both positive and negatively charged ions. This allows us to neutralize either charge quickly and effectively.

For applications that allow you to install close (generally within 2”) to the surface of the material, we offer our Ionizing Bar in lengths ranging from 3”-108”. If a wide area of coverage is necessary, but you can’t get close to it, the same Ionizing Bar is installed on the Super Ion Air Knife to help deliver those ions over a greater distance.

gen4 super ion air knife
Gen4 SIAK

The Ionizing Point is another product that can be used without the need for compressed air. A compact, single point ionizer, this product is ideal for winding, rewinding or slitting operations. It can also be mounted through a duct to neutralize static charges due to moving air or materials.

ionpointCUTCARDS_350x
Gen4 Ionizing Point

The Ion Air Gun combines incredibly fast static decay rates with low compressed air consumption. With a 10’ flexible armored cable and ergonomic handle, the Ion Air Gun is best for applications where an operator will perform the blowoff process.

72G4Iagions_800x

If the airflow pattern from the Ion Air Gun is conducive to your application, but you’d prefer to automate the blowoff or maintain a continuous usage, both the Ion Air Jet and the Stay Set Ion Air Jet provide an identical airflow pattern. The Stay Set Ion Air Jet comes with a magnetic base and Stay Set Hose, allowing you to precisely position the static eliminating ions in your process.

staysetiaj_559x

The Ion Air Cannon delivers a quit, efficient, and concentrated flow of ionized air. It is ideal for hard to reach spaces or confined areas that necessitate a solution to static problems. Designed with a sturdy stand, the pre-drilled holes can be wall, bench, or machine mounted. It incorporates a swivel adjustment for directing the airflow.

Our Gen4 Static Eliminators have all undergone independent laboratory tests to certify that they meet the rigorous safety, health, and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. If there’s a process in your facility that could benefit from a solution to static problems, please give us a call. Any of our Application Engineers will be happy to help select the best option for your process.

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

EXAIR Gen4 Ionizing Bar Removes Static From Corona Treated Plastic

If you want to print on plastic, it’s challenging – most plastics are chemically inert and non-porous.  That means you can apply all the ink you want; it’s not going to stick.  In the 1950’s, a Danish engineer named Verner Eisby experimented with various techniques to overcome these challenges.  He found that exposing the surface to be printed on to gas flame or sparks modified the surface to improve adhesion with the ink.  It did so, though, in a crude & uneven manner, leaving imperfections & inconsistencies in the printed product.  He then tried applying a high frequency corona discharge in a linear array.  The plasma (gas in an ionized state) generated left a homogeneously treated surface on which to print, smoothly & evenly.

This has become the “industry standard” for many of the labels we see on commercial products, from shampoo & wine bottles on the grocery store shelf, to pennants & banners at public events.  It also leaves the surface even more prone to picking up a static charge from rolling or unrolling, stacking, sliding, etc.

One of our customers makes a great many labels for all kinds of these commercial products, and uses an EXAIR Gen4 Ionizing Bar immediately prior to the printing operation:

Model 8024 24″ Gen4 Ionizing Bar removes static from Corona treated plastic label film.

EXAIR Corporation has a variety of Static Eliminator Products to fit most any industrial or commercial application.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

EXAIR’s Gen4 Static Eliminators Product Line

In the winter, as the temperature gets colder and colder and the air is getting drier and drier, static becomes a larger problem. In the summer, water in the air can help dissipate the electrons that we pick up as we move around, but when the air is drier, the static charge collects and clings to surfaces, building up until… zap! This can be a huge problem for companies as static can cause products to bunch up and not process correctly. Or even worse static can build so much it can shock electrical devices causing costly repairs and downtime. That’s why EXAIR has a full catalog of static eliminating products, and we will talk about them and what each product is best suited for!

Gen4 Static
Gen4 Static Eliminators

The most popular Static Eliminator we sell is our Gen4 Super Ion Air Knife! By combining a Gen4 Ionizing Bar with a Super Air Knife, The Gen4 Super Ion Air Knife provides rapid static elimination AND blows off any dust, chips, or debris that was being statically held to the surface.  The laminar curtain of ionized air not only maximizes the rate of static dissipation, but is also ideal for stripping/sweeping away any debris, leaving a clean, static-free surface.  No more jamming, tearing, nuisance shocks to operators, dust attraction, or any of the other host of problems associated with static electricity.

GEN4 SIAKs
(Left) 6″ Gen4 Super Ion Air Knives remove static from bottles in a labeling application. (Right) A 108″ Super Ion Air Knife

EXAIR’s Gen4 Super Ion Air Wipe provides a uniform 360° ionized airstream that is simple to clamp around a part for reducing static electricity and cleaning contaminants. It is great for use on pipe, cable, extruded shapes, hose, wire and much more. We offer the Gen4 Super Ion Air Wipe in either 2” or 4” inner diameter, it is powered by compressed air and an external power supply. The Gen4 Super Ion Air Wipe generates both positive and negative ions that are transmitted the emitter points located on the i.d. of the wipe. Since static charges can be either negative or positive it is easy to eliminate both states of charge due to the mixed polarity of ions being generated.

iaw
4″ Gen4 Super Ion Air Wipe

To put it simple the Gen4 Ion Air Cannon is based on the mechanics of the 2″ diameter Super Air Amplifier with added static reduction capabilities and as its name implies it amplifies the supply air up to 25 times! This highly engineered product is very effective at cleaning product and reducing static at distances of up to 15′ away.

gen4-iacfillbotl_500xsq.jpg
Gen4 Ion Air Cannon

EXAIR’s Gen4 IoAir Jet is a compact ionizer that is capable of delivering a concentrated ionized airflow that will cover a precise spot without disturbing the rest of the process. The quiet, focused air stream can quickly eliminate the static charge on surfaces. At a pressure of 80 psig the Gen4 Ion Air Jet is capable of dissipating a 5kV charge in .18 seconds!

In addition to providing rapid static decay, the Gen4 Ion Air Jet also helps to minimize compressed air use while maximizing the ionizing airflow. Utilizing a specially designed shim, the Gen4 Ion Air Jet entrains ambient air at a rate of 5:1. The airflow can easily be adjusted from a forceful blast to a gentle breeze simply by increasing or decreasing the inlet pressure to the ionizer.

You can also get the Gen4 Ion Air Jet in a handheld gun option, this is called our Gen4 Ion Air Gun. This is great for applications where your operator is doing the static elimination and blow several times a shift by hand. 

Ion Air Gun
GEN4 Ion Air Gun

If you have an application that you believe would be better served by the use of an EXAIR Gen4 Static Elimination product, give us a call.

Jordan Shouse
Application Engineer
Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Gen4 Static Eliminators Sove Static Problems for Printing Co.

When the weather gets dry and cool, static can be generated very easily, and it can become a real nuisance.  For the printing industry, static forces can pull or push the ink droplets which can create poor print quality like “ghost” images.  Static can also cause contamination to “stick” to the surface of the sheets affecting the printing process.  This can slow production, generate high scrap rates, and allow for poor quality.  In this blog, I will share the details about a printing company having static problems and a simple solution with a Gen4 Static Eliminator.

For this printing company, static was causing issues in print quality on their polypropylene sheets. Polypropylene is a non-conductive material which can generate high amounts of static that can cause many issues.  Their manual operation of moving, sliding, and picking up of the polypropylene sheets was generating the static.  Now that we found the cause, I had to determine a solution.

They sent pictures to describe the process in more detail.  An operator would pick up a sheet with the dimensions of 3 feet wide by 5 feet long (0.9 meters by 1.5 meters) from a bin.  He or she would load three polypropylene sheets onto a wide vacuum table next to the printing machine.  The table had an indicating bar which used yellow/green lights to align each sheet.  Once the indicator lights turned green, this meant that the sheet was aligned properly, and the operator would then hit a switch.

A dual rail with vacuum cups would come over and “grab” the three sheets.  The vacuum rail would pull the new sheets onto a sliding platform at the same time removing the printed sheets into a stacking area.  With the new sheets, this sliding platform would travel into the print machine where the print head would create the images.

Once the printing was completed, the sliding platform would come back to the original position where the process would repeat itself.  With all the handling and moving of the polypropylene sheets, static was being generated.  To improve their printing process by removing the static, we had to target an area where we would not have to worry about static regenerating.

EXAIR is a leading manufacturer of Static Eliminators, and we had a good discussion in solving his issue.  Ideally, we want to place the Static Eliminator just before the printing process.  In this application.  I recommended to them to locate a Gen4 Ionizing Bar just behind the indicating bar.  This would remove any static as the sheets were going onto the sliding platform.  Since the sheets were 3 feet (0.9 meters) wide, we needed to cover a span of 9 feet (2.7 meters) total.  Believe it or not, EXAIR manufactures and stocks an Ionizing Bar this long!!!

For this customer, they would not have to worry about any stop gaps in coverage with a single length product.  Also, the profile for the Gen4 Ionizing Bar is very thin and would not interfere with the vacuum rail system.  So, when the vacuum rail picks up the polypropylene sheets, the Gen4 Ionizing Bar will be able to remove the static from the printable surface.

Gen4 Ionizing Bar with 7960 Power Supply

I recommended the model 80108 Gen4 Ionizing Bar with the model 7960 Gen4 Power Supply.  This model can emit ions that can cover a span of 108 inches (2.73 meters).  The Gen4 Power Supply, which generates a 5,000 Volt signal, connects to the Gen4 Ionizing Bar with an electromagnetically shielded durable cable.  The alternating current generated by the Power Supply allows for the creation of both positive and negative ions from each point.  This will ensure neutralization of any type of static.

The Ionizing Bar can be positioned between 0.5” (13mm) to 2” (51mm) from the sheet surface to optimize decay rates.  After they mounted and started using the Ionization Bar, the static was removed quickly, and the printing issues were eliminated.  With a quick and simple set up of the Gen4 Ionizing Bar, they were able to get back on track with great quality and fast productivity.

If you have static issues with your printing process, you can contact an Application Engineer at EXAIR.  We will be happy to make your static issues disappear and your vibrant images reappear.

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