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.   Sheetfed 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 sheetfed 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 elimnate 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                    

EXAIR’s Super Ion Air Knife Stops Painful Shocks to Operators on Slitting/Rewinding Operation

During a recent trip to South America while visiting our Distributor in Lima, Peru I had the opportunity to look at a few applications at an abrasives manufacturing plant. The company manufactures a wide range of abrasive products as well as adhesive tape.

Before we dive in to the application, let’s discuss static generation. There’s three ways that static can be generated. The simplest method of static generation occurs when two non-conductive objects come into contact with one another and separate. Electrons are transferred from one object to another according to the Tribolectric Series. The second method of static generation occurs as a result of friction. When two materials rub together, especially if increasing force presses the objects together, electrons can also transfer from one material to another increasing the static charge. The final method, and the one occurring in this particular application, is detachment static buildup. Due to the large contact surface area, significantly greater static charges can be generated.

triboelectric
Triboelectric series showing the propensity of a material to gain/lose an electron

They had several converting applications that were causing static issues in the plant. The primary concern was the operators that were constantly getting shocked whenever they had to change out the rolls. A side concern was that there was occasionally a buildup of static that resulted in the product jamming, causing production to be stopped while they fix the jam and re-feed the material.

SIAK 3M

The application that I’d like to highlight was on a slitting and rewinding machine. A roll of plastic film was fed through rollers where it is slit into three different sizes and then re-rolled. As the film separates from the roll, a high static charge is generated. After each operation, an operator had to go in and remove all (3) rolls from the machine. Each time he was zapped as he touched the roll. This not only affects productivity as they’re hesitant to remove them quickly, but was also a major concern for their safety department.

The proposed solution was to install (2) Model 112006 Super Ion Air Knives, one above and one below the plastic film just after it was slit. All EXAIR Static Eliminators produce an equal quantity of both positive and negative electrons. So, regardless of if the charge is positive or negative there’s sufficient ions to neutralize it. After installation, the static charge was immediately removed. The operator, although hesitant at first, was able to remove the finished rolls from the machine without getting a nice jolt! As an added bonus, they also no longer had an issue with the material periodically jamming in the machine.

Don’t let static problems cause problems in your process or potential harm to your operators. With a wide range of different Static Eliminators available from stock, EXAIR has a solution available that will quickly take care of it for you. Reach out to an Application Engineer today, you’ll be shocked (no pun intended) at how quickly you’ll notice an improvement.

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

The Wonders of The Gen4 Super Ion Air Knife

The Gen4 Super Ion Air Knife is a powerful static eliminator that prevents jamming, tearing, shocks and dust build up by neutralizing static and blowing away the debris.

The Gen4 Super Ion Air Knife combines the quiet and efficient Super Air Knife with the compact design of the rugged Gen4 Ionizing Bar resulting in a total solution to remove static electricity from plastics, webs, sheet stock and other product surfaces. Removing the static helps reduce or eliminate the process issues that the static electric causes, allowing for greater production speeds, improved product quality and a cleaner product.

The Gen4 Super Ion Air Knife floods an area or surface with static eliminating ions. With a uniform airflow across its length, misalignment to critical surfaces like webs is avoided.  The force can be adjusted from a light breeze, to a full out blast of air. The Gen4 Super Ion Air Knife is electrically powered, is shockless and has no moving parts.

How It Works

gen4siak_hwrks_800x
How The Gen4 Super Ion Air Knife Works

In the diagram above, compressed air flows through an inlet (1) into the plenum chamber of the Gen4 Super Ion Air Knife. The flow is directed to a precise, slotted orifice. As the primary airflow exits, it creates a uniform sheet of air across the entire length, pulling in in surrounding air (2). An electrically powered Gen4 Ionizing Bar (3) fills the curtain of air with positive and negative charges. The air stream delivers the static eliminating ions to the product surface (4) where it instantly neutralizes static and cleans off dust and other particulates.

The Gen4 Super Ion Air Knives are powerful tools, and very quickly dissipates 5kV of static even at low compressed air supply pressures. At 5 PSIG, only 3.7 SCFM (0.3 BAR, only 105 SLPM) of compressed air per foot of length is required!!  Sound levels are also very low, resulting in quiet operation.

super ion air knife performance

Added Features –

  • Compressed Air Inlets are provided on each end and the bottom of the Super Air Knife
  • Thicker shims can be installed easily if a harder air flow is needed
  • Emitter points are sharp, durable stainless steel
  • The high voltage cable is armored to resist cuts and abrasion, and has integral grounding.  Threaded bayonet connector is fully assembled and ready to use
  • Electromagnetically shield cable protects sensitive electronics
  • Gen4 Ionizing Bars and Power Supplies are UL Component Recognized to U.S and Canadian safety standards and are CE and RoHS compliant
  • Power Supplies are 115/230 VAC selectable and come with 2 or 4 outlets
  • Standard lengths from 3″ to 108″ (76mm to 2743mm) are offered, and custom lengths are available to meet your process needs

Successful applications include web cleaning, pre-paint dust removal, shrink wrapper machinery, printing equipment, package cleaning,and bag opening/filling operations.

If you have questions about Gen4 Super Ion Air Knives, other types of Static Elimination products,  or any of the 16 different EXAIR 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.

Brian Bergmann
Application Engineer
Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

Video Blog: Gen4 Super Ion Air Knife Conversion

The video below provides details on the simple conversion to the new Gen4 style Super Ion Air Knife from the previous style or the addition of a Gen4 Ionizing Bar to an existing Super Air Knife to add static elimination to an existing blow off.

If you have questions about the Gen4 Super Ion Air Knife or any of the 16 different EXAIR 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.

Brian Bergmann
Application Engineer
Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

What is a GEN4 Ion Air Cannon?

Quite simply the GEN4 Ion Air Cannon is based on the mechanics of the 2″ diameter Super Air Amplifier that has 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 IAC

The GEN4 Ion Air Cannon comes in a handy stand/mounting unit for easy installation in a wide variety of applications. It can be mounted to machine frames, mounted out of the way from a process, or placed on a bench top.

GEN4 IAC Dimensions

The GEN4 Super Ion Air Cannon can work with as little as 10 PSI supply pressure.

GEN4 IAC Performance

The GEN4 Ion Air Cannon is used in many applications such as bottling, manufacturing of solar panels and preparing new automobile car bodies to be painted – to name a few. Wherever static reduction and/or cleaning is required the Ion Air Cannon can contribute.

It is offered in a kit that can include the 7960 power supply, pressure regulator for fine adjustments, filter/separator to keep the air clean and dry and a shim set for gross adjustments or just the GEN4 Ion Air Cannon and the 7960 power supply.  Of course all components are also available individually.

If you would like to discuss reducing static and/or cleaning materials, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer

Send me an email
Find us on the Web 
Follow me on Twitter
Like us on Facebook

Basics of Static Electricity

Here in the Northern Hemisphere, we are in the middle of winter and that means extremely dry air, and frequent shocks when reaching for a door knob after walking across a carpeted surface.  While a shock is mildly uncomfortable and can be annoying to us, the presence of static electricity in an industrial manufacturing process can be much more problematic.

Problems that static cause range from operator discomfort to increased downtime to quality issues.  Dust can cling to product, product can cling to itself, rollers, frames, or conveyors. Materials may tear, jam, curl and sheet fed items can stick and mis-feed. Hazardous sparks and shocks can occur, possibly damaging sensitive electronics.

EXAIR has put together a useful tool, the Basics of Static Electricity white paper with Interactive Regions to help a person learn more about static.

Basics of Static Electricity

 

Topics covered include Electron Theory, Causes of Static Electricity, Triboelectric Series chart, and Types of Static Generation.  Also, the white paper covers the areas of How to Control Static Charge Buildup, Determining the Source of the Static Buildup, Eliminating or Minimizing the Source Causing the Buildup, and Treating Static Buildup.

The Treating Static Buildup is a comprehensive review of the EXAIR Static Elimination products and how each technology is best applied to different processes and applications.

To receive your copy of the Basics of Static Electricity white paper, click the photo above or the link here.

If you would like to talk about static electricity or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_BB

New Gen4 Super Ion Air Knives Stop Painful Shocks on Printing Operation

Kirk Rudy inkjet
Customer’s Inkjet Machine

I recently received an inquiry from a customer that was having an issue with static on their Kirk Rudy inkjet machine. They print on a variety of different materials for a range of applications, but had some concerns with static that was being generated. Once printed, the material is transported along a conveyor. Operators then remove the pieces by hand. While doing this, they’re receiving shocks as a result of the static, some of which are quite painful! After a little discussion, we determined that a Model 112012 Gen4 Super Ion Air Knife would be the most suitable solution. I recommended the knife to be positioned so that the ionized air stream would pass over the material as it’s coming down the conveyor. The ionized airflow from the Super Ion Air Knife eliminated any residual static, allowing the operators to remove the material without experiencing any painful shocks. This drastically improved workers attitude about performing this operation and eliminated the repeated written complaints that management was getting as a result. Their issue of finding a willing participant to be repeatedly shocked was rectified and the worker quality of life was improved.

EXAIR has just released the new Gen4 Super Ion Air Knives and Ion Bars. The new bar provides a 34% improved performance from previous models, allowing you to achieve the same or better results with less compressed air. These bars and knives are also now CE approved. Some improved features of the Gen4 Super Ion Air Knives are:

-Up to 34% improved performance

-Rugged metal armored and electromagnetically shielded cable

-Integrated ground eliminates additional ground connection

-Durable stainless steel connections to Power Supply

-UL component recognized/CE Compliant

-Modular Power Supply cable eases connections and routing

If you’d like to talk about the benefits of upgrading to the new Gen4 Static Eliminators or have a new application in need of a static eliminating solution, give us a call.

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