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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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

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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
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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
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A Tale of Two Super Ion Air Knives

A manufacturer of plastic bottles had a problem with static charge. Right after the bottles are extruded and cooled, they have an apparatus that “unscrambles” them and places them, single file, onto a conveyor. It does so with some fabric belts and plastic rollers. If you know anything of static electricity, dear reader, you probably recognize that there aren’t too many better ways to generate a static charge than to rub plastic against plastic, or (even worse) plastic & fabric together.  Here’s a prime example of the kind of static charge you can get, just from unrolling plastic film.

The separation of the non-conductive surfaces (like when this plastic film is unrolled) is capable of generating an incredible amount of static charge.

Now, the bottle makers didn’t have a static meter, but they didn’t need one to know they had issues:  the bottles that the “unscrambler” was putting on the belt were still very much “scrambled.”  They installed a Model 112209 9″ GEN4 Super Ion Air Knife Kit, to blow ionized air up from under the bottles as they entered the belt conveyor, and they did see what they’d call an improvement, but not quite what they’d call a solution.

Unfortunately, dissipating the static from just about half of the surface area of the bottle was still leaving them with half a problem.  However, by adding a Model 112009 9″ GEN4 Super Ion Air Knife (the 112209 Kit’s Power Supply has two outlets, and its Filter Separator & Pressure Regulator are capable of handling the flow to two 9″ Air Knives,) they were able to blow ionized air down from the other side, and up from where the first one was installed.  A soft “breeze” was all it took…a stronger air flow would have worked against the “unscrambler” anyway…because even at very low supply pressures, the Super Ion Air Knives produce an extremely fast static dissipation rate.

Even with a 5psig supply…which makes for just a “whisper” of air flow, the EXAIR GEN4 Super Ion Air Knife eliminates a 5kV charge in under half a second.

If you’ve got problems with static charge, we’ve not only got improvements; we’ve got solutions. Give me a call to find out how we can help.