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Static Electricity: Causes and Cures in Web Converting

Presented By: Matt Fyffe

What is Static Electricity?

Electrical imbalance of charge can exist on insulators & isolated conductors.

Insulator Isolated Conductor

What Causes Static?

Friction between materials:

Separation of materials:

Not +ve or ve... but size does matter!

The Polarity of the charge is not very important. You can not tell the difference.

It is the size of the static charge that is important. The larger the charge the greater the problem it will cause.

Force/Speed faster, harder processes increase the charge

Repetition causes further build-up

Heat - heating and cooling can leave an object charged

Humidity low humidity allows high charges to remain for long periods

Type of Material some materials charge very easily (i.e.: PVC film)

What factors affect the size?

Triboelectric Series

Materials above the arrow will naturally charge positive. The materials below the arrow will naturally charge negative.

When contact and friction is generated between different materials the central point shown by the arrow may change relevant to the type of materials

Triboelectric Series

This example shows polyester film contacting a silicon coated roller.

When measured immediately before and after the silicon roller the negative charge on the polyester will reduce or change to positive.

Polyester Film

Silicon coated roller

( + )

( - )

Problems with static electricity in the converting industries are numerous.

Processes where static can be an issue include film sheeting and slitting, wind and rewind stations as well as printing.

The primary problems resulting from high static charge are:

Process Control and Quality Problems Dust Attraction and Contamination Operator/Personnel Shocks Possible Fires and Explosions

Problems Caused by Static in Industry

Passive Eliminators

Nuclear Eliminators Polonium 210

AC Eliminators

Pulsed DC Eliminators

and Static Generation

Methods of Elimination

Passive Eliminators

Nuclear Eliminators Polonium 210

AC Eliminators

Pulsed DC Eliminators (Mid & Long Range)

Passive EliminatorsAdvantages Disadvantages

Low Cost Limited CapabilitiesNo External Power Source Wear Part/Flaking

Low Maintenance

Nuclear Eliminators - Polonium 210Advantages Disadvantages

Perfectly Balanced Annual Lease/CostIdeal for Hazardous Locations Paperwork Requirements

No External Power SourceLow MaintenanceEase of Installation

AC EliminatorsAdvantages Disadvantages

Low Cost Limited Range w/o AirPower/Performance Limited Load CapabilityEase of Installation Maintenance Required

Multiple Bars on Power Supply

Pulsed DC EliminatorsAdvantages Disadvantages

Long Range w/o Air Requires EducationReliability Longer Set Up

Low Maintenance Increased CostAdjustability/Customization

Feedback CapabilitiesInternal or External Power Supply

Very Flexible

Static Eliminators - Comparison

Operating Distances

-

Compressed Air Driven Static Control

Close Range Static Control

Mid Range Static Control

Long Range Static Control

Pulsed DC Nozzle AC Air Curtain Standard AC Bar Long-Range AC Bar Mid Range DC Bar Pulsed

DC Bar DC Bar with Air Boost AC Blower

60

56

52

48

- Install at optimal distance where

possible

44

40

36

32

28

24

20

16

12

8

4

1 -

2 2

0 0 6 0 6 1 4 1.25 6 2 20 6 - 30 12 48 8 60

* Not to scale. Actual positioning will depend on the type of application.

Compressed Air Driven Static Control

Close Range Static Control

Mid Range Static Control

Long Range Static Control

Pulsed

DC Nozzle AC Air Curtain Standard AC Bar Long-Range AC Bar Mid Range DC BarPulsed

DC Bar

DC Bar with Air Boost

AC Blower

60

56

52

48

-Install at optimal distance where

possible

44

40

36

32

28

24

20

16

12

8

4

1 -

2

(-) 2

0

0 6 0 6 1 41.25 62 206 - 3012 488 60

* Not to scale. Actual positioning will depend on the type of application.

Positioning Free air is required on opposite sides of the target

material, not a roller or solid object

Positioning Avoid proximity to grounded parts of machinery as this

will distort the corona and reduce its efficiency

If bars are needed on both sides of the material, they should be staggered

Measuring Static Meters measure actual surface charge

Ion Sensors maintenance tools for testing ionizers

Charge Decay Monitors measure decay times of ionizers Benchtop & Handheld

Surface Resistance Meters measure capability to hold a charge

AC Sensor Pen down and dirty way to test for voltage

Applications

Winding Short Range

Applications

Winding Mid Range

Applications

Winding Long Range

Applications

Turret Winder

Applications

Slitting

Applications

Laminating

Applications

Coating

Static Generation

Static generation describes a method for creating a controlled static charge on a non-conductive material that will allow a sound, but temporary adhesion between surfaces with charges of opposite polarity.

Applications

Static Generation Film on to Roll Cores

Applications

Static Generation Sheet Lamination

Web Cleaning Systems

Web cleaning systems provide effective solutions to problems such as:

Dirty webs causing loss of profit and customer dissatisfaction

Excessive downtime on printing presses

Frequent blanket washing

High reject rates in laminating or coating processes

Unacceptable quality in pharmaceutical or food packaging

Poor print quality

Web Cleaning Systems

Tacky Roll Cleaner

Contact Web Cleaner

Non Contact Web Cleaner

Tacky Roll Contact Web Cleaners

Elastomer cleaning rollers contact the full width of the web with even pressure. Dry, unbonded contamination is lifted from the web surface.

Pneumatics hold the adhesive roller in contact with the elastomer roller. Contamination is transferred from the surface of the elastomer roller to the adhesive roller where it is trapped.

Any static charge present on the web is neutralised on exit from the web cleaner; minimising the risk of statically attracted recontamination.

How it works

Vacuum Based Contact Web Cleaners

Static NeutralizationBreaks the bond between dust particles and web, leaving the web neutral after cleaning.

Breaking boundary layerBrushes destroy boundary layer on fast movingwebs and dislodge any physically attached particles.

Powerful VacuumExtremely high speed airflow through faceplate is very turbulent. The turbulence allows removal of very small particles.

How it works

Non-Contact Web CleanersHow it works The web passes through a cloud of ionization on entry to the cleaning, which neutralizes any

static charges.

The web is then subject to a force of turbulent air created by the blowing and vacuum airflows within the head unit.

High frequency micro-movements of the web are created by the turbulent air.

The combination of the high frequency micro-movements and turbulent air shatters the webboundary air layer, releasing the contamination into the vacuum airflows.

As the web exits the head, it passes through a second cloud of ionization to prevent re-contamination of the web.

Web Cleaners - ComparisonTacky Roll Contact System

Advantages DisadvantagesLow Cost 750'/min max speed

Proven to 0.5 micron Not suited for heavy contaminationCompact Size Ongoing consumable costEase of install

Suitable for sensitive materials

Vacuum Based Contact SystemAdvantages Disadvantages

Excellent for high contamination Not suitable for sensitive materialsSuited for high speed applications Requires installation space for fan

Suited for paper and boardEase of installation

Proven to 5 micron cleaningSuitable for wide webs

Non-Contact SystemAdvantages Disadvantages

Suitable for all materials Double sided onlyProven to 0.5 micron 120" max web width

Compact size Ducting requirementsLow and high end applications Initial Installation Time

Thank you

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