Static Control and Web Cleaning
Controlling the Static Triangle – Speed, Distance and Level of Charge
Kevin Brown, UK Head of Sales, Fraser Anti-Static Techniques
S
tatic control in the dynamic converting industry is a complex and persistent challenge. To achieve the best process effi ciencies, improve output, produce the highest quality material and maintain operator safety, there are a few key factors I use to help clients understand. The chief of these is something I call the static triangle, made up of speed, distance and level of charge. Each element of the triangle has infl uence on the type of equipment required to control static: • Speed of the process that is causing the static. • Level of charge – the amount of charge on the material.
• Distance between the ioniser and the product that needs to be neutralised. There is no ‘one size fi ts all’ solution in electrostatic management. A high level of charge, moving at high speed, will need more powerful static control to keep up. Whereas a high level of charge moving at slower speeds could be managed by a less powerful ioniser. Selecting the correct equipment will often come down to experience, but by considering
the critical factors of level of charge, distance and speed, it is possible to fi nd the right solution to maintain and improve performance and effi ciency.
I recently worked with a UK business that had been using ionisers mid-process for years, but were still getting feedback from their customers about high levels of static charge on their fi nished material. After discussing this in detail, we implemented long range static control devices on the rewinds of their process, reducing the levels of charge on their materials to well below the 3kV required by their customers.
The three factors of the Static Triangle are arguably the most important factors to monitor and will have a huge impact on selecting the correct equipment and overall success.
SPEED
One of the main factors of cutting-edge machinery is its ability to complete the task at greater speed. This means that the ioniser has less time to treat any charge on the material. A 100,000-volt charge moving past the anti-static
system at 10 metres per minute may allow enough treatment time. However, if that speed is tripled or more, then a more powerful anti-static system may be required to achieve satisfactory results.
LEVEL OF CHARGE
The amount of charge can change depending on the material and even the temperature or humidity on the day. Bought-in material should be monitored as it is a variable and will have an impact on the static control. I recommend monitoring the levels over time to fi nd the worst possible combination of low humidity, high level of charge and material most aff ected by static.
DISTANCE
The distance between the anti-static system and the target is a signifi cant factor, it is not always possible to mount an ioniser close to the material. For example, in converting, if you are producing a low static, high-quality product you will need to have static control installed on your fi nal rewind, this will ensure charge is low when you sell it. Due to the nature of the growing roll, the distance between static control and ionising bar will change during winding. In this case, longer range ionisers are required, as short-range units will not be suitable at the start of the roll.
EQUIPMENT CONSIDERATIONS Static control and generation equipment come in many diff erent shapes and sizes. Fast, long range, air driven, technology, intelligent; the list is long. Technology advances have seen AC superseded and now only 24V powered pulsed DC bars, such as the versatile Fraser X-Series, can off er the power, performance and control required for the modern converting industry.
The product itself is key, but it must be combined with experienced technical support to identify the best installation options, maximising performance and value for money. While static might seem like a mysterious force, it isn’t as complex as it sounds. With high performance products and technical support, it is possible to achieve static control and improve effi ciency, quality and operator safety.
24
July/August 2024
www.convertermag.com
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