Static Control & Web Cleaning


Advanced static control solutions for modern converting lines


A


s converting lines continue to increase in speed and complexity, controlling electrostatic charges has become a critical factor in maintaining product


quality, operational effi ciency and safety. Materials such as plastic fi lms, foils and paper webs generate signifi cant static during processing, particularly in high-speed roll-to-roll applications. For converters, the challenge is no longer just eliminating static, but managing it intelligently across the entire production process.


STATIC CONTROL ACROSS THE CONVERTING PROCESS


Electrostatic charge is generated at multiple stages in converting, including unwinding, slitting, coating, printing and rewinding. In some cases, charge levels can exceed 20 kV during unwinding alone, making early neutralisation essential to prevent downstream issues. Simco-Ion addresses this by providing targeted solutions for each section of the converting line. Ionising bars are typically installed immediately after unwinding to neutralise initial charge levels


and prevent dust attraction. Further along the process, additional ionisation points are placed before critical stages such as coating, laminating, or printing to ensure stable material handling. In slitting and rewinding applications, high speeds and friction between rollers and materials create continuous static build-up. Installing ionising bars such as the Performax IQ Easy directly after slitting and before rewinding neutralises this charge, preventing issues such as material defects, dust attraction, operator shocks and telescoping rolls.


INTELLIGENT STATIC CONTROL WITH THE IQ EASY PLATFORM A key diff erentiator in modern static control is the ability to monitor and adjust performance in real time. The IQ Easy platform from Simco- Ion connects multiple devices into a single, integrated system.


At the core of this platform are the Smart SLC IQ and Manager IQ Easy, providing centralised control, real-time monitoring and data logging. Up to dozens of ionisation and charging devices


can be networked together, allowing operators to oversee the entire static control system from a single interface.


By combining ionising bars such as the Performax IQ Easy with Sensor IQ Easy devices, converters can implement closed-loop feedback systems. These systems measure residual static charge on the web and automatically adjust ionisation output to maintain optimal conditions. This ensures consistently low static levels, even as production speeds or environmental conditions change.


ENHANCING SAFETY IN CRITICAL ZONES Static control is also essential for safety, particularly in coating and printing sections where fl ammable solvents may be present. High static charges can lead to electrostatic discharge, creating a risk of ignition. To mitigate this, Simco-Ion off ers ATEX-certifi ed ionisation and sensing solutions designed for hazardous environments. These systems allow safe inline measurement and neutralisation of static charges within explosive zones, helping converters reduce fi re risks while maintaining production performance.


FROM ELIMINATION TO PROCESS OPTIMISATION


In addition to eliminating unwanted static, controlled electrostatic charging can also be used to support specifi c converting processes. For example, in bag making applications, static charge can be applied deliberately to prevent air inclusion or stabilise material during handling, improving process consistency. This highlights an important shift in the industry: static is no longer viewed solely as a problem, but as a parameter that can be actively controlled and optimised.


SUPPORTING HIGH-PERFORMANCE CONVERTING


As converters strive for higher speeds, tighter tolerances and improved effi ciency, advanced static control solutions are becoming increasingly important. By combining targeted ionisation, inline measurement and intelligent control systems, manufacturers can achieve stable production conditions and consistent product quality. With application-specifi c solutions across slitting, coating, printing and winding processes, Simco-Ion enables converters to move beyond basic static elimination towards fully optimised, data-driven production environments.


26


July/August 2026


www.convertermag.com


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