Static Control & Web Cleaning
Getting back in control of static
By Meech Static Eliminators marketing director Iain Cameron
he COVID-19 pandemic has presented many problems for packaging manufacturers and convertors; from staffing levels, to supply chain challenges, and consequent fluctuations in production. But one constant – before, during and after the pandemic – is the issue of static charges and their role in introducing contamination on production lines. With demand for high-quality, reliable packaging greater than ever, brands and consumers alike are looking for assurance that goods are sanitary and protected from contamination. A dependable static control solution is an essential starting point to deliver this. Contaminated products lead to excess waste, particularly where there is an obvious safety concern, such as with food products or pharmaceuticals. But hygiene isn’t the only threat affecting consistent production; contaminants like dust, dirt and other loose fibres can impact on the print and finished quality of packaging, making it less appealing to consumers. This can result in a high level of printed packaging being rejected and rendered unsellable, leading to an increase in both waste and costs for converters. So, both for safety and for commercial reasons, the threat of unwanted static is significant. Static charges can occur via friction, separation or induction. In many converter environments, fast moving machinery and webs are commonplace and are prime places for static charges to be generated – for example, a web being unwound at a fast rate (separation) or running over nip rollers (friction). With static being generated on
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the surface of the web, nearby and airborne particles are drawn to the surface, leading to print work appearing faded or dirty, and where digital inkjet printing is being used, static can repel ink droplets away, leading to incorrect drop placement. Static charges are not the only phenomenon that attracts loose debris. A web, when it is moving at high-speed, creates a natural boundary layer as it drags along ambient air. This boundary layer, which thickens with increasing speed, can cause debris to become trapped within or beneath the surface of the layer. Combatting both of these issues is easily managed through web cleaning and static control technology.
WEB CLEANERS
Web cleaners remove loose, dry debris from a web’s surface, significantly reducing the amount of contamination present. This improves the quality of the end-product, ultimately resulting in less wastage and helping production lines to run smoothly, reducing downtime spent on maintenance, and greater levels of productivity. Web cleaners generally come in two forms: contact and non-contact. A contact roll-on-roll device comes in to contact with the full width of the web, breaking down the boundary layer and lifting contamination from the web’s surface. This is then transferred to a second roller with a high adhesive mass, which removes debris from the first roller, preventing recontamination. Adhesive-roller systems can perform well on small particles but are not designed for more demanding applications where higher levels of contamination are involved, as the adhesive rolls can quickly become saturated. An example of a contact system is Meech’s TakClean, designed for narrow web applications.
Conversely, non-contact systems use air pressure and vacuums, which prevent damage to potentially sensitive web surfaces. Meech’s CyClean–R, an extension to its renowned CyClean product, is a non- contact system that incorporates advanced
computational fluid dynamics that allow converters to thoroughly clean low-tension webs. It is ideal for use in a wide variety of applications that incorporate narrow, mid and wide webs.
While web cleaners can help deter issues surrounding product quality and hygiene, these devices alone will not solve all problems associated with an unclean web. To be most effective, they should be used in tandem with an appropriate static control solution.
STATIC CONTROL SOLUTIONS Static control neutralises static charges. This technology often comes in the form of a DC ionising bar, which is typically placed immediately before, a web cleaner on a production line. These bars direct positive and negative ions of electricity at the web’s surface, which neutralise any charges present. Most modern ionisation technology is available in formats that suit short, medium and long-range applications, and for the age of highly-automated smart technology and ‘Industry 4.0’. Meech’s SmartControl enables operators to see the performance information of multiple static control devices and control them via a mobile phone, tablet, touch screen or PLC . These devices can also be connected to static bar controllers, which automatically alter the levels of ionisation supplied from the static bar.
TAKING ACTION
With health and safety standards stricter than ever, there is a significant need for high- quality packaging that can be produced cleanly and reliably. It’s imperative that converters have the necessary equipment to stay competitive and keep up with industry demands. Failure to invest in the right static control and web cleaning solutions leads to significant cost and waste on the production line, ultimately damaging customer relationships and business profits.
u
meech.com
14
March 2021
convertermag.com
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