Static Control & Web Cleaning
Reducing waste in the production line
Iain Cameron, Marketing Director, Meech International
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ustainability remains a key talking point within the converting industry, and this makes it more important than ever that sustainable measures are put in place throughout all parts of the production line. Static generation is one factor that can pose a significant threat on the quality of packaging while it is produced. If not dealt with correctly and eliminated, it results in nearby and airborne particles being attracted to the surface of a web, hindering the quality of the product, causing print work to appear faded or dirty. Contamination by static on a web can affect ink performance, repelling it away from the surface of a label. Static can also pose a health and safety risk to staff. Static usually occurs when a web is moving at high speed, either via friction when the web makes contact with converting machinery, through ‘separation’, the unwinding of web rolls, or even via electricity from surrounding machinery. A web can become contaminated without the presence of static, when it is moving in high-speed as it drags along ambient air. This creates a boundary layer that can cause debris to become trapped within or beneath the surface of the layer. Contaminated products, whatever the cause, can render a large amount of packaging products inadequate, causing them to be thrown away and affecting the overall production line, increasing waste and slowing down productivity.
Fortunately, highly sophisticated static control and cleaning equipment is available that can counter static charges and contamination, ensuring productivity remains at an optimal level.
WEB CLEANING
Web cleaners act to effectively resolve contamination issues. Available in two forms, contact and non-contact, they are highly efficient at removing loose, dry debris from the web’s surface.
Contact web cleaners, such as Meech’s TakClean, are suitable for the narrow web label market. Designed to make contact with the web and break through the boundary layer, they typically use an elastomer and adhesive roller based system, making them ideal for the
removal of small particles as low as 0.5 micron. Other contact systems utilise steel faceplates and brushes to break the boundary layer, although these
are less suitable for sensitive substrates. Customers should be aware that deciding on the most practical system depends on the web materials being processed, the application, the flexibility required by the converting line, and the available budget. While web cleaners can help deter issues surrounding product quality and staff safety, these devices alone will not solve all problems associated with a statically charged web and are most effective when worked in tandem with static control devices.
STATIC CONTROL
Though web cleaners are effective at removing contamination, the most effective way to prevent it is incorporating static control, which can neutralise
the charge. This is achieved through using an active static control device, such as a DC ionising bar, which is placed before a web cleaner on a production line. It directs positive and negative ions of electricity at the web’s surface, neutralising any charges present. With Industry 4.0 becoming a more prevalent topic within the technology world, static control devices are starting to incorporate automated features. Meech’s SmartControl, for example, enables operators to see the performance information of the static control device and control it via a local user-friendly display, such as a mobile phone, tablet, touch screen or monitor. These devices can also be connected to static bar controllers, which alter the level of ionisation supplied from the static bar.
This measurement can be fed back to the ionising product which automatically adjusts the balance of the output to achieve a completely neutral web. This is a continuous process that constantly measures and adjusts to achieve the best static control.
TAKING ACTION
As sustainability remains a growing trend, web cleaning and static control equipment are must- haves for label and packaging manufacturers to ensure production lines run effectively and with minimal waste.
It is essential for manufacturers to invest in the necessary equipment to reduce waste on the production line and avoid increasing carbon footprint and damaging reputations.
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March 2024
www.convertermag.com
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