If you’re trying to manage static across a wide area, like a packaging line, a wide web of material or a section of factory floor, it can be difficult to find static control equipment that covers the entire production line. Not every static control product offers the same range and coverage, and something that works well for small, close-up applications won’t be practical when you’re trying to neutralise static over several metres or across an open space.
At eStat, we work with manufacturers across the UK who are dealing with exactly the same challenges. The key to keeping static under control, especially in larger areas, is choosing the right equipment for the job.
What makes static electricity harder to manage in large spaces?
Static electricity builds up when materials rub together and/or separate, particularly in dry conditions. In larger spaces, you’ll usually have more movement: films being unwound, sheets being fed through machines, or components being conveyed from one area to another. And since static charge can spread and travel across a room, even small, localised amounts of static can cause issues in a wide area.
You’ll often find static-related issues in the following processes:
- Converting or slitting lines
- Film and sheet unwinders
- Packing and labelling areas
- Web-fed printing lines
- Extrusion or thermoforming machinery
In these environments, static can cause film to cling or misbehave, dust to stick to products, or machinery to jam. This can directly affect both productivity and product quality.
What kinds of static control products help?
Long-range ionising bars
In setups where you can’t mount static control devices close to the material (such as wide web applications or winding and rewinding processes) long-range ionising bars are an effective option.
The ThunderION IQ is designed for these situations. It can neutralise static at distances of up to one metre without the need for air, making it suitable for large and no-airflow production areas. It’s often used in converting, extrusion and packaging lines with wide or shifting materials.
The bar is available in lengths up to five metres and is built for industrial use. This kind of system works well when you need consistent coverage across a wide area, without relying on multiple close-range units.
Intelligent ionisation systems
In larger production spaces, static levels often vary from one area to another, especially when you’re working with different materials, changing humidity, or machines running at different speeds. The Manager IQ system helps manage this by monitoring all connected ionisers in real time and adjusting the ion output automatically.
This kind of system is particularly useful when you’re trying to keep control across a whole setup, rather than dealing with one section at a time. It removes the need for manual fine-tuning of individual devices, and helps make sure static is kept in check throughout an entire process.
Ionising air systems
Ionising blowers use a steady stream of air to carry ions over a wider area, making them particularly effective in situations where static needs to be neutralised at a distance, or through dusty air. They’re often used just before labelling, printing, or sealing, where removing dust and static at the same time helps improve quality and reduces issues like poor adhesion.
Because blowers cover a broader area than standard anti-static bars or ionising guns, they’re well-suited for larger setups. At eStat, we can help assess whether a blower or another type of ionising system is right for your specific situation.
Spot and point ionisers
While tools like ionising nozzles and air guns are best suited to targeted applications, they can still play an important role as part of a wider static control setup. These point solutions are useful for neutralising specific areas, such as the edges of a web, the inside of containers, or small components on assembly lines, where static build-up might persist even with broader ionisation in place.
They’re often used alongside long-range bars or blowers to create a comprehensive system. For example, a packaging line might use a blower to neutralise the general area, while a nozzle targets the inside of each container just before sealing. Or in a converting process, bars might handle static across the width of the material, with guns used for occasional manual intervention at the rewind stage.
What kinds of static control products help?
When you’re deciding which type of static control is right for your space, here are a few key things to think about:
- Distance to the material: If equipment or guards prevent you getting close to the charged surface, you’ll need something with a longer reach – think ThunderION bars or ionising blowers.
- Environmental conditions: In larger spaces, static doesn’t always build up evenly. Dry air, temperature swings and airflow can all affect how static builds up, and how effective ionisation will be. Static monitoring using a Manager IQ system can be a great asset here.
- Dust and airflow: If you want to remove dust and neutralise static at the same time, for example just before labelling or printing, ionising blowers are especially useful.
- Small or awkward areas: Even with broader coverage in place, static can still build up in smaller or more awkward spots. Ionising air nozzles and air guns are useful here, as they let you target specific areas that wider systems might not reach. They’re often used alongside bars or blowers to make sure no part of the process is overlooked.
Our approach at eStat
We know that no two sites are the same. That’s why we offer free site surveys, helping you identify the source of the problem and advising on the most suitable solution for your layout, process, and budget.
We supply a wide range of static control equipment. All our static control products are designed to integrate into your existing setup with minimal disruption.
If you’re unsure where the static is coming from or you’ve already tried a few fixes that haven’t worked, we’re happy to help. Our team has worked with manufacturers across industries to solve persistent static issues and improve both product quality and production efficiency. Contact us today to see how we can help.