In manufacturing environments, static electricity isn’t just a by-product — it’s a variable that needs to be controlled based on the specific requirements of each process.
Depending on the application, that could mean eliminating unwanted charge, generating controlled static, or monitoring levels to maintain process stability. Each scenario demands a different type of equipment, and choosing the right tool for the job is critical to production performance, safety, and compliance.
This guide outlines a structured approach to help engineers and operations managers select static control equipment that fits the needs of their production environment, with clear product examples and selection criteria throughout.
We offer free technical support and site visits to help you identify the right solution for your setup. Get in touch to speak to a technical specialist.
Start with Measurement: Quantify Before You Act
Effective static management begins with accurate measurement. Without quantifying charge levels, it’s difficult to assess risk, identify sources of disruption, or determine the correct type and placement of equipment.
At a minimum, it’s important to understand:
- Where static is building up
- Whether it’s positive or negative
- How intense the charge is — typically measured in kilovolts (kV)
For this, a handheld electrostatic field meter is the most straightforward tool. The Simco FMX-004 is widely used for quick, non-contact surface readings and can help establish a baseline across different zones or production stages.
If more detailed analysis is required – for example, validating ioniser performance in electronics assembly, or simulating charged plate conditions in pharmaceutical cleanrooms or medical device manufacturing – the Model 775 Handheld Periodic Verification System offers a modular approach. It combines a field meter, charger, and detachable plate, making it well suited to quality assurance or preventative maintenance routines.
To check whether charging or discharging equipment is operating correctly, the Simco-Ion TensION provides a quick indication of high-voltage output on emitters or charging points.
Where continuous monitoring is needed, particularly on web-based production lines in industries like converting, packaging, or plastics extrusion, the Sensor IQ Easy provides real-time charge data as part of the integrated IQ Easy platform. This enables proactive static control and system-wide visibility, helping operators detect charge build-up before it causes quality issues, material misfeeds or ESD-related faults.
Define the Objective: Eliminate, Generate, or Monitor
Once static has been measured, the next step is to define what role it plays in your process, and what control method is appropriate. Broadly, static control equipment falls into three categories:
Eliminate Static
Used when charge accumulation is causing operational issues, product defects or safety concerns. This is one of the most common requirements across industrial settings.
Typical applications:
- Rewinding and slitting of plastic or paper webs in converting, printing, and packaging lines
- Preventing operator shocks on automotive or moulding assembly stations
- Reducing dust attraction on surfaces in pharmaceutical, food and drink, or textiles manufacturing
- Improving coating or painting results in wood and automotive sectors
Common tools:
Generate Static
Used when controlled charge is beneficial to the process. This is especially relevant in industries that require precise positioning, bonding or labelling.
Typical applications:
- Holding films or trays in place during high-speed packaging (e.g. food & drink, pharmaceutical)
- Applying in-mould labelling (IML) in plastics and automotive components
- Temporarily bonding layers during lamination in converting or textile production
- Securing paper or board during handling in paper product manufacturing
Common tools:
Monitor Static
Used when static levels need to be continuously tracked, typically after initial measurement has confirmed that charge build-up varies during production or presents a recurring risk. In many cases, the same equipment used for spot-checking can also be configured for real-time monitoring.
Typical applications:
- Monitoring static across extrusion or converting lines where charge build-up varies by material type or humidity
- Real-time quality control in pharmaceutical or electronics packaging
- Preventative maintenance and early fault detection in static-sensitive environments (e.g. engineering, printing)
Common tools:
- Inline static sensors
- Central control platforms (e.g. IQ Easy Manager)
Match the Equipment to the Application
The suitability of each tool depends on process conditions: the nature of the material, surface size, line speed, available space, and environmental factors. The table below offers a practical reference:
| Industry | Example Application | Recommended Tool | Example Simco Product |
|---|---|---|---|
| Automotive | Eliminate static before painting plastic parts | Ionising Air Guns | Performax IQ Easy Anti‑Static Bar Cobra Ionised Air Gun |
| Converting | Neutralise charge during web slitting | Ionising air knives | Performax IQ Easy Airknife |
| Extrusion | Monitor static levels on film during extrusion | Static sensors | Sensor IQ Easy |
| Food & Drink | Use static to hold packaging in place during filling | Charging generators & electrodes | CM5 Charging Generator (via IQ Com) |
| Moulding | Apply static for in‑mould labelling | Charging generators | CM5 Charging Generator |
| Paper Product Manufacturing | Eliminate dust attraction on paper surfaces | Ionising blowers | Performax IQ Easy Airknife |
| Wood | Neutralise static on veneered boards before finishing | Ionising bars | Performax IQ Easy Anti‑Static Bar |
| Packaging | Use static to bond tray inserts or liners | Charging generators | CM5 Charging Generator |
| Pharmaceutical | Continuously monitor static on cleanroom lines | Integrated monitoring system | IQ Easy Manager + Sensor IQ Easy |
| Plastics | Eliminate static before stacking or cutting sheets | Ionising air knives | Performax IQ Easy Airknife |
| Printing | Neutralise charge on printed webs before rewinding | Ionising bars | Performax IQ Easy Anti‑Static Bar |
| Textiles | Remove static from synthetic fibres during handling | Ionising blowers | Performax IQ Easy Airknife |
| Engineering | Monitor multiple static zones across lines | Integrated control platform | IQ Easy Manager |
Each product has specific operating distances, ionisation speeds, and configuration options. For example:
- The Performax bar is designed for neutralising static across high-speed production lines with variable material widths.
- The CleanFlex gun is suitable for manual, operator-led treatment where flexibility and control are required.
- The CM Tiny generator, used with charging electrodes, is effective for small-scale or confined applications where precise static charge is necessary.
Consider Environmental and Operational Requirements
The environment in which static control equipment operates is just as important as the type of tool selected. Conditions across industries vary significantly, and so do compliance requirements.
Here are some key factors to consider:
- Explosive or hazardous zones (ATEX)
Certified devices are required in flammable or solvent-heavy environments - Cleanroom or food-grade production
Equipment should be easy to clean, resistant to shedding, and suitable for hygienic environments (e.g. pharmaceutical or food & drink) - Humidity and temperature fluctuations
These can affect charge behaviour and the performance of ionising equipment - Integration potential
For lines requiring real-time data, remote monitoring, or diagnostic alerts, ensure equipment is compatible with systems like the IQ Easy platform
Environmental compatibility isn’t just about reliability, in many industries, it’s also critical to safety, compliance and audit readiness.
Evaluate Single Devices vs Integrated Systems
For localised static issues, a single ionising bar or charging generator may be sufficient. But when charge-related challenges occur across multiple stations or shifts, or when long-term consistency is key, a system-based approach becomes more effective.
Simco’s IQ Easy System allows for:
- Centralised control of all connected ionisers, blowers, and charging equipment
- Real-time charge monitoring and automatic performance alerts
- Centralised configuration and preventative maintenance scheduling
- Integration with products like the Sensor IQ Easy and IQ Easy Manager for full visibility across the production line
This kind of integration not only improves reliability but also supports process stability, compliance, and operator efficiency at scale.
Common Oversights to Avoid
Even experienced engineers occasionally overlook key elements when specifying static control equipment. A few reminders:
- Assuming static is always harmful: In some processes, it’s essential. Understanding its role is critical.
- Bypassing measurement: In our experience, decisions made without data often lead to poor outcomes or unnecessary costs.
- Neglecting environmental fit: Equipment that performs well in one setting may underperform in another.
- Failing to plan for maintenance: Ionisers and generators require routine inspection and emitter cleaning to maintain effectiveness.
Summary: A Structured Approach to Selection
- Measure: Use a static field meter to quantify charge levels and identify problem zones
- Define: Determine whether you need to eliminate, generate or monitor static
- Match: Select equipment appropriate to your materials, line speed, and layout
- Contextualise: Factor in compliance, environmental demands, and integration potential
- Scale: Choose between standalone tools and platform-based systems based on your process complexity
Need Advice on Equipment Selection?
Static control equipment performs best when matched to the specific role static plays in your process.
If you’re unsure which solution fits your setup, we offer free technical support and on-site assessments to help you specify the right tools, whether you’re starting from scratch or upgrading an existing system.