Static electricity may be invisible, but its effects on industrial machinery and production processes are very real. From materials clinging together to unexpected repulsion of sheets, static-related issues can disrupt efficiency, damage equipment, and pose safety risks. Understanding and managing static electricity starts with accurate measurement. In this guide, we’ll explore why measuring static electricity is essential, the key methods used, and how to apply the right tools for the job.
Why measuring static electricity matters
Static electricity builds up when materials with high electrical resistance come into contact and then separate. This charge accumulation can interfere with production lines, leading to quality control issues, reduced efficiency, and even electrical discharge hazards.
Measuring static electricity provides insight into:
- The presence and intensity of static charge (measured in kilovolts, kV)anti-static
- The polarity of the charge (positive or negative)
- Where static issues originate in a production environment
- Whether anti-static measures, such as ionisers, are working effectively
- The effectiveness of static control equipment over time
Without precise measurement, diagnosing and solving static-related problems becomes a guessing game. Using a static meter allows businesses to pinpoint problem areas and apply targeted solutions. Regular monitoring can also help predict and prevent potential issues before they escalate.
How to measure static electricity
There are several ways to measure static electricity, depending on the application and level of control required. The most common tools include:
Measuring surface voltage
Surface voltage measurement is the most direct way to assess static charge. It involves using a static field meter, such as a handheld electrostatic field meter, to measure the electric field strength on a material’s surface. These meters provide real-time kV readings and indicate whether the charge is positive or negative. They are particularly useful for:
- Identifying areas with excessive charge buildup
- Evaluating static levels before and after using anti-static devices
- Ensuring compliance with industry regulations
- Performing quality control checks in manufacturing environments
Handheld static meters are typically used at a set distance from the surface, with built-in LEDs to indicate the correct measuring position. This ensures accurate and repeatable readings. Some advanced meters also include data logging capabilities, allowing users to track static trends over time and adjust processes accordingly.
Measuring surface resistance
While surface voltage measurements focus on charge intensity, surface resistance measurements help determine how well a material can conduct or dissipate static electricity. A surface resistivity meter is used to measure how easily electric charges flow across a material’s surface.
Surface resistance is measured in ohms (Ω) and is classified into three categories:
- Conductive (<10⁵ Ω) – Allows charge to move freely, reducing static buildup
- Dissipative (10⁵–10¹² Ω) – Slows charge movement, reducing sudden discharges
- Insulative (>10¹² Ω) – Prevents charge movement, increasing static buildup risk
Measuring surface resistance is particularly useful in assessing materials used in static-sensitive environments, such as electronic manufacturing, pharmaceutical packaging, and production lines dealing with flammable materials. Regular checks can ensure that materials remain within safe resistance ranges and that electrostatic discharge (ESD) protection is effective.
Measuring an electric charge in an anti-static bar
Anti-static bars neutralise static electricity by emitting positive and negative ions. To ensure they function correctly, an electric charge detector can be used to check whether the bar is operating at the correct voltage.
The TensION voltage detector, for example, is a handheld tool designed to verify the presence of high voltage on static neutralising bars. This ensures:
- Anti-static bars are correctly positioned and functioning
- Operators can detect potential malfunctions early
- Static elimination processes remain effective over time
- Continuous compliance with safety regulations in static-sensitive environments
For full control in high-speed industrial applications, an inline static sensor bar provides continuous monitoring of static levels across a moving web of material. These systems integrate with static control management platforms to automatically adjust ionisation settings based on real-time data. This proactive approach helps to prevent issues before they cause production delays or defects.
Best practices for static electricity measurement
To ensure accurate and meaningful results when measuring static electricity, follow these best practices:
Use the right tool for the job: Select a handheld meter for spot checks, an inline system for real-time monitoring, or a resistivity meter for material testing.
Maintain consistent measuring distances: Static field meters require a specific distance from the surface for accurate readings. Follow the device’s guidelines.
Check environmental conditions: Humidity and temperature can impact static levels. Monitoring these factors alongside static measurements can improve troubleshooting accuracy.
Monitor trends over time: Instead of relying on single measurements, track static levels regularly to detect patterns and prevent unexpected issues.
Ensure equipment calibration: Regularly calibrate static measurement tools to maintain accuracy and reliability.
Choosing the right static measurement equipment
Selecting the right static measurement device depends on your industry and the specific challenges faced in your production environment.
- Handheld static meters (eg. FMX-004) are compact, easy to use, and ideal for quick checks on surfaces and objects.
- Inline static sensor bars provide continuous, automated monitoring in production lines.
- Surface resistivity meters help assess how materials will react to static charge buildup.
- Voltage detectors like the TensION ensure anti-static bars are operating correctly.
- Data logging static meters allow for in-depth analysis of static charge trends over time, helping to optimise static control strategies.
Static electricity can have a noticeable impact on industrial processes. By accurately measuring static levels, businesses can diagnose problems, implement the right static control solutions, and maintain high production efficiency. Whether using a handheld static meter for spot checks or an inline monitoring system for real-time control, having the right tools in place ensures a static-free and optimised industrial environment.
Implementing a proactive static measurement strategy helps reduce defects, improve safety, and optimise production workflows. If you’re looking for reliable static management equipment, explore our range of static meters and control solutions designed to keep your operations running smoothly.