In the packaging industry, static electricity can impact productivity, product quality, and even safety. Static issues are common across various packaging processes, from blister packing to pallet wrapping.
This blog explores four common scenarios and how to address the issues in question, through the use of anti-static equipment like ionising blowers, nozzles and anti-static bars.
Tackling static at its source keeps operations running smoothly, cuts down on contamination, and keeps your team safe. Let’s dive in.
Issues in Pallet Wrapping
Pallet wrapping presents its own set of challenges. The action of wrapping and winding creates friction, which generates static charges and can cause a range of problems. Issues like attracting contaminants, and creating safety hazards for operators like electrostatic shocks. Even more serious is the risk of ignition, when the products being wrapped are flammable, such as gas bottles and aerosols.
Luckily, these problems can be mitigated by using anti-static equipment such as ionising blowers, mounted strategically to neutralise the static on the stretch film. Anti-static bars can also be mounted parallel to the film, allowing ionisation to travel with the film as the pallet is wrapped. This not only improves safety but also ensures a more efficient wrapping process.
Static Problems in Blister Packing Lines
Blister packaging is a staple of many industries, but it is particularly prone to static-related issues. As materials unwind and thermoform during the packing process, static charges build up.
These charges can attract airborne contamination like dust, clothing fibres and even eyelashes from operators on manual production lines, which compromises product integrity.
The solution? Static neutralisation at each stage of the process. By using anti-static bars to neutralise the material as it unwinds, you can stop airborne contaminants from being drawn in. Then, neutralising static on the blister packaging after thermoforming will minimise the attraction of contaminants from operators. Finally, neutralising the sealing film prevents issues like small products being lifted out of the blister packs. Taking these steps will ensure that your packaging remains clean and properly sealed.
Managing Static in Bottle Powder Filling
Bottle powder filling is another packaging process where static electricity can derail efficiency and quality. During the conveying of bottles and vials, static charges build up, causing powders to cling to the neck of the containers. This can prevent proper sealing, which compromises the product’s integrity. Furthermore, static can keep powders suspended within the container, leading to mis-measured weights.
To resolve this, ionising nozzles offer an effective solution. By neutralising the static charges on each container before filling, ionising nozzles prevent powders from clinging to the neck, ensure that seals are clean and secure, and guarantee that weights are accurate.
Tackling Static in Horizontal Bagging
Horizontal bagging machines are another area where static can wreak havoc. Static charges build up as the film unwinds and is folded into bags. If left unneutralised, these charges become trapped within the material, causing problems further down the line.
For example, static can keep the bag shut, stopping the product from settling at the bottom. If the product creates dust, this can cling to the inside of the bag, interfere with sealing, and potentially lead to spillage or spoilage.
To resolve this, install anti-static bars at critical points in the process. Neutralising the plastic film will prevent static from becoming trapped inside the material at the point of folding, and additional neutralisation at the filling station will eliminate further risks. With these measures in place, the bags open smoothly, products are securely packed, and seals remain tight.
The Key to Static Control
Static electricity may be invisible, but its effects are all too real in the packaging industry! The good news is that static control doesn’t have to be complicated. By understanding where static builds up in your processes, whether it’s during unwinding, forming, sealing, or wrapping, you can apply the right tools, such as ionising blowers, anti-static bars, and nozzles, to stop static in its tracks.
Every process is unique, but by tackling static at the source, you’re setting your business up for success: less waste, fewer disruptions, and higher quality output. If you’re not sure where to start, eStat is here to help. Contact us today to learn more about how we can help to optimise your packaging processes.