In manufacturing, static electricity can certainly be a challenge. However, it can also be a useful tool. When used correctly, static can become an asset, capable of improving processes such as coating or bonding.
In this blog, we’ll explain what static electricity is, how it affects manufacturing, how to control it, and explore examples of harnessing electricity in various manufacturing processes.
What is Static Electricity and How Does it Occur?
Static electricity happens when two materials rub together and then separate, causing an imbalance in electrical charges. One material gains electrons and becomes negatively charged, while the other loses electrons and becomes positively charged. This charge builds up, stays on the surface of the material, and is eventually released when it finds a path to balance itself: often by “jumping” to a conductive object, which can result in a spark.
In manufacturing, static electricity can occur naturally during common processes. Moving materials through machinery, handling items like plastics or paper, and heating materials can all generate static charges. Although it can sometimes interfere with equipment or processes, static electricity also presents valuable opportunities when managed properly.
Controlling Static Charges in Manufacturing
With the right solutions and equipment, manufacturers can control and limit the build-up of static electricity:
- Ionisation: Ionisers release positive and negative ions into the air, which then attach to any static charges on a surface, neutralising them.
- Humidity control: Moisture in the air helps disperse static electricity, as water molecules allow charges to move more easily.
- Earthing (Grounding): Grounding provides a direct path for static charges to safely discharge into the ground.
- Antistatic additives: For materials like plastics that are prone to generating static, antistatic additives can be mixed into the material during production, reducing the likelihood of static build-up.
Harnessing Static to Improve Processes
While controlling static is important, the real value lies in how static electricity can be harnessed to improve processes. Here are several examples of its practical applications in manufacturing:
- Improving coating adhesion: In industries such as automotive, static charges are used to apply coatings evenly. This process involves adding a positive charge to the paint or powder through a spray gun, while the part to be coated is grounded. The grounded part attracts the charged particles, ensuring an even and efficient application.
- Air cleaning: In industries that generate a lot of dust or particles, like cement or chemical production, static electricity can be used to clean the air. Electrostatic precipitators use a static charge to attract and capture airborne particles, helping to maintain a clean work environment and improving air quality.
- Printing: Static electricity plays an essential role in the printing industry, particularly in processes like laser printing and photocopying. By using static to control the placement of ink or toner on paper, manufacturers can achieve precise, high-quality prints with consistent results.
- Plastic film production: During the production of plastic films and sheets, static electricity helps control the movement and positioning of materials. By using static to ensure smooth material flow, manufacturers can reduce defects and optimise production speed.
When controlled effectively, static electricity offers immense benefits to manufacturing processes. It can enhance adhesion, improve air quality, and optimise production lines.
With the right approach, static becomes a valuable tool for improving operations, reducing costs, and maximising outcomes. To learn more about the static generation and static control solutions that we offer, don’t hesitate to contact us.