Topic	Overview/Problem
Converting and Static Control	On converting machines, like slitters, once the web separates from the unwind roll-- static is generated. The static continues to build as the web makes contact and separates from points of friction. In bag making, laminating or converting process, neutralizing static charge is extremely important to the manufacturing process. expanded solution
RFID Tags	Static charges are commonly found in tag and label printing/production operations anywhere along the path from the feed-roll to the rewind. The charges are generated by the contact and separations of the web material from the unwind roll, and as the material travels over the various rollers and process stations as it runs through the press or converting equipment. expanded solution
Engine Block Sleeve Blowoff	The Problem: A manufacturer of large engines installs machined cylinder sleeves in the block to resist wear. After machining, the sleeves are put through a parts washer for cleaning. Heavy amounts of honing oil remained on the sleeves. Numerous wash cycles and frequent changes of the contaminated washing solution was required. expanded solution
Smoke Containment -Engine Test	The Problem: The last step in an engine assembly process is "burn-in" on a test stand. Each engine is connected to a dynamometer and run for a period of one to five minutes. Residual machining oil on the head produced smoke during the test, and the vent hood at the top of the stand had insufficient capacity to contain it. expanded solution
Blowoff On A Bottling Line	The Problem: Bottles emerging from a pasteurizer are conveyed to a labeling station. Water carryover from the bottles created a slip hazard and housekeeping problem. In addition, open air jets drying the bottles upstream of the labeler consumed over 150 SCFM of compressed air. Noise levels were in excess of 90 dBA. expanded solution
Super Air Knife Replaces Fan Cooling	The Problem: A manufacturer of automotive electronics had a problem cooling computers as they exited a wave solder machine. In order to be handled and tested, the computers had to first be cooled to 81°F (27°C). Initially, they had tried banks of 6" (152mm) diameter axial fans across the 8' (2.5m) length of the cooling conveyor. It consisted of 16 fans blowing down from the top and 16 fans blowing up from the bottom at 7" (178mm) away from the surface. After traveling the full length of the conveyor with the fans running at full force (a five minute duration), the computers were still 108°F (42°C). Quality Control personnel sat with an unacceptable backlog of computers waiting to be tested. expanded solution
Air Shielding a Scanner Lens	The Problem: Automotive glass is tempered by subjecting it to a series of heating and quenching operations. An infrared scanner maintains a uniform temperature across the glass surface by sending signals to a PLC that automatically adjusts conveyor speeds and oven temperatures. Dust and other airborne particulate coated the sapphire lens of the scanner and caused it to generate false temperature readings. The result was hundreds of feet of rejected glass. expanded solution
Bakery Creates Clean Break In Icing	The Problem: A bakery had a problem applying the icing to their snack cakes. As the baked sponge cakes moved down the conveyor, a continuous ribbon of icing was applied to the individual cakes. Trying to make a clean break in the icing was next to impossible. Mechanical blades required constant cleaning. Compressed air through a series of holes in drilled pipe used too much air, was noisy and didn?t make a clean break in the icing expanded solution
Eliminating Dip Molding Rejects	The Problem: The dip molding process is used to make anything from the colorful boots around gas pump handles to the grips for pliers and other hand tools. One molder had a high reject problem with many of their parts. As the die was lifted from the molten plastic, excess would run down the part and harden - just like candle wax. The smooth surface was ruined, drastically reducing production. expanded solution
Static On - Sleeve Machine	During the manufacture of plastic bags using the flat bag method, the bags build up a large static charge in the un-wind. Static was created when the bags were originally rolled and more static is created when the bags are unrolled for cutting. expanded solution
Static On - PET Bottle Conveying	PET is a material used to create bottles and other plastic based parts. PET is also a material prone to static charge. Static electricity is added to PET during the process of converting raw PET into bottles and other parts. expanded solution
Static On - Film Extrusion Line	Plastic film is used in multiple industries including medical and packaging. The film is created using an extrusion process. Static charge is generated almost immediately upon exiting the extrusion head. expanded solution
Static On - Labeling Line	Product label application is crucial to any manufacturer. During the process of conveying PET bottles, static electricity builds up. Friction along the conveyer path continuously adds to the static charge. The resulting charge causes the bottles to repel each other, the labels to be applied and downtime from mislabeling. expanded solution
Static On - Multi-head Labeling Line	During the manufacture of plastic bags using the flat bag method, the bags build up a large static charge in the un-wind. Static was created when the bags were originally rolled and more static is created when the bags are unrolled for cutting. Further static is added as the bags pass over and through additional rollers. expanded solution
Static On - Blow Molding/Parison	PET bottles and other similar containers are made using a Parison. A Parison is generally extruded. During the extrusion process, parisons start cooling as soon as the exit the machine. expanded solution
Bag Making (Flat Method)	During the manufacture of plastic bags using the flat bag method, the bags build up a large static charge in the un-wind. Static was created when the bags were originally rolled and more static is created when the bags are unrolled for cutting. Further static is added as the bags pass over and through additional rollers. expanded solution
Bag Wicketer	The Bag Making Industry has become a competitive game where it is important that the machines run constantly and have little or no downtime. One of the causes of downtime and rejects in the bag making process is static electricity. Continuous movement of a tubular or folded plastic web through bag making equipment is the process by which plastic bags are manufactured. expanded solution
Pad Printing Machines	The pads used in the Pad Printing Process are normally silicon-based material, which have a tendency to pick up a static charge during the printing process. The silicon pad coming in contact and separating from the print object generates static. The static charge can cause the ink to repel from the surface or can cause airborne particles to stick to the pads or to the material to be printed. To maintain pad surface cleanliness and image quality, static control devices strategically located on the equipment will reduce part rejects and increase productivity expanded solution
Flexo Printing Silk Screen Printers	The Converting and Printing Industry, especially Flexo Press equipment that utilizes UV curable inks are susceptible to static electricity, even though the static energy may be below the level of shock hazard. Label stock and other substrates such as paper, corrugated board, film, foil and other materials running on Printing Equipment are all affected by reduced print quality, which means downtime ad lower profits. expanded solution
Bag Making	During the Converting Process where plastic film is made into plastic bags on Flat Bag Machines, the film builds up static charges from the Unwind and continues to increase as the material travels through the bag machines. Many times the roll stock already has stored static electricity that is generated from upstream processing as the film is blown and rewound for future converting. expanded solution
Paper Folding	Paper is a dry material by nature. Because it is dry, static charge quickly generates on it’s surface. Static charge generates when paper is unwound, rewound printed on or folded. expanded solution
High Speed Cutting or Sheeting	When a plastic or paper web moves through Converting Equipment like Sheeters, static electricity is a problem, especially at the delivery. As the material travels over the many friction points, especially idler rolls, static build up on the web as it continues on its path toward the delivery or pay off point. expanded solution
Mutli-web Laminating	Laminating or bringing multiple webs together can cause a couple of static related problems. With any unwind static is generated. As the webs come together it is important to neutralize the static charge so it does not become trapped between the layers. Unchecked static can reach levels that can pull particles out of the air, which not only create a source of contamination, but particles can become trapped between the layers, causing defects and possibly de-lamination in some instances. expanded solution
Plastic Parts Conveying	Small plastic parts, bottles and other injection molded or fabricated plastics by nature pick up static in the process. Parts are typically moved and handled by a conveyor until the parts reach a collection point which is usally a tote box. The parts, especially lightweight ones will have a tendency to stick to the conveyor belt and may even stay on the belt instead of dropping into the storage container. expanded solution
Sheet Fed Printing Press	Sheet-fed press related static problems are some of the more difficult to solve due to a couple of factors, which include the material being printed and physical restrictions on the press. The best place to start solving static problems on any sheet fed press is upstream on converting equipment that slits and sheets the material that will be sent to the press. expanded solution
Stacking Machines	When magazines are printed, they are stacked for conveying. The coated stock used in most magazines can slide around and fall off the stack which causes downtime and delays.In order to prevent the magazines from slipping a static charge can be induced. expanded solution