Controlling Static Charges on a Turret Rewinder

Problem:

When the film roll rewinds onto the turret winder, it generates high electrostatic charges, leading to several problems:

1. Dust Attraction
2. Customer complaints about finished product quality
3. Operator shocks and associated health and safety issues
4. Poor overall product quality
5. Structural damage to coatings
6. Wound rolls with poor quality, exposing edges to damage
7. Incorrect tension causing core crushing or drop-out

Challenge:

The static charge needs removal during rewinding, but the design of the indexing turret makes it challenging to position antistatic systems. Finding a solution is difficult as it must prevent static charge buildup on film reels without hindering machine performance.

Solution:

Meech Pulsed DC Systems offers a solution, including model 971 Pulsed DC long-range ionizing bars with the 233v4 controller, available in 24Volt or 110Volt inputs. The key advantage is that the Meech system can be directly installed on the turret. This ensures that the film roll remains in an ionizing zone throughout the rewinding and turret indexing process, effectively neutralizing static charges.

971 Pulsed DC	233v4 controller

ESD & Contamination Control On Re-Winders With Lay-On Rollers

Problem:

Static charges on plastic web during unwinding and rewinding can lead to problems such as operator shocks, dust attraction, poor quality reels, coating damage, and structural issues.

Solution:

To address these problems, use the Meech 924IPS bar positioned at the unwind. Placing a Model 924IPS bar at the unwind controls static charges. For clockwise winding, it neutralizes both sides of the material, while anti-clockwise winding focuses on one side. The constant 30mm distance and powerful ionization of the 924IPS bar minimize residual charges on the rewound roll.

Meech 924IPS bar

Neutralizing Static On A Plastic Web During The Rewinding Process

Problem:

The rewinding process generates extremely high static charges on the plastic web, resulting in several challenges for converters and their clients, including:

1. Operators experiencing unpleasant shocks
2. Attraction of dust, leading to contaminated stock
3. Production of poorly wound reels that are challenging to fit onto machines and may cause feed problems

Solutions:

The optimal solution to address these issues is the implementation of the Meech 971 bar.

Slitting Wide Format BOPP and BOPET Films

Problem:

Customers now demand minimal residual static charges in the production of BOPP & BOPET film. Excessive static can lead to customer rejection, especially when the film needs to be slit and rewound in various directions at speeds ranging from 600 to 1200 meters per minute. Traditional solutions are inadequate to maintain static levels below ± 2-5 kV, particularly at higher machine speeds, allowing less time for control.

Solution:

To meet customer expectations, effective static control is required on both sides of the material and in both rewind directions. The Meech Hyperion 924IPS bar, known for its high performance and compact profile, is an ideal solution. It can be retrofitted onto most wide-format slitting machines to ensure optimal static control.

Advantage:

The Meech Hyperion bar is well-suited to satisfy customers who demand just-in-time material supply with minimal residual static charge, thereby retaining customer satisfaction.

Meech 924IPS bar

Static Issues on Slitter Rewinding Machines

Problem:

Slitter rewinding machines have the potential to generate substantial static charges on insulative materials, leading to various issues such as slitter dust attraction to the web, electrostatic shocks to operators, and incorrect roll tension.

Solution:

To address these issues, the recommended solution involves the strategic placement of the 971 Pulsed DC bar. The diagram to the left illustrates the optimal position for the bar, with an alternative position provided based on the specific layout of the machine.

Static Pinning of Web to Core on Turret Rewind

Problem:

Automated packaging machines face the challenge of seamlessly splicing new reels of material on the fly to enable uninterrupted operation. This requirement necessitates that the ends of the reels cannot be affixed to the core, ruling out the use of adhesives and double-sided tape.

Solution:

To overcome this challenge, a 993R Generator Bar can be employed at the rewind stage of plastic extrusion lines. Working in conjunction with the flying knife, the 993R bar effectively pins the leading edge of the web to the new core. This dynamic solution is powered by an IonCharge30, ensuring robust and effective pinning.

993R Generator Bar	IonCharge30

Static Problem With Post Press Sheeting Of A Paper Web

Problem:

Digital printing leads to paper drying, causing collation and knocking up problems. Another concern arises when the edge trim adheres to the walls of the waste bin, eventually obstructing the edge-trimming knives. Additionally, operators removing the waste bin may experience capacitive electrostatic shocks from the metal bin.

Solution:

To address these issues, place a 915 bar adjacent to the waste chute above the bin. This preventive measure will effectively prevent waste buildup, eliminating blockages and reducing the risk of electrostatic discharges to operators.

Furthermore, installing a Meech 915 bar between the conveyor and sheeter helps disperse electrostatic charges. This prevents the concentration of charges caused by the 915 bar on the metal frame of the conveyor and sheeter, ensuring a smoother printing process. 

Meech 915 bar

Static Problems Caused During Stacking Of Shingled Sheets On A Sheeting Machine

Problem:

When delivering single or overlapped (shingled) sheets onto a conveyor or stack, static electricity causes the sheets to stick together, leading to collating problems. This issue is particularly pronounced in shingle-type delivery systems, necessitating the elimination of static charges from individual sheets.

Solution:

To address this problem, consider using either a single or multiple 261 DC ionizing nozzles with a flexible air output nozzle. Proper positioning allows the ionized air generated by the 261 to flow between the sheets during the delivery process. Additionally, strategically placing Model 915 bars ensures comprehensive and effective neutralization of static charges across the entire sheet width.

The flexible 261 DC ionizing nozzles can be positioned either below the conveyor roller or at the side of the sheets. Their adaptability allows for easy adjustment to suit the machine's requirements. This flexibility enables the installation of the 261 nozzle in positions that may not be feasible with alternative static elimination systems.

Meech 915 bar	261 DC ionizing nozzles

Controlling Static Discharges During Paper & Board Manufacture

Problem:

Static charges generated during the calendar drying and pressing of paper pose a hazard, as uncontrolled static can lead to sparks. These sparks increase the likelihood of igniting paper dust, creating a fire risk.

Solution:

Implementing Meech 915 systems will effectively neutralize static charges, mitigating the risk of fires caused by static discharges.

Meech 915 bar

High Reject Rates During Ribbon Tacking In Newspaper And Magazine Web Converting

Problem:

During the manufacturing or printing process on paper and other materials, multiple webs of material are often brought together before the final cut/fold operation. However, the alignment of these webs can frequently deviate, leading to high reject rates after the cut/fold operation.

Solution:

Employing a 993R bar enables the introduction of a static charge to effectively 'pin' the collated webs together. This ensures that the webs remain in proper alignment for the cut/fold operation. The utilization of a 993R bar significantly reduces reject rates. As illustrated in the diagram, Meech 993R bar bars are positioned facing each other and connected to positive and negative IonCharge30.

993R Generator Bar	IonCharge30

Static Control on a Super Calender

Problem:

In the super calendering process, the web speed can reach up to 1200m/min, leading to a significant build-up of static charges. This static can become problematic during paper breaks, causing the 'tail' of the web to wrap around the rollers and potentially damaging the soft surfaces of the 8m wide rollers, resulting in substantial replacement costs.

Solution:

To address this issue, install 8 pairs of interconnected 915 AC bars, each 2m long, to cover the web before each of the relevant 8 roller pairs. This configuration effectively reduces static charges to a low level. Consequently, during paper breaks, the reduced static makes it less likely for paper tails to wrap around the rollers, significantly decreasing the risk of expensive damage to the rollers.

Meech 915 bar

Material Sticking To The Walls Of The CyClone During Waste Reprocessing

Problem:

When waste material is transferred to a reprocessing plant, it may accumulate static charges due to friction during the transfer process. Consequently, the material adheres to the inner walls of the cyclone.

Result:

The accumulation of material on the cyclone walls leads to the formation of clumps, causing blockages in the grinder.

Solution:

Utilizing a Meech 913 flow tube effectively neutralizes the static charges, preventing jams.

Meech 913 flow tube

Preventing Blockages During Air Conveying Of Waste Trim

Problem:

The air separator at the baler was experiencing blockages caused by strips of trim from coffee filter production, primarily due to static charges.

Solution:

To address this issue, Meech 261 Ionizing nozzles were installed on the two ducts leading to the air separator. The success was evident with eight nozzles mounted in each 250mm diameter pipe, enabling the air separator to operate continuously without encountering clogs.

Considering the elevated position of the installation, the preference for the 261 Ionizing nozzles over a 913 FlowTube was based on minimizing the need for equipment cleaning as much as possible.

261 DC Ionizing Nozzles	913 FlowTube

ESD Damage Or Weakening Of RFID Tags During Die Cutting

Problem:

RFID tags, received on a reel and processed through unwinding and guillotining before application onto products, are prone to static discharges. These static charges, generated during the unwinding process, can exceed tolerance levels on RFID or security tags, leading to various associated problems:

1. Blowing the FRID chip, rendering it useless
2. Operators experiencing unpleasant shocks
3. Attraction of dust and other airborne contaminants

Solution:

To mitigate these issues, a solution involves deploying models 971 and 233v4 targeting the nip of the unwind and rewind rolls. This setup will bathe the reel in ionized air, effectively neutralizing any static charge on the reels and preventing electrostatic discharges that could result in EMP and chip damage. Additionally, further neutralization during the separation of the guillotine is necessary. This can be achieved by using Meech 261 DC Ionizing Nozzles to blow ionized air into the die, neutralizing it.

233v4	261 DC Ionizing Nozzles	Model 971

Preventing Damage Or Weakening Of RFID Tags Due To ESD

Problem:

When applying RFID tags to an adhesive web before laminating, there is a risk of generating electrostatic charges that can potentially damage or weaken the chip in the tag. Failure to control these charges may lead to field failures, product losses, and production disruptions.

Solution:

To address this issue, it is crucial to keep the adhesive web free of electrostatic charge during the transfer of the RFID tag. The process of removing the tag from the paper carrier can generate high levels of electrostatic charge. Installing a Meech 261 flexi nozzle to introduce a controlled airflow over the RFID tag as it separates from the paper carrier can serve a dual purpose. The airflow not only helps in the separation process but also produces a downward force, aiding in the adhesion of the label while neutralizing electrostatic charges.

Additionally, mounting a Meech 971 bar (1) under the web path is essential to control the electrostatic charge on the web during transfer and rewinding. A second Meech 971 bar (2) is required to neutralize the lamination before it is applied to the RFID tags and web, ensuring effective charge control throughout the process.

261 DC Ionizing Nozzles	Meech 971 bar

High Reject Rates During Manufacture Of Carrier Bags

Problem:

In the manufacturing of carrier bags, an extra layer of plastic is introduced around the handle area to enhance strength

During the sealing process, the additional plastic web has the potential to shift, leading to its placement in the wrong position. This results in elevated reject rates and a loss of production.

Solution:

To address this issue, a single Meech  993R Generator Bar can be installed opposite a grounded metal roller. The Meech  993R Generator Bar generates a controlled static charge, effectively 'pinning' the additional web in place and preventing it from deviating from the correct position.

For optimal performance, the Meech  993R Generator Bar is connected to an IonCharge30, ensuring a powerful pinning effect.

993R Generator Bar	IonCharge30

Static Pinning Gusset Into Flat Bag

Problem:

Conventional carrier bags are produced from a continuous material web, sometimes folded to create gussets along each side. Following the creation of gussets, the web proceeds through a sealing head to form individual bags.

A challenge arises as the web moves through the machine before reaching the sealing head – the folded gusset may shift out of shape. This is often due to the entry of air into the folded gusset, causing it to open up. Consequently, bags are sealed with an incorrect gusset, leading to wastage and production loss.

Solution:

To prevent the gusset from slipping out of position before sealing, a Meech 993R Generator Bar can be installed opposite a grounded metal roller. This setup effectively pins the gusset together, ensuring proper alignment before reaching the sealing stage. The result is accurate bag sealing, minimizing waste and reducing downtime. The 993R Generator Bars are connected to a powerful IonCharge30 generator for effective pinning.

993R Generator Bar	IonCharge30

Static Pinning on Side Weld Bag Handles

Problem:

In the production of bags using this method, a handle is created using an in-line punch that cuts a handle shape from the web just before the cut/seal head. The manufacturing process involves pulsing the web forward to the required length. During a momentary pause, a punch shapes the handle. However, when the web moves forward again, air can enter the plastic tube, leading to a jam at the sealing head.

Solution:

To address this problem, a Meech 993R Generator Bar static generator bar is positioned in line before the punch. It is synchronized with the punch to pulse 'on' and pin the web closed during the handle-shaping phase. This prevents the entry of air when the web moves forward, thereby avoiding jams at the sealing head. The 993R Generator Bar is connected to a powerful IonCharge30 for effective pinning.

993R Generator Bar	IonCharge30

Static Problems with Wicketing Machine Bagging Lines

Problem:

During the bag manufacturing process, numerous issues arise due to static charges, and in some cases, static charges are intentionally applied.

Area 1:

Static charges generated during the unwinding of material attract contamination, posing a significant concern for food packaging. Folding the web over the "A" frame traps static charges within the two layers.

Area 2:

• The addition of a gusset requires holding the material in place to prevent the gusset from misaligning
• A reinforcing strip of plastic for the handle section needs secure placement
• Punching a handle through the material can cause the bag to open and adhere to the punch

Area 3:

Static charges on the material entering the sealing and cutting process lead to sticking on rollers, causing feed issues onto the wicketing conveyor belts.

Area 4:

Static charges on bags placed onto pegs result in bags pushing apart and not hanging vertically. Uncontrolled static charges can lead to customer issues as bags fail to open properly. High static charges on individual bags create problems, especially on high-speed machines, at the bag collating area.

Solution:

Various antistatic systems have been assessed, with traditional solutions proving inadequate for newer high-speed machines. The recommended static control system for optimal production efficiency includes:

Area 1:

• Use a long-range ionizing bar like the 971-30 kV Pulsed DC bar to prevent contamination attraction
• Apply a 924IPS bar before folding to remove charges from the inside face of the web, minimizing static impact on the final product

Area 2:

• Apply a static charge using a 993R bar and generator to bond the gusset in position, preventing material movement
• Apply a static charge to the web and reinforcing strip using a 993R bar and generator to lock the layers temporarily before heat welding
• Apply a static charge to the top edge of the web using a 993R bar and generator to bond the material, preventing separation during punching

Area 3:

Use compact 915 AC bars for high-powered ionization, eliminating static charges generated during the production process.

Area 4:

Two Meech 971IPS bars are needed during wicketing. The first bar removes charges from bags on the wicketing arms, and the second, using compressed air, continuously blows ionization over bags on pegs, preventing charge regeneration during the application of the next bag onto the pegs.

Meech 971 bar	Meech 924IPS bar	993R Generator Bar	Meech 915 bar