Knowledge Base
What is Static Electricity?
When a material holds a net electrical charge — either positive or negative — it is said to have a static charge. Unlike current electricity that flows through conductors, static charges remain on surfaces until discharged. The rate of dissipation depends on the material's resistance: plastics retain charges for extended periods, while earthed metals discharge almost instantly.
How Static Charges Form
Static electricity is generated through three primary mechanisms. Friction occurs when two materials rub together — surface electrons transfer from one to another depending on each material's position in the Triboelectric Series. The harder the materials are pressed together and the faster the rubbing, the greater the charge generated. Separation works similarly: when bonded materials are pulled apart, electrons adhere to one surface. The faster the separation, the higher the charge — a common occurrence when plastic webs move over Teflon-coated rollers.
Induction occurs when materials are exposed to strong electric fields from nearby charged objects. Surface electrons are carried away through ionisation of the air, leaving the material charged. This is why operators working near charged materials can become charged themselves, experiencing shocks when touching earthed objects. Additionally, temperature changes play a role — as materials cool after processes like injection moulding, internal charges migrate to the surface, creating significant static.
Factors That Amplify Static
Material type is a primary factor. Some materials charge more readily than others — acetate gains charge very readily while glass charges less easily. A material's position in the Triboelectric Series determines whether it charges positively or negatively depending on what it contacts. Humidity is equally critical: drier environments produce dramatically higher static levels because atmospheric moisture normally provides a conductive path for charges to dissipate to earth.
Repetition compounds the problem — a plastic web passing over multiple Teflon rollers accumulates charge after each roller. The battery effect means many individually charged items (like stacked plastic sheets) can combine to produce extremely high voltages. Static levels of 100kV are common in industry, compared to mains voltages of just 220V. While mains voltage is considered dangerous, static discharges are usually brief — but their effects can be devastating.
Industrial Impact
Problems Caused by Static
Static electricity causes four major categories of problems in manufacturing, with a fifth specifically affecting the electronics industry.
Dust Contamination (ESA)
Charged surfaces attract airborne particles, contaminating painted finishes, food and pharmaceutical products, printing plates, and film surfaces. Even microscopic contamination can cause rejects in quality-sensitive industries.
Material Misbehaviour
Charged webs, fibres, and sheets stick to themselves or equipment, misroute, or repel each other. Automated processes are particularly vulnerable — bottles topple on conveyors, polystyrene trays collapse when stacked, and labels misalign during application.
Operator Shocks
Exiting a vehicle generates approximately 15kV of static. Industrial plastic processing creates 20–60kV charges. While usually brief and safe, severe shocks can cause operator collision with machinery or entrapment — a growing safety concern.
Fire & Explosion Risk
In explosive atmospheres, static discharges carry sufficient energy for ignition. Accumulated charges on grounded objects or isolated conductors can spark, potentially destroying entire production facilities. ATEX-certified equipment is mandatory in such zones.
ESD Component Damage
Modern semiconductors can be destroyed by voltages as low as 5V. Hard drive read heads fail below 3V. Worse than immediate failure is latent damage — components pass testing but fail in the field, the most costly outcome in terms of repair and reputation.
Production Downtime
Static-related jams, misfeeds, and contamination cause unplanned stoppages even on modern production lines. The cumulative effect of reduced speed, increased rejects, and maintenance interventions significantly impacts output and profitability.
Who Is Affected
Industries Impacted by Static
Static electricity affects virtually every manufacturing sector that works with non-conductive materials.
Packaging & Labelling
Printing & Converting
Plastics & Injection Moulding
Automotive Manufacturing
Pharmaceutical & Medical
Food & Beverage
Electronics & Semiconductors
Textiles & Film
How We Solve It
Methods of Static Elimination
The fundamental principle is the same regardless of technique: deliver electrons to positive surfaces or remove them from negative surfaces. This is achieved through ionisation of the surrounding air.
AC & Pulsed DC Ionisation
AC eliminators use high voltage (4.5–7kV) at mains frequency to produce alternating clouds of positive and negative ions at emitter pin tips. These ions are attracted to oppositely charged surfaces, delivering or removing electrons to achieve complete neutralisation. Pulsed DC eliminators operate at lower frequencies (0.5–20Hz) with dedicated positive and negative emitter pins. The longer pulse duration creates larger ion clouds with reduced recombination, enabling effective neutralisation at much greater distances — ideal for wide webs and fast processes.
Measurement & Diagnostics
Accurate measurement is essential for selecting the correct equipment. The Meech 983v2 Static Locator measures surface voltage by detecting the electric field at a calibrated distance of 150mm. The 984v2 Ion Sensor verifies ionising bar performance. For applications requiring precise balanced neutralisation — particularly in electronics where voltages as low as 5V cause damage — advanced systems like the Hyperion™ range with Ion Current Monitoring ensure exact neutralisation to within a few volts of earth potential. Hyperion SmartControl Touch takes this further by enabling real-time remote monitoring and adjustment of all connected ionising bars from a single interface.
Free Service
Free On-Site Static Measurement
Not sure if static is affecting your production? We offer complimentary on-site measurements using professional Meech diagnostic instruments. Our engineers will assess your line, identify problem areas, and recommend targeted solutions — with no obligation. Learn more about our services.
Book a Free MeasurementTest Meech Equipment on Your Production Line
Multi-day demo installations with cleaning, drying, and cooling systems. No commitment.
×
Meech
All products are designed and manufactured by Meech International in the United Kingdom.
Animat is the authorised regional partner for Slovenia and Croatia.