State of the Art Static Control for Flexible Packaging • Presented by: Kelly Robinson, PE, PhD Electrostatic Answers K. Robinson Static Control for Flexible Packaging 1/49 Speaker Introduction Kelly Robinson, PE, PhD, Owner – Electrostatic Answers LLC [email protected] 585-425-8158 • www.ElectrostaticAnswers.com • Business Owner - Founded Electrostatic Answers, an engineering consulting company dedicated to eliminating injury and waste from static electricity. • Industrial Experience – working over 35 years solving static problems in web conveyance and solvent handling manufacturing operations. • Award Winning Engineer Institute of Electrical and Electronics Engineers (IEEE) Fellow cited for “contributions to electrostatic performance of mfg. processes” US Nat’l Fire Protection Assoc. (NFPA), Chair – Committee on Static Electricity Assoc. Int’l Metallizers Ctrs & Lamintors (AIMCAL) - Technical Consultant • Inventor with 15 US patents. • Associate Editor for the Journal of Electrostatics, a leading peer reviewed journal (Elsevier publication) • Contributing Editor, Paper Film & Foil Converter, author of “Static Beat” column on static control. K. Robinson Static Control for Flexible Packaging 2/49 Agenda 1.Introduction – Static control is important 2.Design Principles 3.Measurements – Static Survey 4.Best Practice Static Control 5.Manage Static Performance 6.Summary K. Robinson Static Control for Flexible Packaging 3/49 1. Controlling static is important! 2. Prevent shocks. 1. Eliminate ignitions. 3. Minimize deposition of airborne contaminates K. Robinson Static Control for Flexible Packaging 4/49 1. Controlling static is important! 5. Prevent static problems Image courtesy in customer applications of (sheet sticking, process jams). PSA Label Release liner 4. Prevent spark damage to sensitive coatings such as silicone release liners. (Sparks damage the coatings allowing PSA labels to stick to liners). K. Robinson Static Control for Flexible Packaging 5/49 Agenda 1.Introduction – Static control is important 2.Design Principles – SOTA Static Control 3.Measurements – Static Survey 4.Best Practice Static Control 5.Manage Static Performance 6.Summary K. Robinson Static Control for Flexible Packaging 6/49 2. Design Principles Think “Risk, Threat, and Countermeasure” (FMEA – Failure Modes & Effects Analysis) Static THREAT THREAT (static charge) RISK (static charge) (flammable Fault mixture) Fault A “threat” penetrates to a “risk” only when there are 2 simultaneous The system effectively faults; one in the outer layer and shields a “risk” from a “threat” when there is a single fault. one in the inner layer. A4 Protect risk areas with “2-layer,” fault tolerant static control systems K. Robinson Static Control for Flexible Packaging 7/49 Question 1: With “fault tolerant” design, are critical functions maintained even when any single system components fails? K. Robinson Static Control for Flexible Packaging 8/49 Answers 1: YES! With a “fault tolerant” design, critical functions are maintained when any single system component fails. K. Robinson Static Control for Flexible Packaging 9/49 Agenda 1.Introduction – Static control is important 2.Design Principles 3.Measurements Electrostatic Fieldmeter Static Survey 4.Best Practice Static Control 5.Manage Static Performance 6.Summary K. Robinson Static Control for Flexible Packaging 10/49 2.1 Electrostatic Fieldmeter Carl Friedrich Gauss was a German mathematician and scientist who contributed significantly to many fields, including number theory, statistics, analysis, differential geometry, geodesy, electrostatics, astronomy and optics. http://en.wikipedia.org/wiki/Carl_Friedrich_Gauss Area A E σ Gaussian S,TOP Surface +++++ +++++ Vo l u me V σ S,BOTTOM Johann Carl Friedrich Gauss Born: 30 April 1777 Died: 23 February 1855 Gauss’ Law http://upload.wikimedia.org/wikipedia /commons/3/33/Bendixen_-_ Electric flux penetrating Carl_Friedrich_Gau%C3%9F%2C_1828.jp the surface is proportional g to the charge enclosed. A3 K. Robinson Static Control for Flexible Packaging 11/49 2.1 Electrostatic Fieldmeter (Work horse instrument for solving static problems!) Electrostatic KV measures the fieldmeter E=− 5 electric field in from net charge Charged surface Static charge –– – – – Web ––– – Charged surface Note: Fieldmeter readings may be taken from either side of the web. A3 K. Robinson Static Control for Flexible Packaging 12/49 Question 2: Do electrostatic fieldmeters respond only to the charges on one surface or to the total number of charges on the web? K. Robinson Static Control for Flexible Packaging 13/49 Answers 2: TOTAL NUMNBER OF CHARGES! Electrostatic fieldmeters respond to all of the charges inside the control volume, which is the total number of charges on the web. K. Robinson Static Control for Flexible Packaging 14/49 2.1 Electrostatic Fieldmeter (Work horse instrument for solving static problems!) Monroe 282IS KV/in Simco FMX-004 3M718 KV/in KV/in Meech 983v2 Fraser EX715 KV/(15cm) KV/(10cm) Monroe 257D KV/cm Note: The operator must be grounded for reliable readings. Wear static dissipative shoes, touch grounded metal, or use a grounding cable. K. Robinson Static Control for Flexible Packaging 15/49 Question 3: When using fieldmeters from different vendors, are the displayed static levels the same number? K. Robinson Static Control for Flexible Packaging 16/49 Answers 3: NO! Static meters from different vendors use different units for electric field so the displayed readings must be converted to consistent units. K. Robinson Static Control for Flexible Packaging 17/49 2.1 Measurements Reliable Static Measurements An electrostatic fieldmeters is the work horse for diagnosing and solving static problems. Static Reading E “GeeZE” Rules charges for fieldmeter on film Radius = 2G readings: surface Static 1. Ground the meter operator. Gap 2. Zero the + + + G + + + fieldmeter. Insulating film + + + + + 3. Empty the such as PET, BOPP, PTFE “measurement Measurement sphere.” spherical In your “mind’s eye,” draw a dot the web below the fieldmeter. The dot becomes the center of a sphere that expands to a radius of 2G. For reliable readings, the “measurement sphere” must be empty (except for the meter and your hand). K. Robinson Static Control for Flexible Packaging 18/49 Agenda 1.Introduction – Static control is important 2.Design Principles 3.Measurements Electrostatic Fieldmeter Static Survey 4.Best Practice Static Control 5.Manage Static Performance 6.Summary K. Robinson Static Control for Flexible Packaging 19/49 3.2 Measurements – Static Survey Dryer 1. Take fieldmeter reading Dry Dry Out on each accessible Guider In - web span, - unwinding roll(s), and 1st coat - the winding roll(s). Chill contact Out CT CT SB Out Inspect Coat Out In Chill SD contact CT SB Dance Chill Guide Out Out Out Dance Coat Out Out Dancer Wind Corona treater Span Wind Unwind Inspect Dancer Dance Coat In In Nip Contact Inspect Nip roller Wind Unwind Unwind Coater Out SB roll roll span 2. At each location, record 3. Plot readings on a “Stoplight Chart” maximum, average, and to document static performance. minimum readings. K. Robinson Static Control for Flexible Packaging 20/49 3.2 Measurements – Static Survey Electrostatic Fieldmeter MeasurementsDate 4/23/2019 Measurement # Location Min Max Average Range Shift Static surveys 1Unwind Roll -7.5 -2.5 -5.0 5.0 #N/A might have 2Unwind-Span -1.3 0.0 -0.6 1.3 #N/A 40 or 50 3 Dance In -2.0 -0.5 -1.3 1.5 -0.6 4Dance Out -3.0 -1.3 -2.1 1.8 -0.9 measurements. 5Corona Trt Out 12.5 22.5 17.5 10.0 19.6 6Corona Trt SB Out -1.0 0.0 -0.5 1.0 -18.0 7Coat-In -1.8 -1.0 -1.4 0.8 -0.9 8 Coat-Out -1.0 0.5 -0.3 1.5 1.1 Let’s plot 9Dry-In -1.5 0.0 -0.8 1.5 -0.5 10 Dry-Out -16.0 -6.5 -11.3 9.5 -10.5 the readings 11 Guide-Out -21.0 -11.5 -16.3 9.5 -5.0 to analyze 12 Coat Contact-Out 10.0 15.0 12.5 5.0 28.8 the data 13 Chill Out 15.0 20.0 17.5 5.0 5.0 14 Inspect In 2.5 5.0 3.8 2.5 -13.8 15 Inspect Out 1.3 3.8 2.5 2.5 -1.3 16 Nip In 0.0 2.5 1.3 2.5 -1.3 17 Nip Out -10.0 -7.5 -8.8 2.5 -10.0 18 Nip SB Out -1.3 0.0 -0.6 1.3 8.1 19 Dance Out -3.8 -2.5 -3.1 1.3 -2.5 20 Wind Span -4.5 -3.0 -3.8 1.5 -0.6 21 Wind Roll -10.0-5.0-7.55.0#N/A K. Robinson Static Control for Flexible Packaging 21/49 3.2 Static Survey – Stop Light Chart 25 High Red Zone; ±15 KV/in < E 20 15 Static Nip roller dissipator added charge. 10 Moderate Yellow Zone; ±5 < E < ±15 KV/in OK Static dissipator OK 5 Low Green Zone; E < ±5 KV/in 0 -5 Dryer , guider, -10 Corona Treater idler touching coating added + charge. & chill roller all SB OK added charge. -15 Electrostatic Fieldmeter Reading [KV/in] -20 -25 1. Static Performance: Keep reading in the “Green Zone.” K. Robinson Static Control for Flexible Packaging 22/49 Question 4: What is the common “industry standard” fieldmeter reading for low static? K. Robinson Static Control for Flexible Packaging 23/49 Answers 4: The electric field E should not exceed ±5 KV/in or ±2 KV/cm K. Robinson Static Control for Flexible Packaging 24/49 3.2 Measurements – Source Chart Dryer 1. Take fieldmeter reading Dry Dry Out on each accessible Guider In - web span, - unwinding roll(s), and 1st coat - the winding roll(s). Chill contact Out CT CT SB Out Inspect Coat Out In Chill SD contact CT SB Dance Chill Guide Out Out Out Dance Coat Out Out Dancer Wind Corona treater Span Wind Unwind Inspect Dancer Dance Coat In In Nip Contact Inspect Nip roller Wind Unwind Unwind Coater Out SB roll roll span 2.