Why does the film electrify during processing and how can this be remedied?

Problem with electrifying film

During the production and processing of film - be it packaging, technical or shrink film - excessive electrification often occurs. This phenomenon not only hinders the work of operators, but also leads to problems with product quality, contamination or uncontrolled adhesion. Where does this problem come from and how can it be effectively solved?

Why does the film electrify?

• Friction and layer separation

  When films are unrolled, sealed, cut or laminated, surfaces with different electrostatic potentials come into contact and separate. This generates electrostatic charges.

• High machine speeds

  The faster the material moves through the machine, the greater the friction and the more electrostatic charge builds up.

• No grounding or ionisation

  Machines and rollers that do not have proper earthing or lack a charge neutralisation system promote electrification of the film.

• Dry air

  In low humidity conditions (below 40%), air conducts charges less well, which favours their accumulation on the surface of plastics.

Why is this a problem?

• Dust and particle attraction

  The electrified film acts as a magnet for dust and particles from the environment - degrading product quality and increasing waste.

• Welding problems

  Accumulated charges can interfere with the precise welding process or cause arc jumps.

• Adhesion to machine components

  Electrified film can stick to knives, guides or rollers, leading to jams and machine breakdowns.

• ESD hazard

  In some cases - especially when processing electronic materials - the charges can damage delicate components.

How can this be remedied?

• Use of deionisers

  The most effective solution is to install deionising electrodes or ionising strips along the path of the film. The ions emitted neutralise excess electrostatic charges.

• Maintaining adequate humidity

  The introduction of air humidifiers in production halls increases air conductivity and reduces the tendency for film to become electrified.

• Grounding of all track components

  Rollers, guides, tables and guards should be conductive and correctly earthed to dissipate charges on a regular basis.

• Reducing speed and optimising film guidance

  Sometimes a change in angle of attack, a reduction in friction or a modification of the guidance is all that is needed to reduce charge generation.

What equipment helps?

• Ionisation electrodes JO-96

  Strip, deionising electrodes used in the packaging and film industry - for mounting at the film track, powered by a high-voltage generator.

• High-voltage power supplies TZWM

  Working in conjunction with the electrodes, they provide the energy to emit positive and negative ions, ensuring effective neutralisation.

• Cargo monitoring systems

  They enable continuous measurement of the electrostatic potential and signal when safe values are exceeded.

Summary

Electrification of films is a common problem in industry, but one that can be effectively managed. By using deionising electrodes, proper earthing and controlling environmental conditions, the quality and stability of the converting process can be significantly improved. The investment in a deionisation system pays for itself quickly - in the form of less waste, greater repeatability and safety in production.