It was a humid afternoon on a flexible packaging shopfloor when the operator noticed something wasn’t right. Sparks were visible on the substrate, and he was getting continuous mild shocks. Dust also clung stubbornly to the substrate. He sensed that static charges were spiking!
Static is a familiar issue in printing, coating and converting industries. If unmanaged, it attracts dust and contaminants, causes sheet cling, leads to substrate handling issues and, in solvent laden environments, poses a serious safety risk. Controlling static makes all the difference. The only debate is whether to install passive or active static control solutions.
Understanding passive static control
Passive methods include grounding brushes, tinsel, conductive rollers and carbon fibre brushes. They are simple, low-cost alternatives, not requiring a power supply. In applications where static levels are low, passive solutions may be adequate.
In printing and converting operations, substrates running at high speeds repeatedly come into contact with and then separate from rollers. This continuous contact and separation generates static charges on the substrate. At the same time, due to the nature of gravure printing and coating, flammable solvents and vapours are often present on the shopfloor. If an uncontrolled static discharge occurs, it can ignite these vapours, leading to fire or explosion risks that endanger operators and plant assets.
Passive static eliminators are not effective enough in high-speed environments and cannot neutralise high levels of static build-up completely. Hence, they are not suitable for printing and converting applications.
How active static control works
Active static control systems (with and without air) generate positive and negative ions. When these ions are introduced to the charged surface, static charge is neutralised instantly.
Unlike passive devices, active static eliminators do not rely on physical contact, making them suitable for sensitive substrates as well.
Choosing the right approach
There is no one-size-fits-all answer. Passive static control can be useful for simple applications, short runs or as a supplementary measure. Active static control, however, is suited and strongly recommended for demanding industrial environments where quality, productivity and safety are non-negotiable.
The takeaway
After installing static eliminators on the printing machine, the sparks were gone and the risk was brought under control. The substrate ran smoothly, operators could work without shocks, and the immediate danger of ignition in a solvent-rich environment was eliminated. Static control, in this case, wasn’t about optimisation—it was about protecting people, preventing incidents, and ensuring the shopfloor remained a safe place to work. When safety is at stake, choosing the right static control method becomes a critical decision, not an optional upgrade.
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