axisvalence - Tumblr blog

axisvalence · 2 months ago

Text

Benefits of Static Eliminators in the Printing Industry

In high-speed industrial printing environments, static electricity is more than a minor inconvenience. It poses a significant threat to product quality, operational efficiency, and workplace safety. In the printing industry, where materials like plastic films, paper, and textiles are rapidly moved through presses, electrostatic charges naturally build up due to friction. These charges can lead to multiple complications including print misalignment, dust attraction, operator shock, and even fire hazards in solvent-rich environments.

To address these challenges, static eliminators play a crucial role in maintaining a safe, productive, and high-quality printing environment. In this article, we will explore the benefits of using static eliminators in the printing industry, the different types available, and how they align with specific B2B requirements.

Understanding Static Electricity in Printing

Static electricity is generated when two surfaces come into contact and then separate, causing electrons to transfer and creating an imbalance. In the printing industry, this happens frequently between substrates (paper, films) and rollers or belts. When left unneutralized, this electrostatic charge can result in issues such as:

Ink misplacement or smudging

Sheet misfeeds or jams

Dust and particle attraction to substrates

Shock to machine operators

Spark generation leading to fire hazards

Role of Static Eliminators in Printing

Static eliminators, also known as static dischargers or anti-static devices, neutralize static electricity using ions of opposite polarity. These ions are introduced into the environment using a variety of devices including static eliminating bars, ionizing air knives, ionizing nozzles, and blowers. The following are the major benefits of implementing static eliminators in printing operations:

Improved Print Quality

Uncontrolled static can lead to print defects like smearing, misregistration, and inconsistent ink transfer. By neutralizing electrostatic charges on the substrate, static eliminators ensure uniform ink deposition and alignment. This is particularly critical in CI flexo and rotogravure printing machines where registration precision is essential.

Increased Production Speed

Static electricity often leads to machine stoppages due to sheet misalignment or paper jams. These interruptions slow down production and increase downtime. Static eliminators help stabilize substrate flow and reduce stoppages, allowing presses to operate at optimal speeds, even up to 1000 m/min.

Enhanced Operator Safety

Electrostatic discharge (ESD) can cause painful shocks to operators, particularly in dry conditions or with synthetic substrates. Anti-static bars and Air ionizers discharge these build-ups, ensuring a safer work environment. Moreover, shock-less and spark-free static eliminators prevent workplace injuries and associated liabilities.

Dust and Contaminant Reduction

Static charges attract airborne dust and fibers, leading to contamination of the substrate and defects in the final print. Active static eliminators (AC or DC) in combination with ionizing air knives or blowers remove both the static charge and the contaminants from the surface.

Solvent Safety in Explosive Environments

In solvent-based printing operations, uncontrolled static sparks can ignite flammable vapors. ATEX-certified static eliminators are specially designed for use in Ex-hazardous areas such as rotogravure, lamination, and flexo printing units. These ensure compliance with safety regulations and protect both personnel and assets.

Minimized Material Waste

Misaligned prints, smudging, and debris contamination often result in material rejection and rework. With 100% print quality assurance provided by static eliminators, businesses can significantly reduce waste and lower production costs.

Adaptability Across Applications

Whether it is narrow web or wide web printing, coated or uncoated substrates, or even plastic moulding and textile processing, static eliminators are versatile tools. They are used in a variety of industrial printing setups including:

Gravure printing

Flexographic printing

Offset printing

Web converting lines

Inspection rewinders and slitter rewinders

Types of Static Eliminators Used in Printing

AC Static Eliminators These bars operate by producing positive and negative ions alternately using an alternating current. AC Static Eliminators are suitable for general industrial applications, especially where the target distance is short (20-100 mm).

DC Static Eliminators DC Static Eliminators provide constant polarity ions and are used in complex applications requiring long-range neutralization (up to 1000 mm). Ideal for fast-moving substrates and locations where mounting options are limited.

Passive Static Dischargers Made of conductive bristles, Passive static dischargers do not require power and work well in low-static environments or as a supplementary solution.

Ionizing Air Knives and Nozzles These combine airflow and ionization to blow off dust while neutralizing static. Perfect for cleaning plastic parts before printing or coating.

ATEX Certified Eliminators Specially built for hazardous zones, these static eliminators are compliant with ATEX safety norms and suitable for use in solvent-based operations.

Choosing the Right Static Eliminator for Your Printing Needs

For B2B buyers and plant engineers, selecting the right static control system depends on several factors:

Type of substrate

Web speed

Target distance from static bar

Installation space

Environment (solvent-based or water-based)

Power availability

It’s also essential to evaluate maintenance requirements, certifications (ATEX, CE), integration with existing systems, and ROI through reduced waste and downtime.

Incorporating Static Control in Complete Printing Workflows

For comprehensive process control, static eliminators should be integrated with other quality assurance tools like:

100% print inspection systems

Ink temperature controllers

Web viewing cameras

Surface cleaning devices

This holistic approach ensures that printing operations are efficient, defect-free, and scalable.

AxisValence: Your Trusted Partner for Electrostatic Control

AxisValence, a business unit of A.T.E. India, is a leading manufacturer and exporter of electro-mechanical solutions tailored for industrial automation and process improvement. With a strong focus on static control solutions, AxisValence offers an extensive product portfolio including:

AC and DC static eliminators

ATEX certified static bars

Passive dischargers

Ionizing air knives, guns, and nozzles

Web cleaners and surface cleaning systems

Ink handling solutions

Web viewing and print inspection systems

Heat recovery and solvent recovery units

With robust manufacturing capabilities, certified safety standards, and deep domain expertise, AxisValence has earned the trust of printing, packaging, textile, and plastics industries globally. From enhancing print quality to reducing material waste and improving safety, AxisValence is your strategic partner in achieving operational excellence.

Need more clarity on the best static eliminator for your printing line? Explore AxisValence.com or get in touch with our experts for a tailored consultation.

0 notes

axisvalence · 2 months ago

Text

Comprehensive Industrial Solutions by AxisValence: Advancing Productivity, Safety, and Efficiency

In today’s fast-paced manufacturing world, industrial productivity is driven by precision, consistency, safety, and compliance. Whether it’s printing, packaging, converting, textiles, plastics, or pharmaceuticals—modern production lines demand advanced electro-mechanical systems that minimize waste, ensure operational safety, and improve overall efficiency.

AxisValence, a business unit of A.T.E. India, addresses this demand with a complete range of industrial automation and enhancement products. From static elimination to print quality assurance, ink management, and solvent recovery, AxisValence solutions are engineered to optimize each critical point in the production cycle.

This article provides an overview of the key technologies and systems offered by AxisValence across its diverse portfolio:

Electrostatics: Managing Static for Quality and Safety

Electrostatics can compromise product quality, disrupt operations, and pose serious safety hazards, especially in high-speed processes involving films, paper, textiles, or volatile solvents. AxisValence offers a complete suite of static control solutions:

ATEX AC Static Eliminators: Certified for use in explosive or solvent-heavy environments such as rotogravure or flexo printing lines.

AC and DC Static Eliminators: Designed for long-range or close-range static charge neutralization across a range of substrates.

Passive Static Dischargers: Cost-effective, maintenance-free brushes for light-duty static elimination where power isn't available.

Air-based Static Eliminators / Ionisers: Use ionized air streams for dust blow-off and static removal, ideal for hard-to-reach areas.

Static Measurement & Online Monitoring: Includes handheld meters and IoT-enabled monitoring systems for real-time control and diagnostics.

Electrostatic Charging Systems: Generate controlled static charges for bonding or pinning applications in laminating or packaging lines.

Electrostatic Print Assist (ESA): Enhances ink transfer in rotogravure printing by improving ink pickup and registration.

Camera-Based Web Videos for Print Viewing: Real-Time Visual Inspection

High-speed printing applications require instant visibility into print quality. AxisValence’s ViewAXIS systems are high-performance, camera-based web viewing solutions:

ViewAXIS Mega: Entry-level system with high-resolution imaging for real-time visual inspection.

ViewAXIS Giga: Equipped with 14x optical zoom and X-ray vision for deeper inspection of layered prints.

ViewAXIS Tera: Full repeat system with a 55” display, allowing operators to monitor and inspect the complete print layout in real-time.

Camera-Based Web Videos for Print Viewing systems help identify print errors like registration issues, smudging, or color inconsistencies early in the production run—minimizing rework and improving efficiency.

100% Inspection Systems: Intelligent Defect Detection

Modern converters and packaging companies require automated systems that can identify microscopic flaws at high speeds. AxisValence’s DetectAXIS systems use AI-based image processing and line scan cameras for 100% inspection:

DetectAXIS Print: Identifies printing defects such as streaks, misregistration, color deviation, and missing text at speeds up to 750 m/min.

DetectAXIS Surface: Designed for detecting surface anomalies—scratches, gels, holes, fish-eyes—on films, textiles, and nonwovens.

Real-time alerts, digital roll-maps, and adaptive detection improve quality control while reducing material waste and production downtime.

Ink Handling Systems: Consistent Ink Quality and Reduced Waste

Stable ink flow and temperature directly impact print quality and solvent consumption. AxisValence’s Valflow range ensures optimal ink conditioning through:

Ink Filters: Eliminate contaminants like metallic particles, fibers, and dried pigments that can damage cylinders or cause print defects.

Ink Pumps & Tanks: Efficient centrifugal pumps and round stainless-steel tanks designed for continuous ink circulation and minimal ink residue.

Ink Temperature Stabilisers (ITS): Automatically control ink temperature to prevent viscosity drift and reduce solvent evaporation—delivering consistent print shade and odor-free operation.

Valflow Ink handling solutions are ideal for gravure and flexographic printing applications.

Print Register Control Systems: Precision Alignment in Every Print

Maintaining precise print registration control systemis critical in multi-color printing processes. AxisValence offers two specialized systems:

AlygnAXIS: For rotogravure presses, using fiber optic sensors and adaptive algorithms to deliver real-time register accuracy.

UniAXIS: A versatile controller for print-to-mark, coat-to-mark, and cut-to-mark applications—both inline and offline.

These controllers reduce waste, enhance print alignment, and speed up setup during job changes.

Safety and Heat Recovery Systems: Energy Efficiency and Explosion Prevention

Solvent-based processes require strict monitoring of air quality and heat management to meet compliance and reduce operational costs. AxisValence provides:

NIRA Residual Solvent Analyser: Lab-based gas chromatography system for quick analysis of residual solvents in films.

Air-to-Air Heat Exchangers (Lamiflow): Recover and reuse waste heat from drying processes—improving energy efficiency.

LEL Monitoring and Recirculation Systems: Ensure solvent vapor concentrations stay within safe limits in enclosed dryers using flame ionization or infrared detection.

Together, safety and heat recovery systems ensure both environmental safety and process optimization.

Surface Cleaning Systems: Contaminant-Free Production Lines

Particulate contamination can ruin coating, lamination, and printing jobs. AxisValence offers contactless surface cleaning systems that combine airflow and static control:

Non-Contact Web Cleaners: Use air curtains and vacuum to remove dust from moving substrates without physical contact.

Ionising Air Knives: High-velocity ionized air streams neutralize static and clean surfaces entering finishing zones.

Ionising Air Blowers: Cover larger surfaces with ionized air to eliminate static and debris.

Ionising Nozzles & Guns: Handheld or fixed, these tools offer targeted static and dust elimination at workstations.

Waste Solvent Recovery: Sustainable Ink and Solvent Reuse

Reducing solvent consumption and improving environmental compliance is critical for modern converters. AxisValence partners with IRAC (Italy) to offer:

Solvent Distillation Systems: Recover usable solvents from spent ink mixtures, reducing hazardous waste and cutting costs.

Parts Washers: Clean anilox rolls, gravure cylinders, and components through high-pressure, ultrasonic, or brush-based systems.

Waste solvent recovery systems offer a quick ROI and support zero-waste manufacturing goals.

Why Choose AxisValence?

AxisValence combines decades of industrial expertise with innovative product design to deliver reliable, safe, and efficient solutions for manufacturing processes. With a product portfolio spanning:

Electrostatics & Static Control Systems

Web Viewing & Print Inspection Solutions

Ink Handling and Conditioning Equipment

Heat Recovery and Air Quality Monitoring

Surface Cleaning Technologies

Waste Solvent Management

…AxisValence serves diverse industries including printing, packaging, plastic and rubber, textile, pharma, and automotive.

From single-device retrofits to complete system integration, AxisValence enables manufacturers to improve output quality, reduce waste, meet safety norms, and gain a competitive edge.

Explore our full product range at www.axisvalence.com or contact our sales network for a customized consultation tailored to your industrial needs.

youtube

#Youtube

2 notes · View notes