Four-step plan for anti-static surface cleaning

Have you ever faced a situation where dust has adhered to the surface of plastic, rubber, glass or wooden parts and disrupted your production? If you're struggling to find a solution, SMC offers a proven approach that combats static problems during product cleaning.

Dust that adheres to parts during production is problematic because it can interfere with your manufacturing processes. It can affect the final appearance of your products and even impair their functionality. Static charge is often the culprit, making your attempts to clean with conventional methods completely ineffective.

If you want to improve production performance, reduce downtime and maintain quality, SMC has the solution. In this article, SMC presents the four main pillars for highly effective cleaning of surfaces affected by static electricity: ionization, filtration, blowing and suction.

Emphasis on ionization 

The first pillar in the process, ionization, has a dual function when applied for surface cleaning. On the one hand, neutralizing the static charge makes it easier to loosen dust particles. On the other hand, it prevents re-attraction of dust. Moreover, directing the ions to the cleaned surface using compressed air not only supports neutralization, but also fulfills the cleaning function by blowing away dust particles.

Choosing the optimal ionization solution depends on several factors. For example, if we are talking about manual cleaning, an ionization gun is a good option. However, for an application that requires semi- or full automation, a fixed system is the best solution. Of course, technical parameters such as discharge rate, ion balance and potential amplitude are crucial for certain applications. Nevertheless, generally the size of the surface/product to be cleaned will determine the need. Consider more targeted solutions such as nozzle ionizers, or a more comprehensive solution such as bar-shaped ionizers. Other factors to consider are available installation space and the need for external control of the ionization solution.

Provide clean compressed air

The second pillar, filtration of the compressed air used for blowing, is a very important but often overlooked or forgotten step. In computer terms, there is a saying that fits this perfectly: "garbage in, garbage out. When you introduce unpurified air, you inevitably blow impurities into every surface you try to clean. This wastes both time and money. 

Although the minimum purity class for ionizing solutions according to (ISO 8573-1: 2010) is 2.6.3, SMC recommends the use of higher classes, such as 1.4.1, for cleaning solutions to minimize the dispersion of contaminants such as dust particles, oil and moisture. To emphasize an important point, the use of a single, regular filter is definitely insufficient to achieve even the minimum required purity class (2.6.3). Essentially, the specified humidity level is not achievable without a special dryer. To filter the required size of dust particles and oil concentration, at the very least a mist separator is required in addition to the main filter.

Blow away inefficiencies 

Compressed air blowing combined with ionization is a great way to clean surfaces of products. Although ionizers use compressed air to blow, it can be useful to apply additional nozzles to increase cleaning efficiency. And it is very important to use nozzles, not just some orifices in the form of hose or tube, to achieve a greater pressure impact and therefore a better cleaning effect.

Another factor that supports successful surface cleaning is the choice between pulsed blowing and continuous blowing. By generating pulses, you achieve a greater number of impacts, which in turn allows for better separation of particles. You also save air (and the cost of generating air) because it is not consumed between pulses. With continuous blowing, there is only one impact, which would mean you would have to operate at higher pressures to achieve better results and at higher air velocities.

Instructions for extraction 

Finally, it is important not only to blow away the dust, but to collect and dispose of the cleaned particles of a product using an extraction system to prevent dirt from settling again on the product. If we blow but do not vacuum, we are simply removing dust without any control. For extraction, SMC recommends using vacuum units that provide an extraction flow rate three times higher than the air flow rate supplied (Duster Box unit, ZVB, offers this solution, for example). Depending on the application, the volume of air to be exhausted and the size of the area to be cleaned, it is sometimes more useful to use systems such as high-flow pumps.

For a comprehensive approach and technical guidance for the best solution for your antistatic cleaning process, SMC is ready to help, regardless of your type of application or industry. With its knowledge, it is adept at providing a solution that neutralizes the effects of static electricity and improves the quality of cleaned surfaces. As a result, you will benefit from increased productivity and less downtime, which will give a welcome boost to your OEE (Overall Equipment Effectiveness).