How it works
Electrostatic charges build up wherever materials are separated, rubbed or moved — particularly on non-conductive materials such as plastics, films or glass. Charged surfaces attract dust and particles from the ambient air, interfere with downstream process steps such as painting, printing or bonding, and can affect sensitive components through uncontrolled discharges.
Ionisation counteracts this effect in a targeted way: ionising devices generate positive and negative ions at electrode tips using high voltage. When these ions reach a charged surface, the charge is neutralised. Combined with compressed air — for example in ion guns — adhering particles are blown off in the same operation, without the residual charge immediately attracting them again.
TeSe relies on ionisation technology from its technology partner Simco-Ion and offers both hand-held and stationary solutions. For manual discharging and cleaning, the ion guns Cleanflex Easy, TopGun and Cobra are available in the TeSe shop.
Intelligent charge control: the IQ Easy platform
Today, electrostatics is not just neutralised but intelligently regulated: the IQ Easy platform from Simco-Ion automatically adapts charging and discharging to the values measured in the process — sensors detect residual charge and the devices adjust in real time. As the central controller, the Smart SLC (Simco-Ion Logic Controller) connects up to 84 IQ Easy devices; access is via common control protocols over fieldbus (e.g. EtherNet/IP, ProfiNet) directly from the machine control — or browser-based via laptop, tablet and smartphone. The proven Manager IQ Easy system remains available. Central monitoring and real-time optimisation improve production quality and reduce downtime.
Beyond discharging: targeted charging and measurement
The same technology also masters the opposite direction. In in-mould labelling (IML) — a strength of Simco-Ion — targeted static charging holds the decorative label precisely against the inner mould surface during injection moulding: exact placement, efficient process. Electrostatics also works as a measurement technique: if the charge from a charging bar arcs through a flaw, it can be used to detect film defects and measure perforations — reliable inline quality control in film processing.
Advantages
- Reduces dust attraction on charged surfaces, and with it rework and rejects
- Dry process without chemicals, no drying steps required
- Discharging and blowing off adhering particles in a single operation
- Hand-held devices for the workstation, stationary systems for integration into production lines
- Reduces the risk of uncontrolled electrostatic discharges on sensitive assemblies
- IQ Easy platform: automatic adaptation of charging and discharging to measured process values
- Connection to machine controls via common fieldbus protocols (e.g. EtherNet/IP, ProfiNet)
Typical applications
- Plastics processing: discharging and cleaning injection-moulded parts before assembly or packaging
- Painting, printing and coating: low-particle surfaces prior to application
- Film and print processing with charge-related handling problems
- Assembly and packaging processes where adhering dust impairs quality
- Workstations with ESD-sensitive components
- In-mould labelling (IML): targeted charging fixes labels in the injection mould
- Inline quality control: film-defect detection and perforation measurement via charge breakthrough
Test the process at TeSe
We will verify together, on your own parts, whether ionisation solves your dust or charging problem: 1–2 hours of testing free of charge. In-depth feasibility studies: CHF 1’200 per day, 50% credited towards a machine purchase.
Documents & videos for this process
Datasheets & brochures
Videos
Technology Partner · Simco-Ion