Static electricity might seem like a small annoyance to most people, but in industrial environments, it can be a serious problem. From damaging sensitive components to increasing the risk of fire or explosion, uncontrolled static electricity poses significant safety and operational challenges. That’s why static control is a vital part of any industrial automation setup, and understanding how it works can help you protect your equipment, ensure product quality and keep your workplace compliant with safety standards.
In this blog post, we’ll break down what static control is, why it matters in industrial automation and how modern solutions like ionising air guns and AiRTX static control products can eliminate static-related issues from your operations.
What Is Static Electricity and Why Does It Occur in Industrial Settings?
Static electricity is generated when two materials come into contact and then separate, causing a transfer of electrons. This builds up an electrical charge that can discharge suddenly when it comes into contact with another object. In homes, it might cause a minor shock when touching a doorknob. In industrial settings, it can do far more damage. During processes such as material handling, plastic film unwinding, conveyor movement or powder mixing, static can build up quickly and go unnoticed until it causes a problem. Many industrial materials like plastics, paper and synthetic fibres are non-conductive, meaning they don’t easily release built-up charge.
That makes them particularly prone to static accumulation, especially in dry, low-humidity environments. In automation environments where high-speed production lines and robotic arms are involved, this static electricity becomes even more hazardous. The faster the movement and the more frequent the friction, the more static is generated.
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The Hidden Dangers of Uncontrolled Static Electricity
Uncontrolled static electricity can lead to a wide range of issues in industrial environments. Some of the most common problems include equipment malfunction, electrostatic discharge damage, product contamination, fire and explosion risks and reduced productivity. Electrostatic discharge (ESD) is the sudden flow of electricity between two objects and can easily damage circuit boards, sensors, actuators and other sensitive electronics used in electrical automation services. In environments where flammable gases, powders or vapours are present, a single spark from static discharge can ignite a fire or explosion. For example, in paint booths or grain handling facilities, static electricity must be strictly controlled. Static also attracts dust and contaminants. This can cause contamination in pharmaceutical or food packaging lines, reducing product quality and increasing rejection rates. Static build-up can cause films to cling, packaging materials to misalign or robotic grippers to fail, leading to increased downtime and slower production. Lastly, static build-up may affect the accuracy of sensors and measurement tools. Faulty data can lead to bad batch production or system errors.
Where Static Control Is Needed Most in Automation
Not every industrial environment faces the same level of static risk. However, several sectors and applications are particularly prone to issues. These include plastic and film processing, electronics manufacturing, printing and packaging, food and beverage production, pharmaceutical processing and powder handling operations. These industries often rely on high-speed automation systems where material movement, air flow and friction are unavoidable. That’s where static control solutions come into play.
What Is Static Control in Industrial Automation?
Static control refers to the use of products and techniques to neutralise, eliminate or safely discharge static electricity from people, equipment and materials. This can be achieved through a combination of passive and active solutions. Passive methods include grounding and humidity control. Grounding wires connect materials to the earth, allowing the charge to safely dissipate. Increasing air humidity can also reduce static build-up. However, these methods aren’t always sufficient, especially in environments with moving machinery or non-conductive materials. That’s why most advanced facilities rely on active static elimination devices such as ionising air guns, static bars and ionising blowers. These devices emit a balanced flow of positive and negative ions that neutralise the surface charge on materials, preventing ESD.
Top Static Control Products Used in Automation
Several key technologies are widely used to control static in industrial automation. These include ionising air guns, ionising bars, ionising blowers and power supplies. Ionising air guns deliver a focused stream of ionised air to neutralise static on irregular surfaces, awkward shapes or spot treatments. They are commonly used in assembly, electronics, and quality control tasks. Ionising bars are installed above conveyors or processing lines. They provide continuous static neutralisation across wide surfaces and are ideal for web processing, label application and plastic sheeting. Ionising blowers are used to create a curtain of ionised air in workspaces where large areas must be protected. They are useful in electronics manufacturing or packaging lines. Power supplies are essential for providing voltage to the ionising equipment. They must be matched with the correct devices to ensure balanced ion flow and effective neutralisation.
The Role of AiRTX in Static Control
Decode Automation partners with AiRTX to supply advanced static control solutions for Australian industries. AiRTX products are engineered to be maintenance-free, energy-efficient and easy to install. Their ionising air guns, static bars and accessories are used globally across manufacturing sectors to control static with precision and safety. AiRTX static eliminators use compressed air to deliver ionised air directly to charged surfaces, removing static at the source. Unlike passive devices, these active tools are effective even in fast-moving production environments where static levels change rapidly. For example, an AiRTX ionising air gun can be used to clean and neutralise plastic moulds before painting, preventing dust attraction and paint defects. AiRTX static control systems are also ideal for flexible applications. They can be integrated into existing electrical control systems or used as standalone units, offering flexibility to automation contractors and electrical automation companies looking for tailored solutions.
How Decode Automation Integrates Static Control
At Decode Automation, we understand that static control is not a one-size-fits-all solution. We take a consultative approach to assess your operation, identify high-risk areas and design custom systems using reliable products like AiRTX static eliminators. Our services include full integration with electrical control systems, cabinet cooler installations, air knife solutions, vacuum systems and machine guarding. As electrical automation specialists, we also ensure all components meet relevant Australian Standards for electrical safety and industrial automation. Our team collaborates with electrical engineers, safety consultants and machine guarding manufacturers to ensure that static control systems don’t interfere with productivity, worker safety or regulatory compliance. We work with clients across sectors including packaging, food processing, plastics and mining. Whether you’re looking for a standalone ionising air solution or complete integration with your automation electrical setup, we provide results-focused solutions that reduce risk and improve product quality.
Benefits of Proper Static Control in Automation
When static control systems are correctly designed and implemented, they deliver measurable benefits. These include reduced product defects and rejection rates, extended equipment lifespan, safer working environments, improved system reliability and better compliance with safety and quality standards. Fewer product defects mean less waste and greater customer satisfaction. Preventing electrostatic discharge also reduces wear on control systems and robotic parts. With fewer sparks and less dust accumulation, the risk of workplace accidents and contamination is significantly lowered. Accurate sensors and reliable data allow for better automation performance and fewer shutdowns. Businesses can meet industry certifications more easily and pass audits without issues.
Choosing the Right Static Control Partner
When selecting a static control provider, consider experience in automation, access to top-quality products and the ability to provide custom engineering. Decode Automation brings all of this together. We work with brands like AiRTX, offer custom integration, and understand the specific needs of industries in Sydney and across Australia. Whether you need a single ioniser or a fully integrated electrical and automation system, we can help you choose the right solution.
Choosing the right machine safety products for your industrial facility is essential for maintaining a safe, productive, and compliant workplace. From machine guarding to air vacuum systems, each product plays a crucial role in keeping your workers safe while enhancing the efficiency and longevity of your equipment.
Working with electrical automation specialists, machine safety consultants Sydney, and automation contractors ensures that your safety products are correctly chosen, installed, and maintained. With the right industrial automation solutions in place, you can create a safer working environment while meeting regulatory standards and improving your overall operational efficiency.
Final Thoughts
Static electricity might be invisible, but its effects are very real. From unexpected downtime to safety hazards and product rejections, static is a silent disruptor in many industrial settings. With proper static control using tools like ionising air guns and static bars from AiRTX, businesses can eliminate these risks and improve their overall automation performance.
Decode Automation is committed to helping Australian industries stay safe, efficient and competitive through reliable static control and electrical automation services. Get in touch today to discuss how we can support your industrial automation goals with custom-engineered static control solutions that deliver real results.
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