Dust adhesion and contamination
Production bottlenecks, mysterious faults, or electric shocks
Bulk material fluctuations and color defects
Dust is magically attracted by static charge and contaminates, for example, painted parts.
Static electricity can, for example, cause thin films to be pulled out of the roll, necessitating a re-rolling.
Dangerous for your employees! Uncontrolled loads can seriously injure your employees or cause fires.
Blocked pipes and separators, or problems with filling bulk materials, are often the result of electrostatic charging.
Electrostatics – what is it, actually? In short, electrostatics is the imbalance of existing charge carriers on an insulator.
What does that mean exactly? Let’s assume that on a non-conductor—meaning a material
that does not have freely movable charge carriers—there are still charge carriers present, i.e.,
electrically charged particles. These are initially not mobile—in other words, they are static.
These can be (+) positively charged or (−) negatively charged particles. In an ideal world, there are equal amounts of positive and negative particles located close together—meaning they are balanced or “neutral” on the surface (because, as we know, opposites attract and are then satisfied).
But does this ideal world actually exist?
No! – Just like in real life, there are clusters of positive particles that eagerly seek contact with their counterparts but unfortunately cannot move, and negative particles that linger grumpily among their own kind. And just like in real life, this leads to tension on the surface. In fact, here too, the absolute majority ultimately determines the polarity. Things only get really exciting when, through contact and separation with other surfaces, particles that are normally immobile suddenly encounter each other. All of a sudden, friction creates group sizes that can no longer behave “neutrally” without external help. Whether positive or negative—too much is simply too much! Then all it takes is someone who wants nothing to do with all that tension and simply comes close to settle things. Then—bang! And not just a little! Suddenly, you can (sometimes painfully) feel how much energy is stored in static electricity.
How can one regain control of the situation?
The solution is quite simple – we use various methods of electrostatic control to ensure a more harmonious environment on the surface by generating the ideal world and providing a matchmaking service that finds a suitable partner for every immobile particle on the surface.
The surface provides a highly mobile partner of opposite polarity – so that all particles are satisfied with their partner.
We are familiar with countless production facilities, product characteristics and technical backgrounds, and we can transfer this knowledge to your production.
We don't just sell catalog items, but work with you to find an individual solution and remain available to you even after the purchase.
Being able to control electrostatics in a targeted manner prevents, for example, production losses due to blockages or production jams, thus saving money and time in the long term.
Being able to neutralize static electricity increases the safety of your employees – otherwise, uncontrolled discharges can lead to serious accidents or fires! Secondary accidents (e.g., employees receive an electric shock and subsequently fall into a secured production area or wander disoriented in front of a forklift) also occur more frequently than you might think.
Air ionization: The most effective way to discharge electrostatic charge
Wherever non-conductive or insulating materials are used – for example, in the plastics, film, or packaging industries – electrostatic charging can quickly become a real problem. The solution? Air ionization.
Air ionizers generate targeted positive and negative ions, These ions act as freely moving charge carriers in the ambient air. They are attracted to oppositely charged surfaces and neutralize them in fractions of a second.
The technology behind it is based on the Corona discharge principle:
At extremely fine tip electrodes, charged particles are generated by very high electric field strengths. Electrons are either released from the air or injected into it – depending on whether positive or negative ions are needed. This process enables a fast, contactless and pinpoint discharge.
Ion spray sticks – for line or area applications
Ion spray blower – ideal for longer distances or hard-to-reach places
Air meter with ionization – for simultaneous blowing off and unloading
Ion spray guns – flexible and can be used manually
Ion spray nozzles & inline ionizers – perfect for integrated applications
Measuring devices for monitoring air ionization
Power supplies & high-voltage devices – for a constant and reliable supply
Whether in industrial production, sensitive electronics or cleanroom environments – Ionization is the key technology, when it comes to avoiding disturbances caused by static electricity, ensuring quality and keeping processes running smoothly.
Let us advise you. Together we will find the right ionization system for your application.
Static electricity is often seen as a nuisance – employees get electric shocks, materials stick together unintentionally, and in the worst case, sparks or fires occur. But when used strategically, electrostatic charging can be a real productivity booster.
This technique is already being used successfully in many industries to optimize processes and temporarily bond materials – entirely without adhesives or mechanical fixings. Some typical applications include:
Stabilizing stacks of magazines or newspapers, to prevent slippage during packaging or transport
Address labels on brochures attach them before they are wrapped in foil
Connect the last bag to the roll, in order to pack them efficiently into boxes
Avoidance of telescoping for rolled-up films by spot fixing
Electrostatic charging is also used in many everyday products – often unnoticed. In so-called in-mould labeling (IML), for example, a pre-printed label is electrostatically fixed in the injection mold and then permanently integrated into the product – entirely without adhesive.
Large-scale applications are also impressive: stacks of brochures, laminates, or plastic parts can be electrostatically fixed so that they do not slip even when subjected to vibrations. Further specialized applications can be found, for example, in DVD production, where adhesives are evenly distributed by electrostatically charged surfaces.
If you're considering how electrostatic charging can make your production more efficient, cleaner, or faster, we'd be happy to advise you. Simco-Ion Europe offers a wide range of products – from high-voltage generators to custom-designed electrodes. Our systems are precisely tailored to your processes and are versatile in their application.
Electrostatics with intelligence – the best IQ system ever. For your step towards Industry 4.0.
With the IQ Easy System Simco-Ion helps you get the most out of your production line. Say goodbye to complicated wiring, vulnerable high-voltage components, and cumbersome assembly. The new 24-volt concept brings real convenience to your daily work – and maximum control over your processes.
Safe & low-maintenanceNo more high-voltage cables or separate power supplies needed – simple 24V supply via a standard sensor/actuator cable.
Independent supplyEach ionization rod or blower operates independently – this means greater reliability through redundancy.
Maximum performanceHigh ionization power combined with a compact, robust design.
Intelligent control: Monitoring and evaluation of all components by the IQ system – optionally stand-alone or controllable via controller.
Easy installationOne mounting system for all discharge rod types – this saves time and hassle.
Protection class IP66Ideal for wet cleaning environments.
The 7-inch touchscreen It gives you insight into the status, measured values, and potential sources of error at any time. This makes your ionization solution an active component of your quality assurance.
Whether standard application or special requirements such as IML (In-Mould Labeling) – the IQ Easy System is the clever solution for anyone who wants to take their production processes to a new level.
And the best part: 4-year warranty on all components – because we are confident in our technology.
Reliably detect perforations – high voltage for quality assurance
In film production, even a small hole can have major consequences. Material inclusions, voids, or fine perforations often lead to quality losses – and remain undetected by conventional camera systems. Optical inspection methods quickly reach their limits, especially with transparent or opaque films.
The solution: fault detection using electrostatics
Controlled high voltage can be achieved through targeted high voltage. Spark discharge as a reliable signal for Error detection can be used. The method is based on the principle: Where there is a mistake, a spark is created.
Neutralization the film through ionization – to avoid interference
Charging of the foil web via an electrode that is positioned opposite a grounded roller
Monitoring of field strength:
If the track is intact, the high voltage remains below the breakdown threshold.
At Holes, inclusions or cavities The field changes – a spark is created.
Spark detectionThe charging generator detects the breakdown and sends a signal that can be processed or forwarded (e.g., to the machine operator).
The Perfomaster is a compact, intelligent system for perforation detection:
All-in-one solutionElectrode, high-voltage source and evaluation unit in one device
Easy to useOperates on 24 V DC – no high-voltage cables required
Robust electrode with 3 special tips, interchangeable and relocatable
Status indicator via LED:
Green = Operation error-free
Red flashing light = perforation detected
Pulse output for counting or forwarding the detection signals
Optionally combinable with IQ Manager for complete process monitoring and documentation
Rely on intelligent fault detection – simple, safe and precise.
Measuring electrostatics – making invisible charges visible
Static electricity is often invisible in production – but not harmless. To effectively counteract it, it is crucial to know: Where does the charge originate? How strong is it? And what is its polarity?
This is exactly where our Electrostatic measuring instruments They come into play. They help to visualize, analyze, and control electrostatic charging.
To Localization of charge sources in production
To Review of effectiveness their ionization systems
To Quality assurance in relation to customers or auditors
After a targeted charging process Control measurement and process assurance
1. Manually using the FMX-004 field strength meter
– Ideal for quick, targeted on-site checks
– Measures the field strength without contact over a defined distance
– Easy to use, precise in application
2. Automatically with the IQ Easy sensor
– Integrates into the IQ Easy system
– Continuously provides measured values for the automatic control of your ionization devices
– Enables the Process optimization and data recording for quality assurance via the IQ Easy Manager
With the right measuring instruments, you can keep your production processes under control – safely, efficiently and transparently.
We would be happy to advise you individually on which measuring device is suitable for your application.
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In addition to our consulting services, we offer a selection of products that support your production processes. We place great importance on ensuring that these products are optimally tailored to your needs.
Mr. Schaper has been working with electrostatics for over 35 years as a technical consultant and training expert in all areas of the manufacturing industry. He is happy to share his practical knowledge with you – either on-site at your production facility or in his compact seminars. With decades of expertise and a trained eye, he can identify the (sometimes challenging) solution for your production within minutes and work with you to find the right solution.
Whenever you have open topics regarding production, electrostatics, ionization, or compressed air and require support, he is the contact person you should ask.
His business card simply says: „Technical Sales“ - because...
„Customer-centric individual with a passion for listening and a point of contact for complex technical issues, possessing strong analytical problem-solving skills“... wouldn't quite fit.
