In factories that handle textiles, films, plastics, paper, powders or technical materials, static electricity has a direct impact on process stability. Sometimes this is immediately apparent, with materials sticking together, dust being attracted to surfaces, labels being applied imperfectly or operators feeling minor shocks. At other times, it manifests more subtly, through less precise cuts, uneven material feeding, recurring defects or scrap that is difficult to explain.
The problem arises particularly in environments with dry air, high-speed production lines and insulating materials. Under these conditions, an electrostatic charge builds up on the surface of the materials and begins to affect the production flow before it becomes apparent to the team.
Controlling static electricity is not a one-off measure. Depending on the industry, the solution may include technical checks on equipment, proper earthing, localised ionisation, anti-static materials or humidity control. For factories where dry air contributes to the problem, industrial humidification is one of the most effective methods of stabilising the process.
Within the TeXco portfolio, Condair and Jumag solutions can be considered for humidity control in industrial halls and processes, whilst Bullmer, VEIT and Fortuna equipment contribute to precision, quality and repeatability in the textile, leather and finishing industries. Making the right choice depends on the material, the process, the existing humidity levels and the effects observed on the production line.
How does static electricity arise in production?
Static electricity occurs when two materials come into contact and then separate. In a factory, this happens constantly: fabric passing over rollers, film moving along guides, paper feeding into machinery, powders circulating through systems or plastic reaching the finishing stage.
The faster the production line runs, the more frequent the contacts are, and the charge can build up more quickly. Insulating materials, such as plastic, films, synthetic textiles, paper or fine powders, retain this charge more easily on their surfaces. This leads to behaviours that are difficult to control: sticking, deviation, dust attraction, uneven feeding or touch discharges.
Air humidity plays an important role. When the air is very dry, electrostatic charges dissipate more slowly. In many industrial applications, maintaining relative humidity within a controlled range helps materials to behave more stably and reduces charge build-up on surfaces.
For a factory, the key question is where static electricity affects the process. In the cutting room, it can affect the positioning of the material; in packaging, it can influence gluing, sealing or labelling. In finishing, it can attract particles to surfaces. In processes involving powders or solvents, the assessment must be carried out with particular care, as safety requirements also come into play.
Where can static electricity be observed in the factory?
Static electricity is most easily observed in the behaviour of materials. The effects vary from one industry to another, but they share a common feature: they occur where materials come into contact, rub against one another, separate or move at speed.
Textiles and the cutting room
In the textile industry, static electricity can affect how the fabric lies on the cutting table, the formation of creases, the feeding into machinery and the precision of the cut. Synthetic materials, technical textiles and lightweight fabrics are more susceptible, particularly in workshops with dry air.
When the fabric sticks to rollers, guides or other layers, operators may notice slight deviations, creases, uneven tension or positioning difficulties. In automated cutting, these differences matter. A small deviation repeated many times can result in additional material wastage, rework or parts that do not conform perfectly to the pattern.
This is where moisture control can help stabilise the material, and cutting and spreading equipment – such as the Bullmer solutions in the TeXco portfolio – support process accuracy when the material is correctly prepared for cutting.
Packaging, labelling and in-line products
In packaging, static electricity can attract dust and particles to surfaces, affect the positioning of films or interfere with label application. In the food, pharmaceutical and cosmetics industries, these details are crucial for visual quality, traceability and product compliance.
A slightly misaligned label, a film that does not lie flat, or particles attracted to the surface before sealing can lead to rejects and repeated stoppages for adjustments. Often, the problem does not seem significant in a single cycle, but becomes a major issue when repeated.
In such applications, humidity control must be tailored to the product’s requirements. There are processes where a stable humidity range is beneficial, but there are also processes where the limits are strict and must be assessed before any intervention.
Plastic, film and surfaces for finishing
Plastics and films are insulating materials, so they retain an electrostatic charge on their surface more readily. In packaging production, plastics processing, finishing, painting or coating, this effect is evident in the attraction of fine particles just before the stage where the surface must be clean.
When dust settles on the product before finishing, it increases the risk of visual defects, rework or rejects during quality control. In such cases, it is worth analysing the humidity in the production hall, the line speed, the material flow path and the points where deposits occur, all at the same time.
Leather goods, technical textiles and position-sensitive materials
In leather goods and technical textiles, material stability is crucial during both preparation and thinning, levelling, perforation, die-cutting or cutting. When the air is too dry, some materials become more difficult to control, and the process may require more frequent adjustments.
For these applications, the Fortuna solutions in the TeXco portfolio are particularly relevant for the thinning and levelling of leather, rubber and technical textiles, whilst humidity control can help ensure more predictable material behaviour during processing.
Ironing, finishing and final product stability
In garment manufacturing, finishing is the stage where small differences become apparent. The material must respond consistently to steam, pressure, temperature and handling. In environments with very dry air, fabrics may be more difficult to lay flat, may attract particles or may react inconsistently between stages.
The VEIT solutions in the TeXco portfolio, designed for ironing, finishing, heat-sealing presses and steam generators, are relevant to this part of the process. In factories where steam and humidity are integral to the quality of the finish, the assessment must take into account both the equipment and the environmental conditions.
Electronics and sensitive components
In electronics, static electricity is treated as a process risk. Some effects are immediately visible, but others may only become apparent later, after the component has passed initial testing. For this reason, the electronics industry employs strict ESD protocols, controlled areas, specialised materials and regular checks.
Dusts, solvents and areas with ATEX requirements
In processes involving combustible powders, solvents or potentially explosive atmospheres, static electricity must also be assessed from a safety perspective. Here, we are not just talking about product quality, but about zone classification, documentation, compliant equipment and periodic checks.
Humidity control may form part of the technical strategy, but it does not replace the ATEX assessment, earthing, certified equipment and mandatory documentation.
Signs that static electricity is affecting the process
Static electricity warrants investigation when signs such as the following occur repeatedly:
⚠️ Materials sticking to each other, to rollers, to guides or to the work surface.
⚠️ Dust and particles attracted to the product immediately after a process stage.
⚠️ Fabrics or films that veer slightly off course, are difficult to position or create tension in the line.
⚠️ Labels applied unevenly, films that behave differently from one batch to another, or packaging that requires frequent adjustments.
⚠️ Slight shocks felt by operators when touching materials or equipment.
⚠️ Quality defects that occur intermittently, with no clear link to tools, settings or machine wear.
Before choosing a solution, it is worth measuring the relative humidity in the production hall, particularly during the colder months or in areas with intensive air conditioning. If readings are frequently below 40% RH, dry air can contribute significantly to the build-up of electrostatic charges.
How is static electricity controlled in production?
Controlling static electricity begins with identifying the cause: dry air, insulating material, high operating speeds, repeated contact with rollers or guides, improper storage, or a specific area where the charge accumulates.
In practice, the solution is chosen based on where the problem occurs. If the issue is evident in several areas of the production hall, the first step is to check the relative humidity. If it occurs at only one point on the production line, local measures may be required, such as earthing, ionisation or anti-static accessories.
For factories where dry air affects the behaviour of materials, humidity control is one of the most effective areas to investigate. In many industrial applications, a stable humidity range helps materials to behave more predictably, reduces the build-up of electrostatic charges and supports a more consistent production flow.
Humidity control with Condair and Jumag solutions
Within the TeXco portfolio, Condair solutions are suitable for industrial halls, HVAC systems, production areas and applications where humidity must be kept under control. Condair solutions are suitable for textile factories, cutting rooms, packaging facilities, printing works, paper processing plants, premises containing synthetic materials, or areas where dry air affects process quality.
For applications requiring industrial steam or process humidification, TeXco can recommend Jumag solutions. These are suitable for factories where steam forms part of the production process, for example in textiles, finishing, laundries, dry cleaners, food applications or industrial processes requiring stability.
The choice between Condair and Jumag depends on the objective. Condair is the right choice for controlling air humidity and integration into ventilation or air-handling systems. Jumag is the right choice when a factory requires process steam or an efficient source of steam for its processes.
Cutting, finishing and processing
In the textile, leather and technical materials industries, static electricity particularly affects the stages where the material needs to be positioned, stretched, notched, cut, pressed or finished. Therefore, environmental control must be considered in conjunction with the equipment used on the production line.
Bullmer is relevant for the cutting room, automated cutting, basting and the processing of textiles, leather or technical materials. When the material is stable and the machinery is suited to the application, the process becomes more precise and repeatable.
VEIT covers ironing, finishing, heat-sealing, lamination and steam generation for the textile manufacturing industry, laundries and dry cleaners. At these stages, steam, pressure, temperature and ambient conditions directly influence the appearance of the final product.
Fortuna is suitable for thinning and levelling leather, rubber and technical textiles. In applications where the material must be processed uniformly, its stability before and during the process is just as important as the machine’s performance.
Local ESD measures where required
Humidity control is no substitute for dedicated ESD measures. In applications involving electronics, plastics, films or areas prone to point discharges, earthing, ionisers, conductive mats, antistatic wrist straps, ESD packaging or other specialised solutions may be required.
These must be assessed separately, particularly in ATEX-risk areas, where documentation, zone classification, certified equipment and periodic inspections are mandatory. In such cases, humidification can support process stability, but does not replace technical and legal compliance.
How do you begin the assessment in the factory?
The first step is to measure the relative humidity in areas where sticking, dust accumulation, shocks, unevenly applied labels or material deviations occur. If the values are frequently below 40% RH, dry air may contribute to the build-up of electrostatic charges.
Next, check the materials involved, the line speed, the path through rollers and guides, the contact areas and the exact stage at which the defects occur. Depending on the results, the solution may involve humidity control, process adjustments, more suitable cutting or finishing equipment, or local ESD measures.
Are you experiencing problems with materials sticking together, dust being attracted to the product, or unexplained variations in the process? TeXco can analyse your application and recommend suitable solutions for humidity control, industrial steam, cutting, finishing or material processing.
