May 26, 2020

The results of Dry Fog in different industries

results-of-dry-fog

Application of Dry Fog in specific industries

We have talked about the benefits that Dry Fog can generally bring to a manufacturing industry.

The AirAKI® Dry Fog humidification system and in general the Dry Fog humidifier AKIMistis®“E” are used in various factories such as electronics, printing, paper & pulp, plastic, chemical plants, automotive, textile, agriculture, painting, etc.

Our systems help solving many of our customers issues related to electrostatic discharges, dust adhesion, low humidity level, and even worker’s health management in winter.

In this article, we will share the results of Dry Fog for 3 specific industries: printing, electronics and plastics manufacturing processes.

Printing field

Finding a humidity control suitable for each type of printing press and process has a big impact on the production.

Common problems caused by static electricity

  • Dust adhesion to plate making
  • Poor sticking
  • Paper dust adhesion to printed materials
  • Folding failure
  • Poor paper feeding (two-sheet feeding)
  • Ink scattering
  • Paper jam
  • Ignition of solvent
  • Paper misalignment
  • Responsiveness of high-speed machine

 

 

 

 

 

 

 

Common issues caused by insufficient humidity

  • Paper break 
  • Paper joint failure
  • Curl due to expansion and contraction of paper
  • Punching failure
  • Poor dimensional accuracy
  • Ink drying
  • Poor registration
  • Ink stain
  • Print wrinkles
  • Ruled and back cracks

AKIMist®”E” benefits for Web Offset Printing Process

  • AKIMist® has quickly gained acceptance, as nozzle-type humidification systems are becoming popular in the printing industry.
  • AKIMist® has the best track record in the Japanese printing industry, with over 30 years of strong experience.
  • For sheet-fed printing, UV printing, Flexo printing and others, we have the best-suited solutions for all kinds of printing presses.

Case 1: Benefits of a Dry fog humidity control solution in an offset rotary press

  • Prevention of stoppage during the operation of the printing machines
  • Improvement of the folding accuracy at the folding machine
  • Improvement of the production speed
  • Reduction of wastepaper

results of Dry Fog

results of Dry Fog

Electronics field

An energy-saving humidification method has become the strongest focus of attention.

Common problems caused by static electricity

  • Circuit destruction of semiconductors and electronic devices
  • Clogging of parts feeder
  • Damage (scratch, spot) caused by sparks
  • Product transport failure
  • Mounting error
  • Adhesion issues
  • Adhesion of dust and foreign particles to the product
  • Appearance defect due to particles adhesion contamination

 

 

 

electrostatic-breakdown

 

electronics industry

Common issues caused by insufficient humidity

  • Poor performance of exposure and chip mounter
  • Dimensional defects of films, plates, substrates, etc.
  • Prolonged maintenance period due to product drying
  • Changes in physical properties due to humidity fluctuations

AKIMist®”E” benefits for SMT process

  • By maintaining the relative humidity at an appropriate level, it is possible to prevent various problems caused by static electricity.
  • The Dry Fog cooling effect reduces the building cooling load.
  • With the No. 1 track record as well as 30 years of remarkably good results, we have optimal solutions for a wide range of processes and environments.
  • It is also well-suited for clean room humidification.

Case 2: Benefits of a Dry fog humidity control solution in an IC mounting process

  • Improvement of the adhesion of small mounting components
  • Reduction of internal destruction due to electrostatic discharges
  • Energy saving by cooling effect

Steam humidification has no cooling effect and the humidity does not reach 50% in the summer. The more you add air-conditioning to cool down, the more humidity will escape. That is why the Dry Fog humidification is optimal to save energy cost as it also has a cooling effect while humidifying.

results of Dry Fog

results of Dry Fog

Plastics field

An efficient humidity control allows to create an environment free of static electricity which prevents quality defect.

Common problems caused by static electricity

  • Dust and foreign particles adhesion on the product
  • Plastic products sticking together
  • Discharge ignition of solvents and raw materials
  • Sealing and packaging failure
  • Electric shock to workers
  • Scratches due to discharge

Common issues caused by insufficient humidity

  • Dimensional defects of the product
  • Changes in physical properties due to humidity fluctuations
  • Rise of dust particles
  • Risk of employees catching a cold

AKIMist®”E” benefits for Plastic manufacturing process

  • Plastic material induces various electrostatic disorders due to its property of being easily charged.
  • As a measure against dust adhesion, we propose spot humidification mainly in the punching process and inspection process.
  • By controlling the relative humidity level around 50%, not only is the production more efficient, the temperature level around the molding machine is also lowered by the cooling effect of the Dry Fog, thus, saving energy.

Case 3: Benefits of a Dry fog humidity control solution in a container manufacturing process

  • Prevention of dust and foreign particles contamination during molding
  • Environmental cooling
  • Measure against cold during winter
  • Prevention of product defects due to dust adhesion

results of dry fog

results of dry fog

Results of Dry Fog in other industries

As mentioned in the introduction, our Dry Fog technologies is used in various industries for:

  • Safety measure
    • Chemical industry: reduction of the risk of ignition in the ink and paint formulation process; reduction of the risk of ignition around ink fountains and mixers; reduction of the risk of ignition in the filling process of pigments and paint.
  • Productivity improvement
    • Painting process: elimination of dust adhesion during the painting process; increase of productivity by 10%.
    • Textile industry: elimination of thread breakage; prevention of fiber dust and fiber waste adhesion to machines; prevention of the sewing machine from jumping.
  • Quality improvement: reduction of product defects due to dust adhesion, reduction of airborne waste.

Related articles

If you want to learn more about how static electricity occurs and how increasing humidity helps against ESD, here are our compilation of articles we covered:

How can IKEUCHI help?

Theses results show that an energy saving humidifier system is really good for the productivity of manufacturing processes.

IKEUCHI helps you to choose the best choice for your installation.

As “the Fog Engineers” we’ve studied the best humidity level in industry.

Our none-wetting Dry Fog humidifier offers the adequate solution for sensitive working stations.

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Contact one of our engineers to know more about our different humidifier system.

Nina MONCEAUX – IKEUCHI EUROPE B.V.