Static - A Real Print Problem: Is It Worth the Risk for Your Biggest Print Customers?

The Challenge of Static in Synthetic Printing

Static build-up is the leading cause of issues when printing on synthetic media with digital presses. Stacking problems, sheets sticking together, and unpredictable release issues can lead to paper jams, print defects, misfeeds, and even static shocks – resulting in costly reprints and lost production time.

Does your ideal day in the print room involve constantly clearing jams and battling with materials? Surely not. It’s disruptive, frustrating, and wastes time and money. The good news is, there are ways to avoid the issue! Let’s explore how you can minimise static and keep your production running smoothly while keeping your customers happy and avoiding any headaches for yourself!

What Causes Static Electricity on Synthetic Papers?

Static electricity occurs in synthetic papers due to their insulating properties, which prevent electrons from moving freely. When these materials come into contact with other surfaces – particularly through friction – electrons transfer between them, creating an imbalance of positive and negative charges.

Modern laser printers and colour copiers use an electrostatic charge to transfer toner onto the substrate before fusing it with heat. While traditional paper quickly dissipates this charge, synthetic materials retain static due to their heat-resistant film composition and ultra-smooth surface, making handling more difficult.

How Does Static Electricity Affect the Printing Process?

Static-related issues can disrupt the entire printing process, leading to:

Paper jams – Sheets sticking together, causing feeding problems.
Print artifacts – Unwanted marks or distortions in the final print.
Double feeding – Sheets clinging together, leading to misalignment and order errors.
Stacking problems – Printed sheets not separating properly, affecting post-printing operations.

Key Factors Contributing to Static Build-up on Synthetic Papers

Low conductivity – The material’s insulating nature holds static charges longer.
Friction during handling – Creates and increases static charge.
Coating composition – Smooth surfaces increase charge retention.
Low humidity – Dry environments exacerbate static issues.

Top Tips for Reducing Static and Ensuring a Smooth Print Workflow

To prevent static from disrupting your print jobs, implement these best practices:

Maintain optimal humidity – Keep levels at 45% or higher to reduce static.
Use synthetic paper with anti-static properties – Choose materials engineered for static control.
Fan the stock before loading – Helps separate sheets and reduce adhesion.
Select the shortest print path – Minimises static build-up by reducing friction.
Utilise anti-static tools – Implement ionizers, tinsel, or anti-static bars.

Thankfully, just making some small adjustments can make a big difference in ensuring seamless print production!

Avoid Costly Mistakes – Trust KernowPrint PRO for Unmatched Static Control

Imagine this: Your largest client orders 10,000 ID cards. You set up the job and hit print, only to encounter double feeds, misalignment, and stacking problems – all due to static. The result? Delays, wasted materials, and an unhappy customer.

That’s exactly what happened to a customer who chose a “compatible” synthetic instead of KernowPrint – our most trusted synthetic media range, offering industry-leading static control. At Kernow Coatings, our expert chemists have developed specialised adhesives and coatings designed to enhance print quality and minimise static-related issues.

With KernowPrint PRO, you’ll benefit from:

Jams and feeding issues prevented
Floating and sticking sheets eliminated
Print defects reduced, with no distortion in press
Seamless, efficient production runs

Up to 62% of digital print jobs need to be completed within two days or less – you don’t have time for static-related disruptions. Don’t let print defects and delays jeopardise your business; Trust KernowPrint for superior static control and reliable runability.