Fraser Anti-Static Techniques Helps Kernow Coatings Eliminate Static and Boost Throughput

A recent 12 to 18-month project collaboration between Fraser Anti-Static Techniques and Kernow Coatings delivered ATEX area safety improvements, cleaner sheet stacking, and harmonised static control across coating lines.

Uncontrolled static electricity can slow production, degrade quality, and in hazardous environments increase the risk of ignition. Fraser Anti-Static Techniques Limited, a specialist UK manufacturer of industrial static control equipment and ionisers, partnered with Kernow Coatings to address persistent static build-up across multiple processes and sites.

Kernow Coatings is a global leader in high-performance coating technologies and synthetic print media. The business supplies wide-format and narrow format materials, including self-adhesives, floor graphics, metallics, and PVC-free substrates, and also offers custom chemistry, converting, and toll coating services. With more than 50 years of innovation, Kernow is trusted by printer OEMs and major brands worldwide.

Over a recent 12 to 18 month period, Fraser Anti- Static Techniques worked with Kernow Coatings to improve operator safety, remove speed bottlenecks, and standardise static control products across critical coating and converting lines, including ATEX-rated areas.

The Challenge

Kernow Coatings identified static control issues on key machinery that were directly affecting safety, productivity, and maintainability:

• Static build up increased the risk of electrostatic discharge in ATEX classified zones, with potential implications for fire and explosion safety.
• Static on a roll to sheet conversion line disrupted sheet handling and stacking, forcing operators to slow the line to maintain stack quality.
• A mix of static control equipment from several suppliers created inconsistency in performance and added complexity to maintenance and spare parts management.

Fraser Anti-Static Techniques was tasked with improving safety in hazardous areas, eliminating the speed and quality constraints on the sheeting process, and simplifying the static control equipment across selected coating lines.

Project 1: Sheeting Line, Unwind and Stacker Optimisation

On one of Kernow’s sheeting lines, rolls were converted to stacked sheets. Static charge accumulated during unwinding and cutting, then caused sheet misalignment and poor stack quality. Operators were forced to slow the line to keep stacks tidy, which restricted throughput. Static devices were already installed, but they were not delivering sufficient neutralisation.

Approach

Fraser Anti-Static Techniques assessed the process from unwind through to the stacker and identified two critical points for intervention:

1. The unwind area, where charge was generated on the web as it left the roll.
2. The output and stacker zone, where static interfered with sheet separation and stacking.

Targeted ionisation equipment was specified and installed at both locations. At the unwind, Fraser positioned Fraser 3024F short range ionising technology close to the web to neutralise charge at source, improving health and safety by reducing electrostatic discharge in the operator area. At the stacker, Fraser 3024L long range ionising solutions were configured to promote clean sheet separation and stable stacking at higher speeds.

Outcome

The upgraded static control system allowed Kernow to significantly increase line speed while maintaining consistent stack quality. Operator intervention reduced, the process became more stable, and throughput improved. Kevin Brown of Fraser Anti-Static Techniques commented: “By addressing static at both ends of the process in a consistent way, we removed the bottleneck. Operators no longer have to slow down for stack quality, so throughput is up and safety is improved.”

Kernow Coatings also reported a step change in day-to-day operation:

“Before working with Kevin at Fraser Anti StaticAnti-Static Techniques, we struggled with controlling and dissipating the build upbuild-up of static charges on many of our machines.

Kevin provided invaluable advice in selecting the right products from their range to address the issues we were experiencing. The goods supplied were of exceptional quality and arrived within a few working days.

Thanks to their support and advice over a number of years, we have eliminated our previous problems with static, enhancing the safety of our employees and increasing our running speeds.”

Project 2: ATEX Coating Lines, Standardisation and Simplification

Two ATEX rated coating processes at Kernow Coatings were equipped with static control components sourced from several different manufacturers. This mix of technologies made it harder to maintain consistent performance and complicated spares management. Local engineering teams also faced challenges when troubleshooting, because each line used a different hardware set and layout.

Approach

Fraser Anti-Static Techniques carried out an on-site audit of the installed equipment on both coating lines. The company:

• Assessed the positioning and performance of existing ionisation devices.
• Identified which components were effective and could be retained.
• Designed a standard static control concept based on Fraser ionisation technology, using proven mounting positions on each machine.

The resulting solution replaced disparate components with a harmonised set of Fraser EX1250-S ionising bars powered by Fraser HP Power supplies. Placement was standardised across both coating lines, so that similar sections of each machine were treated in the same way.

Outcome

The upgraded systems delivered several benefits:

• Improved safety in explosive risk areas by achieving reliable static neutralisation in ATEX zones, supporting Kernow’s safety procedures and compliance.
• Simplified maintenance and spares through a common set of Fraser components, reducing stockholding and making it easier for engineering teams to support the lines.
• Greater consistency across machines, enabling clearer standard operating procedures, faster troubleshooting, and easier training for operators and maintenance personnel.

The Results at a Glance

Across the two projects, Fraser Anti StaticAnti-Static Techniques helped Kernow Coatings to achieve:

• Enhanced operator safety through improved static control in ATEX classified areas.
• Higher productivity on the sheeting line, with dramatic speed gains and stable, clean stacking.
• Standardised hardware and layouts on key coating lines, cutting spare parts complexity and improving maintainability.
• Alignment with Kernow’s quality and innovation focus, by using intelligent, efficient ionisation systems that support repeatable, high-quality output.

Why Fraser’s Approach Works

Fraser Anti-Static Techniques combines application understanding with a broad portfolio of industrial ionisation technologies. Its intelligent 24 V DC ionising bars and long-range solutions sense field polarity and adjust ion emission for rapid neutralisation, even at higher speeds and longer distances typical of coating and converting lines.

By pairing this technology with static measurement tools and ATEX or IECEx certified options, the company helps customers make static control both robust and auditable. In Kernow Coatings’ case, this translated into safer ATEX operations, faster sheeting, and a standardised approach that engineering teams can support across multiple lines and processes.

Read more on Fraser Anti-Static Techniques here.

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