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An electrostatic discharge (ESD) can’t usually be seen, but can cause considerable costs at a later stage. Find out about what causes ESDs and what efficient countermeasures can be taken.

It is more than likely that at some time or another – perhaps when shaking hands with someone, touching a metal door handle or grabbing a metal handrail on the stairs – you’ll have felt a small electric shock. Electrostatic discharges (ESDs) like these measure around 3500 volts but are harmless to humans.

The situation is different for electronic components. In fact, even just 100 volts is enough to erase information on a magnetic data carrier or destroy an electronic memory chip. Companies and employees often underestimate the risk for ESD-sensitive (ESDS) components. However, when manufacturing or processing components like these, it is essential to both understand and implement the basics of ESD safety. This is where using ESD-safe components and following certain rules of conduct go hand in hand. 

Would you like to have one document that sets out the most important rules for ESD safety? That’s exactly what the free white paper from item Industrietechnik is. It is ideal as a quick reference guide or for passing on to colleagues:

Definition and significance of ESD

ESD stands for electrostatic discharge. It is a sudden equalisation of electrical charge between objects that are charged differently. There does not need to be any direct contact in order for an electrostatic discharge to happen. This poses a major challenge in industry, because electronic components can be damaged by a sudden electrostatic discharge at almost any point in the production chain. Electrostatic charges are being built up almost all the time, due to friction and movement, for example. Even simple activities at a work bench for manual assembly can cause a charge of up to 6000 volts to build up.

Another challenge posed by ESDs is that discharges often go unnoticed. When manufacturing magnetic hard drives, just 5 volts is enough to damage the sensitive read head. Furthermore, ESDs don’t just originate from employees. Without suitable ESD protection, conveyor belts and equipment such as transport trolleys, tools and work surfaces can also become electrostatically charged.

ESD safety – the basics for industrial production

Damaged conducting paths cannot be detected with the naked eye. In fact, you would usually need an electron microscope in order to identify ESD damage. It is only weeks or months later, when the end customer has the product, that this damage causes the affected component to fail. The consequences can be serious for the companies involved – complaints, expensive warranty claims and a loss of trust. ESD is a worst-case scenario for any company. It is also important to remember that ESD damage can occur at your supplier’s factory and go unnoticed in your own.

How can ESD damage be effectively prevented? The key is consistency – be aware of the issues around ESD and put into practice the basics of ESD safety. Approach and establish protection against ESD as an overarching corporate concept. The process of protecting against ESD starts when you decide which suppliers to use and ends when you safely hand over your product to the customer. Practical regulations for fully implementing ESD safety can be found in DIN EN 61340-5-1. This technical standard sets out a detailed monitoring programme, which documents the key components of an ESD safety concept that all employees are required to follow. ESD protection measures include the following aspects and requirements:

• Compliance with all important technical standards 
• Documented safety procedures for the entire process chain, including suppliers and customers 
• Standard-compliant clothing with electrical conductivity
• ESD coordinators and employees with expertise in ESD safety 
• Electrostatic protected areas that satisfy the applicable technical standards

• Daily checks on relevant work steps
• Continuous internal audits

The role of employees, humidity and operating equipment in ESD safety

Effective protection against ESD relies on well-trained and well-equipped staff. Employees must understand the necessity of ESD equipment and know how to use it correctly. Special training courses should be provided to teach the basics of ESD safety and the specified rules of conduct. Whether in engineering, in the warehouse or in cleaning – all employees must participate in comprehensive ESD safety measures.

Humidity is also crucial for ESD protection. Electrostatic charges accumulate more easily in conditions of low humidity. That’s why, in everyday life, we tend to experience those small shocks particularly often in the colder months of the year. When handling electronic components, relative humidity in the relevant areas should ideally be at least 30 percent. Another ESD risk is associated with materials that have different electrostatic charges when they arrive from suppliers. Use ionisers to equalise the charges on these materials – before they are placed into your intralogistics system.

You can find even more content on ESD safety in the item ESD Media Center. The topics covered range from general basics to the role of intralogistics and a success story:

Electrostatic protected areas and factory equipment – implementing the basics of ESD safety in practice

The DIN standard centres on using an electrostatic protected area (EPA) to implement the basics of ESD safety. An EPA can also be referred to as an ESD protection zone. Electronic components can only be handled or assembled in one of these areas. Ensure your EPA complies exactly with the technical standard. All the materials used in an EPA must be electrostatically dissipative and earthed to the same potential. This stops electrostatic charges and potential differences from building up. Any electrical charges that do build up must be discharged into the ground. An EPA can consist of a single workstation in production, a defined area or an entire building.

Various components ensure ESD safety within an EPA. An ESD Wristband can be connected to an ESD Earthing Terminal or an ESD Earthing Plug via an ESD Connection Cable. This prevents electrostatic charges from building up on employees. An ESD Table Mat will also protect the components being used. When it comes to moving goods around, an ideal solution is to use item SystemMobiles, for example. These versatile material trolleys use an ESD Drag Chain to ensure they are always in contact with the ESD floor and can safely dissipate electrostatic charges. Having the right components doesn’t make ESD safety any less complex, but does make it relatively straightforward to implement. Considering the much lower failure rates you will experience with your products, the effort is well worthwhile.