The hidden enemy of ESD protection: How does improper cleaning damage the crates?
In the electronics and automotive manufacturing sectors, protection against ESD (electrostatic discharge) is sacrosanct. We rigorously check earthed wrist straps, antistatic flooring, special protective clothing and ionisers. However, there is one critical link in the chain that we tend to overlook outside of quality assurance audits: logistics packaging.
KLT boxes, trays and dividers are not merely simple storage aids, but active lines of defence for highly expensive components. Many people think that washing crates is a simple, menial task.
The reality, however, is that washing carried out using unprofessional, DIY methods can compromise ESD protection even at a microscopic level, without there being any visible trace of it to the naked eye.
Let’s see how improper cleaning can become the hidden killer of components!
What is an ESD matrix, and why isn’t it just ordinary plastic?
The main material used in standard ESD boxes is usually polypropylene, which is with conductive additives (such as special carbon particles or carbon fibres) are combined. It is this internal structure that creates the so-called ESD matrix, which ensures that the surface resistance remains within the permitted limits and safely dissipates any static charge that builds up.
If this matrix is damaged, the box becomes ordinary insulating plastic, which attracts dust and is capable of building up a voltage of several thousand volts at the slightest friction.
- Chemical corrosion: The effects of using the wrong cleaning agent
One of the most common mistakes is the use of general-purpose industrial degreasers, alkalis or even household cleaning products during domestic or non-specialist washing.
This could lead to two types of disaster:
- Chemical decomposition: Chemicals that are not alkaline-resistant or are too aggressive attack the polymers and leach conductive carbon particles from the plastic. The structure of the ESD matrix is disrupted.
- Formation of an insulating layer: Many general-purpose cleaning products contain additives (e.g. fragrances, gloss enhancers or surfactants) which, once dry, form an invisible, microscopic layer insulating film form on the surface of the box. The box looks clean and shiny, but its ability to dissipate charge is reduced to zero.
- The temperature trap: Why is washing at temperatures above 60°C not recommended?
Stubborn industrial dirt (machine oils, greases, dust) is easiest to remove at high temperatures. However, what is good for metal parts is disastrous for ESD-rated plastics.
The structure of conductive plastics is heat-sensitive. If the temperature during the washing or drying process exceeds 60°C, the plastic’s molecular chains stretch and shift. As a result, the carbon particles within it move further apart, the conductive network is disrupted, and the material permanently loses its antistatic properties.
The invisible danger: Why is this the most costly mistake?
The greatest risk is that The damaged ESD box looks exactly the same as the undamaged one. Neither the logistics manager, the machine operator, nor even the procurement officer can tell the difference.
The fault only comes to light much later, when the finished printed circuit boards and electronic modules arrive at the end user (for example, a car factory) and become inoperable due to hidden damage caused by micro-cracks. The consequences of this are warranty liabilities, customer complaints and a serious loss of reputation.
What is the professional solution? The Via-Nett approach
In the automotive and electronics industries, component cleaning is not a cleaning task, but rather an integral part of the quality management process.
At Via-Nett, we have designed our technology to ensure not only the physical cleanliness of the crates but also the maintenance of ESD protection to 100% standards:
- Classified chemicals: We use only specialised cleaning products manufactured in-house, which have been specifically developed to preserve ESD properties.
- Strict temperature control: Our systems ensure that the temperature does not exceed the critical level for even a single second during the washing and drying phases the 60°C limit.
- Audit-proof processes: Our cleaning processes fully comply with automotive industry standards.
Washing isn’t just a matter of „dousing with water” – entrust the task to a partner who understands the chemistry of plastics and the rules of manufacturing safety!
Would you like to see how our technology performs? Request a free trial wash and see the quality for yourself, risk-free!