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Celebrating 40 Years In ESD - Trusted UK Supplier Of ESD Control Products Since 1986
Static electricity in manufacturing is the accumulation of electrostatic charge on surfaces, materials, and personnel that discharges uncontrollably as electrostatic discharge (ESD) when two objects with different voltage potentials come into contact. In electronics manufacturing, a single ESD event can destroy or degrade static-sensitive electronic components irreversibly.
Electrostatic discharge is not a minor inconvenience. It is a primary cause of component failure, latent damage, production yield loss, and compliance failures across electronics, medical device, automotive, and aerospace manufacturing. The human body generates a charge with every movement; walking across a floor, removing a garment, or lifting a component from a tray can generate thousands of volts. Modern semiconductor devices can be destroyed by events as low as 100 volts, well below the threshold of human perception.
Preventing static electricity in manufacturing requires a systematic, layered approach: controlling charge generation, providing grounding pathways, dissipating existing charge, and maintaining the performance of every protective measure through regular testing and cleaning.
Electronics manufacturing facilities manage static electricity through an integrated ESD control programme, a structured set of processes, products, and verification activities designed to prevent electrostatic charge from reaching static-sensitive electronic components at any stage of the production process.
An effective ESD control programme addresses four control objectives:
Key entity relationship: Electrostatic charge → surface resistivity → grounding path → ESD event prevention. Every element of an ESD control programme exists to interrupt this chain at one or more points.
Not every area of a manufacturing facility carries equal ESD risk. The following zones require dedicated ESD control measures due to the nature of materials handled, processes performed, or environmental conditions.
Surface mount technology (SMT) lines handle components with ESD sensitivities ranging from Class 0 (below 250V) to Class 3 (above 4,000V). Class 0 and Class 1 devices, including many modern ICs, MOSFETs, and microprocessors, can sustain latent or catastrophic damage from ESD events that produce no perceptible effect on the operator.
Every workstation, conveyor surface, tooling, and component tray in an SMT environment must be within a verified EPA. Operators must be continuously grounded. Anti-static sprays maintain the ESD properties of carriers, tote boxes, and non-conductive surfaces that cannot be replaced with permanent ESD materials.
Static charge accumulates on shelving, bin boxes, tote containers, and packaging materials during normal warehouse operations. When static-sensitive components are removed from ESD-safe packaging and placed into non-treated storage, they are immediately exposed to charge from surrounding surfaces.
Anti-static treatment of storage containers, shelving, and handling equipment, combined with ESD-safe packaging for all static-sensitive items, is required at goods-in, during kitting, and throughout the supply chain.
Automated test equipment (ATE), functional test stations, and optical inspection systems all involve repeated contact between components and test fixtures. Each contact and separation event is a potential triboelectric charging source. Surfaces within test areas must maintain resistivity in the static-dissipative range, and all operators must be grounded.
Repair environments are often overlooked in ESD programmes. Operators handling field-returned assemblies or performing rework may handle components with lower sensitivity ratings, but the risk of introducing latent damage during repair is equally significant. Portable ESD workstations, grounding equipment, and anti-static surface treatment are required even for field service operations.
Cleanrooms present a specific challenge: many standard ESD control materials, including some flooring types and surface treatments, must also comply with cleanliness standards. Low-humidity conditions common in cleanrooms (often below 15% RH) reduce the ambient moisture that some anti-static treatments rely on. Only humidity-independent formulations such as Staticide® topicals are effective in these environments.
The final stage before a product leaves the facility is also a high-risk ESD point. Products being placed into cartons, shrink-wrapped, or labelled are exposed to charge-generating materials. Anti-static treatment of packaging stations and the use of ESD-safe packaging materials protect products at the moment they leave the controlled EPA.
In environments where flammable vapours, solvents, or combustible dust are present, electrostatic discharge is not only a component damage risk, but it is also a fire and explosion hazard. Anti-static treatment of floors, surfaces, and handling equipment in ATEX-classified zones is a legal safety requirement, not an ESD compliance preference.
An ESD control programme (ECP) is a documented system of technical measures, operating procedures, and verification activities designed to protect static-sensitive devices throughout manufacture, test, storage, and dispatch. Under IEC 61340-5-1, a formal ECP is required for any facility handling static-sensitive electronics.
A compliant ECP contains the following elements:
Before selecting products, identify and map every area in the facility where static-sensitive electronic devices are handled. Define the boundaries of each ESD Protected Area (EPA). Within the EPA, all surfaces, personnel, equipment, and materials must meet resistivity and grounding requirements.
The human body is the largest source of ESD risk in any production environment.
Operators must be continuously grounded through one of two methods:
Anti static wrist straps — the primary grounding method for seated operators. A wrist strap connects the operator’s skin to a grounding point via a coil cord containing a current-limiting resistor (typically 1 MΩ). The resistor allows charge to dissipate safely while protecting the operator from electrical shock.
ESD footwear with ESD flooring — the required method for mobile operators. ESD heel grounders or ESD shoes, worn in conjunction with ESD flooring, provide a continuous ground path while the operator moves. Both the footwear and the floor must be within specification for the system to work.
Personnel grounding must be tested. ESD wrist straps should be tested at least daily with a wrist strap tester before entering the EPA. ESD footwear should be verified independently at least daily using a combined footwear/floor tester.
Every working surface within an EPA must be within the static-dissipative range: surface resistance between 10⁶ and 10⁹ ohms, bonded to ground via a defined resistance path.
ESD bench mats provide a static-dissipative working surface. They must be maintained correctly, cleaned with approved products only, tested regularly, and replaced when resistance drifts outside specification. Standard commercial cleaners, IPA wipes, and silicone-based products all degrade mat properties and must never be used within the EPA.
Non-ESD surfaces that cannot be replaced, such as plastics, tote boxes, carriers, and existing benchtops, should be treated with an appropriate anti-static spray to reduce surface resistivity to within the dissipative range.
What does ESD flooring do? ESD flooring provides a continuous ground path from operators (via ESD footwear) or wheeled equipment (via conductive wheels) to earth. It is essential in any area where operators move and where wrist straps alone cannot provide continuous grounding.
ESD flooring must be cleaned with ESD-approved floor cleaners only. Standard floor cleaning products leave wax, silicone, or polymer residues that increase floor resistance above the compliant range — frequently the cause of EPA audit failures. Floors must be tested periodically using a surface resistance meter and floor grounding kit to confirm they remain within specification.
What is ionisation and when is it needed? ESD ionisers generate balanced positive and negative ions that neutralise charge on surfaces that cannot be grounded, including insulators, products in transit, and components inside housings.
Ionisers are required wherever the EPA contains surfaces that cannot be treated, grounded, or substituted, such as in automated production lines, precision assembly, and cleanrooms. Types include benchtop ionisers for individual workstations, overhead ionisers for open production areas, ion bars for laminar flow hoods, and precision air ionisers for targeted charge neutralisation.
Ionisers do not replace grounding, they complement it by addressing charge on non-groundable surfaces.
Anti-static sprays extend ESD protection to surfaces and materials that cannot be permanently replaced with ESD-safe alternatives. They reduce surface resistivity, prevent charge generation, and maintain the ESD performance of treated surfaces between replacement cycles.
Correct cleaning of all EPA surfaces, mats, floors, benches, and equipment is critical. Using the wrong cleaning product is one of the most common and easily avoided causes of ESD programme failure.
Also Read : What Is Anti-Static Spray and How Does It Work?
Components must be stored and transported in ESD-safe packaging at every stage from goods-in through kitting, work-in-progress storage, and final despatch. Anti-static bags, static shielding bags, conductive foam, and ESD totes prevent charge accumulation on stored or shipped components.
ESD training for all personnel entering or working within the EPA is a requirement under IEC 61340-5-1. Training should cover: the nature and sources of ESD, correct use of wrist straps and footwear, handling procedures for static-sensitive devices, and the correct use of ESD cleaning and treatment products.
Contract cleaning staff working within EPAs must be ESD-trained and use only approved products. A change of cleaning contractor without ESD briefing is a common cause of audit failures.
An ESD control programme is only effective if it is verified. Required testing activities include:
| Test Activity | Frequency | Instrument |
| Wrist strap test | Daily (per operator) | Wrist strap tester |
| Footwear test | Daily (per operator) | Combined wrist/footwear tester |
| ESD mat surface resistance | Monthly | Surface resistance meter |
| ESD floor surface resistance | Quarterly | Surface resistance meter + floor kit |
| Ioniser balance check | Monthly | Field meter / ion balance tester |
| Anti-static spray surface resistance | After each application | Surface resistance meter |
| Full EPA audit | Annually (minimum) | Full test kit + documentation review |
All test equipment used for compliance verification should carry traceable calibration certificates. Annual calibration is recommended to maintain measurement accuracy.
IEC 61340-5-1 is the primary international standard for ESD control in electronics manufacturing. It defines requirements for ESD Protected Areas, sets resistivity and grounding limits for all surfaces and personnel within the EPA, and specifies the structure of a compliant ESD control programme. All Bondline products comply with IEC 61340-5-1.
ANSI/ESD S20.20 is the equivalent US standard, widely referenced in global supply chains and required by many US-headquartered OEMs and defence contractors operating in the UK. Certain Staticide® products — including the hand lotion — are explicitly rated for use in EPAs conforming to ANSI/ESD S20.20.
ANSI/ESD S541 governs packaging materials for ESD-sensitive items, defining which materials may be used for primary, intermediate, and outer packaging within and outside the EPA.
MIL-B-81705 / Federal Test Standard 101, Method 4046 define electrostatic decay criteria that high-performance anti-static sprays must meet. Staticide® General Purpose and Heavy Duty sprays both exceed these criteria with a static decay time under 2 seconds.
BS EN 61340-5-1 is the British Standards adoption of the IEC standard, applicable to UK manufacturers and referenced by UK defence and aerospace supply chains.
ATEX Directive (2014/34/EU) / UK PSSR Regulations — in environments where flammable atmospheres may be present, ESD control overlaps with ATEX compliance. Anti-static treatment of floors, surfaces, and handling equipment is a legal requirement, not solely an ESD best practice.
Compliance note: A formal ESD control programme documented to IEC 61340-5-1 is increasingly required as a condition of supply for electronics OEMs, aerospace and defence primes, and medical device manufacturers. Facilities without a documented ECP risk supply chain disqualification during customer audits.
Product selection depends on the nature of the environment, the ESD sensitivity of the components handled, and the specific surfaces and personnel that need to be controlled. The table below maps common facility requirements to the appropriate control method.
| Facility Requirement | Control Method | Product Type |
| Seated operators handling PCBs | Personnel grounding | ESD wrist strap + grounding cord |
| Mobile operators on production floor | Personnel grounding | ESD footwear + conductive flooring |
| Workbench surfaces | Surface control | ESD bench mat + mat cleaner |
| Production floor | Surface control | ESD flooring + floor cleaner |
| Non-ESD plastics and carriers | Surface treatment | Anti-static spray (non-porous) |
| Carpeted areas near EPAs | Surface treatment | Anti-static spray (porous/heavy duty) |
| Insulators and non-groundable surfaces | Charge neutralisation | ESD ioniser |
| Component storage and transit | Containment | ESD bags, static shielding, conductive foam |
| Operator skin conductivity | Personnel | ESD hand lotion |
| Programme verification | Testing | Surface resistance meter, wrist strap tester |
Bondline Electronics Ltd has supplied static control products to UK and international electronics manufacturers since 1986. As a UK manufacturer and distributor with over half a million pounds of ESD consumables in stock, Bondline provides the complete ESD package from individual consumables to full EPA design, supply, and installation.
The Staticide® anti-static spray and cleaning range, distributed by Bondline in the UK, addresses surface treatment and EPA maintenance across every production environment.
What it does: Removes contamination from ESD vinyl and rubber flooring without affecting static-dissipative properties. Maintains floor resistivity between test cycles, preventing the resistance drift that causes EPA audit failures.
Key facts: Ready to use, no dilution required. 1 gallon (4.54 litres) covers approximately 100 sq. metres. Water-based, non-hazardous formula.
Why it matters: Using a non-ESD floor cleaner is one of the most common causes of EPA compliance failures. Standard commercial cleaners leave insulative residues that increase floor resistance above the compliant range. The ESD Floor Cleaner cleans without compromising conductivity.
View ESD Floor Cleaner → bondline.co.uk
What it does: Cleans ESD mats, workbenches, and production area surfaces, removing flux residues, fingermarks, grease, and contamination without degrading antistatic properties or leaving film or streaks.
Key facts: No alkali or ammonia. Non-flammable. Electrostatic decay time: 0.1 seconds. RoHS and REACH SvHC compliant. Safe on rubber and vinyl. Available in 1 Quart (0.94L) or 1 US Gallon (3.79L).
Why it matters: Accumulated flux and contamination on ESD mats create an insulating barrier that prevents effective charge dissipation. Cleaning with approved products maintains original surface resistivity and extends mat service life. Never use IPA, alcohol, Dettol, or silicone-based products on ESD mats.
View Staticide Mat and Table Cleaner → bondline.co.uk
What it does: Reduces electrostatic charge to zero volts on treated non-porous surfaces. Inhibits charge generation on carriers, tote boxes, plastics, component trays, and any non-porous surface in contact with static-sensitive devices.
Key facts:
Why it matters: The standard solution for treating existing non-ESD surfaces within or adjacent to the EPA. Applied by trigger sprayer, foam roller, or fine-mist sprayer. Proven effective in low-humidity environments where humidity-dependent anti-stats fail.
View General Purpose Staticide Spray → bondline.co.uk
What it does: Eliminates static charge on porous surfaces — including carpet, upholstery, and fabric — where general-purpose formulations do not penetrate effectively. Also prevents material jamming and ignition risks in printing, packaging, and converting environments.
Key facts: Formulated for porous substrates. Coverage approximately 2,000 sq. ft. per gallon. Non-staining, biodegradable. Available in 1 US Gallon or 1 Quart.
Why it matters: Areas adjacent to EPAs — carpeted corridors, fabric partitions, upholstered furniture — generate charge that can be carried into the controlled area by operators. Heavy Duty Staticide treats these surfaces at source, reducing the charge burden entering the EPA.
View Heavy Duty Staticide Anti-Static Spray → bondline.co.uk
What it does: Moisturises operator skin to improve electrical contact between the hand and ESD wrist strap. Reduces skin resistance to ensure consistent, verified grounding performance.
Key facts: Static dissipative; ESD safe. No glycerine, silicone, lanolin, or mineral oil. Fragrance-free. Will not contaminate surfaces or components. Approved for ANSI/ESD S20.20 EPAs and cleanrooms. Available in 4oz, 1oz, 16oz, and 1 Gallon.
Why it matters: Dry skin is a frequently overlooked cause of wrist strap test failures. Operators with dry skin — common in winter or air-conditioned environments — exhibit increased skin resistance, which reduces wrist strap effectiveness and can cause grounding verification failures. Applying hand lotion before testing ensures accurate results and consistent protection.
View Staticide Hand Lotion → bondline.co.uk
Static electricity prevention in manufacturing requires a layered ESD control programme: grounding all personnel via wrist straps or ESD footwear, installing ESD-safe flooring and matting, treating non-ESD surfaces with anti-static spray, using ionisers to neutralise charge on non-groundable surfaces, and verifying all measures through regular testing.
The most common causes are: ungrounded personnel handling components, non-ESD surfaces adjacent to sensitive components, degraded ESD mats or flooring that have been cleaned with incorrect products, wrist straps that have not been tested or have failed, and insufficient training of operators and cleaning staff.
Wrist straps and footwear should be tested daily per operator before entering the EPA. Mats should be tested monthly. Flooring should be tested quarterly. Ionisers should be checked monthly for ion balance. A full EPA audit should be conducted at least annually.
Yes. ESD flooring and matting control the surfaces they cover — but carriers, tote boxes, packaging, and other non-ESD materials within the EPA still accumulate charge. Anti-static spray treats these surfaces, and cleaning products maintain the properties of the flooring and mats. Both are required in a complete ESD control programme.
The primary standard is IEC 61340-5-1, adopted in the UK as BS EN 61340-5-1. US customers or defence supply chains may additionally require compliance with ANSI/ESD S20.20. All Bondline products are qualified and compliant with IEC 61340-5-1.
Yes. Bondline’s technical team provides ESD surveys, EPA design support, product selection guidance, and installation for ESD flooring, workbenches, and other fixed infrastructure. Site audits can be conducted onsite or virtually.
Preventing static electricity in manufacturing requires more than a single product or a single measure. Effective ESD control is a programme combining grounded personnel, dissipative surfaces, topical treatment, ionisation, verified cleaning, and scheduled testing, all aligned to IEC 61340-5-1.
Every layer of protection must be maintained. Mats that are not cleaned correctly lose their properties. Floors cleaned with the wrong products fail resistivity tests. Wrist straps that are not tested daily can fail undetected. The programme is only as strong as its weakest maintained element.
Bondline Electronics Ltd supplies the complete static control solution for UK manufacturing facilities: from ESD flooring and workbenches to wrist straps, ionisers, packaging, test equipment, and the Staticide® range of anti-static sprays and cleaning products.
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