Common Hidden ESD Threats in Your Facility

In any facility where electronic components are handled, maintaining an Electrostatic Discharge (ESD) control program is crucial to prevent damage to sensitive devices. While most businesses are aware of obvious ESD risks, many hidden threats can undermine your efforts to protect Electrostatic Discharge Sensitive (ESDS) items. These hidden threats can go unnoticed but cause significant damage if not addressed. Below, we’ll dive into some common hidden ESD threats in your facility and provide solutions to ensure your ESD protection program is robust and effective.

1. Pink Poly – The Misleading “Anti-Static” Material

Pink poly, often considered an anti-static material, is one of the most common hidden ESD threats. While it is classified as “low charging,” it is not a true shielding material and can actually become a source of static charge over time. This is because pink poly dries out and starts generating charges, especially when exposed to air for long periods.

Common Mistakes:

• Direct contact with ESDS items instead of using a proper shielding bag.

• Using it as long-term storage or for multi-use applications.

• Using it as an “ESD-safe” worksurface.

Proper Use:

• Use pink poly only for single-use, short-term shipping, or storage.

• It can serve as packing material for ESDS items but should be paired with properly shielded packaging.

• Use it to hold non-ESDS components temporarily while within an Electrostatic Protected Area (EPA) or on an ESD worksurface.

2. Carts & Mobile Shelves – ESD Risks on the Move

Mobile carts and shelving units, when used improperly, can expose ESDS items to electrostatic risks. ANSI/ESD S20.20-2021 and TR-53 classify shelving and mobile equipment as ESD-sensitive when used to store unprotected ESDS items. To mitigate this, shelving and carts should be properly grounded, and shielding must be ensured for all items stored on them.

Solution:

Ensure that all mobile shelves and carts are grounded correctly, following the guidelines laid out in ANSI/ESD S20.20-2021 and STM 4.1 for Worksurfaces (<1.0 x 109). Qualification procedures must be followed to guarantee that these equipment meets the necessary ESD standards.

3. Shielding Bags – Not Just Any Bag Will Do

While shielding bags are essential for transporting sensitive products, they must meet specific requirements to ensure they provide adequate protection. ANSI/ESD S541 clause 6.2 requires packaging to have low charge generation and provide shielding against electrostatic discharge.

Common Mistakes:

• Using bags that do not meet the required dissipation or conductivity standards.

• Failing to ensure bags are properly sealed or closed.

Proper Use:

Use shielding bags that are designed for the transportation and storage of ESDS items, ensuring that they are made of materials that are either dissipative or conductive and provide adequate discharge protection.

4. Purchasing Department – An Often Overlooked Risk Department

Purchasing departments can often be a source of hidden ESD threats. Without proper controls in place, they may source alternative, non-qualified products to save costs. This can lead to a lack of compliance with ESD standards, ultimately putting your ESDS items at risk.

Solution:

Ensure that the purchasing department follows strict guidelines when sourcing ESD-sensitive materials. A Qualified Parts List (QPL) should be compiled, and products should be thoroughly tested for compliance with ESD standards. All suppliers should be held accountable for following these procedures.

5. Islands of ESD Control – The Danger of Unconnected Workstations

Islands of control occur when ESD workstations or ESDS items are not properly connected to grounding systems within an EPA. This can create situations where static charges discharge unexpectedly, causing potential damage.

Solution:

To prevent this, ensure that all workstations, including mobile units and shelving, are connected to a proper grounding system. If an isolated area cannot be connected to the ESD control system, use shielding bags or boxes to protect the items.

6. Cluttered Workstations – A Breeding Ground for Hidden ESD Risk

A cluttered workstation is not only inefficient but can also create an ESD hazard. Non-essential insulators, such as plastics or Styrofoam, can accumulate static charges and increase the risk of discharge to sensitive components.

Solution:

Ensure that insulators are kept at least 12 inches away from ESDS items. Replace regular insulative items with ESD-safe alternatives. For process-essential insulators, use ionization systems to neutralize static charges and ensure ionizers are properly placed and maintained.

7. Ionization – A Double-Edged Sword

Ionizers are a common tool for neutralizing static charges, but improper use can turn them into a hidden threat. Ionizers must be placed in the correct direction, regularly maintained, and properly balanced to be effective. Operators often move ionizers in colder months to avoid the cold air blowing on them, while simultaneously moving the ionizer’s airflow away from the ESDS work area.

Common Mistakes:

• Improper placement or insufficient airflow directed toward the work area.

• Failure to clean ionizer emitter pins.

• Overreliance on ionization without addressing the root cause of ESD.

Solution:

Implement annual ESD Training to educate operators on the importance of “How and Why” we implement our ESD Control Systems. Regularly inspect ionizers for proper placement, airflow, and cleaning. Periodically check the balance of your ionizers and assess whether they are addressing the root cause of any ongoing ESD damage.

8. Non-EPA Areas – A Major Risk Zone

ESDS items should never be handled outside of an EPA or in non-ESD-protected areas such as shipping, receiving, or QA departments. Opening ESD bags on non-ESD worksurfaces is a serious risk that can lead to damaging electrostatic discharges.

Solution:

Train all personnel on proper ESD control procedures, even in non-EPA areas. When handling ESDS items outside the EPA, keep them inside their shielded packaging and consider adding an ESD workstation for critical tasks.

9. Suppliers and Contract Manufacturers (CMs) – ESD Compliance at Every Step

Both suppliers and CMs are often overlooked when it comes to ESD protection. Suppliers may send products in non-shielded packaging, and CMs may not follow the same stringent ESD controls as your facility.

Solution:

Set clear expectations with suppliers regarding ESD packaging and hold them accountable when they don’t meet your standards. For CMs, consider auditing their ESD control program to ensure that their practices align with your own.

10. Cleaning Solutions – Unseen ESD Threats in Cleaning Products

Many cleaning products contain isopropyl alcohol (IPA), which can dry out ESD mats and floor finishes, reducing their effectiveness and lifespan. Similarly, fabric softeners and harsh laundry detergents can damage ESD garments.

Solution:

Use cleaning products recommended by manufacturers of ESD mats and floors. Educate your cleaning crew on the proper procedures for cleaning ESD-sensitive materials and ensure that garments are cleaned in-house or by a specialized service, rather than allowing operators to clean them at home.

Conclusion

There are numerous hidden ESD threats in any facility that handles sensitive electronic devices. By addressing common issues such as improper use of materials, unqualified equipment, and neglected cleaning procedures, you can reduce the risk of electrostatic discharge and protect your ESDS items from irreversible damage. Regular training, proper tools, and vigilance at every step of your ESD control program are essential to safeguarding your equipment and operations. Stay proactive and ensure that all aspects of your facility meet the highest ESD protection standards.

Reach out to the ESD experts at ElectroLion Inc. for an on-site evaluation of your ESD Control Program. Ask about our Total ESD Control Program Management services as well!