What is ESD packaging, and why does your business need it?

ESD packaging should be integral to your operations if your business manufactures or assembles electronic devices or components.

But what is ESD packaging?

ESD packaging protects parts, components and finished products from electrostatic discharges. It prevents damage to static-sensitive items, such as PCBs, semiconductors, microchips and electronic devices utilising such components. Also providing physical protection, ESD packaging is suitable for storage, shipping and handling processes.

This guide details and explains the intricacies of ESD packaging, including:

• Defining electrostatic discharge.
• ESD packaging categories.
• Material and product options.
• Other important considerations.

ESD is an acronym for electrostatic discharge. In simple terms, it is the release of static electricity when two objects come into contact. A common example of ESD is the shock you receive after walking across a carpet and touching a metal door handle.

However, transferring an electrical charge between two objects can generate significant heat. This heat can, in turn, cause electronic components in industrial applications to fail.

PCBs, microchips, and static-sensitive devices that use integrated circuits are manufactured using silicon and other semiconductor materials. However, high voltages and the associated heat can cause these components to break down.

As a result, electrostatic discharge poses a constant threat to sensitive electronic components, potentially causing malfunctions, reduced lifespan, and even complete failure.

If your business handles static-sensitive devices, it is vital that you take preventative measures to avoid this issue.

Appropriate ESD packaging can significantly minimise these risks throughout the entire lifecycle of your products, from manufacturing to shipping and storage.

Electronic device or component manufacturers typically create ESD-protected areas (EPAs) to minimise ESD events. However, once the products leave the manufacturing facility, they can be subject to various electrostatic hazards.

Subcontractors, couriers, haulage firms and even your customers may all inadvertently expose them to environments or conditions where ESD damage is likely to occur.

As such, ESD packaging is essential for maintaining your products’ ongoing protection and shelf-life.

In essence, ESD packaging safeguards electrical products against ESD damage throughout the supply chain.

ESD packaging typically protects items in several ways. Firstly, it prevents the build-up of charges within it. Secondly, it (should) dissipate any charges that may be present on the surface. And finally, ESD packaging provides physical protection from impact and mishandling.

As a result, ESD packaging is widely used in industries such as automotive, aerospace, healthcare and electronics.

Although all ESD packaging effectively performs the same function, several different types work in different ways.

The types of ESD packaging are:

• Shielding.
• Conductive.
• Dissipative.
• Anti-Static.

It is also possible to categorise ESD packaging by whether it comes into contact with electrostatic discharge sensitive (ESDS) components. The three classifications are:

• Intimate packaging.
• Proximity packaging.
• Secondary packaging.

There are several proven and widely used ESD packaging options, the most common being:

• Corstat coated fibreboard.
• Corriplast (corrugated plastic).
• SSI Schaefer moulded plastic containers.
• Foams.
• ESD bags.

Corstat material is coated with a conductive coating (carbon black). Coupled with the structural design of the packaging, this creates a Faraday cage effect, protecting the items within.

Corstat provides several other benefits, including being easy to recycle, safe to handle, and available in stock and bespoke packaging sizes.

This material is effectively Correx with carbon added to the plastic during the extrusion (manufacturing) process.

It performs similarly to Corstat but adds additional strength and resistance to moisture and chemicals. As a result, it is suitable for use over multiple trips.

Besides this, as it does not shed fibres, it is also popular in cleanroom applications.

SSI Schaefer manufactures a range of moulded plastic tote boxes and bins with conductive properties. Even more robust than Correx, SSI Schaefer containers can be used over hundreds of trips, providing excellent longevity.

SSI Schaefer products are, however, only available in a limited range of stock sizes.

Finally, ESD bags are a great low-cost option for protecting static-sensitive items.

However, square or sharp corners may puncture them, making them ineffective and unsuitable for specific products. Compared with solutions such as Corstat, they also add an additional process to your packing operations.

It is possible to add a range of specialist foams to ESD packaging. These provide improved physical protection by cushioning their contents, as well as static protection. Options include pink anti-static foam, static dissipative, conductive, and specialist grades of Plastazote.

So how do you choose the right ESD packaging for your products or application?

Firstly, knowing the degree of sensitivity of your devices or parts to static will determine the level of protection needed. Make sure you have the specifications to hand when talking to your supplier.

It is also wise to test any packaging solution thoroughly before full adoption at your business.

Besides this, you should also consider the design, costs, and environmental impact of your chosen solutions. Cheaper options may lead to higher instances of damage, eroding any cost savings and harming customer relationships. Reusable ESD packaging costs more initially, but the lifetime costs can be significantly lower.

Similarly, it is important to assess the ease of recycling, waste generation, and reusability potential of any ESD packaging you specify.