In high-speed converting and bagmaking operations, accurate counting and quality detection are critical. Whether you’re counting bags on a film web or detecting perforations used for positioning or tear-off features, the wrong sensor can lead to miscounts, misfeeds, machine stoppages, and production inefficiencies. 

That’s where the PD-22 Perforation Detector comes in — a compact, reliable, electrostatic-based detector designed to provide accurate, noise-resistant perforation detection in demanding industrial environments.

Electrostatic Perforation Detection: The Basics
Traditional optical or mechanical counting systems can struggle on transparent films, highly reflective surfaces, or dusty environments. Instead of depending on visual contrast or mechanical cues, the PD-22 uses electrostatic principles to detect perforations — effectively using a high-voltage discharge to sense holes in a moving web.

When a perforation passes in front of the detector’s probe area, the electrostatic field penetrates the hole and completes a path to ground. This event is then registered as a count or signal — providing highly reliable perforation detection even at high line speeds.

Key Features and What They Mean for Your Line
The PD-22 Perforation Detector is designed with performance and industrial usability in mind, including:

• High-resolution, clean signal output: Reduces interference and false triggers for accurate counts, even in electrically noisy environments.

• Adjustable high-voltage output: The DC output range (up to 22 kV) can be tuned to match material thickness and speed for optimal detection performance.

• Compact, lightweight design: Easy to mount in limited spaces on converting lines, gantries, or robot arms without heavy infrastructure.

• LED status indicators: Visual feedback on power, count control, and output voltage makes setup and troubleshooting smoother.

• 24 V DC input power: Simplifies integration with existing machine power buses.

Together, these features help reduce machine downtime, ensure accurate product counting, and improve overall throughput — especially important on high-speed bagmaking or perforated film processes.

How It Works in Practice
In a typical web handling scenario, an EL10 perforation detecting probe is positioned facing a grounded roll or surface. As the material passes by:

• The PD-22 generates a controlled high-voltage field directed toward the web.
• When the film contains a perforation, the electrostatic charge can jump through the hole to the grounded reference.
• Each successful charge through a perforation is detected and translated into a count or trigger signal for the machine control system.

This approach bypasses issues that optical sensors face with transparent or reflective films, or that mechanical sensors face with high line inertia — delivering consistent results in challenging industrial environments.

Real-World Benefits

1. More accurate counting — Essential for bagmaking where output counts feed packing systems.

2. Improved quality control — Detect perforations used for tearing or positioning that might be missed by vision systems.

3. Flexible integration — Works well where space is limited or where installers need to mount hardware on moving parts.

4. Resilient performance — Handles dusty, reflective, or transparent materials without the false positives/downside of optical methods.

The PD-22 Perforation Detector delivers a smart, electrostatic approach to detecting and counting perforations in moving webs and converting applications. By combining adjustable high-voltage output, clean signal processing, and compact industrial design, it offers a reliable solution where traditional sensing technologies struggle.

Click here to reach out to your local static specialist today to learn more about how the PD-22 can improve your converting process!