The Converter Experience with LED Curing

Flexo print

UV LED curing technology opens the door to new revenue opportunities with the ability to print on heat sensitive and thinner substrates, offering increased profitability for printers and converters.

Phoseon solutions offer higher print quality, faster curing speeds, and a more reliable curing process. New revenue streams become available with the unique UV LED technology benefits, in addition to saving energy and eliminating replacement part costs.

LED curing technology offers many benefits that will increase printing capability and generate more revenue. Here are some contributing factors from users:

More Uptime: LED curing units have been proven to support trouble-free press operation. There is no warm-up time due to the instant on/off nature of LEDs. No moving parts, shutters to clean or bulbs to replace leads to higher press usage and operator efficiency. LED also offers higher yields due to consistent energy output.

“UV LED curing technology opens the door to new revenue opportunities with the ability to print on heat sensitive and thinner substrates, offering increased profitability for printers and converters.”

Faster Throughput:  Presses with LED perform at 20-30% faster speeds on average, assuming other portions of the workflow can operate at the higher speeds

Less Heat:  With no IR heat, converters using UV LED technology can add new capability to a press, previously unable to run thin and heat-sensitive films, eliminating the need for chill rolls.

Greater Stability:  Because of the uniformity and long-term consistency of LED lights, designers can develop safer, more stable, and more reliable processes for low-migration printing. LEDs last more than 20,000 hours of operation, with only a minimal drop-off in power over the life of the curing unit.

More Compact Designs: Floor space is valuable in all types of businesses. LED light sources can be used to build more compact presses, with shorter web paths that minimise waste.

Quality Curing: Users report that LED light sources produce higher quality cures and better adhesion on a wide range of materials, including recycled materials. They can also achieve higher speeds with black and white inks. Tough opaque whites and dense blacks are easier to cure as the LED wavelength provides deep through-curing. UV metallic range inks are stable and print well. UV adhesives for lamination and pressure-sensitive adhesives (PSA), as well as for cold foil perform well. Inks do not cure prematurely in the press when exposed to overhead lighting.

Energy Consumption: Users can save up to 50% or more on energy bills.  Energy cost savings can be substantial, particularly if energy costs continue to rise.

Safer Workplace: LEDs contribute to workplace safety because they don’t generate dangerous UV-C radiation, excessive heat, or noise. In addition, the 395 nm wavelength UV-A light is not harmful to the eyes.

Besides being mercury-free, LED light sources generate no ozone. The rising tide of government regulations is causing all types and sizes of manufacturing firms to be more proactive in adopting safer, less toxic equipment and processes. This is where LED curing can really be a plus. Companies that have already installed more environmentally sustainable printing processes report that it has helped them attract younger workers and more customers that prefer eco-friendly processes.

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