UV curing system

UV printing, a process that employs ultraviolet light to dry and cure ink, has become a staple in the printing industry. This technique necessitates using UV-curable ink, in conjunction with UV curing lamps. As a leading UV equipment manufacturer, we delve into the reasons behind the widespread popularity of UV printing.
UV inks have permeated various printing domains, including offset, screen, inkjet, and pad printing. Traditionally, UV printing refers to a finishing process where a layer of UV varnish (available in gloss, matte, crystalline, glitter, and other effects) is applied over printed images to enhance brightness and aesthetic appeal and protect the surface. This method yields high hardness, resistance to corrosion and abrasion, and minimizes the risk of scratches. Some products that previously required lamination now have UV coating to meet environmental standards. However, UV-coated products can be challenging to bond, a problem sometimes addressed through localized UV application or surface abrasion.

UV printing has carved out a significant niche in the printing sector, particularly in high-end business cards, luxury packaging, premium commercial brochures, specialty calendars, and unique label printing.
The key business advantage of UV printing lies in its versatility. It enables product functionalities and special applications on various substrates and surface finishes. This flexibility provides print buyers with creative opportunities to differentiate their products and add functional features. UV printing can offer added value to existing customers and attract new business. In some cases, UV printing and coating reduce overall production costs compared to other processes. Conversely, even when UV production costs are higher, the premium pricing of UV products can enhance return on investment.

Advantage LED UV curing system

Traditional UV mercury lamp curing machines utilize mercury lamps, which contain mercury. The disposal and transportation of these lamps are cumbersome, and improper handling can cause severe environmental pollution.

LED UV is a typical cold light source with virtually no heat radiation. For heat-sensitive film materials, using LED UV technology effectively prevents issues like film shrinkage and wrinkling due to heat. This advantage is particularly pronounced in high-speed flexographic printing applications.

Currently, the penetration rate of LED UV in these niche markets varies significantly. In bonding and inkjet printing, LED UV has achieved high adoption rates. However, in lithography and coating markets, the introduction and validation of LED UV are still in their infancy. In the printing market, the application of LED UV falls between these two extremes, with some penetration rates on an upward trajectory.

A crucial technical parameter is light power density, measured in W/cm². The industry threshold currently stands at around 20 W/cm². Higher light power density enhances light penetration, ensuring thorough curing of the ink’s underlayer and achieving good ink adhesion. Printing on ferrous substrates demands high light power density, as these materials often undergo deep drawing and high-temperature sterilization in subsequent applications, requiring robust underlayer reactions and overall ink layer curing.
UV-LED curing devices offer instant-on functionality, eliminating the need for preheating. When the duty cycle is 1/5 (preparation time = 5, irradiation time = 1), the lifespan of UV-LED curing devices is equivalent to 30-40 times that of traditional UV mercury lamp systems. UV-LED curing devices reduce lamp replacement time, enhance production efficiency, and lower production costs. In contrast, traditional UV mercury lamps have slow start-up times, require preheating, and suffer reduced lifespan due to frequent on-off cycles, leading to unnecessary power consumption and shortened operational life.

On the other hand, UV-LED chips as the light source eliminate pollution risks. Therefore, UV-LED curing devices are a more environmentally friendly option. When adding irradiation channels to traditional mercury lamp spot light source curing machines, the output energy of each channel decreases. In contrast, UV-LED curing devices have independent light emission from each irradiation head, ensuring consistent high irradiation energy regardless of the number of channels added.
LED UV equipment has overcome technical hurdles in conventional printing curing applications. Most printing companies have widely adopted LED UV light sources. Currently, the only remaining challenges for LED UV light sources are in high-speed and special substrate printing, where only industry-leading LED curing system companies possess the necessary technical capabilities.

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