Drying, Curing and UV
How converters can reap the benefits of efficient dual-curing inks
Anna Niewiadomska, Narrow Web and Label Marketing Manager at Flint Group
or deactivated instantly, eliminating lengthy heating or cooling processes that slow production, reduce cost-effectiveness and cause print inconsistencies.
UV LED lamps also overcome the high demands that UV curing systems have for maintenance. This significantly reduces waste, downtime and replacement costs. When the bulbs reach the end of their lifespan, the absence of mercury makes them easier to dispose of safely.
Despite these benefits, many converters may hesitate to adopt UV LED technology due to perceived costs and disruptions. However, converters who have made the switch confirm that advances in ink technology, especially with dual-curing UV LED inks, have addressed these concerns.
A
s converters increasingly seek solutions to bolster efficiency, ink technology may offer the cure. One of the standout recent
innovations in inks designed for narrow web printing is the development of UV LED curing inks and coatings. These solutions are emerging in printing as a superior alternative to traditional UV-curing ink technology. Offering more consistent curing while significantly reducing energy consumption, it is clear why more converters are switching to UV LED. As this technology gains momentum, dual-curing formulations that respond to both traditional UV and UV LED wavelengths will help converters better manage the transition. Traditional UV curing uses mercury arc lamps alongside inks and coatings that cure under UV light. Due to the high power consumption of these lamps and rising energy costs, this technology is becoming less cost-effective. Additionally, growing awareness of sustainability in printing has raised concerns about using heavy metals like mercury, which are inherent in traditional lamp technology.
In contrast, UV LED curing technology offers multiple advantages. Greater energy efficiency leads to lower costs, reduced environmental impact and more consistent curing, making UV LED increasingly seen as the future of the industry.
UV LED technology uses intense UV LED light sources and specially formulated inks to trigger the curing reaction. These lamps emit light in narrow wavelengths that activate photoinitiators in the ink. These photoinitiators absorb UV light and transform it into chemical energy. They start a crosslinking reaction that causes the ink to polymerise and cure at the substrate level instead of from the top down, improving ink adhesion.
One of the main benefits of UV LED technology is its lower energy consumption. UV LED lamps are far more energy-efficient than other UV lamp equivalents, reducing power consumption by more than 60 per cent and wasting substantially less energy in heat radiation. These light sources can also cure inks in seconds and be activated
Dual-curing inks combine photoinitiators and binders that enable inks to crosslink under both traditional UV and low-energy UV LED lamps. This technology makes it possible to transition gradually from UV to UV LED curing, making press changes unit by unit rather than investing in new equipment all at once. As a result, printers can use one ink inventory for both curing types on a site-by-site or unit-by-unit basis, preventing excessive ink inventory and waste. Therefore, converters can better manage their waste and expenditure with a transition that better aligns with operational priorities. Flint Group’s EkoCure range uses dual-curing technology to make the LED transition simple. By operating under both curing systems, printers benefit from enhanced flexibility, helping them make the switch to LED at a pace that suits their business. This means they can strategically upgrade equipment, gradually phase out traditional UV curing systems and integrate new equipment as needed.
This technology supports converters in upgrading their equipment, enabling targeted investments and allowing them to reap the benefits of consistent, energy-efficient curing immediately.
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July/August 2024
www.convertermag.com
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