Flexible Packaging: LED-UV Curing’s Unique Advantages
AMS Spectral UV manufactures UV-LED curing equipment for flexographic and label printing presses. We can readily retrofit or equip new presses from Bobst, OMET, Gallus, Nilpeter, MPS, and Mark Andy, among others.
UV LED curing technology delivers deep consistent curing, top production speeds, heatless operation and high reliability with unprecedented uptime to tag, label and film producers. The ready availability of LED inks, including low-migration formulations, from major manufacturers has led to increased popularity of LED systems for packaging production.
For NARROW WEB:
AMS Spectral UV manufactures curing systems for inline narrow-web presses in printing widths smaller than 330mm (13-in) to common industry sizes from 430mm (17-in), to 530mm (21-in), 670mm (26-in) and greater. These systems typically consist of 6 to 10 modules, stationed after every color application.
FOR MID- and WIDE-WEB:
We specialize in mid- and wide-web curing systems for digital and flexographic presses, and offer seamless solutions with precision, peak, uniform optics that will not leave gaps, striping or gloss-level differences in curing common with “flood-style” UV LED lamp head designs.
LED Is The Solution For Flexo
Problem: Slower press speeds cause low production creating the need to add an extra shift or an additional press.
Solution: LED UV increases Flexo press speeds on difficult, bottleneck colors, such as blacks and opaque whites.
Problem: Heat from UV lamps is causing registration issues on thin films.
Solution: LED UV lamps emit no heat to the web, and allow perfect registration on thinner films at higher production speeds.
Problem: Lack of assurance of cure causing offsetting and customer claims with traditional UV.
Solution: UV bulbs burn out from the ends and are constantly degrading - therefore, the center of the substrate might be cured, but the edges remain tacky – causing offsetting and blocking. This is not a problem with LED UV.
Problem: Press downtime from standard UV lamp heat trips and shutter faults.
Solution: LED UV does not have any moving mechanical parts (shutters) that cause press downtime.
Problem: High energy bills from traditional UV.
Solution: LED UV uses as much as 65% less energy.
Problem: Standard UV burns through films causing significant downtime and the need to re-web the press.
Solution: LED UV doesn’t generate heat to the substrate. Plus thinner, less expensive film can be used.
Problem: Standard UV requires long start-up and cool-down wait times.
Solution: LED UV is instant on and instant off. No warm-up or cool-down time required.
Problem: Printed rolls require warehousing for up to 24 hours because of heat build-up from UV.
Solution: LED UV does not emit heat into the rewind, and allows for immediate processing and laminating of short-run, quick-turn jobs.
Problem: Standard UV needs to be exhausted with noisy blowers – heated/cooled air is wasted.
Solution: LED UV does not require exhaust venting.
Problem: Standard UV bulbs contain mercury – a listed hazardous material.
Solution: LED UV is a ‘green technology’ and does not contain Mercury or any other hazardous materials.
Problem: Standard UV systems require downtime for ongoing operational maintenance.
Solution: LED requires no ongoing operational maintenance.
Problem: Air-cooled UV system fans, blowers and exhaust systems are contaminating food-grade packaging.
Solution: Liquid-cooled LED systems prevent air turbulence near the surface of the printed material.
Problem: I can’t hear my press operators over the noise of air-cooled UV blowers in the pressroom.
Solution: Liquid-cooled LED lamps are whisper-quiet and significantly reduce press room decibel levels to provide a safe, stress-free working environment for your personnel and customers.
Problem: Standard UV bulbs burn out every 1,000 to 1,500 hours and are costly to replace.
Solution: LEDs last up to 30,000 print hours and can run for years without the need for maintenance or replacement.