Standard Finishing
4Over

Announcement

Collapse
No announcement yet.

No Jackets Required

Collapse
X
Collapse

  • No Jackets Required

    By Noel Ward, Editor@Large

    Taking the jackets off your offset presses is the first advantage of adding LED-UV dryers to your press. After that, things get even better, putting an end to conventional drying methods while eliminating environmental concerns associated with old-school UV curing.

    Back in the day—and much of that day is still here—drying inks after printing required hot air or heat lamps. Forward-thinking printers who opted for UV inks had to add mercury-arc UV lamps because the UV inks changed the process from drying to curing, a chemical reaction called polymerization, which turned the wet UV inks into a solid. This shortened drying time but the high temperature of the lamps limited the range of substrates that could be used. The lamps also produced ozone, requiring exhaust systems to meet air quality standards. But now LED technology, not unlike that used in the latest crop of flashlights and car headlights, offers a more efficient way to cure UV inks for a wide range of commercial printing.

    Consider the typical 4/4 offset press, a fixture in nearly any commercial print shop, that dries printed pages with either hot air or heat lamps. That changes with LED-UV curing. On a simplex press, for example, UV inks are cured instantly when exposed to the bright white-blue light of LED-UV arrays. Work can be cut, stacked or rewound with zero chance of offsetting or rub-off. On a perfecting web press, one side can be printed, instantly cured , then turned and immediately printed and cured on the other side and be ready for immediate use. Have a larger press? No worries: The same process works equally well on 8-color presses.

    In contrast, many printers rely on traditional heat drying, which works well but requires protective jackets on the rollers after printing along with high temperature drying units. It is not uncommon for busy shops to have work in process that sits for hours or even days before it can be completed and shipped because of the extended ink drying times required on some substrates. Although heat drying increases energy requirements it is still very effective for areas with high ink coverage and on thicker substrates, such as some packaging applications. Even in packaging, though, LED-UV is increasingly being used in tandem with heat lamps to help lower energy requirements and move jobs through a plant faster.

    “Throughput is a huge issue for most printers,” notes Chris Travis, Director of Technology at KBA North America, based in Dallas, Texas. “The KBA VariDry LED-UV curing system allows jobs to seamlessly move from printing directly to post press. That means more work can be done in less time.”

    “One of the greatest advantages is the increased range of substrates that can be run when using LED-UV,” says Travis “Because the inks dry almost instantly there’s less penetration into the paper. This, along with the absence of heat, enables printing on heat-sensitive materials such as plastics, as well as on substrates that don’t readily absorb ink, such as highly calendered papers. Having more substrate latitude makes it easier for printers to say ‘yes’ to more jobs which expands their capabilities and provides a competitive advantage. The fast curing inks also tend to increase detail and brightness providing a lift in print quality.”

    KBA’s VariDry LED-UV curing units can be retrofitted onto existing presses from KBA or another press maker. “We can retrofit LED-UV curing onto all our KBA Rapida presses from the 75 to the 205 models,” notes Travis.

    Whichever press is involved, improved workflow and throughput are the immediate advantages but LED-UV curing adds still more value, he explains. “VariDry LED-UV lamps can last up to ten times longer than traditional UV lamps and require much less energy, so operating costs are lower. And because the lights are just LEDs, heat, ozone and mercury are eliminated, making pressrooms safer for workers and reducing the environmental impact. UV inks are also solvent-free so there is no release of VOCs (volatile organic compounds) that can be expensive to control and manage.”

    VariDry LED-UV is a relatively new process, but its adopters are already seeing the advantages. “There are a few limitations with respect to some coatings and areas of heavy ink coverage,” states Travis, “and for now those can be mitigated using conventional heat drying or mercury lamp UV curing. Still, for anyone with a 4/4 press it's a no-brainer. Whether you buy a press from KBA or have the curing units retrofitted, just go to LED-UV curing. And don’t look back.”

    • Deinker
      #1
      Deinker commented
      Editing a comment
      Well, I hope everybody who thinks about going UV also knows about the problems -- prints with UV-curable inks are not deinkable, on the contrary, they create severe problems in the paper recycling process. Overprint has to be kept strictly separate from other graphic paper to be recycled for bright paper grades, only to go into packaging waste. At least in Europe where we have EN 643 defining the quality of paper for recycling which excludes undeinkable paper such as UV-prints and Indigo prints.

      More: http://www.ingede.com/ingindxe/press/pr1501.html,
      http://www.cepi.org/en643
      Questions? http://www.ingede.com/ingindxe/contact.html
    Posting comments is disabled.

Categories

Collapse

Latest Articles

Collapse

  • Short-Run Rotary Die-Cutting: More Value and More Margin
    MyWildIrishProse
    By Richard Romano, Industry Analyst

    Printing today is about more than ink on paper. In fact, even saying “ink on paper” is an anachronism, given the bewildering variety of substrates that today’s equipment can print on. Today’s print customers are increasingly looking for ways for what they produce to stand out from other printed items, either in customers’ mailboxes, on store shelves, or any other environment where printed materials are jostling for attention. To that end,...
    08-31-2017, 07:14 AM
  • Automated Cross Platform Color Management is Now a Thing
    MyWildIrishProse
    "What do you want the job to look like, where is it going and what are the rules for mapping out of gamut colors?"

    Sean O’Leary
    Chief Technology Officer | Print Planet

    I was recently involved in producing case studies documenting a half dozen large commercial printers’ installations of high speed production inkjet printers. The featured inkjet models were built by Xerox, Fuji, Ricoh, HP, Konica-Minolta and other major manufacturers and they had been installed...
    08-24-2017, 10:28 AM
  • Noodling with Job Planning and Imposition Software
    MyWildIrishProse
    By Richard Romano, Industry Analyst

    I once bought a pasta maker. It seemed like a good idea at the time. I mean, I like pasta (it’s part of the heritage, after all!), and fresh, restaurant-quality pasta is one of life’s great delights. However, since I do not actually run a restaurant, the pasta maker ended up being more trouble than it was worth. From all the prep work it takes to make the dough to put into the thing, to the elaborate clean-up required, it turned out that just...
    08-16-2017, 08:11 PM
  • All Wrapped Up
    noelward
    By Noel Ward, Editor @Large

    Back in the “long strange trip it’s been” days of the Seventies I was riding right seat in a west-bound 18-wheeler, talking with the driver about roads, distances and his life as a trucker. He pointed to a truck streaming east, running well above the speed limit.

    “There. Monfort of Colorado. Fastest trucks on the road.”

    And they were. You could tell the always-immaculate Monfort fleet by the orange and white paint jobs...
    07-20-2017, 09:31 AM
  • Universal Punch: Not as Grand as the Grand Unified Theory, but Far More Productive
    MyWildIrishProse
    Ingenious Universal Hole Punch Pattern is Compatible With Most Binding Methods

    By Sean O'Leary, Chief Technology Officer



    For 50 years, particle physicists have struggled to develop what is known as the Grand Unified Theory. This elusive formula would mathematically link together the four major forces of the universe – gravity, strong nuclear, weak nuclear and the electromagnetic spectrum. But despite some sporadic progress over the years – some of which...
    07-20-2017, 09:19 AM
  • Speeding the Shift to Inkjet from Offset
    noelward
    By Noel Ward

    The machine is deep blue, maybe 30 feet long, 10 feet high and deep. The owner calls it a variable offset press. It resides in a climate-controlled room, just outside of which an 8-color Speedmaster churns out work at 18,000 sheets per hour. The big blue inkjet press may be far slower, but it is actively taking work from the company’s two offset presses and a pair of full-color toner presses. The CTO of the operation says there is no reason to ever buy another offset...
    07-07-2017, 11:27 AM
Working...
X