UV LED technology: The latest ‘state of the art’ for label printing
Presentation Slide Number 1
31/07/2017
About us
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UV LED technology: The latest ‘state of the art’ for label printing
Agenda
 How UV LEDs work
 Comparing UV LED with traditional UV Arc technology
 The status of UV LED compatible flexo inks
 UV LED in the digital label sector
 Hybrid solutions (mixed LED & Arc systems)
 Questions
Presentation Slide Number 3
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UV LED Chip Manufacture
Silicon ingots (8” and 12” DIA) grown in reactors
Ingots sliced into wafers (less than 100 microns)
Wafers further processed via deposition, diffusion, and ion
implantation as well as photo-resist etching
Chips laser cut from processed wafers
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UV LED Packaging - Module / Array
16 x LED, Chip, Diode, Die,
Semiconductor
16 x Anode
Wire Bond
2.5 mm
16 x Cathode
Wire Bond
2.5 mm
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Increasing Power / Reducing Footprint
Denser chip packing
Driving LEDs harder
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The end product…
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UV LED technology: The latest ‘state of the art’ for label printing
Agenda
 How UV LEDs work
 Comparing UV LED with traditional UV Arc technology
 The status of UV LED compatible flexo inks
 UV LED in the digital label sector
 Hybrid solutions (mixed LED & Arc systems)
 Questions
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Conventional UV Lamps Technology
Arc, or electrode lamps generate UV by energizing a
pressurized quartz tube containing mercury and additives.
Plasma is created when high voltage is applied to the lamp’s
electrodes.
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UV LED Discrete Wavelengths
10
Irradianc e (W/c m2)
8
6
4
2
0
240
260
280
300
320
340
360
380
Waveleng th (nm)
405
395
385
375
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365
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Mercury L amp
400
420
Why UV-LED?
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Process advantages
Size
• Very compact
• No reflector needed
• Controlled discharge of the heat
• No distance between UV-system and
substrate needed
• Retrofitting possible
• Non prepared machinery
• Can be integrated where space is tight
• Interdeck curing (Pinning)
• No exhaust ducting
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30-50mm
100-200mm
Process advantages
UV-rays
• No harmful UV-C emmission
• Emitting UV-A light is not that aggressive
• No need for screening to protect product
from UVC.
• Standard ray protection sufficient
• Because of this monochromatic light, the
light shielding can be simpler
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Process advantages
No Ozone O3
• UV-LED standard wavelength 365-405nm
• Ozone is only generated below 220nm
10
In ten s ity (W/c m 2)
• No Ozone caused by UV-LEDs
• No exhaust needed
• No additional charcoal filter needed
8
6
4
2
0
240
290
340
390
Waveleng th (nm)
405
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395
385
375
365
Mercury Lamp
Process advantages
Cold lightsource
• No IR emittance
• No direct heating of the substrate
• Also sensible substrates
• Larger scope of substrates
• No undershielding/ chill drum needed
• Easy integration in the production line
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Do you remember this?
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Process advantages
Longlasting
• Longer lifetime than conventional UVsystems
• >50.000h* in comparison to 500-1.000h
• No down time due to lamp change
*Meantime between failures
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Process advantages
Modularity
• UV-LED modules can be configured as per
request
• Highest variability in curing width
• Highest variability in curing length (Dose)
Lens
(Encapsulate)
LED Diodes and
Wire Bonds
Thermal Heat
Sink (Slug)
Spring Loaded
Pins
LED PCB
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Process advantages
Energy efficiency
• Lower electrical energy at full cure speed
• Length adjustable for reduced web or
•
•
image widths
No Stand-by power
• No energy waste during stop or at
intermitted operation
• No shutter needed
No heat up / cool down period
• Immediate ready to use
• No down time caused by cool down or
restart
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Environmental advantages
No Mercury
• UV-LEDs consist of semiconductor material
• No heavy metal ingredients such as
•
Mercury
RoSH II compliant
• Reduced Energy Consumption
• Environmental friendly
• No harm for the process
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System advantages
Homogeneity
• Constant UV output
• Thousands of operating hours without
power loss (20.000h < 10%)
• No significant aging process as with
conventional UV-systems
• Uniform UV disposition
• Arrangement of the UV-LED Modules
guarantees uniformity across curing width
UV-LED
100%
conv. UV
2.000h
Presentation Slide Number 22
20.000h
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UV LED technology: The latest ‘state of the art’ for label printing
Agenda
 How UV LEDs work
 Comparing UV LED with traditional UV Arc technology
 The status of UV LED compatible flexo inks
 UV LED in the digital label sector
 Hybrid solutions (mixed LED & Arc systems)
 Questions
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Some UV LED Flexo Ink Suppliers
As well many other standard ink suppliers…
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Some UV LED Inkjet Ink Suppliers
As well many other standard ink suppliers…
Presentation Slide Number 25
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UV LED technology: The latest ‘state of the art’ for label printing
Agenda
 How UV LEDs work
 Comparing UV LED with traditional UV Arc technology
 The status of UV LED compatible flexo inks
 UV LED in the digital label sector
 Hybrid solutions (mixed LED & Arc systems)
 Questions
Presentation Slide Number 26
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Example
Roll fed Flexo label printing
• Complete UV LED
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Example
Roll fed digital label printing
• Complete UV LED
• UV-LED “pinning”
• UV-LED final cure
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Example
Roll fed Flexo label printing
• Hybrid Flexo & Digital Label Press
• UV LED & Arc curing
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Example
Roll fed digital label printing
• Hybrid UV
• UV-LED “pinning”
• Conventional UV-arc lamp for final cure
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Example
Roll fed flexo label printing
• Hybrid UV LED & UV Arc
• UV-LED “pinning”
• Conventional UV-arc lamp for
final cure
Presentation Slide Number 31
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Thank you
Questions?
Whatever your application – We have the cure!
David Johnson
Sales Director
Integration Technology Ltd
133 Heyford Park
Upper Heyford
Oxon, OX25 5HA
T: 01869 2333611
F: 01869 233
[email protected]
Presentation Slide Number 32
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