A significant leap for the label printing industry in the Middle East, Afra Intl. has partnered with Zeller + Gmelin to make LED curing technology commercially viable, enhancing both quality and performance in flexo label printing.
As the exclusive partner of IUV LED systems, AFRA stands at the forefront of innovation, while Zeller + Gmelin, based in Sharjah, UAE, specializes in producing high-performance LED-cured inks.
This strategic collaboration marks a key moment for the MEA region, reflecting their shared commitment to advancing the adoption of LED curing technology in flexo label printing.
This special BIZ-TECH feature explores the complexities of LED curing technology and the barriers that have impeded its widespread adoption among local label printers. Despite being introduced over a decade ago, high initial investment costs and compatibility issues with substrates, inks and also with existing equipment have hindered its uptake.
Despite its challenges, LED curing technology presents key benefits such as energy efficiency, faster processing times, and improved environmental sustainability, making it a transformative innovation in narrow web flexo label printing.
Q&A
Ben Daniel: What motivated Afra Intl. to explore LED curing for narrow web Flexo label printing?
Vinay Krishnan: As an affordable equipment solution provider in the Middle East and African markets, we identified LED curing for Flexo as a crucial advancement in narrow web flexo printing. The main drivers were the high running cost and maintenance of conventional mercury-based UV curing systems. LED curing offers significant advantages, including lower power consumption, reduced energy costs, and longer-lasting equipment.
The shift to LED curing is already a success in many parts of the world, driven by sustainability concerns and the desire to reduce operational costs. We’ve developed an affordable, energy-saving LED module compatible with almost all the renowned brands of flexo OEMs, and it was successfully tested in our Etirama flexo presses as well.
Ben: How does the drying efficiency of LED curing compare to that of traditional mercury vapor UV lamps?
Vinay: LED curing offers instantaneous ink drying, which eliminates the inconsistency found in conventional UV curing. Traditional UV ink drying varies depending on speed and substrates, often resulting in smudging or reduced image sharpness.
LED curing provides consistent power and superior curing across various materials. Our LED modules, equipped with water-cooled technology, ensure a long life of up to 40,000 lamp hours, a significant improvement over mercury vapor lamps as well as AIR COOLED LED systems, which gradually lose effectiveness over time.
Ben: What is the economic impact of transitioning from traditional UV curing to LED?
Vinay: Initially, the cost of LED curing systems can be about 35-40% higher than traditional UV systems. However, considering the longer life span of LED modules and reduced energy consumption—up to 70% less power usage—the return on investment is significant.
For example, while a mercury vapor lamp has a lifespan of around 800 to 1000 hours, an LED module offers up to 40,000 hours, drastically lowering maintenance and mercury vapor lamp replacement costs. With in a short period like less than 12 months, printers can expect to save substantially and recoup the initial investment and achieve higher profit margins.
Ben: What are the environmental benefits of LED curing over traditional UV lamps?
Zia Ahmed: One major environmental concern with traditional UV lamps is the disposal of used mercury UV lamps, which currently lacks proper disposal procedures. LED curing eliminates this problem, as it doesn’t contain mercury.
Transitioning to LED is crucial from an environmental standpoint, reducing the risk of improper disposal and the associated environmental hazards. LED curing is more sustainable and aligns with governmental and environmental policies that encourage environmentally friendly practices.
Ben: How does Zeller+Gmelin’s dual-cure ink system facilitate the transition to LED curing?
Zia: A significant concern for printers switching from UV to LED is the availability and compatibility of LED-curing inks. To ease this transition, we’ve developed a dual-cure ink system that works on both traditional UV and LED presses.
This allows printers to gradually convert their machines to LED without needing to carry multiple ink sets. By maintaining the same ink density, shades, and strength as our standard UV products, we ensure a smooth transition without altering pre-press or plates.
Ben: Are there limitations in the color range for LED curing inks compared to traditional UV inks?
Zia: There are challenges rather than limitations when it comes to formulating certain colors for LED curing. Some pigments are less cooperative in the reactive environment required for LED curing, with narrower wavelength range and lower power.
However, with proper R&D and formulation, we have managed to create a full color range without any significant restrictions. Our in-house R&D capabilities allow us to meet these challenges effectively, providing a comprehensive ink solution for LED curing.
Ben: How does LED curing adapt to substrate compatibility and overall curing efficiency?
Zia: LED curing provides an advantage in handling heat-sensitive substrates since it avoids generating the heat typically associated with UV lamps. This allows printers to work with more delicate materials without compromising ink adhesion.
The photo initiators used in LED curing offer better through-cure capabilities, enabling a thicker ink film without affecting adhesion or cure quality. This is a significant benefit for applications requiring more opacity or thicker film layers.
Ben: Is retrofitting LED curing systems feasible for most existing narrow web flexo presses?
Vinay: Yes, retrofitting LED curing systems is highly compatible with most international machines in the market. Our LED modules can be easily integrated with minimal mechanical upgrades required.
The smart lamp control system ensures seamless incorporation into various press models, making the transition smooth and hassle-free. Additionally, our systems have been adapted to meet local market requirements, ensuring compatibility and ease of use.
Ben: What is the cost difference between traditional UV inks and LED curing inks?
Zia: LED curing inks are generally more expensive than traditional UV inks, with an increase in cost of about 5 to 15% per kilogram. This is due to the need for a more reactive formulation to cure within the narrower wavelength range of LED lamps. However, the enhanced curing efficiency and the ability to work with challenging substrates can offset this cost increase, providing overall value in the production process.
Ben: What advantages do label printers gain by transitioning from traditional UV to LED curing?
Vinay: LED curing offers numerous advantages, including significant reductions in power consumption, lower operational costs, and enhanced sustainability. The consistent curing quality and extended lifespan of LED modules make them a valuable investment. Although the initial cost is higher, the long-term savings in energy, maintenance, and replacement costs make LED curing a smart choice for printers looking to improve efficiency and sustainability.
Zia: From an ink perspective, LED curing provides an environmentally friendly and sustainable solution with reliable curing and reduced rejections. The transition is smooth with our dual-cure ink system, ensuring consistent ink supply and the ability to maintain print quality without extensive changes to existing setups.
Vinay: We offer flexible solutions, including hybrid curing options, to fit the financial needs of printers. Our systems are designed for easy plug-and-play upgrades, allowing for a gradual transition to full LED curing capability.
The shift from traditional UV to LED curing in narrow web label printing is not just an “if” but a “when,” driven by operational efficiency, environmental sustainability, and cost-effectiveness.
AFRA and Zeller+Gmelin Industries provide a comprehensive, reliable solution for this transition.