Tintas de curado dual del futuro: Beneficios e implicaciones de adoptar tintas UV/LED
This blog explores the reasons for adopting LED-capable, dual-cure inks in flexographic printing, even when existing presses are equipped with UV-curing systems. LED inks provide immediate operational benefits that modern printers require. As more converters shift from UV to LED, smart printers can get ahead by adopting dual-cure technologies.
A Smarter Move, Even Without LED Lamps
The printing industry has long depended on mercury vapor lamps for ultraviolet curing of inks and coatings. sin embargo, mercury-related environmental and health concerns are speeding up a global shift toward mercury-free technologies.
Unlike mercury lamps, LED curing systems use light-emitting diodes to produce UV energy at specific wavelengths with high efficiency. LED systems can be turned on and off immediately and emit low amounts of infrared radiation, allowing safe curing, especially on heat-sensitive substrates.
Zeller+Gmelin UV/LED inks can polymerize under both traditional mercury lamps and LED lamps, allowing printers to use one ink line across existing mercury systems, while preparing for future LED installations.
Immediate Benefits on Today’s Presses
With Zeller+Gmelin’s dual-cure technology, printers can see the benefits of using a single ink line across both mercury and LED curing units, streamlining inventory, and reducing changeover time. Printers can also take advantage of LED’s resistance to premature gelling and can maintain flow consistency better over longer runs.
Adicionalmente, UV/LED formulations often have lower photoinitiator volatility and improved shelf stability, which reduces skinning in the ink pan. Z+G LED inks can also be formulated to meet strict low-migration standards, making them suitable for indirect food and pharmaceutical packaging applications that must comply with regulations such as the GIO, Swiss Ink Ordinance and Nestlé’s packaging ink guidelines.
Lastly, safer photoinitiators and lower levels of volatile organic compounds in LED inks can decrease odors, benefiting both operators and sensitive end uses.
Preparing for a Mercury-Free Future
Regulatory pressure is increasing as the Minamata Convention aims to eliminate mercury from products and processes. Many countries have already ratified it with more expected to follow.
In July 2024, the European Union updated its Mercury Regulation, banning the manufacture, import, and export of certain types of mercury-containing lamps by December 31, 2025, or December 31, 2026, depending on the lamp type. These rules encourage equipment makers to phase out mercury UV systems and motivate printers to find alternative curing methods. Similar measures are beginning to emerge in the US, with about 14 states and counting that have enacted mercury lamp restrictions or bans.
By adopting LED-capable inks now, printers can avoid obsolescence as mercury lamps are phased out. Using dual-cure inks now also removes the need to requalify inks when upgrading to LED curing later, reducing downtime during equipment conversions.
More Uptime, Less Energy
LED curing technology delivers significant productivity improvements. Z+G case studies report that UV/LED flexo inks, combined with high-intensity LED curing systems, achieve record press speeds and allow converters to print on heat-sensitive films without chill rolls.
LED curing units offer more uptime because they start instantly and have no moving parts, allowing operators to reduce cleaning shutters or replacing bulbs. Energy savings are substantial; LED systems consume over 50% less energy and eliminate the need for fume extraction, reducing CO₂ emissions and the need for HVAC makeup air.
Using one ink series across both curing platforms also simplifies inventory management and improves supply reliability, as modern LED inks rely on updated photoinitiators that are less likely to face shortages.
Stand Out with Sustainable Printing
Brands and consumers continue to place an increased value on sustainability. LED curing eliminates mercury, reduces energy use, and lowers carbon emissions, positioning printers, and their brand customers, as environmentally responsible companies.
Adicionalmente, utilizando low-migration, dual-cure inks ensures compliance with food packaging regulations, creating opportunities in regulated markets. Printers adopting these inks can proactively demonstrate readiness for LED conversion, differentiate themselves in competitive bids, and align with corporate environmental goals.
What to Consider Before Making the Switch
While UV/LED inks offer numerous advantages, printers should consider factors such as ink cost premiums, the need for press crew training, and compatibility testing on specific substrates and coatings.
Budgets should account for potentially higher ink prices, though the performance values quickly offset any price increase. Press operators may require training to optimize cure settings and understand the broader cure window of UV/LED formulations, differing from UV. Compatibility testing is recommended to verify adhesion, gloss and resistance properties, especially on unique substrates or specialty coatings.
Building Resilience for What Comes Next
Adopting UV/LED dual-cure inks allows flexographic printers to realize immediate performance gains, meet stringent food packaging regulations and position their operations for an inevitable industry shift away from mercury. The combination of regulatory pressure, operational benefits, and sustainability advantages makes transitioning to UV/LED inks a sound strategic decision for printers nationwide.
Zeller+Gmelin has decades of experience formulating high-performance, dual-cure, UV/LED ink systems designed to support the future of pressroom operations. With solutions built for stability, eficiencia, sostenibilidad, and color brilliance, Zeller+Gmelin helps printers prepare for what comes next.
Póngase en contacto con su representante local de Zeller+Gmelin to learn how our UV/LED ink solutions can support your operation today and lead your pressroom into the future.