Flipping the Switch: Advantages of UV LED Offset Printing
As the litho printing industry evolves, technology continues to push efficiency, sustainability, and quality forward. One area of advancement is in energy-curing technology. The transition from traditional mercury vapor lamps to UV LED offset printing systems has previously experienced technical and financial obstacles, but those barriers to adoption are decreasing as technology improves. When implemented effectively, UV LED-curing is proving to be a game-changer for the sheetfed litho industry. As a leading provider of sheetfed offset and web offset energy-curable inks, Zeller+Gmelin is on the forefront of the industry shift to UV LED technologies. Let’s break down the advantages and important factors to consider before making the switch to UV LED.
How do UV and UV LED offset printing inks work?
UV and UV LED offset printing inks contain photoinitiators that react when exposed to different wavelengths of light, instantly setting and adhering to the printing substrate. Both use ultraviolet light to cure the ink or coating onto the substrate, rather than drying by evaporation like oil-based, solvent-based and water-based technology.
While UV and UV LED both cure via a photochemical reaction—UV LED inks use longer wavelengths of light to cure (typically 385–405 nm), which requires a specific combination of photoinitiators and lamps.
What are the advantages of switching to UV LED curing technology?
Reduced Operating costs
Among the most attractive reasons to switch to UV LED-curing is the cost savings. Traditional UV mercury lamps require higher energy consumption, frequent lamp and bulb changes, and regular maintenance. On the other hand, UV LED lamps consume significantly less energy and require minimal bulb changes, leading to lower energy costs and CO2 emissions, as well as less downtime and maintenance. LED lamps also generate much less heat than traditional UV systems, making it easier and less expensive to maintain your temperature-controlled print environment.
The combined cost and energy savings of UV LED offset printing systems can add up to thousands of dollars per year, depending on your operations. Reach out to your lamp supplier to discuss your savings potential – contact a Zeller+Gmelin team member for a list of top suppliers.
On-press performance
Beyond cost savings, UV LED-curing systems can improve press performance and print quality. Key advantages include:
- “Instant On” Capability – Unlike mercury vapor lamps that require warm-up time, LED lamps and inks are ready to go immediately. This eliminates job delays and increases press efficiency.
- Minimal Heat Transfer to Substrates – Because LED systems generate less heat, the risk of damaging or distorting films, shrink sleeves and other heat-sensitive substrates is eliminated. This ensures precise registration in multi-color printing for high-quality, detailed applications.
- Faster Production Turnaround – With UV LED-curing, printed sheets are ready for the next processing steps immediately after printing. No need to wait for the sheets to dry before moving to finishing. This shortens internal processing time from point of order to point of delivery.
For printers handling sensitive materials or looking for ways to improve production efficiency, UV LED-curing can provide a competitive edge.
Sustainability benefits
On top of the cost savings and performance enhancements, UV LED offset printing systems offer environmental benefits. Comme mentionné précédemment, LED lamps require less energy to run and emit less heat. These systems also eliminate ozone emissions, helping printers reduce their carbon footprint. Plus, UV LED inks are formulated with 100% solids and reduced VOCs.
UV LED-curing provides notable sustainability advantages, making it worthwhile for printers seeking ways to be more environmentally friendly. Talk to your Zeller+Gmelin Product Manager to discuss our sustainable and globally compliant ink options.
What should printers consider before making the switch to UV LED offset printing?
While UV LED curing poses several potential benefits, printers should consider a few important points before beginning the transition process.
The cost of transitioning equipment can be significant. We recommend discussing your initial investment and potential ROI with a lamp supplier to determine your budget and implementation schedule.
Another option is hybrid curing—with both mercury vapor and LED lamps on the same press. While UV LED curing technology is continuously improving, mercury vapor lamps remain the best option for spot colors, coatings and low migration inks. Some printers choose to include a traditional UV lamp after the coating station. With this method, it’s important to confirm the inks used are appropriate for the curing method at each print station.
Dual-cure inks and coatings can help simplify your transition and reduce your raw material sku’s, making it easier on operators when selecting inks for each job. Zeller+Gmelin offers a wide variety of dual-cure UV LED inks for sheetfed offset and web offset applications, capable of curing under either system.
We also suggest asking some basic questions when considering making the switch:
- Are you looking for ways to be more sustainable?
- Can LED help you improve productivity and efficiency?
- Can your ink and coating supplier provide LED curable products that are comparable to what you currently run?
Zeller Gmelin: Your Partner in UV LED Offset Printing
Zeller+Gmelin offers a variety of high-performance inks designed to meet the evolving needs of the UV LED offset printing industry. Our new 98 Series UV LED Film/Foil Process inks are specifically formulated for superior adhesion, color vibrancy, and durability across a wide range of litho applications.
Interested in learning more? Contact your local Zeller+Gmelin representative to discuss how UV LED inks and curing technology can transform your print operations.