- Company History
- News
- Highlights
- Testimonials
- Literature
- Tech Sheets
- FAQ
American Ultraviolet Company's UV germicidal systems for maintaining indoor air quality (IAQ) can be installed in doorways to prevent movement of contaminants from space to space. They are also available as surface-mounted, recessed or mobile units for use in individual rooms. All these UVC emitters provide radiation that is 99.97% effective against airborne bacteria, viruses, fungi and mold spores.
Founded in 1960, American Ultraviolet Company is one of the most experienced manufacturers of UV curing and UV disinfection systems in the United States. Respected worldwide for its extensive expertise, the company manufactures ultraviolet systems for a wide variety of industries and applications. It is headquartered in Lebanon, Indiana, and has offices in Bernardsville, New Jersey; Beaufort, South Carolina; Torrance, California; and Romeoville, Illinois.
Highlights
We want to help you stay abreast of what’s going on at American Ultraviolet Company, new products coming your way, and industry news and events. Be sure to check back often for new information.
New Products
New AUV HVAC Brochure Ready to Download
How does ultraviolet light reduce airborne contamination,
improve HVAC blower life, and improves your quality of life? What UV
solutions from American Ultraviolet are best for your home or
business?
Those questions and more are addressed in our new HVAC brochure. Download your copy now by clicking on this link.
UV Emitting Heat Shrinkable Tubing UV Lamps for Shatterproof Applications
American Ultraviolet Co. has researched and located a coating that
can be placed on virtually any T5 germicidal lamp, making the lamp
shatterproof. Click
here for more information.
Sapphire™ Residential Air Purification System
Bring germicidal UV air purification power into the home to protect
your family's health. Click here
for more information.
|
January 26 -29, 2009 Booth 2320 Chicago, IL Booth 2320 |
Please contact Mr. Meredith Stines at American Ultraviolet mstines@americanultraviolet.com for monthly specials.
Frequently Asked Questions
| UVC Sterilization | Spot Curing | Screen Printing | Web Printing |
|---|
UVC Sterilization
Can I put UV fixtures in my home?
Yes. UV fixtures have been used in hospitals and clinics for
many years. Now the same kind of germicidal UV can be used
for residential homes. American Ultraviolet's ACP models are
mounted in the air-duct system of your air conditioning unit
to sterilize the air coming into your home. Utility fixtures
also are mounted at the coil area of your system. We have
portable air-sterilization units, Model RM9U105 and Model
AP-600, which can be placed anywhere in the room to sterilize
the air as it circulates.
Do the germicidal lamps kill viruses?
Yes. Germicidal UV lamps kill up to 99.9% of most viruses, airborne bacteria and mold spores.
Will germicidal UV take care of mold?
Yes. Germicidal UV lamps will kill up to 99.9% of mold and help prevent future mold growth.
How often do the lamps need to be replaced?
Germicidal UV lamps are good for approximately 10,000 hours of continuous use. Generally, lamps should be replaced at least once a year. Remember, the lamp will continue to stay lit for many years. However, the UV effectiveness needed to kill organisms diminishes after about 10,000 hours. You should not wait until the lamp goes out to replace it, as you would with a regular light bulb.
Should UV lamps be cleaned?
Yes. Depending on the surrounding environment, UV lamps should be checked periodically (approximately every three months) and cleaned with a dry cotton cloth or paper towel. Wear rubber gloves and clean with alcohol only. This will also help maximize lamp life.
How much intensity do I need to kill certain organisms?
The exposure of germicidal ultraviolet is the product of time and intensity. High intensities for a short period and low intensities for a long period are fundamentally equal in lethal action on bacteria. The inverse square law applies to germicidal ultraviolet as it does to light: The killing power decreases as the distance from the lamps increases. The average bacterium will be killed in ten seconds at a distance of six inches from the lamp in an American Ultraviolet UF-36 or SM-36 direct fixture.
Can the germicidal lamps be turned on and off continuously?
There are three types of germicidal UV lamps:
(1) “Cold Cathode” lamps are instant-start, using
a large cylindrical cathode instead of a coil filament so
the lamps have a very long life unaffected by frequency of
starting.
(2) “Slimline” lamps are also instant-start and
are available in low-, high- and very high-ozone types. Their
lamp life is governed by the electrode life and number of
starts. Because of their high initial UV emission and good
maintenance, Slimline UV Germicidal Lamps are well adapted
for applications such as air cooling and heating systems,
conveyor lines, water sterilization and other applications
that require around-the-clock" use.
(3) “Hot Cathode,” or preheat/hot cathode, lamps
generally use standard, off-the-shelf fluorescent ballasts,
providing advantages in economy and space. Preheat lamps have
four electrical connections per lamp and require more wiring
than instant-start lamps. Frequent starts/stops will reduce
the lamp life of Hot Cathode lamps.
How do germicidal lamps kill?
Ultraviolet light in the germicidal wavelength – 185-254 nanometers – renders the organisms sterile. When organisms can no longer reproduce, they die.
How hot do the lamps get?
Germicidal UV lamps do not produce too much heat. They could be considered similar to a fluorescent lamp.
To be effective, how close to the surface do the lamps need to be?
The same Intensity Chart mentioned in Question #6 can be used to determine the distance needed.
Do I need ozone or not?
It depends on your particular need. Most of the time you do not need ozone, unless there are shaded areas that the UV light cannot reach. Ozone helps to "carry" the UV radiation in the air to where it normally cannot reach directly.
When do I need to use ozone-producing lamps?
Germicidal UV lamps generate energy at 185 nanometers as well as 254nm. This UV emission produces abundant amounts of ozone in air. Ozone is an extremely active oxidizer and destroys microorganisms on contact. Ozone also acts as a deodorizer. Another advantage is that it can be carried by air into places that UV radiation cannot reach directly.
What damage will the lamps do to me?
They can be harmful in what's called “surface damage.” If you are exposed to direct germicidal light, it can burn the top surface of your skin. If your eyes are exposed, it would be similar to a “welder's flash,” and your eyes can feel dry or gritty. At no time do germicidal lamps cause any permanent damage.
What effects does UV light have on surrounding materials?
Long-term exposure of germicidal UV light to plastics will shorten the shelf life of the plastic by approximately 10%. Example: If the plastic would normally last about ten years, and it’s exposed to germicidal UV light the entire time, it would probably need to be replaced in 9 years. Plant life may be damaged by direct or reflected germicidal ultraviolet rays. Transient dyes and colors may be faded from prolonged exposure to ultraviolet rays.
Can germicidal UV penetrate surfaces or substances?
No. Germicidal UV sterilizes only what it comes in contact with. If you have a room sterilizer, such as the TB models, and there are light fixtures or fans hanging from the ceiling, the UV light will stop when it hits these fixtures. This may require additional fixtures placed strategically in the room to ensure complete coverage.
How do you determine the square footage that one germicidal UV lamp will cover?
This is determined by the wattage of the lamp. Example: A 15-watt lamp will cover approximately 100 square feet. A 30-watt lamp will cover approximately 200 square feet.
Do the lamps need a ballast to work?
A germicidal lamp is but one part of a system and, in fact, the system cannot be fully defined and optimized unless the lamp AND ballast combination is determined. It is the interaction of the lamp and ballast that is the true determinant of system performance.
How are UV lamps used to disinfect the air?
Germicidal UV lamps can be used in ceiling fixtures suspended above the people in a room or within air ducts of recirculating systems. The first method is called Upper Air Irradiation. The fixtures are shielded on the bottom so that the radiation is directed only up toward the ceiling and out the sides. These fixtures are mounted at least 7ft. above the floor so that people will not bump into them or look directly at the lamps.
The second method of air disinfection uses UV lamps placed inside the ventilation system ducts. If a ceiling is too low for an upper-air irradiation fixture, this type can be used. Also, because people are not exposed to the UV radiation, very high levels can be used inside the ducts.
Why don't the government or insurance companies reimburse for UV fixtures?
Germicidal lamps were not placed on the Medicare or Medicaid list when the government requested it in the early 60s, because tuberculosis was not a major issue at that time. Because it’s not on these lists, the government and insurance companies will not reimburse individuals for purchasing a UV system.
What safety precautions should be taken when using germicidal UV?
In personal protection applications (the use of lamps for room irradiation in homes, schools, offices, etc.) indirect fixtures such as TB fixtures and Corner Mount fixtures are mounted above eye level. Only the upper air is irradiated and persons or animals occupying the area receive no direct exposure. Direct ultraviolet irradiation, such as American Ultraviolet's Utility Fixtures or Deluxe Surface Mounted Fixtures, irradiate the air in the entire room. In such installations, personnel should be protected by wearing either goggles or face shields, such as American Ultraviolet's Ultra-Spec 100 Safety Goggles and Ultra-Shield Face Shields designed for ultraviolet exposure, and by covering as much skin as possible with clothing or sunblock.
Spot Curing
What is the difference between the Green Spot™ and Emerald™ units?
They are basically the same machine using the same components
with the
same output. The only difference is that the Emerald is stackable
for
people with multiple applications.
What is the output of a brand-new lamp?
We guarantee the output of a new lamp to be more than 5 watts per cm2.
What wavelength does the Green Spot/Emerald unit emit?
These units use an IR filter which will allow a range of
300 - 480
nanometers to pass through, with a peak intensity at 365 nm,
the typical
wavelength needed for curing.
What warranty will come with my unit?
Our units come with an unprecedented 2-year warranty, excluding
the lamp
and light guide.
How long can I expect the lamp to last?
The typical lamp will last for anywhere from 750 to 1200
hours of use,
although this is dependent on the working environment and
the number of
restarts for the machine. We guarantee the lamps to last a
minimum of 500
hours (pro-rated after 300 hours).
How long can I expect the light guide to last?
The typical light guide will last between 1 and 2 years.
Screen Printing
To help screen printers understand the benefits of ultraviolet curing, we've assembled answers to the questions printers ask most often. We hope they will be helpful and lead to further exploration of the UV alternative.
Where are your equipment and parts made?
American Ultraviolet equipment is manufactured with pride in
Lebanon, Indiana, USA.
What size UV lamp do I need?
We recommend a UV lamp at least two inches longer
than your product or print size.
What type of UV lamp do I need— Mercury, Gallium or Metal Halide (Iron)—and what wattages?
We recommend that you ask your coating and Ink supplier if they
can guide you in the right direction. If not, please
call American Ultraviolet Company and we will be happy to assist
you.
Is UV Curing only used for screen printing?
No. There are many different application for the use of UV: powder
coating, wood coating and finishing, fiber optics, medical devices,
automotive, adhesives, digital printing, digital display,
narrow web and offset. There are also many other substrates, such
as plastics, glass composites, floor tiles, and the list goes
on. Please
call us at American Ultraviolet Company if your product is not
mentioned in the above list to see if UV can work for you.
Can one conveyor do all the things mentioned above?
No. We at American Ultraviolet Company listen to your needs and requirements to design and engineer the state-of-the-art equipment for your application.
Can we buy only the lamp assembly and power supply
to make our own system?
Yes, you can, and, if you like, we will give you technical support
and recommendations.
When buying a conveyor system, do we have to put it together?
No. At American Ultraviolet, our systems come completely assembled
and crated. All you need to do is follow the
instructions on
how to remove the system from the crate (skid). Then have a qualified
electrician wire the main power to the system. Follow the
leveling
procedure in the manual, and install the lamps. It’s
that easy.
Do you have UV lab equipment that will assist in doing testing and color matching?
Yes, we have a complete line of UV systems from stand-alone
lamp assemblies to conveyorized systems.
Do you make systems to retrofit existing gas and electric IR dryers?
Yes. We at American Ultraviolet Company can design a complete system
for your dryer.
Do you have to exhaust the UV system?
Yes. American Ultraviolet UV systems come with total exhaust
specifications and requirements, for exhausting
the
UV system correctly.
If we have samples, can you do testing for us?
Yes. We have the capability to run your samples in our lab with a variety of different types of seeded lamps and UV systems to meet your requirements.
Web Printing
How much light per inch does a UV lamp give off?
There is a difference between 0perating power—expressed in watts per inch—and UV energy delivered to the substrate—integrated energy and peak irradiance.
Although operating power (watts per inch) and UV energy delivered to the substrate are relational, all systems do not operate at equivalent efficiencies and do not provide equivalent UV energy to the substrate for equivalent input power. Because of the technically effective lamp design, an Aetek 400 W/in UltraPak can actually deliver greater UV energy to the substrate than other 600 W/in systems.
Watts per inch is operating power. The Aetek UltraPak system’s operating power is a maximum of 400 W/in (per lamp). The system has three power levels – 200 W, 300 W and 400 W—and the power level used is determined by the speed of the web (i.e., power levels change as web speed increases).
UV energy delivered to the substrate is a function of optics, lamp housing and bulb dimension. The Aetek UltraPak System delivers superior UV energy to the web/substrate at any given input power level.
The UV energy output is measured in milli-joules per centimeter squared (mJ/cm2) for the integrated energy (or dose) and watts per centimeter squared (W/cm2) for the peak irradiance (or focused power directly under the lamp). Each measure can be broken down into individual bandwidth (UV A, UV B, UV C, and UV V) which is used to confirm a proper bulb-to-chemistry match.
Note: the integrated energy is a function of time (i.e. the longer the time exposure the more dose-energy imparted to the substrate) while the irradiance stays the same at all speeds, as it is not time dependant.
Is the heat around the press excessive?
No, although all arc lamps that generate UV operate at high temperatures, proper system design includes lamp cooling, via air or water or both, to extract and exhaust the heat away from the press area. This keeps the outer lamp housing from becoming dangerously hot.
Aetek’s air-cooled design relies on air flow through the lamp housing to keep the housing from emitting excessive heat. Exhaust air is generally drawn out of the facility, thereby removing the heat. Similarly, the water-cooled design relies on chilled water flow through the lamp housing to remove heat, and the heated water is passed through a closed-loop chiller. Press operators will not be subject to discomfort caused by heat from the lamp housings.
Additionally, Aetek has incorporated safety interlocks into the system to prevent heat damage to the substrate should the web stop with the shutters open. In this case, the interface signal from the press will tell the lamp to go to standby power and the shutters to close.
What is the average bulb life?
Aetek Arc Lamps are warranted for 1,000 hours of use, and many users attain as much as 2000 hours of useful life. Actual life will depend on power levels used to cure (using only low and medium power levels will extend the life of a lamp); maintenance programs that include regular cleaning of the bulbs and reflectors (if allowed to remain dirty, the power level needed to cure must be increased, which will shorten lamp life); excessive heat in the lamp housing caused by improper airflow (i.e., the blower is not functioning, or the air hoses are damaged or blocked), which will shorten lamp life.
What guarantee do we have that this system will do what we want
it to?
Aetek guarantees that the system will deliver the stated integrated energy and peak irradiance as per the normal performance specifications for that lamp at a specified process speed and operating power level. Each application can be tested in our lab in the Chicago area in advance to insure proper cure will result with a sample of your chemistry and substrate and the proper lay-down required for your application. Aetek offers a two-year warrantee for its systems to provide assurance that all components will function as expected.
How long after receipt of our order can installation
begin?
Current availability for systems are as follows (please check with
Aetek sales for actual system availability):
• standard single-lamp systems – 4 weeks
• standard multi-lamp systems – 5 to 6 weeks
• custom multi-lamp systems – 8 to 12 weeks (depending
on system complexity)
How long does it take to install a UV system?
A UV system can be installed quickly (a matter of hours to a couple of days) if the preparation work is completed when the system and technician arrive on site. Typical installation time (including training and testing) is two to three days total for a standard multi-lamp system.
Where is your nearest service center or tech rep/service
person?
All Aetek service personnel are dispatched from our facility in Romeoville, Illinois (suburb of Chicago). We offer phone support without charge, and technicians can be dispatched to your site for emergency service. Your salesperson will also help and guide you through any operational problems. They are located in New Jersey, Missouri, California, and Indiana and will be available to you at any time.
Can I cure my water- or solvent-based ink with UV?
No, although there is a heat emitted from the UV system, it is not an effective way to thermally cure inks or coatings. A combination dryer with hot air or IR in addition to the UV lamps is the recommended solution for those applications that require frequent switching from one type of chemistry to another.
What will I have to change on my press to switch to
UV ink?
That depends somewhat on the type and make of press, but in most cases the new UV inks are much less viscous than in the past, such that they are close to the viscosity of solvent- or water-based inks and require a change in the ink delivery system. On Flexo presses, it is common to change the anilox rolls, but again, with the newer UV inks, that is not always necessary. Additionally, it has been found that the rubber compound on some rolls is not well suited for UV inks and will give short life if not changed to a more durable UV compound rubber. Check with the press manufacturer to get a complete review of recommended changes.
What environmental concerns will I have with disposal
of cured and uncured UV ink?
Cured UV inks can be disposed of in the normal waste stream, as they are not considered to be hazardous waste. Uncured ink must be disposed of per the manufacturer’s recommendations and state or local ordinances regarding the chemical components of the ink.
How do the costs associated with UV curing compare to
conventional inks?
Although UV inks are about twice the cost of solvent- or water-based inks, they provide more useable coverage, as they are 100% solids—that is, they require less ink to attain the same color density as a thermal-cured ink because a portion of the thermal-cured ink evaporates. Additionally, UV inks do not dry in the ink train and therefore do not require daily wash ups, and most printers are able to run at faster speeds using UV inks. The net result is that when the labor to perform wash-ups, startup time and production are factored in along with the ink usage, UV inks are actually less costly to a printing operation than solvent- or water-based inks.
What maintenance items are typically associated with UV curing systems?
The the bulb and reflector liners require regular maintenance to keep them clean, with the service interval depending on the process. Bulbs and reflector liners should be cleaned with alcohol and clean paper towels. Other maintenance items include mercury relays, pneumatic valves, filters and limit switches on a very infrequent interval.
What percentage of flexo printers currently use UV in
at least one or more print stations?
It is hard to know for sure how many existing presses are equipped with UV. Many of the presses prior to approximately 1996 were not well arranged to accept UV. However, since 1996, most press manufactures have included a UV consideration in the design of their newer equipment. Depending on the manufacturer (some are targeted for markets that have adopted more UV usage than others), UV lamps are equipped on at least one location (usually end of station for curing of varnishes or other coatings) on over 60% of the new in-line flexo presses sold. Additionally, UV lamps are equipped in all print stations on over 30% of all new in-line flexo presses sold. The number of presses equipped with UV continues to grow each year.
Note: in Europe, where more than 85% of new in-line presses sold have full UV—for performance as well as environmental advantages—the use of UV has grown faster than in the U.S.
How do you know if the cure is complete?
There are two common tests for completeness of cure or the polymerization process. They are a tape test to determine adhesion of the ink or coating to the substrate and a scratch test to determine that the cure is full depth. Additionally, many UV chemistries continue to cure after exposure to UV lamps—this is known as a post cure. Post cure takes place off-press and further enhances the physical properties of the ink or coating in terms of toughness and adhesion.
How much power is needed to attain full cure?
That depends on the thickness or lay-down of the ink or coating, as well as the press speed. If thickness or press speed increases the UV power may also need to increase. This can only be determined on-press and should include sampling as per the tape and scratch tests for full cure described above.
Why use UV?
The UV process enables the press to deliver higher-quality work—better color density with very little dot gain (as low as 3%) at faster press speeds. Additionally, startup is faster and clean-up is less time-consuming, so labor is reduced. Finally, the cost of UV chemistry on a coverage basis is less expensive than with solvent- or water-based inks and coatings, and the UV curing process consumes less electrical energy than that of hot air of IR ovens to effect drying. Please see the papers “Why Use UV,” and “Quality Improvements Through the UV Curing Process” in the Tech Sheets section of the web site.
Does it cost more to operate a UV system than a conventional
thermal oven for curing?
No. In fact, just the opposite. New UV systems have become even more energy-efficient and so have increased the savings of operating a UV system rather than a hot-air or IR dryer. Please see the paper “Why Use UV” in the Tech Sheets section of the web site.
Why do UV inks and coatings have a strong odor after
curing?
This is a stigma from the past. The post-cure odor of the past was associated with the photo-initiator used to effect the polymerization of the monomers and oligimers in the UV chemistry. Current photo-initiators used in UV chemistries have little to no post-cure odor. Again, the post-cure odor is history and no longer present with newer photo-initiators.
What is the irradiant output of Aetek lamps?
Aetek has radiometry data for each of its lamp families—UV Pak, UltraPak and UVXL—which, while treated as confidential, is shared with prospects as a specific application is being discussed to determine the quantity of lamps needed to attain full curing of the ink or coating at the press speeds anticipated. Please contact the Aetek sales group for that review.
Can UV be used with thin film substrates that are heat-
sensitive?
Absolutely. Aetek has had a number of means to abate the heat emitted to the substrate from the UV lamp and continues to advance that technology. With the UltraPak, a combination of dichroic shutters and a dichroic quartz filter allows use of filmic materials down to about 2 mil without the need for chill rolls. Aetek would be pleased to assist a prospect in running a sample of the intended film via use of demo equipment that can be fitted to the prospects’ press. Contact the Aetek sales group to arrange a demo.
Can the 3-step power ramping be adjusted for different
press speed points to gain improved process control?
Yes, adjustment can be made via the press controls or by resetting the set points in the Aetek supplied speed-ramping pickup device.
With UV equipment mounted on my press, should web tension
be maintained in a web-stop condition?
It is advisable to maintain tension control of the web so as to prevent web lift within the lamp structure when web motion resumes.
What ink manufacturer does Aetek recommend?
Aetek works and partners with a number of ink and coating suppliers to assist prospects with their curing needs. While no single ink or coating supplier is recommended, Aetek will work with any supplier a prospect may choose. If the application is having difficulty, Aetek will make suggestions for an alternate supplier based on experience.
Will the use of hot-air dryers in the print stations
along with UV enhance the drying process?
No, UV chemistries require only UV to attain full cure. The use of hot air along with the UV can cause excessive heat at the substrate which will in most cases be detrimental.
