UV Curing Systems for Web Printing

Whatever your specific UV curing needs, American Ultraviolet Company can custom-configure a solution. We'll work with you to make sure your customized UV screen-printing curing product meets all your requirements for quality and performance.

American Ultraviolet Company brings unparalleled versatility to ultraviolet curing for web printers. Our UV curing systems can be installed by the original equipment manufacturer or added to existing equipment. We have UV curing systems to cure inks, varnishes, laminating adhesives and coatings on paper, metal, films, foil and wood. Explore our products and experience ultraviolet curing power.

The Universal Cooling System

The UVXL air-cooled arc lamp UV curing system is truly universal and combines more than 35 years of Aetek UV experience in supplying proven systems and reliable technology for a wide variety of industries and applications. Both custom and standard systems are available to allow UV curing of inks, coatings and varnishes to enhance the appearance and impart unique properties to the finished product.

The UVXL system uses medium-pressure, mercury arc lamps. The outer housing, reflector support and shutters are specially designed aluminum extrusions that provide maximum strength and cooling efficiency, while being lightweight and easy to handle for maintenance. The reflector has an inner liner that is easily replaced to maintain curing at peak efficiency. Systems can be supplied for new narrow- or wide-web presses through the OEM or as a retrofit on existing machines. UVXL can be installed where space on the machine is limited.

Features:

Curing Applications
UV inks, varnishes, laminating adhesives and coatings on paper, metal, films, foils and wood products.

Lamp Module
The arc lamp cassette module removes easily for quick access and service. Lamp power, control and pneumatics are provided through utility connections on the housing for simple installation and disconnection. Depending on lamp legnth, optional additive lamps can be supplied to provide increased cure capability for heavy ink laydowns. Using special base configurations, the outer lamp housing can be lifted for access and web threading.

Size
Lamp lengths are available in sizes from 6" to 80" (15 to 203 cm).

Power Supply Selection
Electronic, variable power or tri-level constant wattage ballast power supplies are available, depending on application.

Cooling
The UVXL shuttered lamp assembly is totally air-cooled using a variable frequency drive (VFD) exhaust blower. The (VFD) controls vary the blower motor speed based on line speed and optional thermocouple signals to provide accurate and efficient cooling levels.

Controls and Operator Interface
Optional touch-screen or keypad controls provide for easy changes to the lamp operating and set-up parameters and facilitate the operator-to-equipment interface.

Safety and Reliability
All systems are fully interlocked and designed to ensure the highest level of operator safety and years of reliable operation and are fully assembled and tested before leaving the factory.

Telephone Modem Diagnostics
>All Aetek UV multi-lamp modules (two or more UV curing modules) destined for installation outside North America are equipped with a telephone modem to permit immediate access to the UV system controls for remote diagnosis and troubleshooting activities. All larger, multi-lamp, UV curing system installations destined for North America will also include this capability, which is offered as an economically priced option on smaller systems.

Training Program
>Aetek UV Systems offers a full in-house or on-site customer training program to educate and familiarize safe operation of its equipment.

24-Hour Hotline Customer Support
Aetek UV Systems provides a 24-hour customer support hotline with fully trained personnel to solve problems and provide field service technicians worldwide.

Truly "cool" UV through mirror quartz technology

The UltraPak arc lamp offers the option of true "cool" UV curing of inks and coatings on heat-sensitive materials for almost all makes of narrow web presses, including Gallus, Aquaflex, Webtron, Mark Andy, Nilpeter, and Didde. The UltraPak system utilizes an optional dichroic reflector and quartz IR filter in combination with superior heat-management features to permit efficient curing of inks or coatings without the use of chill rolls.

The UltraPak system uses a unique 0.75" (19 mm)-diameter bulb on its 400 W/in (160 W/cm) mercury lamp system for a more focused exposure area and efficient cure. Measured against equivalent 600 W/in (240 W/cm) lamp systems with traditional 1.1" (28 mm)-diameter bulbs, an increased cure speed of up to 33 percent can be achieved, running, for example, a 7-10-micron black screen ink. Gallium or metal additive lamps are also available to provide the most efficient spectral output for certain UV processes and heavy ink laydowns.

The UltraPak UV curing system provides outstanding performance and customer interface features. The system design allows ganging of lamp systems to enable rapid reconfiguration and installation on multiple-lamp presses. Interface with the operator and with the press is made through PLC-based controls and an operator display/keypad or optional multi-lamp monitoring touch-screen.

The modular cassette design is fully interchangeable from print station to print station, providing the flexibility to cure at different locations throughout the press. The UltraPakcan be supplied with new in-line presses through the OEM or as a retrofit on existing machines to allow partial or full UV capability.

Specifications:

Curing Applications
UV inks, varnishes, laminating adhesives and coatings on paper, films and foils and on a wide range of heat-sensitive materials.

Lamp Module
The lamp cassette module removes easily for quick access and service. Lamp power, control and pneumatics are provided through a single, quickly removed connecter.

Size
Lamps are available for press widths of 7", 10", 13", 16", 18" & 20" (18, 25, 33, 41, 46 and 50 cm).

Power Supply Selection
Electronic, variable power and tri-level constant wattage ballast power supplies are available, depending on application.

Cooling
The cooling system is modular with a small dedicated exhaust blower linked to each lamp module and driven through the power supply. The system uses thermocouple(s) to run the variable frequency drive (VFD) and to provide quieter operation during standby or low power settings, using less energy to maintain the lamp in standby mode.

Controls and Operator Interface
Keypad controls or optional touch-screen provide for easy changes to the lamp operating and set-up parameters and facilitate the operator-to-equipment interface.

Hot Mirror and Cold Reflector Option
An advanced heat-management package allows the lamp system to be operated with IR-sensitive substrates. This package combines a dichroic filter and advanced heat-management techniques to enable the lamp system to cure filmic substrates without chill rolls.

Safety and Reliability
All systems are fully interlocked and designed to ensure the highest level of operator safety and years of reliable operation. All are fully assembled and tested before leaving the factory.

Telephone Modem Diagnostics
All Aetek UV multi-lamp modules (two or more UV curing modules) are equipped with a telephone modem to permit immediate access to the UV system controls for remote diagnosis and troubleshooting. It is offered as an economically priced option on smaller systems.

Training Program
Aetek UV Systems offers a full in-house or on-site customer training program to familiarize customers with safe operation of the equipment.

24-Hour Hotline Customer Support
Aetek UV Systems provides a 24-hour customer support hotline with fully trained personnel to talk through problems and dispatch field service technicians worldwide, as needed.

Custom Engineering and Project Teams
Our experienced project engineering team and service technicians are available to help with technical information and to respond to your need for custom-engineered solutions.

M-801™ Water-Cooled UV Systems

With more than 35 years experience in the metal decorating market, Aetek UV Systems has designed and installed more than 100 3-piece can lines throughout the world. A wide variety of systems and designs are available to suit each application.

The water-cooled multiple-lamp system features water-cooled reflectors, base plate assemblies, and pneumatic gear-driven water-cooled shutters that eliminate sticking. The rotary shutter allows immediate access to sheets while the lamp is illuminated and provides for immediate start-ups after sheet jams. Quick-disconnect removable reflector extrusions and replaceable liners provide optimum performance, prolonged cure efficiency, and ease of maintenance.

FlexPak

Designed to meet the needs of the many owners of Mark Andy 2200 presses, the Aetek UV FlexPak and Combination FlexPak allow conversion to arc lamp UV curing without major modification to the press. No need for cutting into side frames or installation of extended side rails. This innovative design concept was developed with the cooperation of Mark Andy and has a U.S. patent pending.

The compact FlexPak is also suitable for a wide variety of presses where space is at a premium. The two FlexPak models provide fast, quality curing of inks, overprint varnishes, and pressure-sensitive and laminating adhesives in a very compact space.

Specifications:
Model FlexPak
For those wishing to convert their press to 100% arc lamp UV capability, the FlexPak, after removal of the hot-air dryer, fits easily between the press side frames without any components extending beyond the side frames.

Model Combination FlexPak
Designed to give the printer maximum flexibility, the Combination FlexPak is a UV curing module and hot-air dryer combined into a single, easy-to-install unit. The hot-air drying unit utilizes the existing heater and blower supplied by the press manufacturer.

Size
Available for press web widths of 7, 10, 13, and 16 inches (18, 25, 33, and 41 cm).

Integrated Assembly
The Combination FlexPak is a single assembly providing either UV curing or hot-air drying. When the air dryer is utilized, the UV lamp module is protected from spray and dust by an integral shield.

Lamp Module
The compact "lamp cassette" design provides for quick access and serviceability, and cassettes are easily moved from station to station as needed. Lamp cassette housings and reflector/shutters are constructed to provide maximum reliability and cooling efficiency from CAD-designed aluminum extrusions. The reflector liners provide high UV reflectance. Both lamps and reflector liners are easily replaced.

Cooling
The lamp module is totally air-cooled using an exhaust blower supplied with the system. Air flow and temperature are constantly monitored electronically.

Safety, Reliability and Support
All systems are fully interlocked and designed to insure the highest level of operator safety. With few moving parts, the computer-aided design of the FlexPak insures reliable performance and is manufactured for years of operation. Prior to leaving the factory, all components of the system are fully assembled and completely tested for optimum performance. Our experienced engineers and customer service technicians are available to help with problems or special operating situations.

WebFlex

For In-Line Web Press Applications
With more than 35 years experience in building UV curing equipment, Aetek UV Systems has designed the WebFlex™ UV system to meet the needs of "cool UV" for interstation and end-of-press installations on high-speed web offset and flexo presses. Applications include the curing of UV inks, clear coatings, adhesives and silicone-release coatings.

WebFlex™ UV System Features:
The WebFlex™ lamp module is compact and provides cool, fast and efficient curing on paper, films and folding carton stock, permitting heat-sensitive materials to be run without heat damage. Interstation dry trapping of the ink provides precise process control at full production speeds. The lamps can be installed on a new press or retrofitted to an existing press when converting to UV. System features include water-cooled elliptical shutters, replaceable dichroic or standard reflector liners for heat minimization and optimum performance, and quick disconnect utilities for ease of cleaning, maintenance, and lamp replacement. The lamp modules are interchangeable and can be easily moved between print stations.

Specifications:

Mounting Arrangements
Lamp mounting base styles include clamshell, pedestal lifts, track slides, front-to-back slides and lamp rotating mechanisms. Lamps can also be mounted over chill plates, chill rollers and conveyors.

Size
The WebFlex is available for web widths ranging from 20" (50 cm) to 72" (1.8 meters).

Power Supply Modules
All lamps are powered by a variable-output power supply which provides 25%-100% of full power. Multiple-lamp systems are integrated into a central power cabinet, which can be positioned behind or above the press. Standard WebFlex maximum power level is 500 W/inch (200 W/cm), plus a standby mode. Lamp power levels ramp up or down automatically with the speed of the press.

Electrical Specifications
208 - 480 VAC, 3 phase, 50/60 Hz with CE certification.

Cooling
WebFlex lamp modules are water-cooled through a central temperature-control/recirculating unit with a water-to-water heat exchanger supplied with the system. Chilled water for heat exchanging is supplied from the end-user's central plant chiller. Variable-speed exhaust blowers provide a small volume of air for lamp cooling and ozone extraction.

Controls and Operator Interface
A full-color TSI touch-screen displays the system status, while the controller monitors the safety interlocks, lamp power levels and shutter positions. System operation and press interfacing are provided via PLC controls. All multiplelamp-systems include a telephone modem for remote diagnostics and troubleshooting.

Safety and Reliability
All systems are fully interlocked and designed to ensure the highest level of operator safety and years of reliable operation. All are fully assembled and tested before leaving the factory.

24-Hour Hotline Customer Support
A 24-hour hotline connects the customer with fully trained personnel to talk through problems —and field service technicians are available worldwide.

Custom Engineering and Project Teams
Our experienced project teams and custom service technicians are available to help with special operating situations or for custom-engineered products.

Options
Ink mist hoods for containment on high-speed presses.