Illuminate Production Dark Spots with LED

Switching from thermal or conventional UV curing to LED does not just save energy but also reduces manufacturing footprint, waste, and time loss due to maintenance. With the added strain on electrical grids across the world, manufacturers are desperately looking for ways to modernize their process and increase throughput. LED answers these questions better than ever before, and the included presentation describes what is being done today in the field. Phoseon’s Director of Sales (Americas) Mike Higgins addresses the true key benefits of LED, and how upgrading can significantly improve production processes. Learn more about sustainability, with examples of production dark spots, and the questions manufacturers should be asking. 

LED Application Segments

LED has an established presence in various UV market segments each of which can benefit from upgrading to LED versus the existing curing technology:

All these applications benefit from energy density (dose) which is optimized by total number and arrangement of diodes.

What are Considered the Key Benefits of UV LED?

The key benefits of LED include:

·       LED systems provide consistency of output over time. If maintained properly, curing systems will last 5+ years.

·       The overall footprint of LED vs traditional mercury or thermal ovens is a fraction of the size. Space is more expensive than ever, why expand when you can significantly reduce an existing footprint!

·       Safer, Sustainable, Uptime: Workplace safety is on top of mind for all business managers. Answering the question “what are you doing to be more sustainable?”.

Uptime is money, increase uptime with instant on/off solid-state technology.

Application Examples: Dark Spots, Challenges, Processes, and Outcomes

Example #1: Industrial Coating Application

·       Dark Spot = The thermal cure process required one hour bake and 2 hours to cool down. The warehouse was filled with WIP waiting to cool while demand increased.

·       Challenge = Will LED cure a coating on metal?

·       Process = The machine builder, coating supplier, and Phoseon LED worked together with the customer to figure out the optimal conditions for curing that proved out with a trial.

·       Outcome = The first system is installed and running well, with several more LED systems expected this year. ROI was seen in less than one year. The new process eliminated paying trucks to sit in the parking lot, with both energy and space saving.

Example #2: Flexographic Printing Application

·       Dark Spot = Customer is maxed out on power draw, cost to add more was $100K+.

·       Challenge = Customer is uncertain about how well LED will cure inks and coatings.

·       Process = The ink company, Phoseon LED and converter proved out the technology by running trials, confidence grew, and transition did not seem as daunting.

·       Outcome = The energy draw on the new system was even less than expected, and the reduction of exhaust through roof and associated infrastructure was an added benefit.

Sustainability

With LED technology manufacturers reap the benefits of: Pollution prevention (50% less CO₂ emissions), waste reduction (no spare parts), energy savings (up to 70% compared to mercury), with an environmentally sustainable, mercury-free, work environment safe from toxic fumes. 

LED Light Sources are recyclable. Phoseon Technology considers recycling an important aspect of responsible stewardship to our environment. A comprehensive recycling program is in effect at Phoseon, providing recycling opportunities for materials and scrap left behind from reliability engineering and manufacturing processes. Most of the recyclable material is electronics waste and scrap, as well as other materials including: power supplies, PCBAs, aluminum, steel, brass, copper and wiring.

What Questions Should You Be Asking?

Although from a chemistry perspective moving from a thermal cure process to UV LED requires some education, the impact on throughput, energy consumption, and production footprint is so impactful it must be considered. These are some of the questions manufacturers should consider:

·       What are the biggest bottlenecks to your production process?

·       What is the true cost of maintaining my existing curing system? (Up time vs downtime for maintenance/warm up/cool down/rework product)

·       Am I paying someone to maintain mercury systems?

·       How will regulations drive future decision making?

·       When was the last time you considered LED? If the answer is 2+ years a LOT has changed

·       LED is not “all or nothing” have you considered how LED can benefit you today? Even 1 station or a lab unit can prepare you for the future.

·       Who are your most strategic suppliers and are they adding value by showing you a path to future savings?

For more information on upgrading to UV LED solutions visit www.phoseon.com today!