With traditional UV curing processes, the tremendous heat associated with mercury UV lamps require a significant amount of electricity to operate, in addition to unseen maintenance expenses. This article will discuss how Phoseon UV LED technologies provide incomparable waste reduction, and energy savings of between 75 and 85 percent compared to mercury drying systems. With Phoseon lamps, there is no need for fume extraction units to remove the gases generated by mercury-vapor UV lamps. UV LED is not only good for the environment, but also has a very positive effect on the finances, sustainability, health, and safety of company operations.

The Hidden Cost of UV Mercury Curing

Phoseon UV LED curing lamps extend beyond 60,000 hours if maintained properly, while conventional mercury lamps need to be replaced every 1000-2500 hours. Additional expenses associated with mercury UV curing include higher power costs, substrate loss associated with each lamp change, cost for proper mercury disposal, cost for re-runs associated with insufficient cure from aging UV bulbs, replacement shutters, reflectors, quarts lenses & dichroic filters. Upgrading to Phoseon UV LED technology dissolves these additional maintenance costs, offering significant environmental benefits with the elimination of mercury. UV LED lamps offer more than 50% lower CO2 emissions. Studies have shown that in certain applications, replacing mercury lamps with UV LED lamps can lead to 67 tons of CO2 reduction per year.

Waste Reduction Savings 

Conventional mercury lamps have a very short lifetime and need to be replaced every 1000-1500 hours. At approximately $200 each, mercury bulb replacements result in sunk costs, and toxic waste. An 8 station flexo press running for 20,000 hours results in 160 blub replacements and a $32,000 expense. In comparison, with Phoseon UV LED curing, the expense and requirement for bulb change is zero. Phoseon is the only company in the industry that can say that we have a proven lifetime of more than 60,000 hours. In UV LED terms, 60,000 hours means that we count only the ON time as turning lamps on and off is instant. Phoseon LED curing lamps extend beyond 60,000 hours if maintained properly. Investing in Phoseon UV LED technology eliminates these replacement costs, offering significant environmental benefits with the elimination of mercury.

Before switching to Phoseon UV LED curing technology, Central Valley Label was spending close to $40,000 to $50,000 per year on spare parts for their old UV mercury presses. When the company switched to the Phoseon UV LED solution, that expense was eliminated. The presses were so productive they were able to eliminate their night shift.

Energy Savings

By significantly reducing energy consumption Phoseon UV LED customers retain both maintenance and operational expenses. The extreme heat associated with mercury UV lamps require extensive electricity to operate. With Phoseon lamps, there is no need for fume extraction units to remove the gases generated by mercury-vapor UV lamps. Phoseon Technology customers have experienced energy savings of up to 85 percent by replacing mercury with UV LED lamps. Here is what some of them have to say.

 “Phoseon UV LED technologies provides energy savings of between 75 and 85 per cent compared to prior drying systems. With Phoseon lamps, there is no need for fume extraction units to remove the gases generated by mercury-vapour UV lamps.” Javier Sequeiros, Technical Director, Impresos Gráficos – Mexico

“To reduce CO₂ emissions and to make production more efficient, Eticod decided to invest in UV LED technology. At the beginning of 2021, a Bobst M5 430, 10-color flexo printing press with UV LED curing was successfully installed and put into operation. The machine now consumes approximately 60 per cent less electricity, which corresponds to an annual saving of approximately 50 kWh, while eliminating 200 tons of CO₂. UV LED is not only good for the environment but also has a very positive effect on the finances, sustainability and health and safety of our company.” Eticod – Poland

“Phoseon UV LED solutions also help lower energy costs, as traditional UV mercury arc lamps use 70 percent more electrical power to operate than low-heat, low-energy UV LED technologies.” Sopano – France