The core components and operation process of UV system (In offset printing press)
This article focuses on the operation mechanism of UV systems for offset printing machines. Starting with core values, it details the advantages of UV systems in rapid curing, multi-substrate compatibility, and print quality improvement. It then breaks down the five core components of the system (UV light source, reflector cover, cooling system, etc.) and their functions. Finally, it analyzes key operation links step by step, including ink supply, UV curing, cooling inspection, and post-maintenance. It provides clear technical references for printing industry practitioners and equipment operators, helping them understand how UV systems break through the limitations of traditional drying technologies and adapt to special printing needs such as packaging and labeling.
1. Core Function
- UV Light Source:
- High-pressure mercury lamps (200-400nm wavelength, wide compatibility but high energy/heat) and LED lamps (365nm/395nm, low energy, >20,000-hour lifespan, no ozone, requires special LED-UV inks).
- Reflector Cover:
- High-reflectivity material, concentrates scattered UV light on substrates to improve energy efficiency and avoid uneven curing.
- Cooling System:
- Air cooling (small units/LED lamps, fan heat dissipation) and water cooling (high-power mercury lamps, circulating water controls temperature at 50-80℃ to prevent substrate deformation).
- Control System:
- Intelligent PLC module, real-time matching of printing speed and lamp power to avoid incomplete curing or ink brittleness.
- Ink Adaptation Components: Light-shielding ink fountain, UV-resistant ink rollers (prevent premature ink curing and wear), and filters (prevent mesh blockage).
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3. Key Operation Links
- Ink Supply & Pretreatment
UV inks/varnishes must be stored in the dark and stirred evenly before use; transferred to the printing plate via ink pumps and rollers, with viscosity adjusted to prevent ink piling/thin layers. Enter the curing unit within 5 seconds after transfer to avoid premature curing from ambient light.- UV Irradiation & Curing
Substrates pass through UV light focused by reflectors, activating ink photosensitizers to trigger resin polymerization (surface curing in 0.5s to prevent smudging, deep curing in 1-2s for adhesion, post-curing in 10-20s to improve hardness). Adjust the 10-15cm irradiation distance by substrate (shorten for metals to increase energy, lengthen for plastics to avoid high-temperature damage).- Cooling & Quality Inspection
Cured substrates are cooled to room temperature via air cooling (low-temperature air curtain) or water cooling (cooling rollers) to prevent adhesion during winding. Online detection alerts in real time if smudging (insufficient power/fast speed) or brittleness (high power/long time) occurs, prompting adjustments.- Post-Maintenance
Test energy after 800-1000 hours (mercury lamps) or 20,000 hours (LED lamps); replace when energy drops to 70%. Clean reflectors weekly and cooling system filters/pipes monthly to prevent heat dissipation failure. -
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