LED Curing Solutions are utilized in the coatings industry because they offer highly reliable UV curing due to being a solid-state device. They provide deep through-cure and allow low surface temperatures that enable less expensive raw inputs. 

UV curing technology with light-emitting diodes (LEDs) is considerably more eco-friendly and resource-saving compared to the traditional technologies. The disposal of heavy metal lamps made of gallium and mercury is no longer required. Working conditions for the line operators are improved as there is no ozone formation and an exhaust system is thus not necessary, which could lead to higher noise levels. The lower energy consumption of LED light sources contributes to the protection of resources.

Characteristics of UV LED Light Sources

Traditional UV lamps produce UV energy by generating an electric arc inside an ionized gas (typically mercury) chamber to excite atoms, which then decay, emitting photons. The photons emitted cover a broad range of the electromagnetic spectrum including some infrared and even visible light. Only about 20% is typically useful for UV curing.

A UV LED generates UV energy in an entirely different way. As an electric current (electrons) moves through a semiconductor device called a diode, it emits energy in the form of photons. The specific materials in the diode determine the photon wavelengths and, in the case of UV LEDs, the output is typically in a very narrow band +/-10 nm.

Due to the low curing temperatures of LED, it´s possible to coat materials such as pine and other resinous woods with significantly lower reject rates. The LED lamps also last thousands of hours, which decreases the overall maintenance cost compared to using conventional UV lamps and, without a warm up cycle, there is less down time. Additionally, LED lamps do not produce high temperatures or harmful ozone, which reduces the environmental impact. Several companies worldwide have already implemented LEDs in their curing lines and there are a variety of LED solutions available today, with interest booming.

LED Technology Benefits

Less Heat

With no IR heat, LED curing technology significantly reduces work-piece surface temperature. With the ability to cure heat sensitive substrates, LED technology can add new capability and higher yields to coating applications. 

More Uptime

There is no warm up time required and less downtime due to the instant on/off of LEDs. LED offers higher consistent yields and reduced waste compared to traditional UV curing. There are no reflectors to clean or shutters to replace. With no moving parts, the maintenance is minimal.

Greater Stability

Because of the uniformity and long-term consistency of LED lights, designers can develop safer, more stable, and more reliable processes. LEDs last more than 20,000 hours of operation, with only a minimal drop-off in power over the life of the curing unit.

More Compact Designs

Floor space is valuable in all types of businesses. LED light sources can be used to build more compact coatings lines, with shorter web paths that minimize waste.

Better Cure

Users report that LED light sources produce better cures and better adhesion on a wide range of materials. The longer wavelength output—such as the UV-A range seen from UV LEDs—penetrates through thick and pigmented systems producing through-cure of the material that ensures surface adhesion and the ability to cure pigmented wood coatings.

Energy Consumption 
Users can save up to 70% or more on energy bills. Energy cost savings can be substantial, particularly if energy costs continue to rise

Safer Workplace
LEDs contribute to workplace safety because they don’t generate dangerous UV-C radiation, excessive heat, or noise. The UV-A wavelength light is not harmful to the eyes.