The client operates a high-speed KBA Rapida 106 8-colour perfecting press at a premium commercial & folding carton printer in Germany producing high-end packaging and synthetic substrate collateral.
Their existing conventional UV curing lamps produced excessive heat causing plastics to warp in the delivery pile. The system also consumed high amounts of energy. Perfecting heavy ink coverage at full speed without ink marking required an efficient inter-deck curing solution before the sheet was turned over.
AT A GLANCE
Printing Press: Koenig & Bauer Rapida 106 8P+L
UV Curing Systems: Conventional UV & ECO-LED
Location: Conventional UV at End-of-Press & ECO-LED Inter-Decks
Benefit: Eliminated excess heat and warp in the delivery pile. Lower energy consumption.
| Technology | Benford Conventional UV |
| Detail | Conventional Arc Lamp UV |
| Curing output | High Intensity Broad Spectrum |
| Lamp Type | Mercury Vapor / Metal Halide |
| Cooling system | High-capacity water & air-cooled reflectors |
| Support | Remote real-time live support (requires WIFI connection) |
| Lifespan | 1,000 – 1,500 hours |
| Warranty | Up to 10 year warranty available |
| Installation lead time | Starting from 6 weeks |
THE BENFORD UV SOLUTION: CONVENTIONAL UV
High intensity curing
Designed for high-speed production, our conventional UV curing lamps provide the broad-spectrum UV output necessary for specialised coatings and high-build varnishes.
Advanced technology
Our custom-cooled reflectors concentrate UV energy exactly where it’s needed while effectively managing infrared heat to protect the press and substrate for the optimal finish.
Intelligent cooling
Our conventional and LED units all utilise high-capacity cooling to ensure stable operating temperatures and to extend the life of the lamps and components.
Live support
Every Benford technology is connected via WIFI so that our engineers can access your system remotely to provide a truly global support, diagnostics and optimisation service, all in real-time.
| Technology | Benford ECO-LED UV |
| Peak irradiance | 40W/cm² |
| Wavelength options | 365nm, 385nm, 395nm, 405nm (or multi-wavelength) |
| Exposure window | 56mm (optimised for dwell time) |
| Cooling system | High-capacity water channels (25°C / 77°F operating temperature) |
| Support | Remote real-time live support (requires WIFI connection) |
| Lifespan | 10,000 – 15,000 hours |
| Warranty | Up to 10 year warranty available |
| Installation lead time | Starting from 6 weeks |
THE BENFORD UV SOLUTION: ECO-LED UV
Deeper curing
Our unique lamp design features an extra-wide 56mm exposure window. This provides the substrate with more time under the UV light, which in turn ensures a deep, reliable cure, even on highly absorbent or difficult stocks.
Precision optics
Custom engineered lenses concentrate the power of our UV lamps which allows for curing from a longer distance. This technology allows our lamp heads to be mounted further from the sheet or web.
Intelligent cooling
We have designed our curing systems with large, high-capacity water cooling channels that precisely maintain a steady 25°C (77°F) operating temperature. This prevents condensation and ensures that the LEDs reach their 10,000 – 15,000 hour lifespan.
Live support
Every Benford technology is connected via WIFI so that our engineers can access your system remotely to provide a truly global support, diagnostics and optimisation service, all in real-time.
RESULTS & IMPACT
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40% Reduction in Energy Consumption: Transitioning inter-deck positions to LED technology dramatically lowered total kWh consumption compared to full conventional UV setups.
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Zero Heat Distortion: Cold-curing LED inter-decks allow delicate synthetic and heat-sensitive substrates to run at maximum press speeds without thermal contraction.
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Instant Finish & Turnaround: Sheets land in the delivery completely dry and ready for immediate die-cutting and finishing, cutting job turnaround times significantly.
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