Constantia Flexibles details initial LED-UV successes at Spear plant in Ohio

Initial discussions revolved around the various ecological and economic advantages that can be realized when running LED-UV lamps and inks, while the Spear plant was also interested in the possibility of increased run speed, improved performance and a reduction in energy consumption as compared with a conventional mercury system.

These discussions resulted in Constantia Flexibles’ decision to retrofit existing presses at the Spear plant in Mason, Ohio with Phoseon Technology FirePower LED lamps, and use EkoCure LED-UV inks produced by Flint Group Narrow Web.

The Mason plant ultimately experienced run speed improvements with UV flexo and screen inks higher than 50 percent. In addition, the LED-UV system used 25 percent of the power that a conventional mercury system used.

Bob Feldman, plant manager of the Spear facility in Mason and who has previously held the position of continuous process improvement manager at the site, said: ‘For us, the initial investment into LED started with a challenge that screen ink curing is the limiting factor when it comes to speed. We wanted Flint Group to help drive our costs down and the biggest obstacle was run speed.

‘Flint Group came in with an Uptime Solutions program aligned to our Lean Six Sigma, and using both, we initiated a challenge to test the limits of our press. Over the course of one week, a 12-person team performed 48 different trials with six inks, two curing systems and two workflows in two press conditions. Performance indicators were defined and measured carefully.

‘What really excited us was speed improvement, as with LED-UV curing we were able to increase our speeds by 50 percent of our baseline, and that was just the initial result. Operating temperatures were lower than with mercury curing equivalents. And, there were no cure issues and no discernible performance differences with ink coverage and mileage.’

Constantia Flexibles spoke at a Flint Group Narrow Web event last year on its work with LED-UV.

Guillaume Clement, global vice president at Flint Group Narrow Web, added: ‘Flint Group and Phoseon would like to thank Constantia Flexibles for the opportunity to perform extended tests with LED-UV.

‘This testing helps both companies, and the industry, see the true possibilities that can be achieved with new technology. Innovation which delivers sustainable economical advantages for our customers is our mission. It is greatly appreciated to have a partner like Spear which is willing to push the technological boundaries of success.’