Label Products and AMS team members in the pressroom

 

Minnesota-based Label Products has purchased two LED systems from AMS Spectral UV – a Baldwin Technology Company. One was installed on an existing 10-colour, 7-inch Mark Andy 2200 flexographic press; the second was integrated into a new, custom-designed Delta Mod Tech converting machine, equipped with both a flexo printhead and a digital printhead for variable data printing.

‘The UV system on our Mark Andy press needed to be replaced. It was several years old and caused unnecessary downtime due to maintenance,’ said Mek Paneinh, production manager. ‘We considered replacing it with another UV system, but when we explored the benefits, we quickly realised that LED was the only way to go.’

Mr Paneinh added, ‘The benefits of LED included faster press speeds; eliminating costly UV bulbs that burn out and need to be replaced; and no moving mechanical parts [shutters] that can cause considerable press downtime.’

LED also requires up to 65% less energy than standard UV and there is no warm-up or cool-down time required because LED is instant ‘on’ and instant ‘off’. Mr Paneinh continued, ‘Because LED doesn’t require exhaust fans, our pressroom became considerably quieter. We no longer have to yell at each other when standing next to the press while it is operating.’

The company sees the investment as a competitive advantage, reducing production costs for labels, but it also opens the door to new market opportunities with brand owners who are seeking out eco-friendly technologies. As LED does not contain mercury or other hazardous materials it has reduced the company’s total energy consumption and carbon footprint.

Stu Knilans, Label Products’ quality manager, said, ‘We had a tricky installation that required some creative engineering. The Mark Andy press was equipped with IR heat dryers, and we didn’t want to lose them in case we had a specific job that required water-based inks. AMS’s engineering design team was able to figure out an LED solution that didn’t require us to sacrifice the IR heat boxes.’

Mr Paneinh concluded, ‘Regardless of all the benefits that LED offers, my press operators have the assurance that when the blue lights are on, the labels are going to come off the press dry – every time – at even higher press speeds. Now that we have seen just what LED can do, we are considering adding it to the rest of our presses.’