IUV Engineering transformed a 10-year-old Mark Andy 2200 press with an LED UV curing upgrade. The project achieved 72.5% energy savings per color unit while boosting speed and material flexibility.
Challenge: Aging Equipment, Rising Costs
The client struggled with high energy bills and limited substrate options. Traditional UV systems consumed excessive power. Frequent maintenance slowed production workflows.
The aging press faced critical pain points:
- Energy Waste: Outdated UV lamps consumed 8.2 kW/hour
- Speed Limits: Slow curing caused production delays
- Material Restrictions: Couldn’t print heat-sensitive substrates
Before vs After: Key Performance Metrics
| Metric | Pre-Upgrade System | Post-Upgrade LED UV | Improvement |
|---|---|---|---|
| Energy Use/Color Unit | 8.2 kW | 2.25 kW | 72.5% ↓ |
| Average Speed | 120 m/min | 142 m/min | 18% ↑ |
| Substrate Types | 4 | 9+ | 125% ↑ |
| Maintenance Frequency | Weekly | Bi-monthly | 75% ↓ |
IUV installed advanced LED UV curing technology. This system uses targeted wavelengths for instant drying. It operates at lower temperatures than conventional setups.
IUV’s 3-Step LED UV Retrofit Solution
- Precision Engineering
Custom-fit LED modules replaced outdated UV lamps. - Instant-Cure Technology
Targeted wavelengths dry inks in 0.8 seconds. - Smart Cooling System
Reduced operating temperatures by 34°C (93°F).
💡 Verified Outcomes
Cost Savings
- $16,800/year saved per color station
- Eliminated $3,200/year lamp replacement costs
Sustainability Gains
- 28.6 tons CO₂ reduction annually per press
- Complies with EU Ecodesign 2023 standards
Expanded Capabilities
New printable materials include:
◼ 0.8mm ultra-thin PET films
◼ High-stretch PE labels
◼ Holographic security foils
📌 Retrofit vs New Press: Key Benefits
| Factor | New Press | IUV Retrofit |
|---|---|---|
| Cost | $520,000+ | $78,000 |
| Downtime | 6-8 weeks | 3 days |
| Payback | 5+ years | 14 months |
Why Choose IUV for Printing Upgrades?
IUV specializes in retrofitting legacy equipment with green tech. Their solutions maximize ROI while minimizing environmental footprints.
IUV’s LED UV retrofit transformed an aging Mark Andy 2200 into a sustainable workhorse. Achieve dramatic cost savings and operational upgrades—contact IUV for your press optimization needs.
