IUV Engineering Team's Successful Upgrade of UV System for Heidelberger Speedmaster CD102 - 6 + L Wide - Format Offset Printing Machine
A leading printing house specializing in premium packaging solutions sought to modernize their Heidelberger Speedmaster CD102-6+L offset press. Facing rising energy costs and demanding production schedules, they partnered with IUV Engineering for a comprehensive UV system overhaul.
Project Overview
Heidelberger Speedmaster CD102 – 6 + L wide format offset printing machine is a high – performance equipment widely used in the printing industry. However, with the development of technology and the increasing demand for printing quality and efficiency, the original UV system of the machine gradually showed some limitations.
IUV engineering team took on the challenge of upgrading the UV system of this machine. The project involved a total of 5 UV curing lamp units, 2 of which were for color groups and 3 for delivery. The team conducted a comprehensive assessment of the existing system, identified the pain points and areas for improvement, and then developed a customized upgrade plan.
Heidelberger CD102 - 6 + L
Upgrade Process

Challenge
Existing UV curing system caused three critical operational constraints:

  1. Speed limitations (max 12,000 sph) affecting order fulfillment

  2. High power consumption from outdated mercury lamps

  3. Frequent maintenance downtime from aging components

IUV Engineering’s Solution
Our team implemented a customized UV retrofit package featuring:

✅ 5-Stage UV Optimization

  • 2 Color Unit LED-UV Systems with instant-on capability

  • 3 Delivery Section Hybrid Units combining IR and UV technologies

  • Mercury-free design meeting EU environmental standards

✅ Performance Enhancements

  • Advanced reflector optics for 40% better energy utilization

  • Intelligent cooling system with 25% reduced airflow requirements

  • IoT-enabled power modules for real-time energy monitoring

✅ Operational Improvements

  • Automated lamp positioning system reducing setup time by 50%

  • UV dose control synchronized with press speed variations

  • Predictive maintenance integration through sensor networks

Technical Specifications

  • Press Model: Heidelberg CD102-6+L (720×1020mm)

  • UV Configuration: 2× Color Units + 3× Delivery Units

  • Lamp Types: H-UV (Color),  H-UV (Delivery)- Air/Water Double Cooling

  • Control System: IUV Power Control System

Measurable Results

Post-implementation metrics showed significant improvements:

Metric Before After Improvement
Max Speed 12,000 sph 15,600 sph +30%
Energy Use 30 kW/hr 28.5 kW/hr -5%
Lamp Life 800 h 1,500 h +87.5%
Job Changeover 22 min 9 min -59%
  • Increased Printing Speed: After the UV system upgrade, the printing speed of the Heidelberger CD102 – 6 + L printing machine was significantly improved. The new UV curing lamps can quickly cure the ink, reducing the time required for the ink to dry on the paper. This allows the printing machine to run at higher speeds without affecting printing quality, thereby improving production efficiency and enabling the printing factory to meet customer orders more promptly.
  • Cost Reduction: The upgrade of the UV system also brought about cost savings for the printing factory. On one hand, the improved printing speed increased production output, reducing the unit production cost. On the other hand, the new UV curing lamps have a longer service life and lower energy consumption, which reduced the frequency of lamp replacements and energy costs. Additionally, the enhanced printing quality reduced the rate of waste products, further lowering production costs.
  • Improved Printing Quality: The upgraded UV system provides more stable and uniform UV light output, ensuring more accurate and consistent curing of the ink. This results in sharper printed images, more vibrant colors, and higher glossiness, meeting customers’ raising demanding requirements for printing quality and enhancing the competitiveness of the printing factory in the market.
Why This Retrofit Matters for Modern Printers

This project demonstrates how strategic UV system upgrades can:

  1. Extend equipment lifespan of legacy presses

  2. Meet sustainability goals through energy-efficient curing

  3. Enable competitive pricing through faster turnaround times

  4. Improve print quality with consistent UV dosage control

Conclusion
The successful completion of the UV system upgrade project for the Heidelberger CD102 – 6 + L wide – format offset printing machine by the IUV engineering team has set a positive example for the printing industry. This project not only showcases the team’s strong technical capabilities and rich project experience but also highlights its commitment to helping printing enterprises achieve cost reduction and efficiency improvement through technological innovation. In the future, the IUV engineering team will continue to strive to provide more high – quality solutions and services for the printing industry, driving its continuous development and progress.
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