From mercury UV to UV LED: 4B Packaging accelerates its technology transition with GEW

Introduction

Faced with sustained increases in energy costs, growing environmental performance requirements and the need to secure printing processes, UV LED technology is gradually becoming established in label-printing plants. In Kervignac, Brittany, 4B Packaging – CIE has embarked on this transition with GEW, taking a progressive approach combining production continuity, technological flexibility and performance improvement.

A label printer committed to evolving its industrial platform

A French specialist in self-adhesive label printing, 4B Packaging has more than 40 years of experience and three production sites. The group brings together printing, converting and finishing activities and regularly upgrades its industrial equipment to meet increasingly demanding customer requirements.

The 4B Packaging site in Kervignac, near Lorient, mainly uses UV flexographic printing for a wide range of markets, including food and beverage, cosmetics, pharmaceuticals, brewing, industry, and wine and spirits. This diversity of applications requires production equipment capable of combining quality, responsiveness and adaptability.

GEW: a long-standing partnership

The relationship between 4B Packaging and GEW predates the transition to LED. The company has been working with the specialist in UV curing systems for many years. Equipment reliability, consistent performance, ease of integration on flexographic presses and the quality of technical support have helped build a relationship based on trust.

When 4B Packaging began considering the move to UV LED in 2023, this continuity was an important factor. The company was looking to address three challenges simultaneously: controlling the impact of rising energy costs, reducing its environmental footprint and further improving process stability.

A transition designed to preserve flexibility

The company selected GEW AeroLED air-cooled systems. Several characteristics influenced the decision: compatibility with existing presses, a compact footprint, no water-cooling circuit and simplified maintenance.

One of the key advantages of the chosen solution is the ability to retain an interchangeable UV technology, allowing operators to switch rapidly between LED UV and mercury UV using the same equipment. In a context where the development of LED inks and, in particular, certain specialist varnishes was not yet fully mature in 2023, this flexibility provided an important safeguard for the printer.

Some mercury lamps are therefore still used for specific applications or when the characteristics of a particular job require them. In the medium term, however, 4B Packaging’s objective is clearly to progressively move towards widespread adoption of UV LED.

Production performance meets expectations

According to 4B Packaging’s experience, the move to UV LED has not required any compromise in production speeds. Production speeds are reported to be equivalent to, and in many cases higher than, those previously achieved with mercury systems, while providing greater curing consistency.

In terms of print quality, the company reports improved process stability and fewer colour variations. Production start-up is also faster and downtime associated with the curing process is reduced, contributing to an overall productivity improvement.

LED UV inks: a smoother transition than expected

The technology change also required an adaptation to LED UV inks, carried out with support from ink suppliers. Operators quickly observed excellent colour density, very good printability and greater production stability.

The cost of LED inks is now considered manageable by 4B Packaging, while availability has improved significantly. Where necessary, the company anticipates its supply requirements and works closely with its partners.

An installation designed to minimise production disruption

The installation of the LED systems was prepared in advance, from the design phase through mechanical integration and commissioning. According to 4B Packaging, the installations were completed without any major difficulties.

Downtime is a particularly tangible indicator for a printer: the company estimates that a maximum of one week of machine downtime is required to complete a full conversion, including testing and restart.

A 60% energy saving on curing units

Energy is one of the main drivers behind the transition. Since adopting UV LED, 4B Packaging reports a 60% reduction in electricity consumption on its curing units.

This reduction in energy consumption is complemented by lower maintenance costs and the elimination of consumables associated with mercury lamps. The company also highlights environmental benefits resulting from lower energy use, the absence of mercury and the longer service life of LED sources.

Beyond the production floor: a commercial and CSR benefit

For 4B Packaging, the move to UV LED is not simply an equipment modernisation project. Environmental performance is increasingly taken into account by customers and is becoming a commercial differentiator.

UV LED therefore provides a response to growing corporate social responsibility expectations and supports the company’s positioning in new markets.

A faster-than-expected return on investment

The company estimates that the return on investment of the LED systems has been faster than initially expected. This is attributed to the combination of several factors: reduced energy consumption, lower maintenance requirements and improved productivity.

At the end of this transition, 4B Packaging associates the GEW AeroLED systems with four major benefits: performance, reliability, sustainability and peace of mind in production.

A technology evolution – but above all, an industrial decision

4B Packaging’s experience illustrates a broader trend in label printing: the move from conventional UV to UV LED can be approached not simply as an equipment replacement, but as a comprehensive evolution of the industrial process.

The ability to retain flexibility between technologies, significantly reduce energy consumption and maintain or even improve production performance has enabled the company to secure its transition.

For 4B Packaging, the message is therefore clear: when properly prepared and integrated into an overall industrial strategy, the move to UV LED represents a strategic investment at the intersection of productivity, cost control and environmental performance.

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Click here for more information on GEW’s UV LED curing systems.

With thanks to 4B Packaging: https://4bpackaging.fr/