Introduction
The printing industry is a highly competitive sector, with large firms often dominating the market due to their advanced technology, extensive resources and high production capacities. Small and medium-sized sheetfed printers face significant challenges in keeping up with the fast-paced demands of modern printing. They need to deliver high-quality prints, maintain cost efficiency and offer quick turnaround times – all while competing against larger firms with greater financial backing.
A modern technology that is helping small and medium sized companies compete in the printing industry is UV LED printing. This advanced printing method offers numerous advantages, such as faster drying times, lower energy consumption, enhanced print quality and more compatible print substrates. By adopting UV LED technology, small and medium-sized printers can level the playing field and enhance their competitiveness in the market.
This article explores the benefits of UV LED technology, discussing its impact on cost savings, operational efficiency, environmental sustainability, and how it allows small-to-medium-sized printers to compete with larger firms.
To begin with though, we want to clarify what UV LED printing is.
What is UV LED printing?
UV LED printing is a modern curing process that uses ultraviolet (UV) light-emitting diodes (LEDs) to instantly dry or “cure” inks, coatings, and adhesives. Unlike traditional printing methods that rely on air drying or heat, UV LED curing works by polymerising the ink using UV light, allowing for instant drying.
Key benefits of UV LED for sheetfed printers
Now that we’ve explained what UV LED printing is, we want to outline the benefits of this technology for sheetfed printers. We will split these benefits into 4 categories, with further subcategories in each:
- Cost savings and operational efficiency
- Expanding print capabilities and market reach
- Environmental and regulatory advantages
- How can small printers gain a competitive edge against larger printers?
Cost savings and operational efficiency
Lower energy consumption
One of the major cost advantages of UV LED printing is its lower energy consumption. Traditional UV curing systems use mercury arc lamps, which require a significant amount of power and generate a great deal of heat. This not only increases electricity costs but also necessitates additional cooling systems to prevent overheating.
In contrast, UV LED lamps operate at much lower temperatures and consume far less power. This reduction in energy usage translates to cost savings for small and medium-sized printers, giving them an opportunity to compete on price with their larger competitors who may be using more energy inefficient technologies to dry their print and packaging work.
Reduced waste and higher productivity
In traditional printing, long drying times often lead to material waste due to scuffing, marking, misalignment or reprints. With UV LED curing, the ink dries instantly, eliminating many of these common printing errors. Printers also experience fewer rejects, leading to less wasted paper and ink, but they also gain a happier set of customers, as errors are less likely to sneak through due to the instant curing.
Faster drying times also mean quicker turnaround for printing jobs. Since the ink is cured immediately, there is no need to wait for prints to dry before they can be handled or finished. This enables printers to take on more jobs in a shorter period, increasing their overall production capacity and revenue potential; it also means customers get their product quicker, improving satisfaction.
Less maintenance and longer lifespan
UV LED curing systems require significantly less maintenance than traditional mercury arc lamps. Unlike conventional lamps, which degrade over time and require frequent replacements, UV LED lamps have a much longer lifespan, lasting up to twenty times longer. This means fewer interruptions for lamp replacements and lower maintenance costs over time. For smaller companies working on a tighter budget, this makes a UV LED curing system a cost friendly option compared to other drying systems, or compared to the investment in a Digital printing press, which can have a high capital investment cost, as well as high subscription costs.
Additionally, UV LED lamps do not require warm-up or cool-down periods, allowing for instant operation. This not only saves time but also reduces wear and tear on the equipment, extending its longevity and reducing downtime. By reducing maintenance costs and increasing equipment lifespan, UV LED technology provides a cost-effective solution for smaller printing businesses.
Expanding print capabilities and market reach
Printing on a wider range of substrates
Versatility is another major advantage of UV LED printing. Unlike conventional printing, which is limited to specific substrates, UV LED technology allows printers to work with a wide range of materials, including non-porous and heat-sensitive surfaces, plastics, synthetic materials, foils, metal-coated papers, recycled papers, textured papers, vinyl, and specialty packaging materials. This opens new opportunities for small and medium-sized printers to expand their product offerings and potentially reach a wider variety of customers, allowing them to compete with larger print companies.
This expanded range of substrates allows small and medium-sized printers to enter new markets and attract a broader customer base. By offering unique printing solutions, businesses can set themselves apart from competitors and create new revenue streams.
Higher quality prints and vibrant colours
UV LED technology also offers improved print quality. Since the ink cures instantly, there is no risk of smudging or spreading, resulting in sharper, more vibrant prints, with richer colours that enhance the overall print quality. The quick curing process prevents ink from spreading, leading to greater detail and better adhesion to the substrate. This ensures a professional, high-quality finish that meets the expectations of even the most demanding customers, giving smaller printers the ability to compete with larger printers on print quality.
This improvement in print quality ensures that finished products are not only visually appealing but also more durable. UV-cured inks offer better scratch resistance and longevity compared to traditional inks, resulting in a higher quality print or package product. Consistent colour reproduction also means that clients can expect the same high-quality results with every print run, increasing customer satisfaction and loyalty, and allowing smaller printers to compete with their bigger competitors.
Environmental and regulatory advantages
Compliance with environmental regulations
Finally, UV LED printing is more environmentally friendly than traditional methods. Since it does not require the use of harmful solvents, it significantly reduces the emission of volatile organic compounds (VOCs), making it a greener and safer option for both printers and customers. This can also be used as a marketing tool to give smaller printers an edge over their larger competitors who may not be as environmentally concerned, allowing them to win the business of customers who care about resourcing printing and packaging from environmentally conscious printers.
Furthermore, Governments and regulatory bodies worldwide are enforcing stricter environmental regulations on industries that emit volatile organic compounds (VOCs). Traditional solvent-based printing emits high levels of VOCs, contributing to air pollution and posing health risks to workers; none of these problems occur with UV LED printing.
How can small printers gain a competitive edge against larger printers?
Faster turnaround and shorter lead times
With UV LED printing, small and medium-sized sheetfed printers can complete jobs faster than their competitors. Larger firms often have longer production schedules, whereas smaller printers can leverage UV LED technology to offer quick, high-quality prints with short lead times.
Cost-effective small batch printing
Larger firms tend to focus on high-volume printing due to economies of scale. However, smaller printers can use UV LED technology to cater to short-run printing, offering personalised and customised print solutions for niche markets.
Businesses seeking customised prints, event planners requiring short-run promotional materials and eco-conscious brands looking for sustainable printing options are just some of the potential clients who can benefit from small-scale UV LED printing.
Differentiation through innovation
By adopting UV LED technology, small and medium-sized printers can position themselves as innovators in the industry. Offering high-quality, fast and eco-friendly printing solutions allows them to stand out from the competition and attract loyal customers.
Conclusion
UV LED technology offers small and medium-sized sheetfed printers a powerful solution to compete against larger firms. With faster turnaround times, lower costs, enhanced print quality, and environmental benefits, UV LED make printers more efficient and open up new business opportunities, leaving them with an edge, even when compared to larger printers.
To learn more about GEW’s UV LED curing system for sheetfed printing, LeoLED2, go here.
