UV curing for synthetic flooring

LeoLED2

For flooring manufacturers under pressure to meet the sustainability demands of global retailers and the architectural market – without compromising on line speed – LeoLED2 provides the definitive solution. It takes LED performance to new heights, offering a 55% increase in electrical power (140W/cm) and a 50% increase in UV dose compared to previous generations.

This specifically solves the ‘speed-versus-sustainability’ trade-off in high-volume flooring production, ensuring that even the most challenging high-build primers, anti-scratch topcoats, and AC4/AC5 wear layers are cured instantly at maximum line speeds.

Eliminating the transition risk with ArcLED

One of the biggest hurdles for parquet, tile, and synthetic flooring manufacturers is the perceived risk of switching entirely to LED while still utilising legacy coating chemistries. LeoLED2 solves this through GEW’s patented ArcLED technology. Available in both cassette and compact formats, LeoLED2 is designed to be fully interchangeable with every current mercury arc lamp in the GEW range.

This allows flooring converters to run a hybrid line – using mercury arc for specific traditional coatings while switching to LED for sustainable, high-efficiency runs – all on the same production line. This flexibility removes the barrier to entry for retrofits, allowing flooring plants to move toward a mercury-free future at their own pace.

Energy customisation

LeoLED2 solves the ‘one-size-fits-all’ problem with two distinct power level options. This allows flooring converters to customise their setup based on their specific energy-saving targets and the unique curing requirements of different substrates (from LVT to solid oak), ensuring they only use the power they need while maintaining the world-class process reliability GEW is known for.

Key problems LeoLED2 solves for synthetic floor manufacturers:

• The throughput problem: The 50% increase in UV dose means you don’t have to slow down your line to achieve a full cure on dense synthetic materials or thick wood coatings.
• The heat problem: Unlike mercury lamps, LeoLED2 is water-cooled and emits minimal IR. This prevents wood resins from bleeding, protects heat-sensitive vinyl (LVT/SPC) from warping, and maintains the dimensional stability of the boards.
• The investment risk: ArcLED technology means you aren’t locked in – you can swap between LED and Mercury cassettes in minutes to suit different customer specifications or coating types.
• The regulatory pressure: It provides a high-performance, mercury-free alternative that satisfies impending global mercury legislation and the strict green supplier audits required by major retailers.

E4C

In the parquet industry, production throughput is the primary driver of profitability. However, the heavyweight protective coatings and high-speed lines required for quality wood flooring often demand more curing energy than standard systems can provide. GEW’s E4C solves this by offering the highest power available from our range, specifically engineered to pass the harshest cure procedures and wear-resistance tests at maximum line speeds. Whether you are curing thick anti-scratch primers or high-gloss topcoats on solid or engineered wood, the E4C ensures a full through-cure where other systems might fail, preventing costly bottlenecks on your production line.

Protecting heat-sensitive wood substrates

High-power mercury lamps often carry the risk of overheating the timber, which can lead to warped boards, resin bleeding, or damage to delicate veneers. The E4C eliminates this risk through its advanced water-cooled reflectors. By optically tuning the reflectors to maximise UV output while simultaneously absorbing IR heat, the E4C limits heat transfer to the wood. This makes it the ideal solution for converters working with heat-sensitive veneers or resinous softwoods that require high-intensity curing without thermal damage.

Solving the maintenance and downtime struggle

Downtime on a high-volume parquet coating line is a major profit-killer. The E4C ensures there are no maintenance headaches with a plug-and-play design. Lamp changes are fast and easy, and unlike traditional water-cooled systems, the reflectors can be cleaned or fully replaced without breaking water seals. This reliability keeps your production moving and reduces the need for specialised technical intervention.

The hybrid foundation with ArcLED

For parquet manufacturers who aren’t yet ready for a 100% LED transition due to legacy chemical formulations or specific finish requirements, the E4C provides the perfect future-proof foundation. Powered by the RHINO system, it features GEW’s patented ArcLED technology. This allows you to run high-power mercury arc curing today while maintaining the flexibility to swap in LeoLED2 cassettes for specific “green” contracts or future upgrades. It means there is no technology lock-in, giving you a system that adapts to your customers’ changing sustainability requirements and impending mercury legislation.

Key problems E4C solves for synthetic floor manufacturers:

• The slow line problem: Its extreme power allows you to increase line speeds without risking an under-cured finish or failing adhesion tests on thick wood coatings.
• Substrate warping and resin bleed: Water-cooling removes the IR heat that causes timber to bend or natural resins to bleed through the surface.
• Cleaning downtime: The ability to clean reflectors without breaking water seals means maintenance takes minutes, not hours, keeping your floor production on schedule.
• The performance gap: It handles the complex, legacy chemistries and high-build coatings that UV LED might not yet cure as effectively at massive industrial volumes.