Printing Services » UV Printing
Is UV Print in your Future?
A white paper on UV printing as a tool to increase marketing effectiveness
In August 2009, three Geographics production managers gathered to discuss how marketing professionals and product designers might take maximum advantage of technical advances in UV print production. This paper summarizes their discussion.
Ray Weidele, plant manager: UV printing is new enough that a short explanation of the process is in order. In conventional sheet fed lithography a viscous oil based ink creates the printed image. The ink becomes a dry film by the process of absorption. Absorption means the ink is drawn into the paper, forming a bond to the fibers and leaving a dry layer on the surface. Absorption takes time and produces dot gain as the ink wicks into the paper.
What if it were possible to lay down a uniform wet film of ink, then instantly convert it to a dry solid? That’s essentially what happens with a UV ink. Instead of absorption the UV ink is cured through a reaction to ultraviolet light energy. Ultraviolet light is the same part of the spectrum that is used in tanning beds. Of course the lights on a printing press are much stronger.
Bill Turner, print manager:The first UV presses were pretty crude. We know because Geographics began working with UV print in 1999. There were compatibility problems; unreliable lighting systems; and first generation inks that were inconsistent. But, when everything worked, the results were spectacular!
So, Geographics made a decision to dig in and master this process. We enlisted our suppliers for: blankets, rollers, chemicals, inks and press. We worked as a team. Especially Heidelberg and Wikoff. We installed a Heidelberg 8 color XL 105 press configured to our specifications in 2007. In my opinion there isn’t a better press made for high quality UV print. Combined with our in-plant ink lab support and Wikoff’s research team, we’ve built a reliable process that routinely produces superlative quality that we once struggled to achieve.
RW:Quality and consistency are certainly advantages for UV printing. Much of the “wow” factor of UV print is a direct consequence of curing with light. The ink stays on the surface so colors are stronger. Dot gain is minimized so highlights are sharper and shadows are cleaner. UV inks dry trap so overprints are easier to control. UV inks are more rub resistant too. We seized the opportunity to use the differences in ways that enhance results for clients.
Marty Hynson, prepress manager:UV technology can be incorporated into a job in many ways; from adding gloss on a cover all the way to 100% UV throughout. Our planning process starts at the most basic level— preparing the separations. Our curves have been refined through systematic press fingerprint tests which we continue as part of our quality program. Our presses are equipped with closed loop color control, so we maintain very tight density ranges during a press run.
We take full advantage of high ink densities and low dot gain. You can easily see the difference when you compare a target printed with UV inks versus one printed conventionally.
BT: One of the most dramatic examples is for a client having a corporate commitment to sustainable production for all parts of their business. That includes sales brochures. Recently, the client decided all sales brochures would be produced on uncoated 100% post consumer recycled fiber. It’s a lot like printing on a sponge.
Conventional print did not allow the color fidelity required and the product images were flat and muddy. We recommended converting to all UV print production. With UV we achieved results on uncoated 100% recycle that were as good, actually better, than they had previously on coated stock. And the client got the pro environment look they wanted.
MH: Environmental benefits are a UV strong point. UV inks require less energy to cure (a lower carbon footprint) and they release less volatile organic compounds (VOC’s). The ink doesn’t cure until it’s exposed, so ink can be saved, further reducing waste. Paper makers have solved one of the early problems of UV inks. The deinking process has improved so paper printed by UV can be recycled.
RW: It’s easy to get excited about what can be done with UV print. We certainly are. Anyone who needs good color should understand how UV fits. We don’t recommend UV for every project. We do recommend clients draw on the expertise of their Geographics account rep. We will often quote a job with conventional inks and with different amounts of UV inks or coatings.
UV inks cost more than conventional inks. Makeready can take a bit more time, but the press speeds can be higher. In general, UV production might add 5- 15% to production cost. This cost can be offset by factors such as drying time, which is shorter with UV, and final product performance requirements. We get excellent rub resistance with UV. That’s important when print might be handled many times by a customer.
So what’s the bottom line? If you use print to sell your product, I predict UV is in your future. It is not a cure-all, but an exciting new technology that market leaders will learn to use. Geographics is ready to help you benefit from our experience. Ask your account rep to show you the possibilities.
