Comparison of UV and EB Technology for Printing
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Technical Paper Comparison of UV and EB Technology for Printing and Packaging Applications U By Stephen C. Lapin V/EB curing technology for high energy required to remove water inks, coatings and laminating from the solids portion of the formula. adhesives has become well This high-energy requirement for water established in certain segments of the is illustrated by comparing the heat of packaging industry—including folding vaporization to some common solvents2: cartons, labels and multiwall bags. water = 540 calories/gram There is also growing interest in UV/EB toluene = 88 technology for flexible packaging.1 The heptane = 76 growth in UV/EB applications is due, in The generation of energy needed to part, from the inherent advantages over operate the driers to remove water solvent- and water-based materials. results in significant CO2 emissions. In The solvent in conventional inks, addition, most water-based materials coatings and adhesives functions do contain some solvents to aid the simply as the “carrier” for the “solids” formation of the polymer film upon drying the ink, coating or adhesive. Also, A clear understanding of the differences between in many cases, water-based materials do not have the resistance or appearance UV and EB can facilitate a selection of which properties to match higher performance technology is best suited to the end-use application. solvent- or UV/EB-based materials. In spite of the clear advantages of portion of the material. In most cases, UV/EB technology over solvent and solvent emissions are handled by water-based technology, there is often thermal oxidation which produces some confusion as to whether UV or greenhouse gas (CO2). Solvents are EB is a better choice. A clear highly refined materials derived from understanding of the differences fossil hydrocarbon sources. It is quite between UV and EB can facilitate a wasteful to use such a high-value selection of which technology is best material for such a low-value temporary suited to the end-use application. function. Solvent-based materials are old technology that is clearly out of º UV and EB Energy step with a sustainable future. Considerations At first glance, water-based inks, There are some fundamental coatings and adhesives would appear differences between UV and EB energy to be an excellent choice from an that provide the foundation for environmental perspective. Water is a understanding the technologies. The relatively plentiful, low-cost and smallest “bit” of UV energy is the environmentally friendly carrier. The photon that is known to have both main disadvantage with water is the particle and wave-like characteristics. SEPTEMBER/OCTOBER 2008 RADTECH REPORT 27
Technical Paper The energy for photons is determined with the media to be cured. The typical substrate, it is possible to make a by the wavelength. The range of chemical bond energy in an organic direct comparison of the total applied wavelengths for UV curing applications material that is the basis of an ink, energy in UV- and EB-curing is typically about 250 to 450 nm. The coating or adhesive is on the order of processes. A typical modern low- shorter the wavelength, the higher the 5 eV. Curing reactions are initiated with voltage EB unit operating at 125 kV energy. Wavelength units may be the breaking of a chemical bond. Since will penetrate into a 50 g/m2 layer. converted to other energy units for UV photons have less energy than the Thus, given 1 kGy = 1 J/gram, and comparison. For example, a 350 nm bond energy, they cannot initiate assuming a 50 gram/m2 substrate, photon is equivalent to 3.5 electron curing on their own. A photoinitiator is then; 20 to 40 kGy = 0.1 to 0.2 J/cm2 volts (eV). UVcuring processes are needed which can be activated by the for typical EB curing compared to: often characterized by the total lower energy photons. The energy of 0.1 to 0.5 J/cm2 for typical UV curing. amount of applied UV energy the EB electrons easily exceeds the impinging per unit surface area (also bond energy of the curable materials; The lesson from this exercise in known as the irradiance). The UV thus they will initiate curing without an energy unit conversions is that energy needed for a curing process added photoinitiator. EB is also known although EB electrons are much more depends on the material and the as ionizing radiation because of its energetic than UV photons, the total application. For an ink, coating or ability to break chemical bonds. UV is amount of energy applied in a typical adhesive for a packaging application, non-ionizing radiation. curing process is not all that different. the UV energy typically ranges from In addition to considering the about 0.1 to 0.5 J/cm.2 energy of the individual photons and UV and EB Penetration The smallest “bit” of EB energy is electrons, it is useful to compare the The nature of the energy determines the electron. The energy of the total energy applied in the curing how it penetrates into a material. electrons is determined by the process. As can be seen from the Curing can only occur in areas that accelerating potential of the EB discussion above, UV curing is are effectively exposed. Figure 1 equipment. The range of accelerating characterized by the energy absorbed provides a cross-sectional illustration potential used for typical packaging per unit area (irradiance), while EB of the differences between UV and applications is about 80 to 180 kV. The curing is characterized by the energy EB penetration. electrons lose some energy when per unit mass (dose). If one considers Penetration of UV energy depends passing through the foil window and a given thickness and density of the on the optical density (OD) of the the air space between the window and the substrate. For example, the electrons from an EB unit operating at Figure 1 100 kV have an average energy of about 70 keV when they reach the Penetration of UV and EB energy substrate. EB curing processes are often characterized by the total amount of energy absorbed per unit mass of the substrate (also known as the cure dose). The dose for EB curing depends on the material and the application. For an ink, coating or adhesive for a packaging application, the cure dose typically ranges from about 20 to 40 kGy (2 to 4 Mrads). It is interesting to compare the energy of a typical UV photon (3.5 eV) to an EB electron (70,000 eV). Clearly, EB electrons are much more energetic than UV photons. This has a significant impact on how this energy interacts 28 RADTECH REPORT SEPTEMBER/OCTOBER 2008
Technical Paper material. Clear materials are “optically thin.” In general, UV energy can easily Figure 2 penetrate clear materials such as overprint coatings and clear films. Depth/dose profiles for low-voltage EB Even if a portion of the UV spectrum is blocked by a clear layer (such as a PET film), effective curing can usually be achieved throughout the thickness of the layer by selecting the proper photoinitiator package. Penetration of UV energy becomes a significant challenge when curing “optically thick” pigmented materials. Many pigmented printing inks can be UV cured as long as the pigment loading and/or ink thicknesses remain relatively low. It is typically difficult to UV cure through printed, white opaque, heavy black or metallic inks.3 Penetration of UV energy can be controlled, to a degree, by the peak EB penetration is controlled by the quite limited in printing and packaging irradiance of the lamp. The peak accelerating potential (voltage) of the materials.7 irradiance depends on the power and EB equipment. Figure 2 shows EB EB equipment is based on electrically the focus of the lamp system. High- penetration as a function of voltage. operated filaments and grids contained power, tightly focused lamps can Low-voltage EB equipment operating within a vacuum chamber. The improve curing of some higher OD ink from about 70 to 125 kV is ideal for electrons are accelerated through a layers4; however, the OD can reach a curing thin inks, coatings and film window/foil structure to reach the point in which curing is not possible layers used in most printing and substrate at atmospheric pressure. with any commercial lamp system. packaging applications.6 EB equipment includes “curtain” and EB penetration depends upon the scanning type units. The curtain type mass density and thickness of the UV and EB Equipment is used almost exclusively for printing material. Electrons penetrate more The most common UV equipment and packaging applications. Most EB deeply through lower density materials for printing and packaging applications equipment includes an active pumping (such as polyolefin films and paper) is based on medium-pressure mercury system to maintain a vacuum in the compared to high-density materials lamps. These lamps may be energized electron gun chamber. A new such as metal foils. Mass density and through electrodes (arc type) or by generation of modular 10- and 16-inch thickness taken together may be microwaves (electrodeless). Medium- wide EB equipment based on expressed as the basis weight of the pressure mercury lamps produce a permanent vacuum emitters is also material. For most printing and characteristic UV-emission spectrum now available. There have been some packaging applications, the basis with multiple peaks between 250 nm to initial investigations incorporating weight is expressed in units of grams/ 450 nm. Mercury lamps may also be these modular emitters in printing meter 2 or pounds/3000 ft2. Electrons doped with various elements to shift the applications.8 are “color blind” and penetration is not spectral output to better match the inks, affected by pigments and opaque coating or adhesive that is being cured. UV and EB Equipment Safety substrates. EB is ideal for curing high- Other types of lamps, such as UV lamps used in printing and opacity white, black and metallic ink xenon lamps, are available but are not packaging applications produce layers. EB can also penetrate reverse commonly used for printing and significant short wavelength UV printed, metalized and white films as packaging applications. UV-light emitting output. This intense UV energy can well as papers to instantly cure adhesive diodes (LEDs) are now available with cause skin and eye damage. layers for laminating applications.5 higher powers, but their use is still Commercial UV lamp equipment used SEPTEMBER/OCTOBER 2008 RADTECH REPORT 29
Technical Paper for printing and packaging applications management components) is relatively of the press with a single EB unit. The is completely shielded and interlocked compact and lends itself well to development of modern low-voltage to contain the damaging UV energy. In interstation installation between EB equipment coincides nicely with most cases, no special personal printing decks (Figure 4). Interstation the development of web offset presses protective equipment (PPE) is installation allows curing of each ink incorporating variable repeat length required other than the PPE normally color. Multiple colors are combined in a technology. This has facilitated recommended in the printing and “dry trapping” process to create the expansion of web-offset printing packing production plant environment. graphic image. Interstation curing also technology beyond folding cartons to In addition to UV energy hazards, allows press designs in which the flexible packaging and labels.10 mercury lamps also operate at very high printed side of the web may be turned Flexographic printing utilizes liquid temperatures. Hazards from thermal up against an idler roll between stations. inks so, historically, it has been necessary skin burns are minimized by the lamp Original industrial EB equipment to use interstation curing to dry trap housing which surrounds the bulb. was quite large (Figure 5). Modern inks. This interstation curing has been Electrons from EB equipment low-voltage EB equipment can be less achieved by thermal or UV curing present limited hazards because of than one-half the size of original technology. Recently new technology their limited ability to penetrate. The industrial EB equipment. In spite of (Wetflex™) has been developed to wet main hazard of EB is the secondary the size reduction, it is still not trap flexographic inks.11 Wet trapping X-rays that are generated when practical to use this equipment for allows interstation curing to be electrons interact with matter, interstation curing; though the smaller eliminated and replaced with a single EB including metal components within the footprint is still very attractive for curing station at the end of the press EB reaction chamber. Modern EB end-of-press installations.9 The most (Figure 7). This technology has also equipment is completely self-shielded. common installation of this type of been shown to give extremely low dot The shielding is interlocked and equipment is at the end of a web offset gain which results in superior quality monitors are present which will shut press used for the production of printing. It should be noted that Wetflex down the EB unit if X-rays are folding cartons (Figure 6). Offset is limited to central impression (CI) flexo detected. Radiation is not present if (lithographic) printing uses paste inks press configurations in which the printed the machine is not energized. Most EB which are designed to be “wet trapped” side of the web does not contact idler installations will include a person without any interstation drying. This rolls until after EB curing. Flexographic trained as a Radiation Safety Officer lends itself well to EB curing at the end CI printing is often the preferred (RSO). Periodic radiation surveys are typically conducted to supplement the continuous monitoring of the equipment. Worker exposures above normal Figure 3 environmental background levels are extremely rare. UV Lamp system components Both UV and EB equipment are very safe to operate and there are no significant drivers for selection of one technology over the other based on safety. UV Lamp Cassette Photos courtesy of Mark Andy Inc. Equipment Size The components of typical UV curing systems include the lamp, power supply, air handling equipment (blowers) and control panels. These components are pictured in Figure 3. Blower Power Cabinet The lamp (which includes the bulb, reflectors, shielding and heat 30 RADTECH REPORT SEPTEMBER/OCTOBER 2008
Technical Paper multiple wet-trapped ink and coating Figure 4 layers may be cured with this single unit. EB curing units are easily sized Interstation UV installation on a flexo press for wide-web (>60 inches) printing applications. Even though a single UV lamp is significantly lower in cost than an EB unit, when one considers the total capital cost of a wide, high-speed line, EB may be comparable or lower in cost than a multilamp UV installation. Operating Costs One of the primary advantages of UV and EB curing is the reduced energy costs compared to thermal drying ovens.12 Another major component of the operating expense is the cost of the inks, coatings and adhesives. When comparisons are made based on the “solids” that are applied, it may be seen that the cost of UV/EB materials (which are near 100% solids) may not command a significant premium. In general, there does not tend to method for flexible packaging since it 30 kGy (3 Mrad) cure dose at greater be a significant difference in cost provides superior handling of extensible than 1,000 ft/min. As discussed above, between UV and EB inks, coatings and film substrates. New permanent vacuum modular Figure 5 low-voltage equipment makes it possible to consider interstation EB Industrial EB processing equipment curing. So far this does not appear to be a commercial reality, but it is an area for potential future development. Capital Costs The cost of a UV lamp for a narrow application is relatively low. For many printing and packing applications, a single lamp operating at input powers up to 600 w/in will cure a single ink or topcoat up to about 300 to 400 feet/ minute. Installation of six or more press stations running at 800 to 1,000 ft/minute could require 12 or more lamps. Original industrial EB curing units typically cost more than $1 million. Modern low-voltage equipment has reduced the cost by at least half. A single EB unit is capable of delivering SEPTEMBER/OCTOBER 2008 RADTECH REPORT 31
Technical Paper is inhibited by atmospheric oxygen. Figure 6 Oxygen itself exists in a biradical (triplet) state and will rapidly diffuse Low-voltage EB equipment on web offset press into the surface of an ink or coating and terminate the polymerization (curing) reaction. UV formulations can be designed to cure in an air atmosphere. In air curing systems, the radical initiation essentially outcompetes the oxygen termination. This is possible because of the high surface irradiance illustrated in Figure 1. The ability to UV cure in air can be advantageous for some printing and packaging applications. In particular, air curing is very important in sheet-fed printing. Sheet-fed equipment is very difficult to inert because of the mechanisms present to transport the sheet through the press. In some cases, it may be advantageous to inert UV-cured systems. Inerting can adhesives for printing and packaging and significant savings compared to greatly accelerate UV curing which can applications. This may be due in part thermal curing. increase line speed, reduce the number to a declining cost of photoinitiators of lamps, and/or reduce the amount of following the expiration of some key Inerting photoinitiator needed for curing. patents. Comparison of UV and EB Free radical curing—commonly Inerting may be an attractive option for operating costs is, therefore, more used in both UV and EB applications— food packing applications in which related to the equipment itself. With mercury-based UV lamps, about one-half of the electrical energy Figure 7 input is converted to UV energy. The remaining energy is lost as heat. Some WetFlex™ EB flexographic printing additional electrical energy is consumed in the operation of blowers for air cooling which is most common for printing and packaging applications. EB equipment is more efficient at converting electrical energy into curing energy compared to UV equipment. Some additional electrical energy is needed for vacuum pumps and water cooling of the emitter. Another operating cost of EB is nitrogen, which is needed to inert the curing zone for most ink and coating applications. A detailed comparison of operating costs for UV and EB can be made for a specific application. Often, this analysis will show similar costs for UV and EB 32 RADTECH REPORT SEPTEMBER/OCTOBER 2008
Technical Paper migration of the photoinitiator and inner (food contact) layer. This is heat exposure. Most arc lamp-based their fragments may be a concern. particularly important when the inner web systems include shutters to EB curing of free-radical inks and layer is designed to be heat sealed when prevent the web from burning when it coatings requires inerting to displace the packaged is filled and sealed.14 is stopped. Other strategies used to the atmospheric oxygen in the reaction In some cases where porous minimize lamp heat effects on the chamber of the cure unit. EB energy is substrates (such as paper or cavitiated substrates include dichroic reflectors, deposited more evenly throughout the films) are used, it can be advantageous hot mirrors and chill drums.15 thickness of the ink and coating. to use EB to cure materials which have EB is a cooler process compared to The absence of excess energy at the penetrated into the substrate. UV. Some internal components of the surface does not allow curing reactions EB’s effect on the substrate can be EB emitter (including the window) to compete with oxygen termination beneficial. Cross-linking may enhance utilize water cooling. Little heat is (Figure 1). the properties of some polyethylene- transferred to the substrate which EB laminating involves irradiation based films. EB-induced ionization of allows most packaging films to run of the adhesive that is contained the film surface may result in without any effect on the dimensional between two layers of substrate. EB enhanced adhesion by grafting of the stability of the film. A chill drum may laminating does not require inerting ink or coating layer. EB can also be integrated into the EB unit for because the substrates are generally effective at preventing the diffusion of In general, there does not tend to be a significant oxygen into the adhesive layer. Inerting is most commonly achieved difference in cost between UV and EB inks, with nitrogen gas. Nitrogen serves to coatings and adhesives for printing and displace oxygen from the reaction chamber. The most common source of packaging applications. the nitrogen gas is a tank of liquid nitrogen. The liquid offers the high- potentially be used for simultaneous applications that are very sensitive to purity nitrogen and volume needed for curing and surface sterilization of the heat. In this configuration the the curing process. Most modern EB food contact layer. substrate is in direct contact with the equipment is designed with nitrogen Since UV is non-ionizing radiation, chill drum during irradiation. knives to remove the surface boundary effects on the substrates are minimal. layer of air. Optimized inerting systems Since grafting is not expected, a primer Food Packaging can reduce the amount of nitrogen that layer may be needed for adhesion to UV-curable coatings and inks have is used.13 some films. been used in food packaging applications for many years. These applications are Effect on Substrates Heat Control possible with packaging designs that Since EB is ionizing radiation, it Mercury lamps used for UV curing include a functional barrier between may affect the thermal and mechanical produce significant heat. This is due to the ink or coating and the food. Taint properties of substrates. EB affects high temperatures needed to create and odor problems can usually be different polymer films in different and maintain a plasma within the prevented by using properly formulated ways. References are available which quartz bulb. Approximately one-half UV-curable inks and coatings. describe the effects. Fortunately, with of the electrical energy input into Photoinitiators and photoinitiator the relatively low dose (20 to 40 kGy) the lamp is converted to heat (IR) fragments can be a source of concern used in most curing applications, the energy. UV systems for printing and for migration, odor and taint. New effects are minimal and the films are packing applications are commonly systems have been developed that still fully functional for the intended cooled by moving high volumes of air include polymeric photointiators, application. Another strategy to over the lamp. Water-cooled lamps are reactive photointiators,16 and oligomers minimize film damage is to use low also available. that contain a “built-in” photoinitiator voltage in the range of 70 to 110 kV. Many packaging films may be moiety.17 Some of these systems have These voltages allow the beam to easily adversely affected by heat from the been effective but may still lack cost/ penetrate the coating and ink layer lamps. High-speed transport of the performance properties needed for while minimizing the energy at the substrate under the lamp minimizes practical applications. SEPTEMBER/OCTOBER 2008 RADTECH REPORT 33
Technical Paper Since EB does not require an cut-and-stack processing of the aging may also not be uniform across initiator, it is often considered to be packaging allowing off-setting to occur the width of the lamp causing more “food friendly.” EB-induced prior to filling. Migration testing or inconsistent curing at the edges of the breakdown of components of inks, calculations can often be used to sheet or web relative to the center. The coatings, adhesives and substrates may establish food law compliance in process itself may be able to tolerate be a source of other taint, odor and these cases.18 The recent successful this variability in lamp output. The migration issues that merit Food Contact Notification (FCN) can most common way to minimize the investigation for a given application. also help assure food law compliance variability is by preventive In many packaging constructions, and provide additional assurances for maintenance which consists primarily the functional barrier is obvious and end-users.19 of bulb replacement and reflector there is no reasonable expectation of cleaning or replacement. The typical adulterating the food. Examples Consistency/Maintenance lamp maintenance interval is about include labels on rigid containers and Process consistency and 1,000 to 3,000 hours. The cleanliness folding cartons that have an additional maintenance required to assure of the process can have a major effect inner layer of packaging around the product quality may also merit on the need for maintenance. Ink mist, food. There are many constructions in consideration when comparing UV and paper dust and other sources of which the barrier is less obvious. This EB technology. The output of UV contamination will shorten the useful may include cases in which a relatively lamps will decrease as the lamps age. life of the lamp. Lamp temperature thin polyolefin film is the only layer This decrease may not be uniform control is also critical for maximum life. between the UV/EB material and the across the spectral output with short EB output tends to be very consistent food. It may also include applications wavelengths output degrading before with time. No significant change is in which the UV/EB printed/coated longer wavelengths. This can affect the expected with age. Variability in cross- surface is in contact with the food surface versus throughcure web uniformity is typically less than contact surface during roll-to-roll or characteristics of the process. The 10%. Essentially, all EB systems are 34 RADTECH REPORT SEPTEMBER/OCTOBER 2008
Technical Paper directly linked to line speed. Beam The selection of UV or EB should be 22. A. Testoni, S. Norasetthekul, P. M. Fletcher, RadTech UV&EB Technology current automatically ramps to based on the best fit for the selected Expo & Conference, May 2008. maintain a constant cure dose at all application. For some applications the speeds. The typical preventive choice is obvious. Others may require a —Stephen C. Lapin, Ph.D., is an maintenance interval is 4,000 to 8,000 cost/benefit analysis in order to make Applications Specialist, BroadBeam, hours and mainly involves changing the best choice. ◗ with PCT Engineered Systems LLC, Davenport, Iowa. window foils and filaments. Factors affecting the EB maintenance cycle are References 1. A. Mykytiuk, Flexible Packaging, process cleanliness and window August 2000, p. 16. temperature control. 2. A. J. Berejka, RadTech Report, One factor to consider is that when September/October 2003, p. 50. an EB unit is down for maintenance 3. R. W. Stowe, RadTech 1996 the process must stop. With a multilamp Conference Proceedings, p. 472. UV system, it may be possible to slow 4. S. Whittle, Flexo, January 2005, p. 40. but not stop the process while waiting 5. S. C. Lapin, RadTech Report, November/December 2006, p. 45. for repairs on one of the lamps. 6. I. Rangwalla, E F. Maguire, RadTech Report, May/June 2000, p. 27. Measurement 7. T. Molamphy, RadTech UV&EB Curing Measurement is critical for Technology Expo & Conference, maintaining a constant process for UV Conference Proceedings, May 2008. and EB. There is a wide range of 8. M. Laksin, J. Epstein, RadTech Report, March/April 2007, p. 15. radiometers available to measure the 9. I. Rangwalla, RadTech Europe ‘05 output of UV lamp systems. These Conference Proceedings, October include electronic probes which may 2005. be temporality inserted or fixed in the 10. R. Meij, RadTech Europe ‘05 Conference Proceedings, October lamp housing. Radiometers are also 2005. available which can be attached to the 11. M. Laksin, V. Linzer, T. Best, J. Modi, moving substrate.20 UV-sensitive films S. Chatterjee, TAPPI PLACE Division are available that can attach to a Conference, August 2004. substrate and not interfere as they 12. R. Sanders, RadTech Report, March/ April 2006, p. 20. pass through press stations or rollers. 13. D. Meskan, A. Klein, RadTech Europe The films may produce a visible color ‘91 Conference Proceedings, change or require a subsequent optical September 1991, p. 93. reading which is related to the UV 14. I. Rangwalla, TAPPI PLACE Division Conference, September 2005. exposure.21 The limits of each type of 15. D. Samide, E. Midlik, TAPPI PLACE radiometer must be understood in Division Conference, September 2005. order to be used effectively. 16. J-L Birbaum, R. Huesler, J-P Wolf, S. The most common type of EB Ilg, S. Villeneuve, RadTech 2006 measurement involves exposure of thin Conference Proceedings, April 2006. films containing radiochromic 17. S. Narayan-Sarathy, M. Gould, A. Zaranec, L. Hahn, American Ink Maker, indicators. The optical changes in the March/April 2004 films are subsequently measured 18. C. R. Nielson, G. G. Misko, RadTech against calibration cures which are Report, July/August 2001, p. 12. generated from films traceable to 19. M. Marrapese, RadTech UV&EB Technology Expo & Conference, NIST standards.22 May 2008. 20. R. W. Stowe, RadTech 2002 Conclusions Conference Proceedings, p. 475. UV and EB are environmentally 21. R. W. Stowe, J. W. Guerniere, sound technologies well suited for RadTech Europe ’07 Conference printing and packaging applications. Proceedings, November 2007. SEPTEMBER/OCTOBER 2008 RADTECH REPORT 35
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