What is UV LED cast and cure process?

UV LED CAST CURE is a method to create microstructure (such as holographic effect, optical effect and so on)on printed film or paper through a UV LED curing process. UV LED cast cure process is a simple technical method to help our clients increase more eyes catch design on the products. Compared with traditional UV cast, DPL UV LED technology to provide better production efficiency and lower cost.

How does UV LED CAST CURE Work?

UV LED cast cure also use an embossed holographic cast film (normally it’s BOPP film) as holographic master. The different between nickel master and cast film, it’s cast film cannot provide “deep solution” hologram feature. It means most UV LED Cast cure process only be used as “decoration”.

The general process includes two nip rolls, one is called as a master cylinder on which have holographic or other microstructure feature, and the other is pressure rubber roller. When film or paper passes through these two pressure, the holographic image on the master cylinder will be cast on the surface of film or paper. The UV LED curing lamp will dry UV LED lacquer on film or paper after the casting process, so holographic or other microstructure will be on the surface as well. Compared with traditional UV cast and cure process, UV LED curing system use typical single wavelength, for example, 395nm or 385nm, which is easier pass through film if the lamp is installed on the back side of the film. Also LED curing system uses cold light source so curing temp is also lower than Traditional UV lamp. Because LED lacquer is a single wavelength so it will not be dried by visible light.


Ozone free UV lamp for coating equipment

What is ozone free  UV lamp?

Many finishers today are considering adding UV coating equipment to create a more attractive surface on their printing products to catch their client’s eyes. The big change challenge for them is the safety and handling issues that go along with the process after they start to use “anti-UV” cream on their face and body when they lay on the beach. So how dangerous when you use UV equipment?

Most UV/EB curing materials generally are not “hazardous waste” (toxic, corrosive, flammable, or reactive) as defined under RCRA regulations. However, as with all chemicals, contaminated materials and wastes should be disposed of in accordance with federal and local requirements. In addition, UV/EB curing materials contain little to no VOC’s and typically contain no hazardous air pollutants (HAPS) as specified by the EPA. They are not typically specified in any federal or state Community Right-to-Know list as well.

The only sideproduct of the UV lamp is Ozone Gas. It has a pungent sweet odour and is distinctive enough that concentrations well below the threshold limit value (TLV) of 0.1 ppm are still noticeable. At high enough concentrations, ozone gas and odours can cause headaches and fatigue. After repeated exposure at high concentrations, ozone can cause dryness of the upper respiratory tract, pulmonary irritation and possibly respiratory infections.

Many experts tell you that this is very simple, you only need to increase ventilation. but it is not the truth.

When the device is using a high-power suction and exhaust device, it may cause the UV lamp to open abnormally due to the low temperature.

To solve this problem, the first thing we need to understand is why the UV lamp produces ozone.

The UV curing device produces ultraviolet light having a wavelength in the range of 200 to 425 nm. Among them, when short-wave ultraviolet light below 275 nm is in contact with oxygen in the air, ozone is easily generated, which is a great source of the irritating odour. From the reaction mechanism point of view, the short-wave ultraviolet light will decompose the oxygen molecules in the air, thereby generating free oxygen. Because the positive and negative electrons carried by the free oxygen are unbalanced, it will combine with the oxygen molecules to generate ozone. These ozone often cannot be decomposed by themselves, not only floating in the air but also remaining on the surface of the printed product (the printed product is adsorptive and will retain some of the odours)

How to make an ozone free UV lamp?

On the one hand, the DPL ozone free UV lamp adopts a fully enclosed design. Even when the shutter is opened, the air cannot enter the lampshade and combine with the low-band UV light to generate ozone. On the other hand, when the UV light passes through the special filter function glass window in the lampshade, only the long wavelength UV light can be directed to the printing material, thereby preventing the short wavelength UV light from coming into contact with the air to generate ozone.

DPL ozone free UV lamp is a patented product of our company and has been certified by CE and ul to meet the safety standards of the European Union and the United States.


What is UV curable soft touch coating technology

What is Soft touch coating technology?

Soft touch coating technology is more and more used for packaging design. As you know, you feel different between the film or paper and your cloth when you touch them. You feel softer when you touch your cloth or textile sofa. Soft-touch or soft-feel coatings are employed to create a variety of haptic effects on plastic, paper and metal substrates. So that you feel touching a paper as a cloth.

What is the advantage of soft touch coating technology?

The answer is simple,  it will help you sell more products. Recently, California Polytechnic State Universit had a research on marketing different between soft touch designed products and traditional packaged design. Compared with traditional design, soft-touch coatings span a variety of markets including automotive interiors, small electronics, and appliances. It shows not only did customers prefer cosmetics packaged in a container with a soft touch coating versus a traditional coating, they were willing to pay a 5% price premium.

What is UV Curable soft touch coating technology?

To make soft touch coating on film or paper is typically created by crosslinking multifunctional isocyanates with polyols. This process creates hard regions from the isocyanates distributed in softer regions created by the polyols. The problem is, it also takes longer curing time when we coat these two continents. This is why we use UV curable soft touch coating technology.

What can DPL Help you on soft touch coating technology?

As one of the oldest UV LED curing technology developer in Europe, DPL has many experiences on how to design your curing process. DPL specially design  UV curing lamp for soft touch coating industry, not only provide higher UV energy output but also better uniformity. So that our system can reach high-quality request for UV Curable soft touch product. Compared with other suppliers, DPL special design UV Curing lamp for soft touch coating, provides better working lifetime as well. More detail or need technical help, welcome to call us at +45 28871021 or email to


What is High-speed UV LED ink ?

High-speed UV LED Ink is the most important fact affect your printing quality and efficiency.  Well-formulated inks ensure continued print quality, system uptime reliability, and high productivity without user intervention.

What is UV LED ink?

Compared with traditional UV ink, UV LED inks only active for typical wavelength. Because of special consideration of photoinitiators and pigments
in the ink formulation, which only matches the spectral output of
the LED lamps. These special photoinitiators absorb at a higher
wavelength as opposed to traditional photoinitiators and are
typically more expensive. The spectral output of a LED lamp to
cure UV LED inks is very narrow, 365 – 405 nm, as compared to
a UV mercury system which operates from 200 – 700 nm range.

What is UV LED Curing?

Because of the limited spectral wavelength, UV LED primarily
operates in the UV-A zone and considered to be ‘safe’ because
it is closest to visible light. However, prolonged exposure to
this energy can be dangerous. The UV-B and much of the
UV-C spectrums of light are primarily used for germicidal and
sterilization purposes. The light produced at these wavelengths are
not only harmful to microorganisms but are also dangerous to
humans and other forms of life that may come in contact with it.
These lamps should always be shielded and never viewable to
the naked eye, even though it may appear that little or no light is
emanating from the device. Exposure to these wavelengths may
cause skin cancer and temporary or permanent vision loss or

How does high-speed UV LED ink work?

Compared with traditional UV lamp, UV LED lamp only active on typical wavelength. However,  it doesn’t mean UV LED ink need less UV energy for curing. You can see from the following picture of our UV LED Ink testing report, good DOSIS energy will help for improving curing speed and quality. Therefore, we have confidence that even use the same UV LED ink, DPL high power UV LED curing system can cure faster and better.


UV Led curing technology

UV LED curing technology is more and more popular in industry developing.  Because UV LED curing technology offers many benefits over traditional broad-spectrum UV light curing.

What is UV LED Curing Technology?

Compared with traditional UV lamp, UV LED lamp provides typical wavelength light to reach our requirement. For example, when we turn on a UV lamp, the light will cover wavelength from 100 to 410nm.  But for UV LED lamp, we can choose which wavelength we want to have according to the different request by ink or coating lacquer.

What is the advantage of DPL UV LED curing system?

  • DPL Customer Designed UV LED module

DPL eAsycureTM LED curing system use our own design LED Modules with wider curing area (41x60mm per unit) and high-resolution optical lens, which can provide high curing energy up to 26w/cm2

  • Individual Power for each LED Module

    Each LED module has one LED driver with stable voltage and adjustable electric current, which provide high uniformity energy output up to 98%. Independent driver unit also increases LED module’s working lifetime and decrease LED energy damping.

DPL eAsycureTM UV LED curing system series is build up with length from 82mm to 2240mm. We also provide custom design service.

DPL eAsycureTM UV LED curing system includes one set of lamp house, one set of LED Driver, one set of PLC. Clients can use their own chiller or our recommend brands. To protect LED Modules’s working life, we request chiller should have flower sensor so chiller will be automatic switch on/off according to DPL temperature sensor in lamp house.

  • Long lifetime: >20.000h

With our highly effective water chilling construction, DPL LED curing system keep the low temperature even at power at 26w/cm2 . DPL cooling system optimizes the heat extraction from the LED chip, which provides surface printing temperature lower than 40oC. Low temperature also reduces wastage and rejects with heat sensitive substrates.

  • “Plug & Play” smart system:

DPL LED Curing system is a smart system with “plug &play” design, easy to operate and suitable to install in the existing machine

Is your UV lamp safe?- Harmful ozone

Is your UV lamp safe?

In modern industry, more and more people pay attention to how to produce “safe product” with the green process.  For example, you can find more and more organic markets in our city.  Back to our  printing and coating industry, more and more people are thinking about how to reduce pollute, one of the good ways is using more green source instead of difficulty recycled material, such as in printing and coating process, use UV lamp as drying source instead of heating source, because UV light or LED light drying source can cure the ink in very short time.

Harmful Ozone

Is your UV lamp safe? I believe that you have the experience when you walk into a UV printing production in China, or when you visit a printing machine exhibition, you can smell “Rotten egg”. That is Ozone smell.

The Environmental Protection Agency (EPA) warns that although ozone in the stratosphere protects us from harmful UV radiation, low-level ozone is dangerous. Infants, children, and those with respiratory problems may be in particular danger.

How UV lamp produce Ozone?

Before we try to solve this harmful ozone problem, we need to find out how UV lamp produces ozone.  UV light includes different wavelength light from UVA to UVC. When UVC hits oxygen (O2) molecules, it produces ozone.

With our patent design of UV lamp house, DPL UV curing lamp system is an “Ozone free” system. See the following video, which will introduce you how to design an ozone-free system.

DPL UV Lamphouse uses a closed design house construction. Therefore after you close the house, UV light will not touch outside air.Also, there is only very low-density air inside lamphouse, very low-density ozone will be produced when you just close the lamphouse, which is proofed by Denmark and European Industry. It means that our client doesn’t need to install expensive “ozone exhaust” system, their worker can work in a clean “Ozone free ” production.


DPL Super wide Cold UV curing lamp at 2000mm

What is Super wide UV curing Lamp?

Super wider UV curing lamp means lamp provides curing width over 1700mm.

For graphics printing and coating business, more and more clients are looking for the more efficient printing process to reduce production cost.  Therefore, our clients also need wider web printing or coating machine equipped with Super wider UV curing lamps. But super wider UV lamp is not only just wider. Compared with standard width UV lamp, super wider lamp need to consider more than the width.

DPL Pattern Lamphouse construction

DPL Super wide Cold UV curing lamp at 2000mm with specially coated reflector and our pattern design on lamp construction. For example, from the top to two side frame of lamphouse, there is UV radiation refect coating. When UV lamp is on, these coating layers will reflect light to the bottom quartz window. Quartz window has very high UV transmission, means more than 95% UV light will pass throw. In order to reduce production cost, there are many manufacturers use the cheap reflector or even don’t use specially coated UV reflector. But as you know, more than 60% light energy of UV lamp is IR. The problem of IR is to dry the solvent or water-based content inside of UV Ink or lacquer. The Result is the outside of ink is dry, but inside ink cannot be dried. Because the dried top side is too hard to go throw.

High-efficiency  chilling channel

Inside of lamphouse, DPL high-efficiency chilling channel can cool down lamphouse frame by automatic controlled chilling water. The chilling control sensor can automatically increase or decrease water flow.


DPL Super wider curing Lamps are designed for super wide printing and coating machine. Lamp carry on DPL’s focus on cold curing temperature and uniformity, which is suitable for super wide touch screen or printed electrics process.


How to design Cold UV curing Lamp?

What is Cold UV curing system?

Before we start to explain what is cold UV curing system, we have to explain some basic knowledge of UV curing technology.

How does UV lamp work?

According to the different application, there are several types of UV Lamp.  For example, we can see many UV lamps when we visit emergency or operating room in hospitals. They are UVC lamp, which uses for disinfecting. UVC means the light wavelength from 100-280nm.  For graphics printing and coating industry, we use kinds of Gas-discharge UV lamps or UV LED lamp. Gas-discharge lamps are a family of artificial light sources that generate light by sending an electric discharge through an ionized gas. For UV LED lamp, we will introduce later. 

What is DPL cold UV curing system?

As you know, UV lamp output includes 60% IR energy, a normal metal reflector reflects IR energy out of the lamp head/house, and heat up the touch temperature between your base material and lamp head. Every DPL lamp head/house use specially coated reflectors from the top frame to the two sides frame. These reflectors can absorb 90% IR from your lamp and transfer to the chilling system. Therefore,  the surface temperature of your printing material is the only 5-10C degree higher than your environment temp.

What is the advantage of Cold UV curing system?

Besides of which we mentioned before, reduce UV curing temperature can help improving printing quality. Cold UV curing temperature can also help improving UV lamp bulb ‘s working lifetime. By our pattern design lamphouse, the general lifetime of our UV lamp bulb is over 2000 to 3000hours. On the other way, the lower curing temperature is good for curing  UV lacquer on the thermal sensitive material. For example, even for printing base film as PET film, lower curing temperature will help improving printing accuracy.

More information, welcome to watch our video.


Why Choice DPL as your UV LED curing system supplier?


DPL are much more than just products, we also share our experience on UV curing printing, UV coating, and UV bonding onto wood, glass, metal, plastic and paper products. We sold more than 3000 sets of UV curing system to our clients in the world.

How to choose the right UV curing system?

UV inks are typically very thick. Although lower viscosities are available, UV inks generally range from 1000-5000 centipoise (as compared with water-based inks in the vicinity of 100 centipoises).Therefore, a right UV curing lamp is one of the most important fact that all printers have to be considered.

Why is DOSIS Energy the most important fact for UV curing system?

As you know that, more than 60% output of UV lamp is IR (heating), means you can only get 80w/cm UV energy output even from a 200w/cm UV lamp, if the lamp doesn’t have any special treatment.

Three ways to improve your UV Curing Efficiency

  • Cold Mirror reflector coating technology
  • Hot Mirror Coating technology for bottom window
  • Focus Lens technology