company news about Old production line revitalized: Packaging plant introduces our UV curing technology, improving yield rate

In today's manufacturing industry, where the pursuit of ultimate efficiency is paramount, even the smallest flaws on a production line can be a black hole that devours profits. Recently, a well-known high-end packaging manufacturer in China successfully upgraded its existing production line by introducing a UV-LED curing module customized by our company. Data after the upgrade shows that the overall yield rate of the production line has increased dramatically from 85% to 99%, not only solving the long-standing problem of paint peeling that plagued the company, but also achieving a significant reduction in energy consumption.

As a leading company in the packaging industry, this client primarily undertakes screen printing business for high-end cosmetics and wine bottles. However, their original production line used a traditional mercury lamp curing system, and over time, various problems arose:

• Incomplete Curing: The unstable energy output of traditional mercury lamps led to insufficient ink adhesion in batches of products, resulting in frequent failures in cross-cut adhesion tests.
• High-Temperature Damage: The large amount of infrared heat generated by the mercury lamp caused the glass bottles to heat up too quickly, causing some coatings to become brittle and peel off, keeping the yield rate hovering around 85%.
• Frequent Downtime: The long preheating time of the mercury lamps and their short lamp life (only about 1000 hours) meant that frequent replacements and adjustments severely disrupted the production schedule.

Based on the client's actual production line space and process requirements, our technical team conducted multiple on-site investigations and tailored a high-energy UV-LED curing solution:

• Precise Energy Control: Utilizing imported high-power chips, the output wavelength is precisely locked at 395nm. The powerful instantaneous irradiation intensity ensures deep curing of the ink from the surface inwards, completely eliminating the risk of paint peeling.
• Zero Heat Damage: Thanks to excellent heat dissipation design and cold light source characteristics, the bottle temperature rise is reduced from over 40°C to below 5°C, perfectly protecting the special coating and texture of the bottle surface.
• Intelligent Compensation System: The module has a built-in sensing chip that automatically monitors light intensity and compensates in real time, ensuring consistent curing effects throughout the year and regardless of shift schedule.

The upgrade project, completed in just two days over a weekend, achieved seamless production line integration. Three months after implementation, the customer provided encouraging data:

• Significantly Increased Yield: The yield rate stabilized above 99%, and scrap costs due to curing issues were virtually eliminated.
• Energy Efficiency Revolution: UV-LED modules are ready to use immediately without preheating, reducing overall power consumption by approximately 70% compared to the original mercury lamp system.
• Plummeting Maintenance Costs: LED chips have a lifespan of up to 20,000 hours, requiring no consumable replacements for two full years, resulting in a 15% increase in production efficiency.

The packaging plant manager stated during the acceptance inspection, "This upgrade is not just about equipment enhancement, but also a leap forward in our production quality. The technical support from XX manufacturer has shown us the international standard of domestically produced UV curing equipment."

Shenzhen Super-curing Opto-Electronic CO., Ltd. is committed to helping customers solve production pain points with more advanced UV curing technology. Whether it's building a new production line or upgrading an existing one, we will provide professional solutions to help you stand out in the fierce market competition.