General UV Curing Information

Lamp Information
The lamp emits large amounts of ultraviolet radiation, which can be extremely
harmful to eyes and skin. Great care should be taken to insure that personnel are not exposed
to direct or reflected radiation from the lamp. Suitable eye and skin protection must be employed
when lamp is in operation.

The lamp generates ozone gas during operation. Operating equipment and work areas
should be adequately ventilated to comply with the OSHA regulations for ozone.

The lamp should be handled only when cold and with clean cotton gloves. Alcohol can be
used to remove fingerprints and all external foreign matter. Premature devitrivication and
dramatic poor lamp performance are directly related to a clean outer surface.

UV Curing Principle

Ultraviolet curing is a photochemical process in which an abundant amount of UV energy is

(A) Chemical Compound – Each monomer will cure at a different rate, depending upon the
composition and amounts of sensitizer, pigment, and chemical additives.

(B) Thickness of Coating – The thickness of a specific coating is not directly proportional to
exposure time. The amount of UV energy inside a layer of coating decreases
exponentially with depth. If 70% of the UV energy is absorbed in the top .001” of
coating, then 70% of the remainder or 7% of the initial amount will be absorbed in the
second .001” of coating. Thus, a two-fold increase in thickness requires a ten-fold
increase in UV intensity.

(C) Amount of UV per Unit Surface – Normally, the curing speed will increase with the
amount of UV energy per unit surface at a nonlinear rate. If a 200 watt per inch mercury
lamp was increased to 400 watt, the curing speed would increase ten fold.

The information contained thereon is the property of SPDI, Inc. Reproduction or use in whole or in part of this
manual and the information thereon by anyone, except authorized persons in the furtherance of the business
SPDI, Inc. without the written consent of SPDI Inc. is STRICTLY PROHIBITED
 The sensitizer should absorb UV in the range which is not absorbed by the monomer or
pigment. The wavelength produced by a medium mercury pressure lamp should coincide
with the wavelength absorbed by the sensitizer. The continuous light spectrum produced
by these lamps in the 200 to 440 nanometer range propels technology to a plateau of
efficiency.

(D) The UV Spectrum – Once the basic concept of radiation has been understood,
how ultraviolet radiation fits into the scheme of things, and what UV curing contains,
then, one can easily understand the advantages and disadvantages of various
light sources. UV curing lamps display the following characteristic in Figure 1.

Figure 1
The far ultraviolet lies between 200nm and 300nm and is classified as Germicidal or UV-C.
The middle ultraviolet lies between 280nm and 320nm is called Erythmea (suntan) or UV-B.
The near ultraviolet lies between the 320nm and 400nm and is commonly called Black Light
(long ultraviolet) or UV-A.

(E) Advantages of UV Curing

(1) A drastic reduction in “air pollution” becomes possible with the monomer system of
excitation. No solvent need be evaporated and expelled into the atmosphere.

(2) The fast and rapid curing rate UV lamps.

(3) Huge savings in plant space, labor costs, and the highest quality in improved
appearance cannot be overlooked.

The information contained thereon is the property of SPDI, Inc. Reproduction or use in whole or in part of this
manual and the information thereon by anyone, except authorized persons in the furtherance of the business
SPDI, Inc. without the written consent of SPDI Inc. is STRICTLY PROHIBITED
 UV Safety
Ultraviolet Safety…
The spectra available for ultraviolet curing and drying is quite varied. Coatings, inks, and
adhesives may be composed of formulations that require strong UV intensity of various
wavelengths. Longwave ultraviolet radiation (320-420 nanometers) is considered most practical.

Shielding is absolutely mandatory. Medium pressure UV lamps radiate harmful UV

While thermal burns are felt immediately, UV burns are not felt for several hours. Short
exposure to lamp radiations can cause severe burning of skin and eyes. UV burn of the eyes affects
the cornea that takes several days to heal. UV burn is identical to ‘Welder’s Burn’ and will feel like
sand in the eyes that cannot be washed out. The discomfort is transitory. Extreme caution must be
taken – high power UV radiation can cause blindness.

Exposure to UV radiations, of only limited time, will evoke erythema on normal skin. Such
erythema is transitory and will not produce blistering, nor tanning, as only a small amount of
radiation penetrates the Malpighian layer. Extreme caution must be taken – high power UV
radiation can cause severe burns to the skin.

Shielding material can be of cloth, glass, plastic, wood, or metal. As infrared energy is
generated along with intense visible light, fireproof as well as opaque material that does not
degenerate under UV radiation must be utilized.

Direct light from the UV processor should not be visible to the operator nor other personnel.
Bounce (reflected) light should be minimized and avoided. Total shielding with openings minimized
for product entrance and egress from the UV processor should be incorporated into processor design.
Reflective surfaces coated with black UV absorbing paint reduce reflected UV radiations. Protective
clothing and safety spectacles should be worn if optimum shielding cannot be attained.

Thermal Safety…
Infrared energy, an inherent product of the arc utilized to create UV energy in UV
processors, can cause overheating of processor components when adequate safeguards are not
incorporated into the UV processor design and application.

Cooled heat sinks should provide protection to the press, conveyor, and other process
components in or near the UV processor. The cooling system should be carefully designed and
properly maintained. In air-cooled systems, filters must be properly cleaned or replaced on a
maintenance schedule related to powder, dust, and dirt conditions where the UV processor is
operating.

Halon #1211 fire extinguishers are to be used in the event of fire. CO2 fire extinguishers
with dry chemical or water are NOT recommended.
The information contained thereon is the property of SPDI, Inc. Reproduction or use in whole or in part of this
manual and the information thereon by anyone, except authorized persons in the furtherance of the business
SPDI, Inc. without the written consent of SPDI Inc. is STRICTLY PROHIBITED
 If a fire occurs, all residue of damaged substrate should be removed from curing area. Soot
and ash must be cleaned from lamps and reflectors before re-start.

Investigation to determine the malfunction causing the fire is most important. Correction
must be made to eliminate re-occurrence.

UV processor electrical systems should be serviced only by qualified electricians.

Ozone Safety…
Triatomic oxygen or ozone (O3) is the only by-product of the UV lamp. It is formed by
oxygen being exposed to 254nm wavelengths of UV energy.

Ozone can be effectively eliminated in the processing area by exhausting air of the cooling
system of the UV processor to outside the building. Such exhausting has no danger as the hot gas is
very unstable and breaks down to oxygen rapidly in ducting.

UV Lamp Handling…
Fused quartz (Silicon di-oxide, SiO2) with a high melting point and excellent UV
transmissivity is used in fabrication of UV processor lamps. A 22 x 25 mm diameter tube with wall
thickness of 1.0 to 1.5 mm used with tungsten electrodes sealed into each end is typical. Lamps are
manufactured from 1” to 180: arc length. Quartz is very fragile and special cushioned packaging is
utilized for safe transportation.

Upon receiving new lamps the carton should be opened fully so the lamp can be lifted out of
the packaging with no twisting or pulling. Unpacking should take place in an area large enough to
eliminate the possibility of inadvertently striking lamp against walls, pillars, pipes, beams, or
machinery.

Lamp must be wiped with alcohol before placing in service. Bare skin contact with the
quartz envelope must be avoided. Compounds from the skin when heated on lamps operating at
600o to 850o C will form permanent etching (devitrification) on the quartz surface, decreasing UV
energy transmission. A contaminated lamp eventually will overheat causing premature failure.

The information contained thereon is the property of SPDI, Inc. Reproduction or use in whole or in part of this
manual and the information thereon by anyone, except authorized persons in the furtherance of the business
SPDI, Inc. without the written consent of SPDI Inc. is STRICTLY PROHIBITED
UV Processor Maintenance…
Lamps and reflectors must be clean at the time of installation and maintained so the UV
energy generated can reach the ink or coating.

Since the UV processor is an optical system, all types of dust, powder, grease, smoke, and
coatings must be cleaned from the lamp and reflectors. Electrical fittings must also be kept clean to
prevent arcing between fitting and lamp ends.

Dirty reflectors will reduce cure rates and increase temperature. The reflectors return
approximately 50-60% of lamp energy. Overheating from a dirty condition can cause warping,
possibly reducing electrical spacing, and cause a short of the arc to ground.

A mild detergent and distilled water mixed at a ratio of 1¼ ounces to 1 gallon makes a good
cleaning solution. After cleaning, rinse with clear distilled water and wipe or polish with a clean
cloth.

Grease or ink on the lamp or reflectors will require washing with a solvent rather than
cleaning with a detergent solution. Clean alcohol or ammonia and distilled water can also be used
for cleaning. The use of steel wool, emery paper, or abrasive powders is not recommended for
cleaning lamps or reflectors.

CAUTION
Ultraviolet lamps emit radiation, which is harmful to eyes and skin. Great care should be
taken to insure that personnel are not exposed to direct or reflected light.

The information contained thereon is the property of SPDI, Inc. Reproduction or use in whole or in part of this
manual and the information thereon by anyone, except authorized persons in the furtherance of the business
SPDI, Inc. without the written consent of SPDI Inc. is STRICTLY PROHIBITED