Client & Challenge
A California label converter runs two Weigang ZBS-320 flexo presses for food and beverage shrink-sleeve and film label jobs. Their mercury arc lamps couldn't keep up at the designed speed of 50 m/min—curing was inconsistent above 35 m/min. Worse, California's strict VOC regulations and growing brand demand for low-carbon production put them at a competitive disadvantage. The heat distortion on thin films also drove their scrap rate above 5%.
Solution & Installation
We replaced their mercury lamps with a custom water-cooled UV-LED system at 395nm, delivering 10 W/cm²—just enough to cure at full speed. The LED head mounted directly onto the existing housing using adapter brackets, requiring no modification to the press structure. We also provided EPA-compliant energy test reports to support their application for state energy incentives and a mercury-free certification to strengthen their sustainability profile.
Results & Savings
The press now runs consistently at 50 m/min with full cure. Energy consumption dropped from 14 kW to just 3 kW per hour, saving over $20,000 annually in electricity based on California industrial rates. VOC emissions fell sharply, meeting South Coast Air Quality Management District standards. The mercury-free operation became a key differentiator in food packaging bids, and scrap rate dropped from 5% to under 2%.
Client Feedback
Their production director summed it up: "This wasn't just about speed—it solved our compliance and branding issues too." They used our data to secure a state manufacturing incentive and highlighted the UV-LED upgrade in their sustainability report to a major food brand client. They're now planning to convert their second ZBS-320 and have shared the case with peers in their network.