UV and Aqua Varnish Coating Machine Fully Automatic

About UV and Aqua Varnish Coating Machine Fully Automatic

A UV (Ultraviolet) coating machine is a crucial piece of equipment in the printing and finishing industry. It applies a liquid-based, often glossy, clear coating to printed materials, which is then instantly cured (hardened) by exposure to ultraviolet light. This process enhances the aesthetic appeal, durability, and protection of the printed product.

Here's a comprehensive breakdown of UV coating machine specifications:

I. Types of UV Coating Machines:

Before diving into specifications, it's helpful to understand the different types:

1. Full/Flood UV Coaters: Apply UV coating to the entire surface of the material.

2. Spot UV Coaters: Apply UV coating to specific areas of a print, creating a contrasting matte and glossy effect (often using a printing plate similar to offset).

3. Drip-Off UV Coaters: A specialized type of spot UV that creates a textured, "drip" or "orange peel" effect by applying a matte varnish followed by a high-gloss UV coating.

4. Roller Coaters: The most common type, where the coating is applied via a series of rollers.

5. Spray Coaters: For irregular shapes or specific industrial applications.

6. Tabletop UV Coaters: Compact models for small-scale operations or testing.

7. Online vs. Offline:

   • Online: Integrated directly with a printing press, applying the coating immediately after printing.

   • Offline: A standalone machine where printed sheets are fed after the printing process.

II. Key Specifications of UV Coating Machines:

1. Coating Method:

   • Roller Coating: The most prevalent for sheet-fed applications.

   • Spray Coating: For irregular surfaces or specialized industrial use.

2. Maximum and Minimum Sheet Size:

   • This defines the dimensions of the paper, board, or other substrate the machine can coat. Common ranges include:

     • Max Sheet Size: From 386 x 515 mm (15" x 20") for smaller machines up to 730 x 1040 mm (28" x 40") or even larger for industrial models.

     • Min Sheet Size: Can be as small as 125 x 180 mm or 210 x 250 mm.

3. Material Thickness Compatibility (GSM or mm):

   • Paper/Board: Typically ranges from 60 GSM to 450 GSM. High-end machines might handle up to 600-800 GSM board.

   • Other Substrates: Some machines are designed for wider thickness ranges to coat plastic sheets, PVC, wood, metal, glass, etc., handling thicknesses from 1 mm up to 60 mm.

4. Coating Speed (Impressions Per Hour - IPH or meters per minute):

   • Varies significantly based on automation level, machine size, and coating type.

   • Automatic Machines: Can range from 2000 to 8000 IPH.

   • Semi-Automatic/Manual: Lower speeds, often 1000-3000 IPH or 15-40 meters per minute for conveyor-type systems.

5. UV Lamp Specifications:

   • Number of Lamps: Typically 1 to 3 UV lamps. Some larger systems may have more.

   • Lamp Intensity/Power: Measured in Watts per inch (W/inch) or Kilowatts (kW). Common intensities are 200-500 W/inch.

     • Example: 400 Watt/inch (equivalent to 10.0 kW to 20.8 kW for wider machines).

   • Lamp Life: Important for maintenance planning.

   • Cooling System: Essential to dissipate heat generated by UV lamps (e.g., blowers, water cooling systems).

   • UV Ray Leaking Prevention Device: Safety feature.

   • Automatic Lamp ON/OFF: Lamps turn off if the conveyor stops or material flow is interrupted.

6. IR (Infrared) Curing/Drying System (Optional but common):

   • Used for aqueous (water-based) coatings or for pre-drying before UV coating.

   • Number of IR lamps and their power (e.g., 24 x 1KW lamps).

7. Automation Grade:

   • Manual: Operator feeds sheets one by one.

   • Semi-Automatic: Features an automatic feeder, but delivery might be manual.

   • Automatic: Includes automatic feeding, coating, curing, and stacking/delivery systems.

8. Feeding System:

   • Automatic Feeder: Often a vacuum suction feeder for smooth, continuous sheet feeding.

   • Pile Height (Feeder): The maximum stack height the feeder can handle (e.g., 350 mm, 800 mm).

9. Delivery System:

   • Chain Delivery with Receding Stacker: For neat stacking of coated sheets.

   • Automatic Down Pile Delivery: Automatically lowers the stack.

   • Vacuum-based Absorption Paper Delivery: Ensures stable paper movement throughout the coating process.

10. Coating Control:

    • Adjustable Coating Thickness: Allows for varying gloss levels and protection (e.g., 3-8 GSM coating thickness).

    • Roller System: Precision rollers (e.g., rubber, metering, impression rollers) for uniform coating application.

    • Speed Differential Oil Delivery System: For optimized coating.

    • Grid Ceramic Roller / Anilox Roller: For precise and consistent coating application, especially for spot UV.

11. Power Requirements:

    • Voltage: Usually 220V/380V/440V (three-phase is common for larger machines).

    • Total Power Consumption (kW or HP): Can range from 2 kW (for smaller models) to 55 kW or more for large, fully automatic systems.

12. Machine Dimensions and Weight:

    • Crucial for factory layout and installation.

    • Dimensions (L x W x H) and weight vary widely based on size and features (e.g., Weight: 700 kg to 8500 kg+).

III. Additional Features and Considerations:

• User-Friendly Interface: Touch screen control panels for easy operation and monitoring.

• Safety Features: Emergency stop buttons, UV ray leaking prevention, automatic shut-off if covers are opened.

• Precise Registration (for Spot UV): Features like swinging-downward front lay or rotating side lay for accurate sheet positioning.

• Anti-Scratch/Anti-Static Devices: To prevent marks and ensure smooth material handling.

• Automatic Roller Cleaning System: Reduces maintenance time.

• Chemical Circulation System: For efficient management of UV varnish.

• Durable Construction: Stainless steel and mild steel components for longevity.

• Versatility: Ability to handle various types of UV and aqueous coatings (gloss, matte, textured).

• Applications:

  • Printing Industry: Brochures, business cards, book covers, posters, calendars, magazines.

  • Packaging Industry: Carton boxes, product packaging, labels.

  • Other Industries: Wood panels, furniture components, plastic sheets, metal plates, glass, PVC profiles, medical devices, photography.

When purchasing a UV coating machine, it's vital to assess your production volume, the types of materials you'll be coating, desired finish quality (full, spot, drip-off), and budget. Manufacturers in Faridabad and across India (like Autoprint, Decent Print Lines, P3 Machinery, SK Ensure Machinery, Unison Machinery, etc.) offer a wide range of options to suit different business needs.