The ultimate guide to UV curing in the wood coating sector

Wood coating is an essential process in ensuring the durability, appearance, and functionality of wood products. As technology advances, the methods used for wood coating have evolved, with UV curing emerging as an enterprising solution. This article looks at the importance of UV curing in the wood coating sector, exploring its benefits, applications, and the reasons behind the recent shift to UV curing with state-of-the-art LED technology.

---

1. Introduction to wood coating and UV curing

Wood coating is a critical process that enhances the aesthetic and functional qualities of wood products. It involves applying a protective layer that shields the wood from environmental damage, wear and tear. This also seals in chemical compounds that are present in the wood product, to prevent degradation in its visual appearance and structural properties, over time. Wood coating also enhances the visual appeal of the product being manufactured.

Among the various methods of drying wood coatings, UV curing stands out due to its efficiency and effectiveness. UV curing involves using ultraviolet light to instantly harden or cure the coating, providing numerous benefits over traditional methods. Find out more about these benefits, here.

2. Why wood coating is necessary for wood products

Wood is one of the most versatile and widely used materials in the world, with applications ranging from construction, to furniture or parquet, to decorative items and functional tools.

However, raw wood, regardless of its properties and natural beauty, is often replaced by socially and economically supported wood alternatives, or supported structural wood substrates, such as plywood, board of frame (BOF), Medium Density Fibreboard (MDF), High Density Fibreboard (HDF), veneered particle board and laminated particle board. These alternatives influence the final weight of the product, the thermal or sound insulation properties, the mechanical or chemical resistance and, of course, the cost of the product.

However, like natural wood, its substrates are susceptible to many problems that can damage its integrity and appearance in the long term. Therefore, as the variety of coated surfaces increases, more sophisticated coating methods and coatings are needed.

This is where wood coating plays a crucial role, offering a host of benefits that ensure the longevity and aesthetic appeal of wood products. Benefits include:

Protection from environmental factors

One of the primary reasons for coating wood is to protect it from environmental factors such as moisture, UV radiation, temperature fluctuations, and pollutants. Moisture is particularly detrimental as it can lead to appearance of stains, warping, change in dimensions due to swelling, and decay, causing malfunction. UV radiation can degrade the wood’s surface, causing discoloration and weakening its structure over time. A good wood coating provides a barrier that protects against these elements, preserving the product’s integrity and appearance.

Enhanced durability

Wood products, especially those used in high-traffic areas like flooring, chairs, tabletops, doors, and outdoor furniture, are subjected to considerable wear and tear. Coatings enhance surface durability by adding layers that resist scratches, abrasions, and impacts. This not only extends the lifespan of the wood product but also maintains its appearance. A durable product also meets today’s environmental expectations to be longer lasting and therefore more sustainable.

Aesthetic enhancement

Coatings can significantly enhance the aesthetic appeal of wood by bringing out its natural grain and colour. Whether it’s a glossy, matte, or satin finish, the right coating can transform a piece of wood, highlighting its beauty and making it more attractive. Wood stains, for example, can accentuate the natural grain patterns, while paints can provide a uniform colour and additional layer of protection.

The aesthetic appearance of the coating can also be enhanced by imitating wood pattern and structure, with the use of digital printing or decor roller-coaters. These techniques enable an almost infinite number of decorative effects to be achieved.

Resistance to chemicals and stains

Wood surfaces in domestic situations, laboratories, and industrial settings are often exposed to chemicals and staining agents. A well-applied coating creates a resistant barrier that prevents chemicals and stains from penetrating the wood or board. This is particularly important in maintaining the cleanliness and appearance of surfaces like countertops, cabinetry, and flooring from factors such as spilled wine, coffee, or elementary oil-based stains.

Improved hygiene

Coatings can also play a role in improving the hygiene of wood products, especially those used in food preparation or medical environments. Certain coatings have antimicrobial properties that inhibit the growth of bacteria, mould, and mildew, making the surfaces safer and easier to clean.

Fire resistance

In certain applications, fire resistance is a critical consideration. Some wood coatings are formulated to provide a degree of fire resistance, slowing down the spread of flames and reducing the risk of fire-related damage. This is particularly important in construction and public buildings where safety regulations are stringent.

Economic benefits

Investing in quality wood coatings can lead to significant economic benefits in the long term. By extending the lifespan of wood products, reducing maintenance costs, and minimising the need for replacements, coatings can result in substantial savings. Additionally, the enhanced appearance of coated wood can increase its market value, making it more attractive to buyers.

A correctly chosen, high-quality coating can also hide minor defects in the coated surface that are caused by procedural preparation errors, so the importance of paint should not be underestimated.

Versatility in applications

Wood coatings are highly versatile and can be tailored to suit various applications. From clear varnishes that preserve the natural look of the wood, to pigmented paints that offer vibrant colours, a wide range of coatings are available to meet specific requirements. This versatility makes wood coatings suitable for a myriad of applications, including furniture, flooring, cabinetry, panelling, mouldings and decorative items.

Coaters can also choose from a broad range of application methods, coatings formulations, drying methods, and sanding treatments, whilst at the same time considering changeable economic factors and environmental pressures.

Environmental considerations

With increasing awareness of environmental sustainability, many modern wood coatings are formulated to be eco-friendly. The changing requirements and obligations of the EU and the USA play an important role in this regard, for the entire global market. Water-based coatings, for example, emit fewer volatile organic compounds (VOCs) compared to traditional solvent-based coatings, reducing their environmental impact. Additionally, durable coatings that extend the life of wood products contribute to sustainability by reducing the need for new resources.

In summary, wood coating is necessary for protecting wood from environmental damage, enhancing its durability, improving its aesthetic appeal, and providing resistance to chemicals, stains, and fire. The correct coating can transform a simple piece of wood, ensuring it remains beautiful and functional for years to come. It can also enhance the appearance – and extend the functionality and service life of secondary products – such as lightened chipboard, MDF, HDF honeycomb board, plywood or composites.

3. The role of UV curing in wood coating

UV curing has revolutionised the wood coating industry by providing a fast, efficient, and high-quality method for curing coatings. This technology involves using ultraviolet light to initiate a photochemical reaction that instantly hardens the coating. The solid content in so-called 100% UV coatings reaches almost 100%, and it never requires any hardener, diluent, or thinner. It is not limited to pot life and can be stored for relatively long; therefore, it is valued by users. The benefits of UV curing in wood coating are numerous and have made it a preferred method in modern manufacturing processes.

Speed and efficiency

One of the most significant advantages of UV curing is its speed. Traditional curing methods, such as air drying or oven drying, can take hours or even days to fully cure a coating. In contrast, UV curing can complete the process in a matter of seconds. This rapid curing time allows for much faster production cycles, increasing throughput and reducing lead times. An essential factor is that UV systems are much more compact, so the process avoids bulky convection dryers altogether, unless hybrid systems are used, where water-based coatings must be evaporated first and then cured.

Energy savings

UV curing systems are highly energy-efficient compared to traditional curing methods. Oven drying, for example, requires significant amounts of energy to maintain the necessary temperatures for curing. UV curing, on the other hand, uses ultraviolet light, which consumes less energy and produces less heat. This not only reduces energy costs, but also minimises the environmental impact of the curing process.

Improved finish quality

UV curing provides a high-quality finish that is difficult to achieve with other methods. The process results in a hard, durable coating with excellent resistance to scratches, chemicals, and UV light. This ensures that the finished product not only looks good, but also performs well under various conditions. In most cases, UV curing is the only way to achieve the highest resistance requirements. The consistency and reliability of UV curing also mean fewer defects and higher overall product quality.

Environmental benefits

Traditional curing methods, especially those involving solvents, can release volatile organic compounds (VOCs) into the atmosphere, contributing to air pollution and health issues. UV curing, and in particular UV LED curing, significantly reduces VOC emissions. This makes UV curing a more environmentally friendly option that aligns with modern regulations and sustainability goals.

Versatility in applications

UV curing is suitable for a wide range of wood coating applications. Whether it is furniture, flooring, cabinetry, doors, profiles, mouldings or interior panelling, UV curing can provide the desired finish and protection. The technology can be used with multiple types of coatings, including varnishes, lacquers, oils, stains, and opaque finishes, making it highly versatile and adaptable to different needs. Furthermore, coaters can choose a variety of paint bases, such as 100% UV/LED products, or oil-based coatings that can be UV/LED cured. This opens a wide window for applications, from curtain coating to roller coating, vacuum, and various methods of spraying.

Immediate handling and further processing

One of the practical benefits of UV curing is that the coated products can be handled and processed immediately after curing. There is no need to wait for the coating to dry, which can significantly speed up the production process. This immediate handling capability is particularly beneficial in high-volume manufacturing environments, where time is of the essence.

UV curing has become a game-changer in the wood industry, which for many years was very conservative. Speed, as one component in mass production, makes furniture more affordable in poorer countries, and more competitive in other markets.

Consistency and reliability

UV curing systems offer consistent and reliable performance. The controlled curing process ensures uniform coverage and hardening, resulting in a consistent finish across all products. This reliability reduces the likelihood of defects and rework, further enhancing production efficiency and product quality. Furthermore, linear quality monitoring systems can be integrated, reducing human errors by highlighting possible deviations from the norm.

Compatibility with modern coating formulations

The development of UV-curable coatings has been a significant advancement in the wood coating industry. These formulations are specifically designed to work with UV curing systems, providing optimal performance and finish quality. The compatibility of UV curing with modern coatings ensures that manufacturers can achieve the best possible results. Using UV in non-traditional methods for the wood industry simply requires greater involvement of designers and engineers, integrating dryers into more complex spaces. But for the most part, there are already working solutions for this.

Safety and workplace environment

UV curing systems, especially UV LED systems, are generally safer to operate than conventional drying systems. They produce less heat, reducing injury risk and fire hazards. Whilst there are risks associated with extreme exposure to UV light, UV LED curing minimises this risk. In comparison, self-flammable oils present fire risks, particularly if operator’s clothing is thrown away with regular production waste; it is essential to sort waste correctly, as fires usually begin in the waste container. Another cause of fires is when parts stick under operating lamps. This is one of the reasons why profile and moulding manufacturers are particularly interested in changing from UV to LED.

In general, UV materials do not present a risk of spontaneous combustion or explosion, which gives them significant advantages over conventional solvent-based products. This allows them to be stored and transported more easily. Also, most UV materials are not harmed by sub-zero temperatures, which makes both transportation and storage cheaper during the winter.

It is always important to note that prolonged hand contact with UV material can cause adverse effects, so hands and skin should be washed immediately.

Additionally, the reduction in VOC emissions and improved air quality contribute to a safer and healthier workplace environment for employees, although VOCs in most common wood coating materials only account for around 1-3% of the wood content.

Economic benefits

While the initial investment in UV curing equipment may be higher than traditional methods, the long-term economic benefits are substantial. The increased production speed, reduced energy consumption, improved product quality, and lower maintenance costs all contribute to significant cost savings over time. These economic advantages make UV curing a wise investment for manufacturers looking to enhance their operations.

UV curing plays a vital role in the wood coating industry by providing a fast, efficient, and high-quality curing process. Its numerous benefits, including speed, energy savings, improved finish quality, and environmental advantages, make it a preferred choice for modern wood coating applications.

4. The shift to UV LED curing in the wood coating market

The wood coating industry is experiencing a significant shift towards UV LED curing, driven by advancements in technology and the growing need for more efficient, cost-effective, and environmentally friendly curing methods. This section explores the reasons behind this transition and the benefits that UV LED curing offers over traditional UV curing and other methods.

Energy efficiency and cost savings

One of the primary reasons for the shift to UV LED curing is its superior energy efficiency. Traditional UV curing systems use mercury vapour lamps, which consume a considerable amount of power and generate significant heat. In contrast, UV LED systems use light-emitting diodes (LEDs) that are much more energy-efficient, consuming less power and producing minimal heat. This results in substantial cost savings on energy bills and reduces the overall carbon footprint of the manufacturing process.

Longer lifespan and reduced maintenance

UV LED lamps have a significantly longer operational life compared to traditional mercury vapour lamps. While mercury lamps typically last for around 1,000 to 2,000 hours, UV LED lamps can last up to 40,000 hours or more. This extended lifespan reduces the frequency of lamp replacements, lowering maintenance costs and minimising production downtime. The reliability and durability of UV LED systems make them a more cost-effective solution in the long term.

Instant on/off capability

Traditional UV lamps require a warm-up period before they reach their optimal operating temperature and light output. This can lead to delays and energy wastage. UV LED systems, on the other hand, can be turned on and off instantly without any warm-up time. This instant on/off capability provides better control over the curing process, improves production efficiency, and reduces energy consumption.

Consistent performance

UV LED curing systems offer more consistent output over time compared to traditional UV lamps, which can degrade and lose efficiency as they age. The consistent performance of UV LED systems ensures uniform curing and high-quality finishes across all products. This reliability is particularly important in maintaining product quality and meeting stringent manufacturing standards.

More specifically, a UV lamp that degrades unevenly along its length poses challenges due to colour drift over the entire curing area, and different lamp intensities can affect the degree of surface gloss. With LEDs, these common problems are eliminated because of the aforementioned consistency of output.

Environmental benefits

The shift to UV LED curing is also driven by environmental considerations. Traditional mercury vapour lamps contain hazardous materials such as mercury, which poses disposal challenges and environmental risks. UV LED lamps are mercury-free and do not produce ozone, making them a safer and more environmentally friendly option. Additionally, the lower energy consumption of UV LED systems contributes to reducing greenhouse gas emissions and aligns with global sustainability goals.

Improved safety

UV LED systems are safer to operate compared to traditional UV lamps. The reduced heat generation lowers the risk of burns and fire hazards, creating a safer working environment for employees. Moreover, the elimination of mercury and other hazardous materials further enhances workplace safety and reduces health risks. The LED system does not produce ozone during the process, so no additional air extraction is necessary, contributing to reducing the environmental impact.

Compatibility with modern coating formulations

As the wood coating industry evolves, so do the formulations of the coatings themselves. UV-curable coatings are designed to work optimally with UV LED curing systems, providing enhanced performance and finish quality. This compatibility ensures that manufacturers can achieve the best possible results with UV LED curing, making it a preferred choice for modern wood coating applications.

Flexibility in application

UV LED curing systems offer greater flexibility in application compared to traditional UV lamps. They can be easily integrated into existing production lines and are available in various configurations to suit different curing requirements. This adaptability allows manufacturers to tailor their curing process to specific needs, improving overall efficiency and product quality. Due to the lower operating temperature and the absence of air extraction, the systems are more easily integrated and managed, even in the most complex installations.

Economic benefits

While the initial investment in UV LED curing equipment may be higher than traditional UV systems, the long-term economic benefits are substantial. The energy savings, reduced maintenance costs, longer lifespan, and improved production efficiency all contribute to significant cost savings over time. These economic advantages make UV LED curing an intelligent investment for manufacturers looking to enhance their operations and remain competitive in the market.

Industry trends and adoption

The adoption of UV LED curing in the wood coating market is being driven by industry trends and the influence of major brands. Leading companies are recognising the benefits of UV LED technology and are making the transition to improve their production processes and meet environmental regulations. This shift is expected to continue as more manufacturers discover the advantages of UV LED curing and invest in this advanced technology.

In summary, the shift to UV LED curing in the wood coating market is driven by the need for more efficient, cost-effective, and environmentally friendly curing methods. The numerous benefits of UV LED curing, including energy efficiency, longer lifespan, instant on/off capability, consistent performance, and improved safety, make it an attractive option for modern wood coating applications.

If you would like to know more about UV and UV LED curing with GEW, speak to our Sales team now:

5. Applications of UV curing in wood coating

UV curing has proven to be a versatile and highly effective method for wood coating, suitable for a wide range of applications. Its ability to provide a fast, durable, and high-quality finish makes it ideal for various wood products. This section explores the specific applications of UV curing in wood coating and the benefits it offers for each.

Furniture

Furniture manufacturing is one of the primary applications of UV curing in wood coating. The quality and durability of the finish are critical for furniture pieces, which are subject to daily use and wear. UV curing provides a hard, scratch-resistant surface that enhances the longevity of furniture, while maintaining its aesthetic appeal.

• Enhanced durability: UV-cured coatings offer superior resistance to scratches, impacts, and chemicals, ensuring that furniture retains its appearance and functionality over time.
• High-quality finish: The fast-curing process results in a smooth, high-gloss or matte finish, depending on the desired look. This enhances the visual appeal of furniture pieces, making them more attractive to consumers.
• Fast production cycles: The rapid curing times of UV systems allow for faster production cycles, increasing throughput and reducing lead times.

Flooring

Wood flooring requires a robust finish that can withstand heavy foot traffic, spills, and other forms of wear and tear. UV curing is particularly suitable for flooring applications due to its ability to provide a hard, durable surface.

• Wear resistance: UV-cured coatings provide excellent resistance to abrasion and wear, making them ideal for high-traffic areas such as residential homes, commercial buildings, and public spaces.
• Chemical resistance: The cured coatings are resistant to chemicals and stains, making it easier to clean and maintain wood floors.
• Resistance to sunlight: UV coatings reduce the effect of sunlight and protect light colours from yellowing.
• Immediate usability: Floors coated with UV-cured finishes can be used immediately after curing, eliminating downtime and allowing for quicker installation and use.

Cabinetry

Cabinetry in kitchens, bathrooms, and other areas requires a durable, moisture-resistant finish that can withstand frequent use and exposure to various elements. UV curing offers several benefits for cabinetry applications.

• Moisture resistance: UV-cured coatings provide a barrier that protects against moisture, preventing warping, swelling, and decay in kitchen and bathroom environments.
• Stain resistance: The hard, non-porous surface of UV-cured coatings makes it easier to clean and resist stains from spills and splashes.
• Aesthetic appeal: UV curing provides a smooth or structural high-quality finish that enhances the visual appeal of cabinetry, making it more attractive to homeowners and designers.

Interior panelling

Interior wood panelling, used for walls and ceilings, benefits significantly from UV curing due to its ability to provide a durable and aesthetically pleasing finish.

• Consistency and uniformity: UV curing ensures a consistent and uniform finish across large surfaces, providing a professional look for interior spaces.
• Protection from UV light: UV-cured coatings protect the wood from discoloration and degradation caused by exposure to sunlight, preserving the panelling’s appearance over time.
• Easy maintenance: The smooth, hard surface of UV-cured finishes is easy to clean and maintain, ensuring that interior panelling remains in good condition with minimal effort.

Decorative items

UV curing is also suitable for smaller, decorative wood items such as mouldings, door frames, picture frames and crafts. These items require a high-quality finish that enhances their appearance and protects them from damage.

• Aesthetic enhancement: UV curing provides an attractive, high-gloss or matte finish that enhances the natural beauty of decorative wood items.
• Durability: The cured coatings offer excellent protection against scratches, impacts, and environmental factors, ensuring that decorative items remain in pristine condition.
• Fast production: The rapid curing process allows for quick turnaround times, making it easier to produce decorative items efficiently and meet market demand.
• UV-LED curing at lower temperatures: Decor profiles made from pine can be painted more safely, avoiding the movement of resins in the wood.

Industrial applications

In addition to consumer products, UV curing is also used in industrial applications where wood components are subjected to harsh conditions and heavy use.

• Heavy-duty protection: UV-cured coatings provide robust protection for wood components used in industrial settings, ensuring they can withstand demanding environments.
• Chemical resistance: The coatings resist exposure to chemicals and solvents, making them suitable for use in industrial processes and facilities.
• Long-term durability: UV curing ensures that industrial wood components maintain their integrity and performance over extended periods, reducing the need for frequent replacements.

6. Comparison of drying methods in wood coating

The wood coating industry employs various drying methods, each with its own set of advantages and limitations. Understanding these methods is essential for manufacturers, to be able to choose the most suitable one for their specific applications. This section compares the primary drying methods used in wood coating: air drying, oven drying, infrared drying, electron beam and UV curing.

Air drying

Air drying is the most traditional method of drying wood coatings. It relies on natural or forced air to evaporate solvents or water thinners and diluents from the coating, allowing it to dry and harden over time.

• Advantages:
  • Low cost: Air drying requires minimal equipment and energy, making it a cost-effective option for small-scale operations.
  • Simplicity: The process is straightforward and easy to implement without the need for specialised equipment.
• Limitations:
  • Slow drying times: Air drying can take several hours to days, depending on the coating type and environmental conditions. This slow process can lead to production bottlenecks and increased lead times.
  • Inconsistency: Variations in temperature, humidity, and airflow can result in inconsistent drying, affecting the quality and appearance of the finish.
  • Environmental impact: The prolonged exposure of coatings to air can lead to higher VOC emissions, contributing to air pollution and health concerns.

Oven drying

Oven drying, also known as thermal curing, uses heat to speed up the drying process. Coated wood products are placed in an oven or kiln where controlled temperatures, possibly with humidity regulations, facilitate the evaporation of solvents or water, and curing of the coating.

• Advantages:
  • Faster drying times: Oven drying significantly reduces drying times compared to air drying, improving production efficiency.
  • Controlled environment: The controlled temperature and airflow in an oven ensure more consistent and uniform drying.
• Limitations:
  • High energy consumption: Maintaining the necessary temperatures for drying requires substantial energy, leading to higher operational costs.
  • Potential wood damage: Excessive heat can cause wood to warp, crack, or degrade if not carefully controlled.
  • Space consuming: Equipment requires considerable space for the process.
  • Environmental concerns: The energy consumption and emissions from oven drying contribute to the environmental impact of the process.
  • Higher volumes = further costs: Larger companies, when they reach fixed limits, must install expensive filter systems to stop the release of solvents into the environment.
  • Comparatively slow: slower drying process, when compared to UV curing.

E-beam

It is one of the most sophisticated drying methods in the market. Electron beam (e-beam) drying uses high-energy electrons emitted from a source and accelerated through an electric field, creating a focused beam of electrons to affect various surfaces. During the process, electron beams interact with the molecules in the material, causing polymerisation or cross-linking reactions to occur rapidly, resulting in the material hardening or drying almost instantly.

• Advantages:
  • Environmental impact: E-beam processing does not require the use of harmful chemicals, eliminates the need for solvents making it an environmentally friendly option.
  • Instant curing: The high-energy electron beam allows for rapid and efficient curing of materials compared to traditional methods.
  • Non-thermal processing: Since E-beam technology is a non-thermal process, it is suitable for heat-sensitive materials, which might be damaged or altered by high temperatures.
  • Enhanced material properties: E-beam treatment can improve the mechanical properties of wood surfaces, such as hardness, wear resistance, and dimensional stability.
  • High penetration power: E-beams have a high penetration power, allowing them to treat materials with complex geometries or significant thickness.
• Limitations:
  • High initial investment: The cost of setting up E-beam systems is significant due to the need for specialized equipment and infrastructure. This high initial investment can be a barrier for many wood processing businesses, especially small to medium-sized enterprises.
  • Material sensitivity: Some types of wood and wood-based materials may be sensitive to high-energy electron beams, potentially leading to damage or undesired changes in their properties.
  • Operational complexity and maintenance: E-beam systems require skilled personnel to operate and maintain them. The complexity of the equipment and the need for regular maintenance and calibration can lead to increased operational costs and downtime.
  • Radiation shielding requirements: Facilities using E-beam technology must implement significant radiation shielding to protect operators and the environment, which can be costly and space-consuming.

Infrared drying

Infrared drying uses infrared radiation to heat and dry the coating on wood surfaces. Infrared heaters emit radiant energy that is absorbed by the coating, speeding up the evaporation of organic solvents and curing process.

• Advantages:
  • Rapid drying: Infrared drying is faster than air drying and can significantly reduce curing times.
  • Efficient heating: The direct transfer of radiant energy to the coating results in efficient and targeted heating.
  • Reduced VOC emissions: The faster drying process can help reduce VOC emissions compared to air drying.
• Limitations:
  • Equipment costs: Infrared drying systems require specialised equipment, which can be costly to install and maintain.
  • Surface heating: Infrared radiation primarily heats the surface of the coating, which may not fully cure thicker or multi-layered coatings.
  • Limited penetration: The effectiveness of infrared drying can be limited by the depth of the coating and the material properties of the wood. Lamps are usually installed as an additional tool for tunnel dryers or surface preheating.

UV curing

UV curing uses ultraviolet light to initiate a photochemical reaction that instantly hardens or cures the coating. This method is widely used for its speed, efficiency, and high-quality results.

• Advantages:
  • Instant curing: UV curing completes the process in seconds, offering the fastest drying times of all methods.
  • High-quality finish: The cured coatings are hard, durable, and resistant to scratches, chemicals, and UV light.
  • Energy efficiency: UV curing systems consume less energy and produce less heat compared to oven drying.
  • Environmental benefits: UV curing emits fewer VOCs and is more environmentally friendly, especially when using UV LED systems.
  • Consistency: The controlled curing process ensures uniform and consistent finishes.
• Limitations:
  • Initial investment: UV curing equipment can be expensive to purchase and install, although the long-term benefits often outweigh the initial costs.
  • Specialised coatings: UV curing requires coatings formulated specifically for UV curing, which may limit the choice of materials.

If you would like to know more about UV and UV LED curing with GEW, speak to our Sales team now:

7. Advantages of UV and UV LED curing over other methods

UV and UV LED curing offer several distinct advantages over traditional drying methods, making them the preferred choice for many wood coating applications. This section highlights the key benefits of UV and UV LED curing compared to air drying, oven drying, e-beam and infrared drying.

Speed and efficiency

UV curing is significantly faster than other drying methods. The process can be completed in seconds, compared to hours or days required for air drying and oven drying. This rapid curing time translates to higher production throughput, reduced lead times, and improved overall efficiency. The ability to handle and process coated products immediately after curing further enhances production speed and flexibility.

Energy savings

UV and UV LED curing systems are more energy-efficient than oven drying and infrared or NIR drying. Traditional ovens require substantial energy to maintain high temperatures, while infrared heaters consume energy to emit radiant heat. In contrast, UV curing uses ultraviolet light, which consumes less power and generates minimal heat. UV LED systems are even more efficient, providing further energy savings and reducing operational costs.

Improved finish quality

UV curing provides a superior finish quality that is difficult to achieve with other methods. The cured coatings are hard, durable, and resistant to scratches, chemicals, and UV light. This ensures that the finished product not only looks good but also performs well under various conditions. The consistency and reliability of UV curing result in fewer defects and higher overall product quality.

Environmental benefits

Traditional curing methods, especially those involving solvents, can release volatile organic compounds (VOCs) into the atmosphere, contributing to air pollution and health issues. UV curing, particularly when used with UV LED systems, significantly reduces VOC emissions. This makes UV curing a more environmentally friendly option that aligns with modern regulations and sustainability goals, and makes high powered UV LED systems such as those offered by GEW, more appealing to furniture manufacturers. Additionally, the lower energy consumption of UV and UV LED systems further reduces their environmental impact.

Longer lifespan and reduced maintenance

UV LED curing systems have a longer operational life compared to traditional mercury vapour lamps used in conventional UV curing. UV LED arrays can last up to 40,000 hours or more, compared to the 1,000 to 2,000 hours typical for mercury lamps. This extended lifespan reduces the frequency of lamp replacements, lowering maintenance costs and minimising production downtime. The reliability and durability of UV LED systems make them a more cost-effective solution in the long term.

Instant on/off capability

Unlike traditional UV lamps that require a warm-up period before reaching optimal operating temperature and light output, UV LED systems can be turned on and off instantly. This instant on/off capability provides better control over the curing process, improves production efficiency, and reduces energy consumption. The ability to turn off the system when not in use further enhances energy savings.

Consistent performance

UV LED curing systems offer more consistent output over time compared to traditional UV lamps, which can degrade and lose efficiency as they age. The consistent performance of UV LED systems ensures uniform curing and high-quality finishes across all products. This reliability is particularly important in maintaining product quality and meeting stringent manufacturing standards.

Safety and workplace environment

UV LED curing systems are safer to operate compared to traditional UV lamps, although both technologies present a lower risk than tunnel drying, for example. UV LED curing systems produce less heat, reducing the risk of burns and fire hazards, when compared to conventional arc UV systems. Additionally, the elimination of hazardous materials such as mercury further enhances workplace safety and reduces health risks. The reduction in VOC emissions and improved air quality contribute to a safer and healthier workplace environment for employees. Furthermore, UV LED curing does not generate ozone, as arc UV curing does.

Users of UV LED technology must ensure they are not exposed to direct UV light, as this can be harmful to the eyes and skin. Most manufacturers, including GEW, have shielding systems in place to ensure this risk is kept to a minimum.

Compatibility with modern coating formulations

The development of UV-curable coatings has been a significant advancement in the wood coating industry. These formulations are specifically designed to work with UV curing systems, providing optimal performance and finish quality. The compatibility of UV curing with modern coatings ensures that manufacturers can achieve the best possible results, making it a preferred choice for various wood coating applications.

Flexibility in application

UV and UV LED curing systems offer greater flexibility in application compared to traditional curing methods. They can be easily integrated into existing production lines and are available in various configurations to suit different curing requirements. This adaptability allows manufacturers to tailor their curing process to specific needs, improving overall efficiency and product quality.

Economic benefits

While the initial investment in UV and UV LED curing equipment may be higher than traditional methods, the long-term economic benefits are substantial. The increased production speed, reduced energy consumption, improved product quality, and lower maintenance costs all contribute to significant cost savings over time. These economic advantages make UV and UV LED curing a wise investment for manufacturers looking to enhance their operations and remain competitive in the market.

In conclusion, UV and UV LED curing offer numerous advantages over traditional drying methods, including speed, energy efficiency, improved finish quality, environmental benefits, longer lifespan, and reduced maintenance. These benefits make UV and UV LED curing the preferred choice for many wood coating applications, providing both economic and environmental advantages.

If you would like to know more about UV and UV LED curing with GEW, speak to our Sales team now:

8. GEW’s UV and UV LED solutions for wood coating

GEW is a leading provider of UV and UV LED curing systems, offering innovative solutions tailored to the wood coating industry. The company’s key products for wood coating applications are:

• GEW E4C system: A highly efficient, high powered arc UV curing system designed for rapid curing of wood coatings, with low energy consumption.
• GEW LeoLED2 system: An advanced UV LED curing solution that offers high output, consistent performance, and long operational life.
• GEW ArcLED hybrid system: Combines the benefits of both UV arc and UV LED technology, providing flexibility and efficiency for various curing applications.

These systems are designed to meet the demands of modern wood coating processes, ensuring high-quality finishes, reduced production times, and environmental compliance.

To find out more about E4C, go here.

To find out more about LeoLED2, go here.

Watch our case study video to learn more

BJS are a manufacturer for a major Swedish furniture retailer. In this video, they discuss the benefits of switching their coating line to GEW’s LeoLED.

Watch now to learn more:

9. Why wood coaters should use UV curing

In conclusion, UV curing represents a transformative approach in the wood coating sector, offering unparalleled speed, efficiency, and quality. The shift to UV LED curing further enhances these benefits, providing energy savings, longer operational life, and environmental advantages. GEW’s innovative UV and UV LED solutions are at the forefront of this technological evolution, helping wood coaters achieve superior results while meeting modern production demands.

If you are a wood coater looking to enhance your production process, improve finish quality, and reduce your environmental impact, you should consider UV and UV LED curing. Explore GEW’s range of UV curing systems and transform your wood coating operations.

Speak to our team

If you wish to discuss how GEW’s UV curing can serve your needs, then contact our Sales person below: