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Why UV? (PDF 25 kb)
Maximizing Your UV Coating Quality With Roller Coaters (PDF 37 kb)

UV Roller Coater Systems

Protect the printed sheet with a high gloss coating applied by an ultra violet curing roller coater. After 15 years of product development and machine design we can now offer a UV roller coater which is made to coat up to 15 or 22 inches, has easy set-up and clean up, easy automatic return to settings, it is completely enclosed for safety and odor control, made of sturdy construction, allows minimal odor in the plant area, low sound emitting vacuum blowers, low outside machine temperature to prevent burns, low speed capability due to unique lamp control and high quality gloss, satin or matte finish.

Roller Coater System

After 15 years of research and development, equipment design, pilot studies and manufacturing we have available for immediate sale a system which can feed, coat, UV cure and stack high gloss, satin and matte coatings on paper and plastics.

We are capable of supplying all parts of the system. Some parts may not be required based on budget constraints or customer requirements. Please let us know if you require testing of your specific substrate or a formal quotation which meets your and your customers’ requirements.

We will provide all parts of the systems including the coatings. The system cost is as low as $10,000.00 up to $30,000.00 depending on what features are required by the end user.

UV clear gloss coating FDX 951 is the industry standard coating for this special UV roller coater. It is available from Fergesen Design Co., Inc. in pails. Drums and one gallon containers plus special one quart feed systems for low volume users.

Some things to look for when evaluating these systems are as follows:

  • Ease of set-up and clean-up
  • Easy return to settings
  • Complete enclosure
  • Sturdy construction
  • Odor control for people operating and in the plant area
  • Blower noise
  • Stock temperature rise below 100 F even at slow speeds
  • Width of coater 15″, 22″ 22″+
  • Speed control of sheet matched to lamp output
  • Quality uniform finish on every sheet
  • Low maintenance long lasting low energy consuming green technology LED curing instead of mercury vapor lamps

Slot Die Coating System

Basic components of slot die web coating systems:

  • Standard unit can be made for coating widths of 5 to 12 inches by changing the width of the slot die and the width of the backing idlers.
  • The slot die is supported by a dual rod single cylinder. The storke of the cylinder is 50mm and the die can be easily retracted for cleaning.
  • The position of the die, when coating, can be done by using adjustable stops on the two rods. (this positioning controls the amount of “wrap angle” in relation to the die)
  • The two idlers are mounted on a yoke which can be rotated so as to optimize the web position.
  • The over bite and under bite of the two die halves is adjustable, again for thickness control.
  • The slot die is comprised of three parts. The bottom is a Delran cavity, the shim between the two halves and the top half made of stainless steel. The cavity half has a flex lip which allows the die gap to be adjusted if necessary. In most case it is not necessary.
  • The over all dimensions are 12 inches parallel to the web, 5 inches high and the web width which is standard at 8 inches for a 6 inch unit and 14 inches for a twelve inch unit.
  • The idlers are 1.5″ diameter for the 6 inch unit and are 2.0 inch diameter for the 12 inch unit.
  • In a standard systems the coating system is fed to the die by a pressurized tank similar to the “paint pot”
  • All feed adhesive flow controls and web interface will be designed at purchase and provided at installation.
  • Demonstration of feasibility test samples can be made if requested.

Glue Types: Pressure sensitive permanent, removable and, freezer grade adhesives plus many other coatings can be purchased in various physical forms: hot melt, which is solid; UV curable, also solid; and water and solvent based adhesives, which are liquids.

Methods of drying: hot air dryers, IR dryers and UV curing

Advantages of slot die coaters:

  • It is a closed delivery path.
  • Unlike many coating processes that are open to atmosphere, the slot die provides a more sterile environment, minimizes evaporation, reduces solvent discharge and prevents contamination from airborne particles and viscosity buildup from entrapped air.
  • A pre-metered application in the slot die process affords uniform, consistent coatings, unlike processes that wipe, spray or blade to spread coatings on a substrate.
  • It is easy to change the width of the coatings with the slot die process, as well as apply machine directional stripes of coated and non-coated areas. Today, this process can even apply patches of coated areas across the web of the substrate.
  • Multiple cavity slot dies are used to apply different layers of different fluids to the substrate in a single coating station.
  • A slot die, in many cases, can be designed to process a broad range of viscosities and percent solids. These can typically handle a fairly wide range of coating speeds and fluid delivery flow rates.

Custom Design from Fergesen Design Company, Inc.

Fergesen supplies design, installation and training for each application:

When we meet customers, we talk about the coating type, thickness, speed and the range of production requirements. We help the customer determine which adhesive slot die application method fits their design parameters. We can even assist their selection of adhesives or coatings. Once the process is designed we will assist with the best feed and control system available for the process.

Label manufacturer example of Slot Die application:

A label manufacturer wants make special labels. We will talk with them about where the applicator is installed, what are the various ranges of slot die they may wish to use, how and when they wish to install the unit, and discuss the finished product results required. We determine if it is best for the label manufacturer to use a hot melt or UVLED or UV medium pressure mercury vapor lamp curing. Or if they wish to use water based or solvent dispersed adhesives they can accomplish the task with a solvent or water based dryer after application.

Some challenges encountered when using adhesive application methods:

At start up it is best to retract the slot die away from the paper or film substrate. The adhesives can soak through he edges and break the web. It is very difficult and time consuming to re-web a press. We have brackets which will retract the head or pull the web away from the applicator head. At start-up the pumps are slowed down in unison with the press and therefore prevents excessive adhesive application and applies just the amount of adhesive at all press speeds.

After print applications:

The adhesive can be applied to printed or converted material at the end of the press run as well. Such operations as folders, sheeters, collators can use the slotted die process. The adhesive can be applied across the web or with the web.

For more information contact Dave Fergesen:

Dave@FergesenDesign.com;   Phone: 908-745-8990

Hand-Held UV Lamps: for electronics and automotive applications

Hand Held UV Lamp

Since 1981 Fergesen Design has been designing and constructing hand held and bench mounted ultra violet curing systems to meet our customers’ requirements. They can and are being used for replacing solvent and water based technologies for the following industries:

  • Medical
  • Electronics
  • Automotive
  • Aerospace
  • Telecommunications
  • Optical
  • Packaging
  • Industrial: glass, wood and metal finishing

Some of the materials cured using this technology are adhesives, coatings, encapsulants, shallow potting compounds, masking material and gaskets. Fergesen Design provides spot and flood lamps, curing conveyors and specialty designed ovens to cure these special materials.

These materials cure faster and use less energy than silicones, cyanoacrylates, two part epoxies, two part urethanes, hot melts and solvent based adhesives coatings and inks.

The lamps are designed to fit the customers’ part requirements but the basic curing science remains the same. The customer applies the adhesive, coating or ink. The part is conveyed, held or passed under the lamp. The lamp is set at the distance or at the exposure time necessary to cure the part. In seconds the material is cured up to 1/4″ to 1/2″ thickness. Because of the flexibility, adhesion characteristics and scratch resistance built into the cross linked resins the resulting coating or adhered part far surpasses that of most silicone, 2 part epoxy, 2 part urethane and cyanoacrylate coating or bonding methods.

We welcome a chance to show our technology please contact us if you require additional information.

Portable Hand-Held UV Lamps

Our portable and hand-held UV Curing Systems are designed for a wide range of industries from the fine arts, small part manufacturing, wood surfacing or concrete surfacing professionals with the desire for quick and efficient setup, operation and ease of use. Our small portable units warm up rapidly and also have a cradle that automatically puts the unit into “standby” mode without requiring a complete cool-down cycle when not in use. Optionally, our portable units can all be placed into our small conveyor system that has a low cost, but many high-tech features for small part curing.System Capabilities

  • Max. Width of Cure: 2″, 3″ and 5″
  • Power:   300 Watts per Inch to 500 Watts per Inch
  • Low Power Mode while in cradle for Portable Units
  • Portable Unit with Wheels and Handle
  • Can be plugged into any Standard 20A Outlet.

Special Features

  • Low power mode while in cradle allows for quick and flexible use.
  • Portable unit with wheels and telescoping handle
  • Can be plugged into any standard 20A outlet
  • Setup is a snap.
  • Enclosed design to minimize UV and heat from the unit when in standby mode
  • Fully automatic controls
  • Industrial construction:   welded steel frame, powder coated, heavy-duty 16-gauge covers
  • Includes a FREE safety kit:   face shield, gloves, protective overalls and warning signs
  • Our optional conveyor is equipped with high-temperature silicon-Kevlar belts that never have tracking problems, a vacuum hold-down system, low-noise exhaust blower and variable speed control that can be configured to a wide range of throughputs.

Shuttered lamp systems and controls for application to webs

Hand Held UV Lamp

For those not familiar with ultra violet (UV) systems pictured above is a basic UV lamp system. This entire system is composed of three key components.

The lamp which is a medium pressure mercury vapor lamp
The reflector housing which includes reflector, shutters and lamp cooling system
The power supply which is the electrical controls of the lamp and interface the lamp using the latest touch screen controls.

With the state-of-art controls we have we can fit the irradiator housing into a label, sheet fed and web press from 6″ to 90″ wide. The result is an EPA compliant system which eliminates VOC’s and HAP’s and reduces carbon dioxide emissions.

Since 1981 Fergesens’ UV air cooled and water cooled curing systems have been manufactured and designed to cure UV inks at high speeds for both web and sheet fed presses. Fergesen Design Systems are an EPA recommended dryer/curing technology because UV inks and coatings eliminate VOC’S and HAP’S in the press room and tyen surrounding environment. Now with the latest ruling on carbon dioxide emissions the result with this technology is an acclaimed ‘green’ technology that offers savings in electricity and elimination of natural gas; decreasing the carbon foot print of the printing operation.

Some examples of recent installations for the technology are:

Mitsubishi web 5 unit perfector with in line coater all equipped with UV lamps operating at 1600 FPM.

Curing flexo inks label presses with your choice of medium pressure mercury lamps or LED’s. The system offers easy touch controls for high level UV systems and UV process controls. It has a detailed operator work station screen and screens for UV lamp status and system diagnosis all tied into press operation controls.

UV Curing Units

The Fergesen Design Shuttered UV curing units are simple, easy to install, and easy to maintain.
We allow the user to install a range of lamp powers using a single head design that has a minimum of moving parts. Using an L-shaped heavy aluminum shutter with integral heat sinks, with proper cooling blowers this unit can stay shut for extended periods even with higher-powered lamp systems.

The unit is cooled by a single vacuum blower that is attached to the end of the irradiator using a standard 6″ round duct connection. The irradiator has a high degree of adjustment available to precisely control and balance the airflow for proper lamp cooling both in the shutter open and closed positions. Our users have found that they can use less lamp power than they originally expected. Because the reflector remains fixed, very precise point focus of the UV light can be achieved.

Specifications:

  • Model Number FE-IRR0N0*uv-shutter-configuration
  • Number of Lamps per head 1-4
  • Watts per inch 200-500wpi
  • Arc Lengths 2-60 inches
  • Pneumatic Pressure 60-80 psi
  • Irradiator Overheat Sensor Normally Closed Contacts

*Note: Irradiators that can be custom built for a range of lamps, from 2″ to 60″. The lamp arc will determine the model number of the custom irradiator built.

Clean Energy UV-LED Curing Products

Clean Energy UV-LED Compared to UV Arc LampsThe science behind creating UV curable materials has grown to be more than a billion dollar industry enabling new applications for curing across many different markets. UV curing is a technology that offers its users both savings in time and money as well as relief from increasingly restrictive environmental regulations. As materials have progressed, so too must UV light source technology. Creating UV light with the desired properties has evolved with recent significant improvements showing there is a new light on the horizon. Technology has proven that there is a solution to the problems users of UV light sources have expressed:Operating CostThe savings realized from using UV-LED technology cover not only reduced down time, but actual operating costs as well. Electricity prices for industrial uses in the US have more than tripled over the last 20 years. Therefore, end users are paying closer attention to electrical requirements of their production equipment. Electrical consumption (kWhr) is up to seven times less when using UV-LED technology, vs traditional arc lamps. Traditional arc lamps operate at very high temperature (850-950 degrees C) requiring air extraction and an additional burden on the factory HVAC system. When using UV-LED technology which operates at 60 degrees C, there is no requirement for air extraction.Traditional arc lamps create light from mercury vapor, and discarded lamps cannot simply be thrown away. Therefore, there is a cost associated with waste removal.Labor costs associated with lamp replacement and maintenance is virtually eliminated when using UV-LED technology.ProductivityWhen the curing process stops working due to insufficient UV output, the output is typically replenished by replacing the UV source. The UV source replacement frequency, as well as general maintenance, will impact productivity.UV Source Expected Lifetime:
Arc Lamp   500-1000 hrs*
UV-LED Technology   >  10,000 hrs
*Arc lamps will continue to generate output, but when the output drops below the process window for a given application, the lamp must be replaced. Replacement of UV lamps involves the time it takes to physicall change the bulb, in addition to cool-down and warm-up time. Many arc lamps also use special reflectors to filter unwanted wavelengths of light. These reflectors must be inspected, cleaned and replaced when necessary, which can take up to five hours quarterly. Since UV-LED technology has a significantly longer lifetime, downtime associated with changing UV sources is reduced from up to once a month to once a year or less. The improvement in system uptime associated with UV light source replacement alone is reported to be from 97% with arc lamps to greater than 99% when using UV-LDE technology.YieldUV-LED technology makes monitoring UV light source operating parameters easier to ensure higher yield. Since UV-LED technology does not drop over time like arc lamps, the process is more reliable, reducing not only down time but increasing yield.*Feedback from end users that have replaced arc lamps with UV-LED technology indicates that yield improvements have gone from 95% to 99%. This is particularly true for UV curing of pressure sensitive adhesives, where too much or not enough UV dose will require that the product be scrapped.HeatMany applications are sensitive to heat, e.g., printing onto plastics such as styrene. Since UV-LED technology operates at less than 60 degrees C while lamps operate at more than a factor of 10 higher temperatures, the risk associated with excess heat is correspondingly less.Regulatory Compliance

The need for restricting the use of hazardous substances and solvents is becoming more and more of a deciding factor for moving to UV cured materials to address restrictions on solvents. However, there are also considerations related to the UV light source itself. Traditional arc lamps use an electric discharge from mercury vapor to produce light. At the moment, arc lamps are exempt from the Reduction of Hazardous Substances directive, but there are concerns related to having such a toxic substance in the workplace.

Traditional arc lamps emit light over the full spectral range. When oxygen molecules are exposed to light in the 180-220 nm wavelength range, they split into atoms and recombine with oxygen molecules to form ozone. Ozone is a hazardous material which must be extracted. Conversely, UV-LED technology produces only the targeted UV light which does not produce ozone.

Conclusion

UV-LED technology works to solve many of the problems resulting from traditional arc lamps, and to simplify the UV curing process. UV-LED technology is available to answer the call for a better UV light source.

Fergesen Design creates both air cooled and water cooled UV-LED curing solutions, based on patented technology. UV-LED technology applies micro-cooling and optical technology to provide some of the most powerful UV-LED sources available on the market. They are available in a wide range of shapes and sizes and are being used today in commercial applications for curing inks, coatings, adhesives and a variety of other materials. Recent developments from OEM’s in a high speed card personalization system features UV-LED curing technology. The printer is a black ink jet card identification process which is available in four print widths. The ink is cured by using a 75mm X 50mm, 125mm X 20mm or a 225mm X 20mmm cure zone. These cure zones are available in peak irradiance of 8W/cm2.

Dispensing and Coating Technology – Many Applications

  • Highly accurate/automated dispensing and coating technology is presently the method used by the photovoltaic (PV) industry to spray back sheet and pot the junction box.
  • In the medical industry it is used to spray the moving stent with a protective coating. It all involves technology readily available to Fergesen Design. We will analyze the customers’ requirements and determine what method of application and drying/curing is best to meet their pilot and product requirements.
  • In the wind energy industry the coating is selectively sprayed to very large metal wind energy fan pieces and cured with ultra violet hand held systems and automated UV systems where necessary. The system is applicable and readily applied for solder pastes, silicones, epoxy, UV acrylates, UV methacrylates, and cyanoacrylates.Fergesens’ latest technology can be used can be used for selective coating, surface mount adhesives, meter-mix dispensing, custom automation, manual dispensing, non contact dispensing and sophisticated industrial UV paint and UV clear coating spraying systems.

We will assist in your selection of the highest performance lowest cost method to meet your customers’ needs.

Custom IR Water-Based Ink/Coating Dryer

IR Drying Systems

Fergesen Design provides simple, yet powerful and reliable IR drying systems to be integrated with your press, coating system, or manufacturing line. Fergese Design can build bare bone variable control units, or we can integrate our IR with your manufacturing using highly accurate PID loop controls, or integration with your manufacturing system. Our custom units can have the following features:

  • Highly efficient infrared (IR) elements with gold reflector coating.
  • Instant-on SCR control for a full range of variable output control mounted at the side of the press
  • Integration to run while your press is running or with your manufacturing system
  • 120V, 208V, 240V, or 480V AC Single or Three Phase Designs
  • Integral E-Stop and fully cooled NEMA approved enclosures
  • Fused and fully compliant with national electrical safety codes
  • Remote Control box that can be mounted anywhere in the plant

Fergesen/Fenimore Feeder and/or Stacker

Feeders & Stackers

Fergesen Design is pleased to offer superior products designed to enhance a wide range of Roller Coaters, precision-manufactured to perform consistently with minimum maintenance in a production environment.Short Pile Friction Feeder

  • F1418 Short pile friction feeder to handle up to a 14″W x 18″L sheet size. Perfect reliable solution for handling smaller sheets, 8.5×11 and 11×17 stock, postcards or short run jobs. Can be easily removed for manual feeding.
  • F1520 High Pile Integrated Suction Foot Vacuum Feeder- 15″W x 20″L sheet size. Approximately 20″ of stock can be stacked. This unit uses press-style suction vacuum feet in its operation, and is designed to be integrated with the FE-15B Coater, but can roll up to any small coating system.
  • F2028 High Pile Integrated Suction Foot Vacuum Feeder- 20″W x 28″L sheet size. High volume users will require our high pile vacuum feeder for larger production runs. Approximately 20″ of stock can be stacked. This unit uses press-style suction vacuum feet in its operation, and can be integrated with the roller coater.
  • F2840 High Pile Integrated Suction Foot Vacuum Feeder- 28″W x 40″L sheet size.
  • F4028 High Pile Integrated Suction Foot Vacuum Feeder- 40″W x 28″L sheet size.
  • S2228 – Automatic High Pile Stacker, 22″W x 28″L Maximum. Our high pile stacker comes with large circular air piston joggers to ensure consistent a consistent stack. It also comes with a rolling cart for holding the completed stock, or can be modified to accept your pallet of choice to be lifted with a fork truck or pallet jack.
  • S2840 – Automatic High Pile Stacker, 28″W x 40″L Maximum.
  • S4028 – Automatic High Pile Stacker, 40″W x 28″L Maximum.

 

Fenimore Fed-15