Industrial UV Air System Technology and Applications

OEMs across the globe utilize industrial UV air systems due to an increasing awareness of the importance of protecting our environment and the consequences when we do not. Clean air is at the front and center of those concerns and today’s advanced industrial UV air systems provide a broad range of industries with the perfect solution. By safely purifying and destroying harmful chemicals from the air as well as eliminating offensive odors, industrial UV air systems deliver economic, environmental, and human benefits.

UV Germicidal Technology

Scientists have been studying the effect of UV light as a method for interrupting the transmission of airborne pathogens for well over a century. In 1877, two English scientists, Downes and Blunt, discovered that sunlight kills bacteria. Their studies showed that sugar water placed on a shaded windowsill became cloudy while a similar solution in direct sunlight remained clear. When examining the two jars, “they realized that bacteria were growing in the shaded solution but not in the one exposed to sunlight.”

The two men later found it is the shorter spectrum of UV light that kills bacteria and effectiveness is dependent on the amount and duration of light. Today we know that for a UV air system to effectively kill and render microorganisms unable to reproduce it requires prolonged exposure as well as a specific intensity and wavelength of UV radiation.

Germicidal Lamp Applications

Germicidal UVC lamps provide industries a way to disinfect and improve the quality of air in the workplace and the immediate environment without the need for toxic chemicals that are not only harmful to humans but the environment as well. Furthermore, UVC lamps are simple to operate and maintain and help industries to comply with strict local codes and national regulations. For industries such as food processing plants, farms, commercial kitchens (HVAC), kennels, and wastewater plants, odor control is important to not only the employees but to those that must work or live around the plant. Learn more about UV air disinfection, the types, applications, benefits, and where to get quality UV germicidal lamps.

The LightSources Advantage

One of the reasons why so many industries trust LightSources and LightTech for their industrial UV air systems is that we have designed proprietary, longer-lasting lamps than those of many of our competitors. This saves OEMs both time and money by reducing the need to replace lamps as often or the expense of buying new ones. Additionally, our lamps offer a compact design, which means retrofitting is not a problem, and we fully customize almost every part of our lamps, including length and diameter, power, ceramic bases, and fitting sockets.

UV Paint Curing

UV light produces a chemical reaction that is used in industrial applications such as UV paint curing, primers, fillers and clearcoats as well as inks and other types of coatings.  Much quicker and more efficient than traditional baking methods, UV paint curing systems also offer significant energy savings without producing any hazardous byproducts.  First introduced in the 1960’s, UV lamps have rapidly gained acceptance by a diverse range of industries and are now the preferred choice of many OEMs across the globe.

To instantly cure paints, and a variety of other coatings and finishes including lacquers, glazes and varnishes, high-intensity ultraviolet lamps are used to create a photochemical reaction.  On the other hand, conventional water and solvent based thermal drying methods work by solvent evaporation, which not only takes time but also creates polluting emissions.  With UV light systems’ instant curing, manufacturers report higher production rates, better bonding, no loss of volume and less likelihood of product damage as in slower drying methods.  Along with being environmentally friendly, UV lamps are also easy to operate and maintain.

Light Sources and our European partner, LightTech are global leaders in designing, engineering and manufacturing high-tech UV curing lamps.  We produce three main types of UV curing lamps including: medium pressure UVA curing; high pressure curing; and low pressure UVC amalgam curing.  Our lamps are extremely long-lasting and energy-efficient, and our compact design makes retrofitting easy-to-do.  In addition to our line of high-quality standard lamps, we can also design and develop a highly customized system to meet your specific needs.

All of our UV lamps are constructed from the highest quality materials and manufactured in state-of-the-art facilities.  We invite you to browse our website for more information regarding UV light applications, and keep in mind, our experts are more than happy to discuss the various aspects of our UV curing technology as well as our other MPUV products.

LightSources in the U.S. and our strategic partner in Europe, LightTech represent the leading high-tech designers and manufacturers in the lamp industry today.  Our products are used world-wide in a multitude of applications and industries such as our UV air treatment systems that offer patent-protected, OEM-oriented solutions.

UV Polymer Curing

UV Polymer curing is a process that uses UV light to alter the properties of a polymer, or photopolymer.  A photopolymer is the term for a polymer that responds to UV light, which is basically invisible electromagnetic radiation.  When a photopolymer, which can be a variety of resins, is exposed to the UV radiation, it will typically harden and seal, creating a strengthened surface or an unbreakable bond.

UV Polymer Curing Applications

UV Polymer curing is used in many industrial applications to instantly dry ink or to create a hardened surface without use of solvents or chemicals.  Some common examples of useful applications include:

  • Adhesive Bonding

  • Inks / Varnishes / Lacquers

  • Decorative Glazes

  • Coatings

  • Label Printing

  • Graphic Designs

  • Disinfection of Medical Equipment

These are just a few of the many industries that are using UV lamps for curing various polymers.  There are many additional applications for UV curing, and more and more businesses are seeing the benefit of this process.  UV curing was first introduced in the 1960’s, and it is increasingly being adopted by companies as there are many advantages over prior methods of curing polymers.

Curing Lamps

There are three types of UV lamps used for UV polymer curing.  High Pressure UV (HPUV), Medium Pressure UV (MPUV), and Amalgam Lamps.  High Pressure (HPUV) curing lamps are also referred to as Metal Halide lamps, and use mercury with short wavelength outputs.  The HPUV lamps are typically used for the altering of polymers by hardening resins in many of the applications mentioned above.  Medium Pressure lamps (MPUV) are often used for water and air disinfection purposes, while Low Pressure Amalgam lamps are typically used for curing catatonic inks which are inks that are typically an epoxy based resin and respond to UV lighting.  LightSources and our European partner, LightTech, are proud to have pioneered new pellet technology for amalgam lamps.

There are so many benefits to using UV lights for curing it will be difficult to list them all.  We can begin with efficiency.  Imagine a conveyor belt full of parts passing under a UV light as they head to their next destination, possibly quality inspection or packaging.  While no one touched the parts, sprayed solvents on them, or even laid eyes upon them, they underwent a very important process.  Just by passing under the lights, the surface was hardened and strengthened, a strong scratch-resistance texture was enhanced, and any printing or graphic design needing reinforcement was just instantly dried and strengthened.

Now imagine a different manufacturer that does not use UV curing.  They must have an assembly line with people spraying solvents on the parts, requiring face masks and ventilation and still exposing the employees to harmful chemicals in the air and on the skin.  This also opens the door for human error, uneven coating, and inconsistency.

As you can clearly see from these two examples, the efficiency of UV curing is definitely one of the most valuable benefits.  This efficiency also leads to increased production speeds as several parts can be treated at once simply by passing under a row of the proper high intensity UV lighting.   Choosing to cure your parts with UV lighting will increase your output dramatically, while not requiring an investment in an increased labor force, workstation for an added process, or supplies of chemicals that are most likely harmful to the environment.

In addition to efficiency and cost savings, consistency is another big advantage of using UV curing over any other process.  With UV lighting, the amount of exposure is constant, and consistent.  There is no chance of human error in applying an outer coating unevenly on a large amount of parts.  This consistent process results in less quality issues such as internal rejects and the worst rejects of all, customer returns and complaints.   A consistent process is something that all quality minded OEM’s are searching for as consistency results in superior quality, time and again.

Efficiency and consistency are and should always be a top consideration for any production process, (both result in increased profits), but let’s not forget an even more important benefit – the health and safety of your workers and the environment.  Simply by using UV radiation to cure your parts, you are saving your employees from inhaling harmful chemicals, you are not emitting pollutants into the air, and you also do not have to worry about properly storing or disposing of such harmful chemicals.   Any chemical substance on a worksite must be handled with proper storage and disposal guidelines, while maintaining material safety data sheets on the chemical or solvent.

Not only does the increased efficiency and consistency provide an instant return on your investment and a quick increase to the bottom line, not purchasing, storing, disposing of or documenting alternative substances is also a huge savings, and instant increase in profitability.

With all of these benefits, it is difficult to imagine why a manufacturer would choose an alternative method over UV polymer curing.   Efficiency, consistency, safety, less regulations, increased profits, and last but not least – longevity.   LightSources UV curing bulbs will retain their energy output up to 90% of their end of life cycle, enhancing and prolonging all other financial benefits.  As we all know, time is money.  Less time spent processing parts, or replacing bulbs, is an immediate increased profit.

LightSources in the United States, and our European partner, LightTech, provide quality custom UV bulbs to OEM’s large and small all over the world.   If one of our standard sizes does not fit your application, contact us to see how we can assist you in providing custom built bulbs for your required process.   LightSources and LightTech are also the only manufacturer to offer universal installation.   Our lamps can be installed either horizontally or vertically while maintaining equal efficiency.  This feature is exceptionally critical when applying the UV polymer curing process to three dimensional parts, allowing an even exposure to the UV radiation reaching what were previously hidden dimensions.

LightSources in the U.S. and our strategic partner in Europe, LightTech represent the leading high-tech designers and manufacturers in the lamp industry today.  Our products are used world-wide in a multitude of applications and industries such as our UV air treatment systems that offer patent-protected, OEM-oriented solutions.  We invite you to contact us to learn more about our wide selection of lamps.

Leading Patented Technology in High-Caliber Lampholders

Along with our valued partners Voltarc and LCD Lighting, the LightSources Group has developed the most advanced, high-caliber electrical wiring devices and incandescent lampholders in the industry.  Our innovative designs combined with patented technology provide superior lamp components with extraordinary long-life combined with convenient features for safety and durability.

LightSources and its affiliated companies have been designing, engineering and manufacturing customized lighting solutions for over 30 years. With vast expertise in UV germicidal lamps, UV ballast water treatmentUV air treatment, UV curing bulbs, specialty fluorescent lamps, tanning lamps, and outdoor sign products, we have the team and resources to make lamp designs a reality.

With dozens of designs and styles to choose from, LightSources offers standard or custom designed lampholders for virtually any application, indoor or outdoor with UL listed CSA approved equipment.

Ground Fault Protection

Voltarc is a leader in the lighted sign industry, with patented Dead Front housing technology to protect your equipment from ground faults.   This innovative design eliminates rivets in the face of the lampholder, completely isolating it from the ground.  A key component of this design is the Fabulex™ mounting clip manufactured from thermoplastic engineering resin with durable properties of 9,000 PSI Shear Strength and a Tensile Elongation Strength of -68° F to 158° F. Voltarc’s patented O-rings are specially designed for long life with no drying, featuring a blue silicone treatment for water and condensation resistance which prevents bonding during re-lamping.

Kulka® IS-Series Lampholders

The Kulka IS-Series is specially designed for Electronic Sign Ballasts, with an integrated shunt design used for instant start ballasts.  The IS-Series are the only lampholders to feature new single Leadwire technology.  Patented Red-O Ring technology distinguishes this single lead wire lampholder from the two lead Blue-O Ring technology for safe and simple operation. The Kulka IS-Series of lampholders are all UL listed with the Circle I Rating, and CSA approved.

572 & 573 Series Slimline & Cold Cathode Lampholders

Additional Kulka wiring devices offered by Voltarc include the 572 and 573 Series of Slimline Cold Cathode Lampholders.  The slimline 572 lampholder is rated for 660 Watts at 1000V, while the 573 is rated for 660 Watts at 600V.  These can be mounted with various brackets or with butt-on mounting. All Slimline series lampholders are UL listed and CSA certified for outdoor use in enclosed signs and fixtures.

582.GDF & 583.GDF Stationary or Spring-Loaded Series

Voltarc’s 582.GDF™ and 583.GDF™ Series lampholders are Recessed Double Contact Lampholders suitable for 800 and 1500mA Lamps.  These lampholders contain no metal clips therefore there is no risk of electrical grounding or corrosion.  This stationary series of lampholders completely isolates the socket face from the ground, and features our patented Blue O-Ring technology. The 582 and 583 series lampholders are UL listed and CSA certified for outdoor use in enclosed signs and fixtures.

530.1K & 530.2K Series Snap-In Lampholders

Convenient lampholders such as the snap-in series from Voltarc include the 530.1K™ & 530.2K™ Series Snap-In Recessed Double Contact Lampholders for 800 and 1500mA Lamps.  The 530 series utilize a snap-in mounting system, and are rated at 660 Watts with dual rating of 600V or 1000V.

1550 Series Turn-Type Lampholders with Medium Bi-Pin

The 1550 series features medium bi-pin, in a turn type lampholder with slide-on mounting for 18 or 20-gauge panels.   These lampholders can be wired at the factory for custom specifications with length, wire or strip material.

1640 Series Slide-On Lampholders

Voltarc also features the 1640 Series Slide-On Lampholders with recessed double contacts for 800 and 1500 mA Lamps.  The 1640 Series of lampholders is ideal for outdoor application when they are enclosed properly.  Each end features slide wire horizontal contacts.  All slide-on lampholders are UL listed and CSA certified for outdoor use in enclosed signs and fixtures.

Voltarc and the LightSources group offer the most advanced lampholders in the lighting industry, with patented technology for any application.  Our lighting components are manufactured with the highest of quality processes, providing patented solutions to OEMs around the globe.  With a full line of standard components or the option to custom design your lighting solutions, we are sure to find the perfect lighting solution for your needs.

LightSources, Voltarc and LCD Lighting specialize in extraordinary design and manufacturing of specialty fluorescent lamps, low pressure UV lamps used in germicidal and UV curing applications, avionics display, and lamps used in medical applications.  Contact LightSources for long-life fluorescent lamps and wiring components used in the lighted sign industry.