UV curing technology creating an active packaging

What is Active packaging

Active packagingintelligent packaging, and smart packaging refer to packaging systems used with foodspharmaceuticals, and several other types of products. They help extend shelf life, monitor freshness, display information on quality, improve safety, and improve convenience.

The terms are closely related. Active packaging usually means having active functions beyond the inert passive containment and protection of the product. Intelligent and smart packaging usually involve the ability to sense or measure an attribute of the product, the inner atmosphere of the package, or the shipping environment. This information can be communicated to users or can trigger active packaging functions. Programmable mattersmart materials, etc can be employed in packages.

Depending on the working definitions, some traditional types of packaging might be considered as “active” or “intelligent”. More often, the terms are used with new technologically advanced systems: microelectronicscomputer applicationsnanotechnology, etc.

How does DPL Easycure work for your active packaging?

The easy and economic way is UV Cast and Curing technology. UV casting and curing technology a kind of microembossing technology, which can create rich, high gloss holographic effects on a variety of substrates in both sheet fed and web. Casting film is embossed BOPP Film, which already have holographic feature. When this film nip with base substrates, the holographic construction on BOPP will be embossed into UV lacquer on the surface of base substrates. Said it in an easy way, BOPP film is more or less like die head in this process, so this film can be reused several times After cure system, the holographic feature will be stable on the surface of base substrates. UV Casting films are available in a variety of diffraction patterns, similar to hot foils.

DPL Easycure UV curing system is an intelligent “Plug&Play” system, easy to operation and install in existing machines.



Case study – how LED UV curing system working in security printing process

What is security printing?

Security printing is the field of the printing industry that deals with the printing of items such as banknoteschequespassportstamper-evident labels, product authenticationstock certificatespostage stamps and identity cards. The main goal of security printing is to prevent forgery, tampering, or counterfeiting. More recently many of the techniques used to protect these high-value documents have become more available to commercial printers whether they are using the more traditional offset and flexographic presses or the newer digital platforms. Businesses are protecting their lesser-value documents such as transcripts, coupons and prescription pads by incorporating some of the features listed below to ensure that they cannot be forged or that alteration of the data cannot occur undetected.


One of the key technology of security printing is – Hologram.

hologram may be embedded either via hot-stamping foil, wherein an extremely thin layer of only a few micrometers of depth is bonded into the paper or a plastic substrate by means of a hot-melt adhesive (called a size coat) and heat from a metal die, or it may be directly embossed as holographic paper, or onto the laminate of a card itself. When incorporated with a custom design pattern or logo, hologram hot stamping foils become security foils that protect credit cards, passports, bank notes and value documents from counterfeiting. Holograms help in curtailing forging, and duplication of products hence are very essential for security purposes. Once stamped on a product, they cannot be removed or forged, enhancing the product at the same time. Also from a security perspective, if stamped, a hologram is a superior security device as it is virtually impossible to remove from its substrate.


LED UV curing and hologram embossing process?

Normally hologram embossing process is a hot and press process. Film pass through nip rollers (steel roll+rubber roll or steel roll+ steel roller which has high temp and high pressure, so the hologram image on one of the rollers will be embossed into the surface of film. The problem for most film is high temp in this process, for example a stamping foil need pass more than 190C in embossing process, meanwhile PET film’s TG temp is about 150C. It means film is stretched in this process, which also damage registered mark in the film as well.


LED UV embossing is one of the lasted technology to solve “registered problem” caused by hot hologram embosser. Compared with normal traditional mercury UV lamp, LED lamp curing temp is only 60-70C even at the same energy output. On the other way, LED curing system’s single wavelength also provide the possibility to improve hologram brightness and sharp edge effect.


More details, welcome to DPL International service team, we are happy to share our experience on security printing process with you.



how multi-wavelength LED light improve curing quality


DPL LED Curing systemCompared with general Mercury Lamp, normal LED can only provide a very narrow band. See the left side figure, which compare the output of a multi-wavelength( 365nm-410nm) LED lamp with traditional mercury lamp. At the same wavelength 365nm,LED lamp can output much more energy than traditional mercury lamp, means LED lamp can provide more high energy output in UV-A range.

DPL eAsycure LED curing system use the latest LED technology on LED chip combination to reach high Joule Energy (DOSIS Energy), so it can easily cure UV ink in UVA range instead of single wavelength LED ink. According to our client’s ink performance, DPL LED Curing system can setup different output energy at different wavelength. If you have any question,please contact with our service team at dpl@dpl.dk


what is Modularity LED drive system

DPL Industri A/S introduce Modularity LED drive system to control our high power led curing lamp serial. Clients can install different numbers of power module according to their energy output. With this kind design, the uniformity and radiation will be controlled and keep stability for each led power module.

Each power module has 600W. Each LED module will be connected to each power module or subject to client’s request. So the led UV radiation will be linear regulated up to 26W/cm2.

Each power module can be turn on/off, in order to save lifetime for the led module. This function can be used when client need different size of cure area.

DPL led-driver
DPL Modularity LED drive system- STATION 5#

DPL has two types of LED Driver system, Station 2# can be installed up to 2 pieces of power module of each 600W, up to totally 1200W. Station 5# can be installed up to 5 pieces of power module of each 600w, totally output power up to 3000w.










Technical Specification:


LED Driver Station 5#

(DPL Code: 50870)

3 pieces of

Power Modules

4 pieces of

Power Modules

5 pieces of

Power Modules

Input Mains Voltage 1 phase 100V-240Vac
Input line freq. 50-60Hz
Input current. 21A 28A 35A
Power Factor. 0.95 at 100% power
Standby power <2.5w
Current regulation 0-10V regulation or PWM regulation
Output Output power. 1800w 2400w 3000w
Output Voltage 66v DC
Output current 0.5-9.15 A
Protections Overload, Overcurrent, short circuit, Temperature
Operation Temp: 0 to 40 C
Dimensions: 450mm x 380mm x 320mm


DPL eAsycureTM UV curing system

DPL are much more than just products, we also share our experience on UV curing printing, UV coating and UV bonding onto wood, glass, metal,plastic and paper products. We sold more than 3000 sets of UV curing system to our clients in the world.



Cold UV Curing Temperature


UV lamp output includes 60% IR energy, a normal metal reflector reflect IR energy out of the lamp head/house, and heat up the touch temperature between your base material and lamp head. Every DPL lamp head/house is equipped with special coated reflector, which can absorb 90% IR from your lamp and transfer to chilling system, so the surface temperature of your printing material is only 5-10C degree higher than your environment temp.


High UV Energy Output Efficiency


As you know that, more than 60% output of UV lamp is only IR, means you can only get 80w/cm UV energy even from a 200w/cm UV lamp. All DPL lamp head/house use “Energy Focus” design.The output UV energy will be focused into a narrow line about 5-10mm width through your web way, which can increase curing efficiency by 30% up.


Multi-input Lamp Source and Chilling Source


DPL UV Lamp head/house is equipped with multi-channels, so our clients can use water chilling as basic chilling source, but when they print or coat on thermal sensitive material, they also can use “chilling air input/out” port in our lamp head. Chilling air input/output channel is also suitable for Nitrogen air solution.

DPL Easycure Cold UV curing system
DPL Easycure UV lamp house

Ozone Free


High concentrations of ozone near ground level can be harmful to people, animals, crops, and other materials. Ozone can irritate your respiratory system, causing you to start coughing, feel an irritation in your throat and/or experience an uncomfortable sensation in your chest.


With our patent design of UV lamp house, DPL UV curing system is a “Ozone free” system,our client dont need install expensive “ozone exhaust” system, their worker can work in a clean “Ozone free ” production.

UV Curing Width


UV Lamp House Width


UV Lamp House Size ( W xH xL)

95x 16mm x (500-1998mm)


up to 240w/cm




What is LED curing?

LED Means light ­emitting­ diode.

It is a semiconductor diode that emits light when an electric current is applied in the forward direction of the device, as in the simple LED circuit.

The effect is a form of electroluminescence where incoherent and narrow ­spectrum light is emitted from the p­n junction in a solid state material.

An LED is usually a small area (less than 1mm ­2mm) light source, often with optics added directly on top of the chip to shape its radiation pattern and assist in reflection. The color of the emitted light depends on the composition and condition of the semiconducting material used, and can be Infrared, visible or Ultraviolet.

DPL Easycure LED curing system is base on the latest LED curing technology, which combine with a high effective and smart construction ensure a stable and perfect curing quality for different types of coating, printing, bonding application.

DPL LED curing system series is build up with length from 82mm to 2240mm. We also provide customer design service.

High UV curing energy output:
with our special construction of LED Chips, DPL LED curing system can reach 146w/cm,
output energy up to 650mj/cm2 by 100m/min printing speed, Peak energy up to 26w/cm2.

Long lifetime:
with high effective water chill construction, DPL LED curing system can reach more than
20.000 hours by 100% Radiation.

Suitable for LED or mercury UV ink:
DPL LED curing system provide high Joule energy (DOSIS ENERGY) with wave length from 365-395nm.

“Plus & Play” smart system:
DPL LED Curing system is smart system with “plus &play” design, easy to operation and
suitable to install in existing machine.


Micro-LED Can Be Game Changing for LED Industry as It Brings an Array of Value-Added Opportunities, Says LEDinside

LEDinside, a division of the global market research firm TrendForce, held LEDforum 2016 at National Taiwan University Hospital (NTUH) International Convention Center on September 30. This conference, which focused on micro-LED as the next-generation display technology, featured presentations by industry and research heavyweights including Epistar, Trillion Science, hTC, PlayNitrides, OSRAM Opto, Macroblock, Industrial Technology Research Institute (ITRI), X-Celeprint and CEA-Leti.

“Potential applications of micro-LED extend beyond display systems,” said Roger Chu, research manager of LEDinside. “Many value-added opportunities related to the development of this technology could lead to reshuffling and extension of various component chains.”
LEDinside forecasts that the value of the global LED market will increase at a compound annual growth rate of just 2% from 2016 to 2021. The industry is now exploring new application markets to overcome the limits of its expansion.

“Looking at the display application, OLED has already undergone a period of significant development,” Chu noted. “With South Korean technology enterprises controlling most of the crucial OLED patents, those companies that are now considering entering this market will have little chance of catching up. Micro-LED, on other hand, is a technology that has room for new entrants to develop market opportunities.”
By scaling down the size of LEDs to the micron level, the light emitted at every pixel on a micro-LED display can be controlled individually. Greater brightness, lower power consumption, enhanced color saturation and extremely high resolution are also some of advantages that micro-LED possesses. It is even possible for this technology to combine with flexible substrates, thus creating curved displays comparable to ones based on OLED. All these qualities give micro-LED a wide range of application options.

A recent analysis by LEDinside finds that having all wearable devices and public displays on the market to switch to micro-LED would consume as much as 50% of the current LED production capacity worldwide. Moreover, to have all the smartphones on the market to adopt the technology would require four times as much of the global capacity.


Why Uniformity is import for UV curing process?

It’s very important to many application that UV light has a good uniformity output, for example, touch screen UV bonding, electric printing board or cell and so on.

Many traditional UV curing lamps have a uniformity up to 65-75%, which bring a bad side curing result on edges.

DPL EasycureTM use our special design mirrors which reduces the disturbance of the linearity of the UV light source, resulting in a uniformity, which is better than 85%.

For very sensitive screen production with stationary irradiation, DPL Unicure TM with special light trap that would eliminate UV light sources disturbance of the linearity. With this solution, DPL UnicureTM can reach a uniformity better than 90%.untiformity-dpl

-www.dpl.dk more details, you can email to us at dpl@dpl.dk