ExciRay Lamps

GEW cooling systems are custom engineered to ensure every UV system runs at optimum performance for many years of heavy industrial use.

All UV systems produce excess heat which must be efficiently removed to ensure uniform, stable & long-term output of the ultraviolet radiation. GEW utilises air, water and/or nitrogen cooling across the wide variety of products produced. All cooling systems are rigorously designed and tested internally by GEW to ensure perfect compatibility with your UV system.

Air cooling systems typically consist of a central fan connected to a rigid steel ducting manifold which runs the length of the press. Outlets at regular spacing are connected to the lamps via flexible ducting and an automatic damper valve controls the volume of air passing through the lamphead ensuring it remains at constant temperature. The central fan is ducted to atmosphere outside the factory.

Controlling temperature is critical for many applications. GEW’s array of cooling options ensures even the most powerful UV systems do not damage substrates.

The UV curing process is energy-intensive and causes both direct and indirect heating of the target substrate, which in the majority of cases needs to be controlled. For safety reasons, some form of barrier behind the target substrate to shield off and dissipate stray radiation from the lamp is essential for protecting the machine and its operators. The three most common methods of substrate cooling that meet both of these requirements are:

Air cooled heatsinks
Water cooled heatsinks
Water cooled chill rollers

Where roll material is being processed, the most common solution for this is an extruded aluminium heatsink plate. GEW have a very neat solution for this which is integral to the UV lamphead and can be either air or water cooled, depending on the application. For the majority of processes this method is very effective, unless very heat sensitive materials are being used.

AeroLED2 is a next generation, higher power UV LED system for full cure, printing, coating and converting applications up to 70cm wide; AeroLED2 offers a 30% increase in electrical power (70W / cm), a 30% increase in UV dose (170mJ / cm2) and a 40% increase in UV irradiance (26W / cm2) compared to its predecessor, AeroLED.

AeroLED2 is also ArcLED compatible. Using the same fan and ducting arrangement as the industry standard E2C, customers have total flexibility to switch between UV arc and AeroLED2 on any station. No filters are required due to the high redundancy, making maintenance a breeze. Moreover any customers with GEW’s RHINO/RLT power supply platform can upgrade to LED within a matter of hours, by simply changing the cassettes and running a software upgrade.

Following its predecessor, in an AeroLED2 system air is extracted by a single centralised fan sited away from the press. There is no need for integrated fans or electronics in the individual lampheads, which eliminates the high pitched noise and risk of failure that these bring. AeroLED2 features the same LED chassis and core components as GEW’s LeoLED2 lamphead, for proven reliability. As with LeoLED2, the lamphead has tough watertight seals to protect the LED modules from ingress and to make cleaning easy and safe. Every aspect of the design has been carefully considered to deliver robust performance and long-term reliability.

AeroLED2’s efficient optical design enables the lowest energy usage of all GEW products. This delivers energy savings of up to 55% when compared to a conventional UV arc system – you can find out your potential energy savings on our ROI calculator. In addition to offering greatly reduced operating costs, printers upgrading to AeroLED2 are able to free up >50% of mains capacity, which can then be used to install new machinery and subsequently increase production capability. Two AeroLED2 systems have a lower electrical supply requirement than just one conventional arc UV system.

A further advantage of LED is its predictability and stability of UV output in the curing process. AeroLED2 delivers improved process control by ensuring stable UV output year after year, and eliminates the uncertainty of conventional UV lamps, reflectors and mechanisms to ensure consistent production quality. As is the case with all new GEW UV products, AeroLED2 uses GEW’s RHINO power supply and control range, for ultimate reliability with Industry 4.0 approved, IoT Remote Monitoring as standard.