Long Perfecting with LED-UV Technology

 Premier Printing LTD. headquartered in Winnipeg Manitoba and founded in 1962 has long been a leader in the long perfecting world. With three machines distributed across its facilities in Canada, they first adopted LED-UV in 2014 on a 2001 MAN Roland 700 8-color long perfector. The project began on how to get this press back into full production, This particular press did not have changeable perfecting jackets on the impression cylinders which caused so much marking that it was not feasible to run the press.


 Tom Bennett Production Manager for Premier began looking for options to get the press back in shape. One option was to replace the cylinders at a cost close to half million dollars and that was not going to happen. Premier would have never seen an ROI with a press of this age taking on a project like that. Tom began looking at inline curing options to solve these marking issues. He found Air Motion Systems (AMS) and with the help of there team came up with a win-win plan. That plan was to install the AMS XP7 LED-UV modules at the perfector and after the 8th unit with an iron clad performance guarantee. If it doesn’t solve the marking issues AMS would remove the system at no cost!


 Installation took place in September 2014 with production starting immediately after completion. After fixing a few bugs due to the press sitting unused for so long, testing was begun. It was apparent even with the first make-ready that the marking issues no longer existed. Curing the first 4 colors completely dried side 1 before the sheet was perfected and the final 4 colors were laid down. After analyzing the first press run Premier noticed an improved ink holdout and no marking. Next trial was to see how fast the press would run with the same results. To their surprise speed made absolutely no difference even at the highest press speeds.


Typical work being produced at Premier is saddle-stitched self-cover publications. After a short time running the new system Premier wanted to see just how fast they could actually turn 5000 – 32 page booklets. By pulling the 1st signature at 2500 sheet into the run, they were able to begin setting up and running the folder. By the time the two press runs were done signature 2 was already folding and setup was begun on the stitcher. The entire project was completed and ready to ship in just three hours. Previously this project would have hung around the shop for dry time and start to finish would have taken 3 days to get to shipping. As an added benefit Premier was able to use a smaller sheet size, as large gutters were no longer required to accommodate the slow down wheels in the delivery.


"LED-UV is the future of commercial printing'" declared Tom Bennett of Premier who shared      their story at the PRINT UV 2015 Conference held in Las Vegas as he played a video showing the LED-UV presses in action. "With LED-UV we're achieving excellent cure even at our highest speeds, our turnaround time has decreased by 40%, we have immediate bindery processing, and the ink has better holdout for brighter, more intense color".


Overall cost savings have been achieved in multiple areas including no time spent cleaning dried ink from the delivery pans or cleaning spray powder from the press and surrounding area.

Normally a bi-weekly process eating up valuable hours of production time. Coating and varnishes have also been eliminated just to protect the sheets in finishing.


In February 2015 Premier Printing LTD added another AMS LED-UV system to their 2012 Heidelberg XL105 10-color long perfecting press and are planning to upgrade the Heidelberg SM74 sitting right next to it. This will make Premier Printing LTD the first all LED-UV printer in Canada.


Published on by Allen Jenkins.