Energy-cured coatings are recognized to provide significant advantages in terms of faster cure times, often improved coating properties, reduced VOCs, waste, and energy consumption, and smaller manufacturing footprints. Below are listed a few examples where these and more benefits have been realized.

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UV lamination of oxidation-prone decorative metal sheets1: A UV-cured clearcoat provided better scratch-, UV-, and graffiti-resistance and was more uniform than the previous vinyl laminate, resulting in reduced scrap material. Productivity was increased due to higher throughout, while efficiency was improved due to the much higher coverage of the UV-cured coating (and less storage space was required).

UV curing of metal containers2: The replacement of solvent-based coatings that required oven curing with 100% solids UV-cured coatings reduced not only the energy consumed for the process, but the reject rate due to failure of a heat-sensitive seal and the work-in-process. Faster line speeds also helped meet growing demand. UV-curing technology was chosen over low-heat powder curing two-component solvent-based technology. It had the best energy efficiency and lowest overall cost. An added benefit was a reduction in the number of booth filter changes needed which increased productivity and reduced labor costs.

EB curing for metal coil lines3: EB is attractive for metal coil coating when coatings with high pigment loadings are required. Electron beams penetrate to the substrate surface regardless of color (including metallics) of the coating or the pigment concentration. This benefit is combined with the ability to achieve high throughput and use of low VOC coating formulations. Today, coatings that cure via both radical and cationic mechanisms and that have desirable viscosities and an appropriate mix of oligomers, monomers, and various fillers and other additives can be designed to meet the adhesion, impact resistance, hardness, and other properties of a given application.

Many reasons for many applications4: The specific set of reasons for using radiation-cured coatings for any given industrial metal application can vary significantly. For instance, in some cases, heating can cause failure of some aspect of the product. At the same time, the economics are improved because unused product can be reclaimed and reused. For products that are offered in multiple colors, energy-curing technology may facilitate rapid color changes due to the elimination of the need for heating. In some cases, it is simply a significant need for greater line speeds that drives the use of radiation-curing technology. For some applications, the use of energy-cured coatings can eliminate lamination or other steps, leading to increased efficiencies and cost savings. In others, the environmental advantages, including elimination of any reporting requirements, is a major driver of adoption. The ability to achieve a specific coating thickness may be important for yet other applications.

References

  1. Christianson, M., “UV Coatings Enhance Decorative Metals,” Radtech Report, 10-11 (July/August 2007).
  2. Hagood, D., “UV Coat-and-Cure System for Metal Containers,” Radtech Report, 30-33 (September/October 2009)
  3. Berejka, A.J., “Electron Beam Curing of Coil Coatings,” Radtech Report, 47-53 (September/October 2003).
  4. Kelly, M., “The Miracle of UV Light,” Radtech Report, 17-19 (March/April 2008).