GEW LeoLED-UV can easily upgrade all major press brands.
The Voice of Our Customers
GEW LeoLED UV Curing Systems for Sheetfed Offset Presses
Transform your offset press with the most effective LED-UV curing technology
What Makes GEW LeoLED UV Best?
LED-UV polymer inks allow successful printing on almost all stock types as they will adhere well to non-absorbent materials like PE, PET, PU, synthetic paper etc.
LED-UV brings addd value, increased product diversity and new product offerings with coated and uncoated papers, plastics and foil laminated sheets.
Unlike H-UV or traditional mercury lamps, LEDs emit very little infrared heat towards the substrate.
This avoids common heat-related issues in printing such as high pile temperatures, curling of heat-sensitive stock materials and loss of moisture in paper, printed sheets are crisp and fresh as new.
The low heat profile of GEW LEDs means fire risk, costly shielding and preparation of print units is avoided.
Instant On/Off switching means that with LED no energy is consumed when the press is idle. The higher electrical efficiency of LEDs and purity of the UV output allow typical energy savings in excess of 50% compared with and H-UV lamp system.
The printer never waits for the UV lamps because GEW's LEDs' instant On/Off switching means no warm-up or cool-down cycles. Mechanical maintenance time is eliminated because no lamps, shutters or reflector mechanisms require servicing.
GEW LeoLED UV Curing
- Highest UV dose supports the fastest printing speeds
- Compact design fits almost all press types
- LED array is fully sealed from environment for easy cleaning and resilience to ink and dust ingress
- Direct UV irradiation path means no UV is lost in reflections
- Movable between print units
- Continuous remote monitoring of lamp?LED characteristics ensures the most reliable operation and faster support of any manufacturer
- Uniform UV output and wavelength across the curing area
- Long-term consistent output over the full life cycle of the LEDs
|Width||To suit all machines|
|Emitting Window Width||50mm|
|Operating Temperature||41 to 104°F|
|Durability||In Excess of 20,000h|
* Other wavelengths available on request
** Measured at window
RHINO GEW Power Electronics
- Embedded Service - RHINO Control is connected to the internet and encrypted system performance data is sent live to GEW 24/7. This ensures the fastest and most precise response to service issues available in the industry.
- System Performance Reports - Regular system performance reports are sent to nominated customer email accounts. These lay out energy usage, uptime % and a performance report to give unparalleled analysis of press productivity to operational management.
Combined with comprehensive instruction and service manuals available from GEW, your press operators will have total confidence in their new UV system.
The Event Log continually records system use and operating parameters. The log can be checked to ensure the system is working at peak efficiency, avoiding energy waste and unplanned downtime.
Multilingual instructions are easily accessible on every screen ensuring operators can always fully understand the UV control.
- Fail-Safe Operation - Military-grade electronic design protects the UV system from damage caused by incorrect voltage, short-to-ground, dropped phases, power spikes and lighting strikes. In the event of a serious power disruption, the system powers down in a safe mode.
RHINO is designed to run in harshest conditions at ambient temperatures of up to 140°F (40°C). The system is also unaffected by dust, ink mist and other atmospheric contaminants.
- Lowest Operating Costs - With intelligent power management the current draw from each power phase is balanced and harmonic distortion is minimized, reducing the energy demand registered by the electric meter.
- Minimal Footprint RHINO Rack - A compact cabinet that houses power supplies for up to 12 lamps and provides perfect cooling, atmospheric protection and power distribution.
Power supplies slide in to the rack and connect quickly, enabling more lamps to be easily added to the system in future.
- 5 Year Warranty Available - Using GEW's embedded service package gives total confidence in the reliability of GEW power electronics and minimizes unplanned maintenance costs.
GEW is the only UV supplier to offer this level of warranty as standard.
GEW Retrofit: How it Works
GEW provides all peripheral equipment required for proper integration and operation of the LED-UV lamp. Discover the benefits of GEW technology and the array of applicable optional extras available.
High powered LED-UV for demanding industrial and print applications.
The compact form factor is ideal for sheetfed offset presses and installations with tight space constraints.
GEW’s LeoLED has a unique concept: deliver more UV dose for your money than any other product available. Over 5 years of product development & the latest LED technology combine to transform the economics of LED-UV curing. Fully water-cooled, LeoLED provides over 35% more dose and 40% higher irradiance than GEW’s previous LED models.
LeoLED Standard is water-cooled with a compact 40x100mm profile while extensive customization integration is available to ensure our system fits your press. Furthermore, the system has a large window which allows for maximum light extraction from the lamp and delivers maximum UV dosage to your substrate.
Like all our UV products, LeoLED is powered by GEW’s RHINO power supply which uniquely allows GEW customers the flexibility of ArcLED without having to invest in a new independent power system. It is also controlled by RHINO control which comes as standard with IoT remote monitoring for the fastest most effective service response in the industry.
Also available in a Cassette version, LeoLED Standard is perfect for sheetfed offset printing machines and can be manufactured from 15cm to 170cm, with multiple lamp-heads being used in tandem where greater curing widths are required.
RHINO Control Systems: Simple touchscreen controls backed up by an internet-connected remote monitoring service - GEW RHINO control in unparalleled in the industry
GEW UV systems are controlled by a combination of user commands and settings (entered on a modern industrial touchscreen), as well as machine signals which are either hardwired or electronically communicated the GEW RHINO power units. Gew's proprietary RHINO software is able to handle a vast array of common industrial interfaces from simple relay logic to web-based APIs.
The HMI itself has a simple user interface for operating all key parameters on up to 16 lamps simultaneously, customised for each specific machine configuration. Optional accessories such as GEW’s UV monitoring or inert gas chambers are also controlled through the same user interface. It can be mounted freestanding in any location on or around the press or bevel mounted for seamless integration in machine panels.
Industry 4.0 / IoT Technology:
RHINO control systems are continuously connected to the internet and encrypted system performance data is sent live to GEW. 24/7 monitoring of all system parameters ensures the fastest, most precise service response in the industry. Our preventative maintenance program will recommend software or hardware changes to out of tolerance parameters before an issue arises on site.
Comprehensive monthly system performance reports are sent to nominated customer email accounts showing energy use and uptime % so that press productivity can be monitored more accurately than ever before.
GEW LED-UVs have a number of cooling options available such as chillers and fans for your press
All UV systems produce excess heat which must be efficiently removed to ensure uniform, stable & long-term output of the ultraviolet radiation. GEW utilizes 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 lamp-head ensuring it remains at constant temperature. The central fan is ducted to atmosphere outside the factory.
Water cooling systems typically consist of a central air cooled chiller with a water manifold mounted close by. Flow and return hoses run to each lamp-head with flow indicators and monitoring on each channel.
GEW’s experienced team of engineers will specify and engineer a solution to fit the specific project needs and can, if required, handle extremely complicated cooling systems. We have a wide range of cooling systems available and all are supported by our global network of service partners.
RHINO Power Supplies
All GEW RHINO power supplies are rack mounted, able to run arc and LED lamps, and internet connected with 24/7 continuous online monitoring.
GEW UV arc and LED systems are powered by the proprietary RHINO and RLT power supplies. Available in a range of sizes up to 27kW, they are custom designed and manufactured by GEW, exclusively to power our UV systems. They meet the highest international safety standards (including ETL listing for all RHINO units), are monitored over the internet 24/7 and can be purchased with up to a 5-year warranty – unparalleled in the industry.
Every power supply is equipped with GEW’s ArcLED technology, enabling both UV arc and LED to be powered interchangeably by the same unit. Every RHINO & RLT system in the field is ready to run LED – only the LED lamp and chiller are required to make this change.
Military grade design and safe shutdown protects the RHINO from a wide range of common electrical issues and it is proven to run for many years in the harshest environments on Earth. Intelligent power management balances mains draw and minimises harmonic distortion leading to reduced energy demand and the fastest return on investment.
RHINO is the most advanced and reliable power supply in the industry.
GEW power supplies are housed in a RHINO Rack cabinet which provides mains power distribution, filtered air cooling and various control functions. Power and communication cables run from the cabinet to the UV lamps and peripheral equipment located on press.
RHINO Racks are extremely compact and can be stacked 2 high allowing up to 24 lamps in a 1.8m2 footprint. They are engineered for low maintenance and quick, simple installations.
GEW LED modules are available in a range of wavelength to suit different applications.
UV LED modules are sub-assemblies incorporating tens or hundreds of roughly millimetre square LEDs arranged in a matrix of rows and columns. Multiple LED modules are arranged in various configurations within lamp head assemblies to span the desired UV emitting length and width.
The UV spectral output of an LED is relatively monochromatic compared to broadband mercury sources. The material structure of the LED semiconductor determines the exact UV output wavelength, which is fixed and unchanging for each individual diode. Typically, a UV LED module will contain many LEDs with very similar UV spectra and will be specified at a nominal peak wavelength (e.g. 395 ± 5nm).
All GEW LED modules are available with peak wavelengths of 365, 385, 395 or 405nm, with a range of market leading irradiancies to suit many different applications.
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 meeting 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.