‘From Mercury to Mindset: The Shift Towards LED Curing in Industrial Screen Printing’ Implementing UV LED Curing

The topic of sustainability in screen printing might not sound as flashy as a new product launch or a breakthrough in technology — but what if itold you that curing ink with UV LED could help change the way our industry approaches energy, waste, and improve worker safety?

We all know screen printing is a workhorse in manufacturing. From appliance panels to automotive dials, the process is still going strong. But curing the printed layers — that crucial step where the ink is dried— has traditionally been anything but sustainable. Solvent-based, mercury cured or even ceramic inks cured in ovens are still common, despite the disadvantages: mercury, high heat output, running costs and a dependence on extraction systems.

Now imagine changing that. No mercury. No ozone. No harmful VOCs. Lower energy consumption. Instant on/off. That’s the advantages of UV LED curing — though, like any industry shift, the adoption curve still has a chasm or two to cross.

IKEA’s Lightbulb Moment — An LED journey- IKEA converts all lighting to LED for a more sustainable life at home

IKEA transitioned its entire lighting range to LED technology, completing the shift globally by September 2015. This move positioned IKEA as the first major global retailer to offer only LED lighting products, ahead of the EU's 2018 ban on halogen bulbs . LED bulbs consume up to 85% less energy than traditional incandescent bulbs and can last up to 25,000 hours, offering significant energy savings and reduced carbon emissions. Additionally, the compact size of LEDs allows for innovative lighting designs, enhancing both. Yes, we are talking curing and not lighting in our LED topic, but the base technology -LED dies is the same and is a proven technological solution.

IKEA’s switch to LED lighting was a mindset shift, not just a technology one. IKEA didn’t just reduce energy use — they reimagined what lighting could be, unlocking design potential along the way. The same philosophy applies here. UV LED curing is not just a greener option — it’s an enabler. New substrates, immediate handling, reduced maintenance — and in Ikeas case more creative freedom for engineers and product designers.

But… Why So Slow?

If LED curing is so good, why hasn’t every industrial printer jumped on board? The barriers are a familiar story: legacy infrastructure, lack of awareness, upfront costs, and conservative mindsets. But it’s changing. Legislation on emissions, consumer pressure, and good old-fashioned cost savings are pushing operations to rethink their processes.

A statistic that has stuck with me — the world’s urban population has exploded. From 12 cities with over a million people at the start of the 20th century to over 500 today, and growing. More people mean more consumption, and more consumption means more responsibility in how we produce. The case for cleaner, more efficient manufacturing isn’t theoretical anymore.

The Hidden Superpower: Addressability

One of the standout innovations in the INTECH LED curing systems is something called “addressability”. Think of it as pixel-level control — being able to switch individual LED segments on and off, or dial their intensity up and down, only where and when curing is needed.

Unlike traditional UV arc lamps that are either on, off, or shuttered, LED heads consist of hundreds (sometimes thousands) of individual emitters. With addressability, you can cure precisely — reducing energy waste, controlling heat exposure, and even remotely managing system performance.

In one case study (The Compost Bag Company), this level of control was a game-changer — allowing them to cure only the printed areas, reduce substrate film thickness reducing their energy footprint and simplifying maintenance through remote diagnostics. No over-curing, no excess heat, just controlled, focused energy.

Think Industrial. Think LED. We often talk about “the future” like it’s some distant concept. But the systems are already here — they’re being installed and implemented by companies who understand that LED isn’t just about sustainability, cost saving it’s also about competitiveness and future proofing.

IST INTECH offers solutions from basic head-and-cable kits to fully integrated curing systems, complete with power supply units, digital/analog I/Os control architecture. Whether you're retrofitting or building new, we've got modular solutions ready to scale.

And if you’re wondering about cost? There’s a cost comparison calculator that lays it out clearly: LED curing saves energy, reduces CO₂, and cuts long-term operating costs. Contact IST INTECH to calculate ROI based on your configuration.