Made in India: APL LED UV S9-50

The APL LED UV S9-50 is APL Machinery’s new generation LED UV curing system, which was launched at Drupa 2024.  "We designed this system in such a manner that, using the maximum output of the chips optically, we can achieve almost 50% extra power than our competitors worldwide; at the same time, reducing the consumption of electricity," CP Paul, chairman of APL Machinery, says. "The way it was designed was that we worked from where the base wafer is made up to the curing application."

Solderless technology
The LED UV curing system is installed in flexo, offset, rotogravure, screen and digital presses to cure the inks and coatings. The LED UV S series was launched in 2019. The latest version, LED UV S7-50, was launched at Drupa 2024.

In the last one-and-a-half years, APL Machinery has installed more than 500 units of this series. In total, APL has now installed more than 2,500 units across the globe. "There are certain OEMs and ink-makers in Europe who love the power label of our product. They also love the unique design," Paul says. “The other USP of our design in the LED UV system is that it is solderless technology."

He adds, "For an OEM, to give service to their customers is important. So, most of the systems around the world need to send them back to the factory where it is made. We have designed it in a way that we just open the screws and the chips, which can be done by the machine operator. It's like how we used to change batteries in a mobile phone before the smartphone era."

Customer wishlist
Paul says that globally, before investing in such a system, customers look at how advanced the system is, its ease of use and its ease of service. OEMs especially look for a high-powered system. Another major concern is the sustainability of the system and how easily it can be serviced.

These systems are primarily used for curing inks, varnishes, and coatings on diverse substrates like paper, film, labels, and cartons, offering faster production, energy efficiency, and superior print quality. He gives the example of a customer who uses the APL LED UV system for high-speed flexographic printing on ultra-thin film. The company achieved 220-m/min on an eight-micron film using standard flexo technology, where typical speeds are limited to around 130 to 150-mpm.

In another remarkable case, APL’s LED UV S9-50 was integrated into a CI flexo press, successfully running at speeds exceeding 400-m/min with LED inks, demonstrating unmatched curing power, stability, and efficiency.

"These examples highlight how APL’s technology is not just meeting, but pushing the boundaries of print speed, substrate compatibility, and energy-efficient curing," Paul says.

The parts
The APL LED UV S9-50 has several unique characteristics that set it apart.

The system delivers up to 50% more optical power than conventional systems. For example, printers using high-speed CI flexo presses have achieved speeds of 400+-m/min with LED inks, previously unattainable in this segment.

Unlike traditional systems that require factory servicing, APL’s chip modules can be replaced on-site by simply unscrewing and swapping, similar to how mobile phone batteries were replaced in earlier models.

Despite its power, it consumes significantly less electricity, making it ideal for high-speed, cost-sensitive production environments. Its structure allows quick maintenance, reducing downtime, critical for print houses running tight schedules.

The system features custom-designed lenses that focus and enhance the LED output for uniform and efficient curing. It has an intelligent driver system that ensures stable performance and energy efficiency. It also has integrated thermal management for consistent operation during long runs.

Paul says that while there are European and US-based manufacturers, the APL LED UV S9-50 stands out with its superior curing power, exceptional cost-effectiveness, and adaptability across flexo, offset, screen, and digital printing, making it a preferred choice over global competitors, especially in performance-driven and price-sensitive markets.

APL's productivity mantra
In terms of productivity, the APL LED UV S9-50 enhances printing speed and uptime. Its high curing power enables printers to run at much faster speeds. The quick, solderless chip replacement reduces downtime drastically, allowing operators to perform maintenance on-site without waiting for factory repairs. Energy efficiency and stable output mean fewer machine overheats and fewer production halts. Overall, this translates into higher throughput, faster job completion, and better on-time delivery for printers using the system compared to many alternatives.

According to Paul, the APL LED UV S9-50 is very easy to use. Its modular, solderless chip design allows quick on-site maintenance without specialised tools. The user-friendly control panel simplifies operation and monitoring, making it accessible for machine operators and reducing downtime.

APL Machinery offers training for the LED UV S9-50, including hands-on onsite sessions, periodic online and offline sessions to update on the latest upgrades, and dedicated technical support to ensure seamless installation, operation, and maintenance.

For 2025-26, APL wants to increase installations beyond the current 18+ countries, focusing on emerging markets with high demand for cost-effective, high-power curing solutions. "We want to achieve a significant growth in unit sales by targeting both retrofit projects and OEM partnerships," Paul signs off.