Natgraph’s Drying Solutions Centre is an open resource available to the screenprinting industry world wide to carry out drying trials. Located within Natgraph’s Nottingham factory, this 3,000 sq. ft area has a modern, flatbed screenprinting machine and dryer ready to produce sample prints. This state of the art dryer has PLC control, operated via a touch panel, this system has detailed data logging of the complete process for full analysis.
The technology includes, pre IR energy, 200 degrees C variable speed forced air controlled to within 1 degree C, combined with adjustable output IR energy, high power Ultra Violet radiation in either fully focussed and semi focussed reflectors, ambient cooling air and refrigerated cooling air.
The testing room is a unique facility equipped with the most comprehensive combination of drying technology available, which is installed within a purpose built Air Force Dryer by Natgraph and is available to any company having a surface coating to dry, visit Natgraph to confirm exactly how, when and why.
Natgraph’s Intelligent Energy Control System (I.E.C.S.) and Heat Exchanger Units will dramatically reduce the running costs of the already energy efficient range of Air Force Dryers when drying solvent based inks. This is achieved by ensuring the drying process uses the absolute minimum electrical power to maintain the required process temperature, (but only when needed) and with the recovery of up to 60% of wasted energy extracted in the solvent/fume removal process.
The Natgraph Intelligent Energy Control System (I.E.C.S) is a new, unique and revolutionary control system that can be ordered as a power saving option on new Natgraph Air Force Dryers. This dramatically reduces the use of electrical power when drying by convection with heated air.
Tests conducted with a varied selection of Natgraphs customers, proved that in normal operation a conveyorised dryer will only be actually drying printed substrates for between 45 and 65% of its operational time. This information prompted Natgraph to develop a control system that will automatically switch the complete dryer into a stand-by state with minimal power usage, whilst maintaining a controlled internal environment ready to re-start production on-demand.
The I.E.C.S uses a substrate sensor, or signal from the print machine to automatically control the dryer’s run-condition. When no substrate is detected for a pre-set period, (for example 90 seconds), the dryer is put into stand-by state.
The Natgraph manufactured range of Heat Exchangers have been developed to lower the operating costs of drying screenprinted products by re-using the wasted energy normally extracted to atmosphere. These units have an aluminium (up to 250oC) or stainless steel (250oC) core that transfers heat from the exhaust (contaminated) air to the intake (clean) air, that can then be taken back into the dryer to lower its operating costs. Each and every Natgraph Air Force Dryer in which hazardous solvents are processed complies with the EN 1539:2009 European Safety Standard and so is designed to continually extract a minimum percentage of the recirculated air to atmosphere, this is to ensure that the solvent concentration within the dryer cannot rise above the allowed LEL (Lower Explosive Limit). Therefore approximately 75% of the running cost of a forced air dryer is wasted energy in the form of heat, extracted from the dryer. The energy recovery level of a Natgraph Heat Exchanger can be as high as 60% from these normally wasted, hot exhaust gases and so by the correct installation of these units (available in three sizes depending upon the dryer specification), the operating costs of a Natgraph Air Force Dryer can typically be reduced by up to 25%. Available in 3 versions, as a free-standing unit (connected directly behind the dryer), stand mounted (above the dryer), or in-ducting mounted, these units are fully insulated with a large access door which allows the core to be withdrawn for cleaning or replacement if needed.
Natgraph’s Electronic UV system has been developed to take Ultra Violet curing to a new level of efficiency and control. It delivers higher levels of curing power but at drastically reduced running costs, resulting in a vastly improved yield for the UV curing process. Available as an option throughout the full range of new conveyorised Natgraph dryers’ this technology utilises revolutionary electronic power supply technology that allows the optimum lamp power to be selected on a true stepless percentage basis. Full power is 170watts/cm (450 watts/inch), with a typical power saving of over 50% when compared to conventional transformer driven UV systems.
Standard transformers can only be operated at set power levels, (typically 70% and 100%) whilst Electronic UV power levels can be selected on an infinitely variable percentage basis from 40% to 100% of full power, allowing selection of the actual required power required and not just the nearest available power level, resulting in major cost savings. Settings can be saved into the PLC touch screen memory of the dryer to ensure the optimum condition is used on each and every job. Also, operators’ have no time to switch a dryer down to stand-by when a pause in printing is required to attend to an inclusion, to replenish the ink, to check register or even to get a colour match approved. Many operators will leave the dryer switched on during a drink break or even over lunchtime. Operators do not usually realize how much energy a UV dryer can consume and will not appreciate the (rising) costs of electrical power. This system does all of that for them, automatically. To test the case, Natgraph installed monitoring software within the standard PLC control system of several UV dryers installed in the field to confirm the typical percentage of time a UV dryer is actually curing prints during a shift. The results showed that the typical time the dryer is actually curing varied from 40% to 55% of a shift. Add this wasted operational energy to the increased energy consumption of transformer systems, then add in the higher power used when the dryer can only be set at the nearest available power level and the savings are massive. Also add the benefits of extended UV lamp life (because of the lower power stand-by periods) and Electronic UV can save over 50% of power usage, every shift, every week and every year.
Natgraph manufacture a range of Freestanding Ultra Violet (UV) Dryers that has been developed from many years of experience gained in the production of over 500 conveyorised UV Dryers, in daily use world-wide. Natgraph UV dryers are widely acknowledged as the coolest and most efficient available.
These dryers have been designed for curing UV surface coatings applied to promotional, electronic, credit card, glass, display and telecommunications products, as well as 3D objects etc. If there is a UV curable ink available for an application, Natgraph will have a solution.
With 8 standard belt widths, Touch Screen PLC Systems, 4 layouts, optional pre IR, Ozone Filters and Intelligent UV Control Systems, this range of dryers is extremely adaptable, versatile and efficient.
Natgraph also manufacture a range of Compact UV Dryers for applications where space is restricted and less temperature sensitive substrates are to be processed. This range utilises the Natgraph 1m UV Module to provide a high specification UV system in the minimum of floor space.
Natgraph manufacture a range of Air Force UV Combination Dryers that has been developed from many years of experience gained in the design and production of over 400 Combined Forced Air and Ultra Violet Conveyorised Systems, in daily use world-wide. These versatile dryers have the ability to dry both solvent based inks and Ultra Violet curing inks in the same unit
These dryers have been designed, developed and manufactured for drying surface coatings applied to graphics, glass, telecommunications, automotive and electronics etc, if there is a UV ink available for the application, Natgraph will have a solution.
With 7 standard belt widths, Touch Screen PLC Control System, 4 layouts, UV lamp systems with 1 or 2 lamps and modular design, this range of dryers is extremely adaptable, versatile and efficient.
Natgraph manufacture a range of Air Force Dryers that has been developed from many years of experience gained in the design and production of over 700 Forced Air Conveyorised Systems, that are in use world-wide.
These units have been designed, developed and manufactured for drying surface coatings applied to graphics, glass, medical products, textiles, automotive, electronics and aerospace etc, so no matter what the application, Natgraph have a solution.
With 7 standard belt widths, Touch Screen PLC Control System, 4 layouts and modular design, this range of dryers is extremely adaptable and offers the versatility and efficiency that is required in today's production environments.
Natgraph manufacture a range of Air Force High Temperature and IR Combination Dryers that has been developed from many years of experience gained in the design and production of over 150 IR High Temperature Conveyorised Systems, in daily use world-wide. These versatile dryers have the ability to dry specialist inks using either a combination of Infra Red radiation and hot air, hot air alone or even combined with UV.
These dryers have been designed, developed and manufactured for drying surface coatings applied to textiles, glass, telecommunications products, automotive and electronics etc. If there is a special ink available for the application, Natgraph will have a solution.
With 8 standard belt widths, Touch Screen PLC Control System, 4 layouts, IR lamp systems, hot air up to 200°C and modular design, this range of dryers is extremely adaptable, versatile and efficient.
Netgraph manufacture arange of UV Bridges that has been developed from many year of experience gained in the production of over system to add a UV curing capability to an existing air dryer. These UV Bridges are designed to be easily fitted onto the dryer to cure the UV ink before the substrate enters the forced air section.
These units have been designed for curing UV surface coatings applied to promotional, credit card, glass, display and telecommunications products. If there is a UV curable ink available for an application, Netgraph will have a solution.
A further and very popular development is the UV Bridging Module, this is a 1m wide unit that has the Uv Bridge lamphouse located on the top, this module is installed between the drying/cooling module of the existing dryer.
Table Top UV Dryers are compact and efficient units available in 2 sizes, with high power and comprehensive specification.
Netgraph also manufacture a range of UV Curing Kits for installation within existing printing units, dryers or reel to reel machines.
UV Bridging Modules:-
The Nategraph range of UV Bridging Modules has been designed to be installed within an existing forced air dryer to provide a cost efficientand cool UV dryering capability to an existing dryer. Available with 1 or 2 lamps, in 8 standard curing widths 70cm through to 215cm, all standard print formate can be pocessed.
The all aluminium lamphouse has high efficiency, fully focused anodised aluminium reflectors and a flate quartz infra red heat filter window fitted below the lamps, that isolated the lamp cooling air from the substrate. This filter reduces the effect of the infra red energy from the UV lamps, resulting in a much reduced 'impact temperatur' on the substrate. In addition, all ozone produced by the lamp is extracted through a dedicated fan that is mounted either directly onto the end of the lamphouse, or as a seperate unit, which can either be floor or wall mounted. Natgraph's technology ensures that this UV system is probably the coolest available, reducing substrate shrinkage and ensuring consistent print registration.
UV Bridging :-
The Natgraph range of UV Bridges has been designed to be installed on the inlet of an existing forced air dryer to provide a cost effective, efficient and cool UV dryng capability to an existing dryer. Available with 1 or 2 lamp, in 8 standard curing widths from 70cm through to 215cm, all standard print formats can be processed.
The all aluminium lamphouse has high efficiency, fully focused anodised aluminium reflector and a flat quartz infra red heat filter window fitted below the lamps, that isolates the lamp cooling air from the substrate. This reduces the effect of the infra red energy from the UV lamps, resulting in much reduced ' impact temperature' on the substrate. In addition, all ozone produced by the lamp is extracted through a dedicate fan that is mounted either directly onto the end of the lamphouse, or as a separate unit, which can either be floor or wall mounted. Natgraph's technology ensures that this UV system is probably the coolest available, reducing substrate shrinkage and thus ensuring consistent print registration.
Table Top UV Dryers :-
The Natgraph Table Top UV Dryers have been developed for smaller print formats and are based on our proven technology ensuring the highest quality and efficiency. These dryers utilise an ozone free medium pressure mercury vapour lampo, which provides high power curing of 131 watts per cm, this being withot the need for exttraction. All the control gear, cooling fans, motors etc contained in the extremely compact all steel construction make these units ideal for any situation.
These units will accept objects up to 40mm high as standard, but special version can be made to accept larger objects. Table Top UV Dryers are used in the PCB and membrane switching industries, for 3D items, as well as conventional graphics, and are equally at home in full production situations and test laboratories. An optional, with storage shelf and castors.
UV Curing Kits:-
UV Curing kits are available to fit into existing production machinery including web systems. These kit can be made to fit into restricted spaces, with multiples of lamp, heat filter, supplementary reflectors etc. Control system can be designed to operate with ink drying, adhesive curing or paint application. Custom designed UV is available from Natgraph to operate in a wide range of applications.
Natgraph’s range of Infra Red Dryers, has been developed from years of experience gained in manufacturing 100’s of units that are in world-wide daily use. This equipment has been designed to cure surface coatings in the textile, electronic, glass, nameplate and promotional print industries, as well as many other applications. Plastisol, Discharge, Water Based and 2 pack inks can be processed through these versatile units.
Model P Infra Red Dryer :-
The Natgraph range of Model P Infra Red Dryers has been developed to provide a versatile and efficient conveyorised infra red dryer for many applications. A combination of a short wave infra red pre-heat section and a height adjustable, long wave infra red element tray make these dryers usable in many industries.
Natgraph's Automatic Sheet Stackers have been developed over many years with 100's of these units in daily use world-wide. Available in 8 standard sizes, there are also purpose built versions for high pile/high speed applications and special substrates.
An optional CCTV Stack Monitoring System can be added to allow the print machine operator to view the operation of the stacker remotely.
Natgraph also manufacture a range of Collection Trays for smaller print runs, these are available in all 8 standard sizes, as well as special versions for side take-off applications.
A range of Vibrating Collection Trays is manufactured to all Natgraph's standard dryer sizes.
Natgraph have introduced The Angled Exposure System to meet the demands of a changing industry by combining a standard stencil exposure machine with the ability to also expose Computer to Screen (CtS) photo stencils produced with wax jet or ink jet applied positive images. In developing this new concept, Natgraph have designed a unit that overcomes the problems experienced in high quality and high volume photo stencil processing.
This unit is the ultimate in fully automatic operation, with touch screen control of every aspect of the process that can be saved to memory for instant re-call. The sloping design of the glass allows easy loading/unloading and reduces the possibility of scratching the glass. It also allows the Metal Halide Light Source to be positioned further away from the stencil than in conventional enclosed systems. This improves light distribution and lowers glass temperature therefore improving definition and reducing film positive distortion.
Available in 3 standard sizes, with a variety of light sources, this system will accept a wide range of frame sizes. All models include a PLC based operating system giving the operator full control of all parameters and automatic operation, allowing better use of manpower within the stencil department.
For industrial, graphic and textile applications this is the ultimate exposure system capable of exposing all types of photo stencil automatically in the minimum of floor-space to the highest quality and consistency.
Natgraph manufacture a complete range of Metal Halide Light Sources to expose photo stencils or other Ultra Violet light sensitive products. Power levels from 1600 watts to 8kW provide the power and light distribution to expose stencils for CD printing frames through to large format display printing. Diazo (420nm)
or Photopolymer (365nm) output lamps can be fitted. Stand mounted or
overhead versions of these Light Sources are available.
All Natgraph Light Sources can also be operated by the in-built pre-set timer, or the optional, Natgraph Light Integrator Unit to ensure accurate exposures, in varying conditions each and every time.
Natgraph manufacture a complete range of Hand Operated Screen Process Printing Tables to provide a versatile production unit that can be used for the 'one off' job through to large production print runs. Available in 4 standard sizes, there is a unit available for all popular manually printed formats.
The Natgraph range of Screen Process Drying Racks has been designed to meet the drying requirements of smaller quantity screenprinting, whilst being both versatile and functional. Substrates can be left to air dry on the 50 open mesh trays of the rack, thus utilising available floor space to the maximum.
Natgraph manufacture a complete range of Stencil Processing Units and Washout Booths in 7 standard sizes to accept screen frames from small through to large print formats.
This equipment is designed to meet the operational needs of fine quality stencil processing and manual screen cleaning, as well as environmental and safety requirements.
The Stencil Processing Units are brightly illuminated to aid in 'image washout' and are equipped with an in-line water heater and hand held spray head.
The Washout Booth is available in 2 versions, for stencil removal with water and screen cleaning (ink removal) using solvents. The ink removal version has an in-built ducting system for the extraction of solvent laden air. An optional fan is available, this complies with the ATEX directive 94/9/EC required by European legislation.
Natgraph manufacture an optional Solvent Recirculation Unit to be used when screen cleaning by hand, this unit saves on solvent usage as well as preventing solvents from entering the mains drainage system.
This unit also complies with the ATEX directive.
The Angled Light Box is designed to aid in 'touching in' photo stencils, available in 4 standard sizes these units allow convenient access to even the largest of sizes.Stencil Processing Units, Washout Booths, Extraction Fans, Solvent Recirculation Unit, High Pressure Washers & Angled Light Boxes
Natgraph manufacture a range of Freestanding Ultra Violet (UV) Glass Dryers developed from years of experience gained in the production of over 500 conveyorised UV Dryers that are in daily use world-wide. Natgraph UV Dryers are widely acknowledged as the coolest and most efficient available.
These dryers have been designed for curing UV surface coatings applied to glass, in the automotive and gaming machine industries. Whatever the requirement for curing a UV ink onto glass, Natgraph have a solution.
With 8 standard belt widths, 2 transport systems, Touch Screen PLC Control Systems, 4 layouts, optional pre IR, Ozone Filters and Intelligent UV Control Systems, this range of dryers is extremely adaptable, versatile and efficient.
Natgraph manufacture a range of Air Force IR Glass Dryers that has been developed from years of experience gained in the production of 100's of IR High Temperature Conveyorised Systems, that are in world-wide daily use. These versatile dryers have the ability to dry typically 'slow' pine oil and water miscible inks using a combination of Infra Red radiation with Hot Air and / or ambient or refrigerated air cooling from above and below.
These dryers have been designed, developed and manufactured for drying surface coatings applied to glass products from 0.6mm through to 24mm thick and up to 3m wide. This glass is used in the automotive, architectural, domestic appliance, solar energy, electronic display and furniture industries. Whatever the requirement for drying ceramic inks onto glass, Natgraph have a solution.
With 5 standard belt widths, Touch Screen PLC Control System, 4 layouts, combined Hot Air/IR lamp systems, double sided cooling, special transport systems and modular design, this range of dryers is extremely adaptable, versatile and efficient.