Don't Get Rung Out

Efficient drying equipment can save money in big ways, and can be the difference between staying in the black or seeing red.

SAVING A BUCK is at the top of everyone's mind right now, especially in light of the steep rise in energy costs. At this point, there is really nothing converters can do when they get an electric bill, other than pay it or get their power cut off. But taking some simple steps in the converting process can produce some big savings.

One area converters can improve cost savings is to look at their drying processes. Many drying equipment suppliers are working in tandem with their customers to provide suggestions and solutions to the energy-cost crunch which has everyone reeling these days.

Into thin air

There's no magic with drying a freshly printed substrate. In basic terms, energy is added to a substrate/ink combination, which evaporates the liquid, usually water. This energy can be supplied by either hot air or by infrared radiation (IR). With the extraction of the water, the thickness of the coating will appear thinner, which is typically the affect the converter is vying for. Because the drying process is an important and necessary step in package printing, converters must know how to make the drying process as cost effective as possible. A good place to find this information is with the dryer supplier.

"Energy efficiency is a top concern for our customers with the rapid rise of energy costs," said Matt Litzler, president, C.A. Litzler Co. "To help with high costs of energy, we encourage our customers to use variable speed drives, increase the insulation of the system and the exterior ductwork, optimize the efficiency of the gas burners, and minimize the exhaust rates.

"Litzler also offers engineering dryer surveys to audit the efficiency of existing dryers. Our engineers can evaluate the existing operating conditions and make recommendations to improve energy efficiency or improve product quality," he added.

Most importantly he said, "The biggest energy improvement is optimizing the proper exhaust rates to maximize the recirculation of the air."

One example of how C.A. Litzler is helping printers save on their energy bills is by offering its Perfect Float floatation dryers. "These dryers give converters a very efficient drying method by using high-velocity air flow. A flotation dryer can be less than one-half the length of a traditional roll support dryer. The per-foot energy costs may be higher, but the material can be dried in a shorter space," Litzler said.

A peek at the competition

Competition is fierce in the printing business. Printers must provide high-quality print jobs, at the lowest cost, with fast turnarounds. Easier said than done in some cases! But Dave Douglas, vice president, business development, PRI Technologies offered some advice to all converters: "It is critical that equipment not only be reliable, but user-friendly, easy to maintain, and efficient. All of these factors play a part in the overall profit margin.

"Printers are faced with ever-increasing short-run and/or fast-turnaround business. Competition within the industry has forced them to become more efficient than ever before in order to remain competitive in the marketplace," said Douglas.

One example of this is PRI's Quik Dry™ infrared drying system. This drying system makes fast printing possible, while reducing the power needed for drying in the paper delivery section of the press. Also, the Quik Dry process does not just dry the ink on the surface but also within the ink, which shortens printing time for difficult work and fast-turn jobs.

Another example of how drying equipment manufacturers are helping their customers save money is with DRI's RA Series Radiant-Air Electric IR Dryer. "Our customers have been looking for solutions that will increase productivity and product quality, and we finally have a solution for them—the RA Series that can be adapted to many drying and heating processes and, best of all, it's moderately priced," said Doug Misercola, president, DRI.

The RA Radiant-Air dryer modules are available in various heated lengths from 10˝ up to 150˝ long. And this IR dryer has been specifically designed to give users the additional heating and drying capacity required for difficult drying and heating applications.

Advancements and products

Since the dawn of package printing, printers and their suppliers have formed a special bond with each other—printers want a product that will increase their productivity and save them money, just as much as the suppliers want their customers happy and profitable. One example of this synergy is FlexAir Inc.'s new line of dryer systems that completely eliminates the chill drum. "Our company's philosophy is to educate the new customers about the drying process. This leads to a better designed dryer system for the customers' specific needs and helps the converter to improve efficiencies in other areas of the press," said Mark Atkins, president, FlexAir Inc.

AAA Press is also working to develop drying equipment that can save money for printers. One such product is the electric infrared, air impingement dryers designed for the Mark Andy 2200 and 4000 series presses. This dryer can provide improved product quality because the temperature can be controlled individually at each print station. Heavy ink coverage print station dryers can be set at maximum heat output, while low ink coverage print stations can be set at low heat output ranges. Having the capability of adjusting the thermostat can give the printer an opportunity to optimize the drying process and save energy-related costs.

The Dortmann Interstation Dryer for flexo presses from Radiant Energy Systems Inc. is another dryer product that has hit the market in recent times. The dryer was specifically designed for drying water-based flexo inks on film, paper, or foil, and the long-term savings to the printer is reaped from the dryer's high-velocity and low-temperature running conditions. This system consists of a Dortmann 8000 nozzle, duct heater, re-circulating blower, and a control panel.

Another way a dryer can be considered efficent is by saving on items that are in short supply, such as premium floor space. One example of this is XericWeb Drying System's compact IR-convection dryer for water-based inks and coatings, and because this dryer combines infrared heat with high velocity air jets to supply high-speed drying which ultimately leads to faster printing speeds. Combine the fast speeds with the compact footprint, and this dryer can be considered efficient.

by Megan Wolf

Assistant Editor