UV CURING WITHOUT PHOTOINITIATOR

The printing and coating industry is evolving rapidly. Manufacturers are facing a common set of challenges – stricter regulations, increasing sustainability requirements and constant pressure to improve efficiency.

UV curing remains a cornerstone technology in many of these segments. Its ability to deliver instant curing, compact system integration and high productivity has made it indispensable across a wide range of printing processes. However, as market expectations shift, conventional UV systems are increasingly being pushed to their limits.

FREEcure is a new development from IST METZ – created in collaboration with BASF. It introduces a different approach – photoinitiator-free UVC curing. This technology is not just an incremental improvement. It represents a meaningful evolution in how UV curing can be applied across modern printing environments.

“FREEcure takes a fundamentally different approach to UV curing – by enabling direct UVC-induced cross linking without photoinitiators”

In traditional UV systems, photoinitiators are essential components. They absorb UV light and trigger the chemical reactions that lead to curing. While effective, this approach introduces several challenges that are becoming more relevant across multiple printing segments. These include migration risks in sensitive applications such as food packaging, as well as potential odour and extractable. Additionally, they increase regulatory scrutiny of certain substances.

Furthermore, oxygen inhibition at the surface can limit curing efficiency, often requiring nitrogen inertisation in demanding applications. This adds complexity, cost and maintenance effort – factors that affect both narrow web and sheetfed operations alike. 

As a result, many printers and converters are looking for solutions that simplify the process while ensuring compliance with current and future requirements. 

FREEcure takes a fundamentally different approach by eliminating the need for photoinitiators. Instead of relying on chemical initiators, the system uses high-energy UVC radiation to directly activate the binder system. This enables cross-linking without additional substances, simplifying both formulation and process conditions. 

From an operational perspective, this shift delivers the advantages of reduced dependency on complex ink and coating formulations. It also improves suitability for regulated applications and offers a more straightforward curing process.

The system’s water-cooled design ensures consistent performance, even under demanding production conditions and across different machine configurations.

One of the strengths of this technology is its versatility. It is not limited to a single process or market segment, but can be applied across a wide range of printing and coating applications:

Simplified Production Environments – By reducing or eliminating the need for inertisation, printers can streamline their processes. This applies to both web-based systems and sheetfed presses. 

Improved Energy Efficiency – The targeted use of UVC radiation allows for highly efficient curing. In many cases, fewer curing units are required, reducing overall energy consumption and supporting more sustainable production.

Compact System Design – With fewer lamps needed, the curing system can be integrated more easily into existing press configurations. This is particularly relevant for retrofits and hybrid systems.

High Performance at Industrial Speeds – The technology supports the productivity requirements of modern printing, from high-speed label production to industrial coating applications.

Sustainability and safety are key drivers across all areas of printing. By eliminating or significantly reducing photoinitiators, FREEcure supports the development of low-migration inks and coatings. This is an essential requirement for food packaging and other sensitive applications.

At the same time, the reduction in energy consumption and system complexity contributes to lower CO₂ emissions, reduced operational costs and improved overall environmental performance.

The compatibility with water-based UV systems further enhances its sustainability profile, offering additional flexibility for printers aiming to reduce solvent use.

Adopting new technology in printing must be both practical and economically viable. FREEcure has been designed with this in mind. The system can be integrated into new press designs or retrofitted into existing UV installations.

This flexibility allows printers and converters to adopt the technology gradually, aligning investment decisions with production needs and market demands.

Beyond process optimisation, photoinitiator-free curing opens up new possibilities in application development. Printers can explore formulations that are particularly suited for food and pharmaceutical packaging, high-purity coatings and applications where regulatory compliance is critical.

This creates opportunities not only to improve existing products, but also to expand into new markets with higher value-added requirements.

UV curing has always been about speed and efficiency. Today, it must also deliver simplicity, compliance and sustainability. Photoinitiator-free UVC curing represents a significant step in this direction. By rethinking the fundamentals of the curing process, FREEcure provides a solution that is adaptable across different printing technologies and application areas.

However, as with any new technology, successful implementation depends on real-world validation. Different substrates, ink systems and production environments require careful evaluation before full-scale adoption.

This is where practical testing and knowledge transfer become essential. With facilities such as the IST Campus, companies have the opportunity to evaluate new curing technologies under realistic production conditions, run application trials and gain hands-on experience with emerging UV solutions.

Such environments bridge the gap between innovation and industrial application – helping printers and converters make informed decisions and accelerate the transition to next-generation curing processes. 

In a market defined by change, technologies that combine performance with practicality will shape the future of printing. Photoinitiator-free UV curing is one of those technologies ready to be implemented now. 

FREEcure: The future of photoinitiator-free UV curing of inks and varnishes

FREEcure Webinar EN - Curing without PI