Comprehensive comparison between UV ink and traditional ink
Date: Mar 11 2025 From: Star Color
Against the backdrop of a global printing market exceeding $500 billion (Smithers data), traditional inks face significant challenges: solvent-based inks are subject to a €0.8/kg environmental tax in the EU due to 30–70% VOC emissions, while oxidative drying inks with 2–24-hour drying cycles struggle to meet the immediate demands of e-commerce packaging. Conversely, UV inks are emerging as an industry favorite with a 7.2% annual growth rate, redefining environmental and efficiency standards through their 100% solids content, zero VOC emissions, and 0.1-second curing speed. Below is a multi-dimensional comparison of the two ink types.
I. Fundamental Differences in Core Mechanisms
1. Curing Mechanism
- UV Ink: Photoinitiators (e.g., TPO) absorb 395nm UV light, instantaneously activating acrylate molecules to form dense 3D networks via rapid "zipper-like" polymerization within 0.1 seconds. This creates an adhesion layer 5× stronger than conventional inks.
- Traditional Ink: Relies on solvent evaporation (30–70% VOC) or oxidative reactions (2–24-hour drying), achieving crosslink density only 1/5 that of UV ink.
2. Formulation Comparison
| Key Parameter |
UV Ink |
Solvent-Based Ink |
| Solids content |
95–100% |
30–60% |
| Surface tension |
32–36mN/m (high wettability) |
40–45mN/m (substrate-limited) |
| Pigment dispersion |
Nanoscale (D50≤200nm) |
Micron-scale (D50≤5μm) |
3. Performance Test Data
| Test Item |
UV Ink |
Solvent-Based Ink |
Standard |
| Wear resistance |
500 cycles no abrasion |
50 cycles start peeling |
ASTM D5264 |
| Ethanol rub resistance |
>200 cycles |
<50 cycles |
GB/T 13217.7 |
| Adhesion (cross-cut) |
5B |
3B |
ASTM D3359 |
| Yellowing index ΔY |
<1.5 (1000h aging) |
>5.0 |
ISO 2470 |
4. Productivity & Cost
- Energy consumption: 0.3kW·h/kg (UV) vs. 1.8kW·h/kg (solvent-based).
- Defect rate: <1% (UV) vs. 3–5% (traditional).
- Environmental cost: No VOC treatment (UV) vs. ¥1.2/㎡ exhaust fees (solvent-based).
IV. Engineering Differences in Production Processes
4.1 Equipment Configuration
| System Module |
UV Printing Machine |
Traditional Printing Machine |
| Drying system |
UV-LED lamps (395nm) |
Hot air tunnel (60–80℃) |
| Energy efficiency |
0.3kW·h/kg |
1.8kW·h/kg |
| Exhaust treatment |
No VOC recovery needed |
RTO incineration system |
4.2 Process Control
- UV system requirements:
- Inert gas protection (oxygen content <200ppm).
- Lamp power density 80–120W/cm.
- Solvent-based system requirements:
- Solvent balance (50±5% humidity).
- Drying airspeed 8–12m/s.
V. Economic & Environmental Cost Analysis
5.1 Total Cost of Ownership
| Cost Item |
UV Ink (¥/㎡) |
Solvent-Based Ink (¥/㎡) |
| Material cost |
1.5–3.0 |
0.5–1.2 |
| Energy cost |
0.8 |
2.5 |
| Environmental treatment |
0.05 |
1.2 |
| Defect rate |
<1% |
3–5% |
5.2 Carbon Emissions
- UV system: 0.8 tons CO₂ equivalent/ton ink (mainly from electricity).
- Solvent-based system: 2.3 tons CO₂ equivalent/ton ink (VOC incineration + energy).
VI. Ink Selection Decision Matrix
| Consideration |
Prefer UV Ink |
Prefer Traditional Ink |
| Short-run printing |
✓ (plate change <5min) |
|
| Chemical resistance |
✓ (pharmaceutical/automotive) |
|
| Cost sensitivity |
|
✓ (bulk publications) |
| Heat-sensitive substrates |
✓ (PET/PE films) |
|
| Environmental regulations |
✓ (VOC <5g/L) |
|
UV ink has triggered a photochemical revolution in the printing industry, achieving material utilization 3× higher than traditional processes (Frost & Sullivan data). While water-based inks retain cost advantages for porous substrates like corrugated boxes, UV ink continues to gain traction in high-value sectors. By 2026, UV ink is projected to occupy 38% of the industrial printing market, with innovations in nanomaterials and smart-responsive technologies driving next-generation functional printing solutions.
Zhongzhixing UV Ink: Your Partner for Efficient & Sustainable Printing
In an era of rising demands for quality and sustainability,
Zhongzhixing UV Ink stands out as the ideal choice for packaging, advertising, and labeling applications. Key advantages include:
- Environmental Leadership
- Zero VOC emissions, compliant with EU RoHS, US FDA, and other global standards.
- Low odor for safer working environments, ensuring food/drug packaging safety.
- Rapid Curing & Productivity
- Instant drying in 0.1 seconds via UV technology, reducing cycle times and energy use.
- Optimized for high-speed production lines, cutting costs and boosting output.
- Superior Performance
- High adhesion, scratch/wear resistance across diverse substrates (paper, plastic, metal).
- Excellent colorfastness and weatherability for long-lasting outdoor durability.
- Custom Solutions
- Special effects (matte, gloss, fluorescent) and tailored formulations available.
- Precision printing for intricate designs and complex processes.
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