DRIVING SUSTAINABLE INNOVATION IN LED CURING

Under the leadership of Managing Director David Wright, Integrity Print Ltd continues to evolve as one of the UK’s most progressive, independent print manufacturers. The company has more than a century of print heritage and is located at a modern production facility in Midsomer Norton near Bath. The business supports commercial brands, retailers and regulated sectors requiring secure, high-quality print and direct-mail communications delivered with speed, precision and reliability.

“IST INTECH supplied a fully functioning SCX HD demonstration system”

Demand for agile, high-quality print production is growing. Particularly in sectors such as direct mail, retail communications and regulated customer communications. As a result, Integrity Print has continued to invest in technologies that enhance both production performance and environmental responsibility. 

IST INTECH Ltd – the UK arm of the IST Group – is supporting printers such as Integrity Print in their transition towards more sustainable production. As a specialist in UV and UV-LED curing systems, IST INTECH works closely with customers to optimise curing performance while improving energy efficiency and operational reliability.

In October 2024, this long-standing relationship developed further when Integrity Print installed the SCX HD UV-LED curing system across five presses. This achieved a significant step in the company’s sustainability and energy-reduction strategy.

For Integrity Print, the transition to LED curing was not driven simply by compliance pressures but by a clear strategic goal. Its aim – to future-proof production, while maintaining the speed and quality demanded by modern print buyers.

The company operates in sectors where production reliability, colour consistency and turnaround speed are critical. Particularly required in high-volume direct mail and regulated communications. Maintaining these standards – while reducing energy consumption and carbon output – was therefore essential.

Integrity Print works within Climate Change Agreements and Energy Savings Opportunity Scheme (ESOS) reporting frameworks. This means that any future investment needs to deliver measurable energy reductions without compromising press performance or production throughput.

David Wright explains, “Our focus has always been on staying ahead of industry change. Our customers rely on us for quality, security and speed of delivery, so any move towards more sustainable production has to enhance – not compromise – those capabilities.”

From IST INTECH’s perspective, this reflected a broader industry trend. Printers were no longer looking at LED purely as a technology upgrade, but as a strategic tool to meet compliance targets and control operating costs.

The challenge was clear – deliver equivalent or improved curing performance while significantly lowering energy demand.

“For Integrity Print, performance was non-negotiable”

Integrity Print already operated conventional UV systems manufactured by IST Metz – another arm of the IST Group. This existing relationship created a natural starting point for the exploration of LED alternatives.

Rather than proposing a like-for-like swap without validation, IST INTECH supplied a fully functioning SCX HD demonstration system. This unit was installed and tested under live production conditions. This allowed for performance to be assessed against real substrates, inks and press speeds.

For Integrity Print, performance was non-negotiable. For IST INTECH, proving output capability in a demanding commercial environment was equally critical. Trials confirmed that the SCX HD could meet curing requirements while offering the significant energy advantages associated with LED technology. Just as importantly, the system supported a retrofit approach. This enables upgrades without full press replacement, reducing capital expenditure and production disruption. This validation phase laid the foundation for a five-press rollout.

With five presses scheduled for conversion, both teams agreed that a phased installation programme would minimise risk and protect production continuity. Each press presented slightly different integration considerations. Close co-operation between Integrity Print’s engineers and IST INTECH’s technical team needed to be maintained. As a result, correct interfacing of trigger signals and precise curing control, aligning with existing press parameters, was ensured.

The first installation became a joint development opportunity. During commissioning, enhancements were identified to further strengthen the SCX HD configuration for Integrity Print’s specific environment. The initial unit was reworked and all subsequent systems were manufactured to the improved specification. This iterative process reflected a shared engineering mindset – refine, optimise and standardise.

Operator training was delivered with each installation. This built confidence and made sure that the transition to a hybrid UV/LED production environment was smooth and free of disruption.

“Testing demonstrated an 85% reduction in energy consumption”

The performance gains were immediate. Testing demonstrated an 85% reduction in energy consumption compared to conventional UV curing. For Integrity Print, this translated into substantial electricity savings and meaningful progress towards carbon reduction commitments.

From a financial perspective, the projected return on investment (ROI) across all five presses is just two years. This saving accounts for LED-compatible inks costing approximately 18% more than standard UV inks.

Operational efficiencies have also improved. LED curing systems require less frequent servicing than traditional UV lamps. Therefore, maintenance demands are reduced and press uptime is increased. Standardising the SCX HD system across all five presses further simplified maintenance planning.

A spare, interchangeable lamp head was included as part of the package. In the event of a failure, it can be installed in approximately five minutes, ensuring production continuity. The LED units are also field-serviceable. This allows Integrity Print’s engineers to carry out most repairs locally, with IST INTECH providing additional support when required. The result is not only lower energy consumption, but greater operational resilience.

“LED curing systems require less frequent servicing than traditional UV lamps”

For Integrity Print and IST INTECH, the project represents more than a technology upgrade. It reflects a partnership built on engineering expertise, innovation and a shared commitment to sustainability.

Wright highlights the collaborative nature of the project, “Both teams genuinely enjoyed working together on this upgrade.” He continues, “Whenever technical challenges arose, they were tackled quickly and collaboratively, which ensured production continued without disruption.”

He also notes the responsiveness of the IST INTECH team by saying, “The speed and positivity of the support we received from 
IST INTECH was excellent. Their hands-on approach gave us confidence at every stage of the installation and optimisation process.”

Simon Roberts, Managing Director at IST INTECH, comments, “Integrity Print is exactly the forward-looking company we seek to partner with. Integrity Print recognises the energy savings and sustainability of upgrading their equipment to LED UV.” He concludes, “They can add the value and green credentials that their customers demand.”