中文Glunz & Jensen has launched the Halo LED Kit, a retrofit technology designed to upgrade conventional flexo exposure units from mercury UV-A tubes to modern LED exposure — without replacing the entire machine. The launch represents a pragmatic engineering approach to one of the most pressing transitions in flexographic platemaking: moving from mercury-based UV exposure to LED technology at a pace and cost that plate rooms can actually manage.
The Technology Transition Problem
LED exposure is increasingly recognised as superior to conventional mercury UV-A tube exposure for flexo platemaking. LED technology provides immediate readiness without warm-up time, consistent irradiance that does not degrade with tube aging, and improved process control that supports repeatable plate quality across shifts, production sites, and repeat jobs. The environmental case is also clear: LED is mercury-free, consumes less energy, generates less heat, and eliminates the waste and regulatory burden associated with mercury-containing UV tubes.
The problem is cost and timing. Not every plate room is ready to invest in a brand-new LED exposure unit, and in many cases the existing conventional machine is still mechanically sound — the lamp technology is outdated but the platform is functional. Replacing a complete exposure unit when only the light source needs upgrading is economically wasteful and operationally disruptive.
How Halo Works
Halo addresses this gap by providing LED lamps and dedicated LED drivers that can be installed in the existing lamp positions of many conventional exposure units. No additional frames, wiring, software changes, or brackets are required in typical applications. The conversion is designed for fast, service-led installation by qualified technicians, reducing mechanical complexity and minimising downtime.
“Halo expands the options for flexo plate makers,” said Per Arild, Chief Commercial Officer at Glunz & Jensen. “Not every customer is ready to replace a complete exposure unit, and in many cases, the existing machine is still mechanically sound. Halo gives those customers a practical route into LED exposure, while our Flex-Pose LED 420 and 520 remain the solution for customers investing in a new integrated LED exposure platform.”
Exposure Consistency and Process Control
A central advantage of Halo is exposure consistency. The system delivers homogeneous exposure across the plate surface and precise back exposure, supporting stable floor formation and predictable plate relief. Glunz & Jensen specifies back-exposure precision within less than 0.02 mm tolerance — a figure that matters in flexo platemaking because plate relief directly affects print quality, especially in fine halftone reproduction and highlight dot stability.
Halo also offers flexible light intensity control, with output options of 22, 25, and 28 mW/cm². This adjustability allows the exposure process to be tuned to specific plate materials and customer requirements — a capability that conventional mercury tubes cannot match because their output is fixed at manufacturing and then degrades over time.
Addressing Oxygen Inhibition
The move to LED exposure also helps address one of the persistent technical challenges in flexo plate production: oxygen inhibition. During photopolymer exposure, oxygen can inhibit polymerization at the plate surface, influencing dot formation, shoulder structure, and fine image reproduction. By providing a stable, controllable, and immediate UV-A light source, LED exposure can help reduce process variation linked to oxygen inhibition and support more consistent dot formation — particularly in demanding packaging applications, flat-top dot workflows, and high-resolution screening.
Environmental and Operational Benefits
Halo is mercury-free, reducing waste associated with conventional UV tubes and helping users prepare for tightening regulation around hazardous substances. LED technology consumes less energy, generates less heat, and requires no pre-heating, improving both sustainability and plate room efficiency. According to Glunz & Jensen, Halo can reduce exposure times by approximately 20–30 percent depending on plate type, settings, and production conditions. The LED tubes are specified for more than 10,000 hours of guaranteed lifetime, reducing replacement frequency, maintenance interruptions, and variation caused by tube aging.
Availability and Formats
Halo is available for common exposure formats including 3647, 4260, and 5280. Custom sizes and additional equipment platforms may be evaluated upon request, subject to technical assessment. The solution is intended for installation by qualified service technicians to ensure correct electrical integration, optical alignment, safety, and exposure validation. It is available globally through Glunz & Jensen and its authorized sales and service network.
Source: labelsandlabeling.com
