IR Hot Air Hybrid Dryer for Printing Machines
Combined Infrared Dryers and Hot-Air Dryers for maximum energy efficiency, stable post-print processes, and flexible integration into modern flexographic printing lines.
When is Hybrid Drying the right choice?
In modern flexographic printing systems, high ink loads and increasing production speeds must be reliably managed. Depending on the application, purely convective or purely infrared systems reach their physical and economic limits.
Hybrid dryers combine the rapid energy transfer of infrared radiation with the effective moisture removal provided by hot air. This results in a particularly stable and energy-efficient drying process.
The primary focus of application is currently on corrugated board post-printing and sheetfed applications. Depending on the system design, however, hybrid solutions can also be effectively used in continuous web processes—particularly to shorten convective drying sections.
Technical Principle of Hybrid Drying
The Infrared Hot-Air Hybrid Dryer specifically combines the advantages of both technologies. The IR emitters first heat the paint layer and the surrounding process air. The heated air is then circulated throughout the system and used to absorb and remove the evaporated moisture.
The combination of IR pre-evaporation and convective removal prevents moisture buildup in the process and stabilizes downstream production steps.
Thanks to the closed air circuit, the heat generated in the IR module can be reused multiple times, resulting in a particularly efficient drying process. At the same time, targeted airflow ensures stable temperature conditions across the entire working width.
Thanks to optimized airflow and a compact design, hybrid solutions can be flexibly integrated into various machine concepts.
Hybrid Concepts at a Glance
Integrated Hybrid modules are available for sheet-fed machines, combining IR emitters and air nozzles in a single assembly.
Features:
- Compact design for post-printing
- Direct combination of radiation and convection
- Optimized airflow management
- Ideal for limited installation space
Main application: Corrugated board post-printing (sheet-fed machines)
Hybrid Machines with Separate Modules
Alternatively, hybrid concepts can also be implemented at the machine level. In this approach, infrared dryer modules and hot-air dryer modules are strategically combined between the individual printing units. The design is customized according to the print image, line speed, and available drying section. This solution is used in both sheetfed and selected web configurations.
Hybrid Support in Web Print Processes
In continuous web printing systems, IR technology can be specifically used to support convective dryers.
Typical implementations include:
- Placing an IR module upstream of a hot-air dryer
- Integrating an IR module within a drying section
- Replacing individual air modules with IR modules
The goal of these concepts: IR preheating accelerates evaporation and enables a reduction in the length of the subsequent air dryer as well as improved energy efficiency.
Advantages of Hybrid Drying in Flexographic Printing
- High Drying Efficiency: Rapid evaporation combined with reliable moisture removal.
- Flexible Integration Concepts: From compact modules to hybrid machine solutions.
- Reduced dryer lengths possible: IR support can shorten convective sections.
- High Process Stability: Stable production even with high moisture loads.
- Optimized for Corrugated Post-Print: Particularly economical in sheet-fed applications.
- Retrofit-Capable: Also suitable for existing plant designs.
Limitations of Hybrid Technology
For applications with very low moisture loads or simple printing requirements, a pure infrared or hot-air system may be economically sufficient. Even with very simple machine layouts, combined technology is not always necessary. The optimal design therefore always depends on the specific printing process, the machine speed, and the ink application.
Frequently Asked Questions About Hybrid Drying
When is a hybrid dryer a better choice than IR alone?
Especially for high ink loads and high speeds, when effective moisture removal is required in addition to rapid evaporation.
When is a compact hybrid module a good choice?
Especially in corrugated post-printing applications with limited installation space.
When is a machine-integrated hybrid the better solution?
For complex line layouts or when maximum flexibility is required.
Is hybrid technology energy-efficient?
By combining IR heating and air circulation, the applied heat can be utilized particularly effectively.
Can a hybrid dryer be retrofitted?
Many systems can be integrated modularly into existing flexographic printing presses.
Why is IR used before air dryers?
For rapid pre-evaporation and the potential shortening of the convective drying section.