DUO#ModulDry™ – Modular Infrared Dryer for Printing Presses
Modular Infrared Dryer System with cassette-based power control for maximum process control and energy-efficient high-speed production lines.
Customized Energy Application Instead of Standardized Drying
While conventional infrared systems often heat the entire working width uniformly, the DUO#ModulDry™ addresses the issue of energy waste. In modern printing lines, print widths and ink application vary constantly. The DUO#ModulDry™ addresses these issues through its modular cassette system with individually adjustable power output. This allows the drying energy to be precisely adapted to actual requirements, significantly improving both process stability and energy efficiency in modern flexographic printing lines.
Technical Operating Principle of the DUO#ModulDry™
- The DUO#ModulDry™ is based on a modular infrared cassette system.
- Each drying cassette is equipped with four or five infrared emitters and can be controlled individually. The radiant energy is primarily absorbed by the wet paint layer, causing the water content to evaporate quickly.
- A Highly reflective reflector plate ensures uniform energy distribution across the substrate surface.
- The Borofloat protective glass used offers high transmission in the relevant wavelength range and reliably protects the emitter area.
DUO#ModulDry™ Modular Cassette Systems
- The reflector is made of a special material
- It reflects light with a reflectance of 95%
- It is durable and scratch-resistant - The protective glass is made of special glass.
- It has a light transmittance of 95% in the wavelength range of 300–3000 µm
- It is temperature-resistant up to 450°C and exhibits high mechanical stability. - This enables approximately 10% higher infrared output from the emitter compared to other systems.
Unique Air Management of the DUO#ModulDry™
- The integrated air management system removes the evaporated moisture while simultaneously using the cooling air as preheated process air.
- The cooling air is directed through the radiator section and fed into the inlet section as hot process air for moisture absorption.
- As a result, the quartz glass plate reaches a maximum temperature of 150 °C -> reduced fire hazard.
- The hot air nozzle provides effective process air and reduces dust formation on the quartz glass plate.
DUO#ModulDry™ Air Management Precise power control with DUO#WidthsControl
OFF | 40% | 100% | OFF | OFF | OFF | 60% | OFF | OFF |
- Zone-by-zone power control: Each DUO#ModulDry™ infrared cassette can be individually controlled from 0–100%.
- High Energy Efficiency: Power is delivered only where it is needed in the printing process.
- Uniform Drying Across the Width: Optimized reflector technology ensures homogeneous energy distribution.
- Easy Maintenance: Cassettes can be replaced in seconds when maintenance is required.
- High Process Reliability: Integrated air management and optional monitoring systems.
DUO#ModulDry™ Easily expandable with the DUO#Toolbox
The DUO#ModulDry™ can be optionally expanded with the safety and performance modules from the DUO#Toolbox. These system modules enhance operational safety, improve process monitoring, and support energy-optimized production in modern flexographic and digital printing lines.
Depending on the system design, monitoring, control, and protection functions can be integrated—ranging from camera-based process control to temperature-controlled power regulation. As a result, the DUO#ModulDry™ evolves from a high-performance infrared dryer into a fully monitored and process-reliable drying solution.
Applications of the DUO#ModulDry™
The DUO#ModulDry™ system is specifically designed for printing environments where precision and format flexibility are top priorities.
- High-performance flexo post-printing with variable web widths: Ideal for systems that frequently switch between narrow and wide substrates. Thanks to zone control, only the width actually needed is heated.
- Finishing and coating: Precise drying of dispersion coatings in commercial printing, where exact thermal control is crucial for the degree of gloss.
- Industrial sheetfed printing (corrugated board & cardboard): Optimal adaptation to different sheet formats to prevent energy loss in the edge areas.
- Retrofit Projects in Tight Printing Units: Thanks to its modular design, the DUO#ModulDry™ is the top choice for retrofitting existing lines with limited space.
Technical specifications based on working width DUO#ModulDry™
The dryer cassettes are available in 4 power classes
- 5.4 kW (Länge: 555 mm) pc1 (End dryer)
- 3.9 kW (Länge : 455 mm) pc2 (Intermediate dryer plus new)
- 3.3 kW (Länge : 356 mm) pc3 (Intermediate dryer Standard)
- 3,0 kW (Länge : 310 mm) pc4 (Intermediate dryer compact)
The cassettes can be combined into standard modules with different working widths:
150 mm Widths | 192 mm Widths | ||||||
|---|---|---|---|---|---|---|---|
|
| Compact | Standard | Long | Compact | Standard | Long |
Length in mm | 310 | 355 | 555 | 310 | 355 | 555 | |
kW per | NIR | 5,6 | 6,4 | 10,0 | 7,0 | 8,0 | 12,5 |
KW | 3,2 | 3,6 | 5,7 | 4,0 | 4,5 | 7,1 | |
MW | 2,9 | 3,3 | 5,2 | 3,6 | 4,1 | 6,5 | |
Frequently Asked Questions About ModulDry™
When is ModulDry a better choice than a conventional IR dryer?
Especially when dealing with varying print widths, high speeds, and when zone-specific power control is required.
Is the ModulDry retrofittable?
Yes, the modular design is very well suited for retrofitting existing flexographic printing presses.
How quickly can cassettes be changed?
The cassette design allows for replacement within a few seconds.