In the fast-paced world of custom sign fabrication, it’s easy to overlook the small details that make a significant impact. One of the most commonly overlooked aspects of polymer ADA-compliant sign manufacturing is the condition of your UV bulbs. While they might seem like a minor component, they play a crucial role in ensuring the quality and compliance of your signage. This blog will explore the importance of UV bulbs, how to manage their effectiveness, and why regularly replacing them is essential.
The Role of UV Bulbs in Photopolymer Sign Manufacturing
UV light exposure is critical in the photopolymer sign manufacturing process. The photopolymer material used in this type of ADA-compliant signage reacts to UV light by hardening the exposed areas, while the unexposed polymer is washed away during the washout process. This process forms the raised elements, such as characters, room numbers, braille, or pictograms necessary for ADA compliance.
However, the effectiveness of this process is directly tied to the intensity of your UV bulbs. Over time, intensity decreases, leading to longer exposure times and potentially compromising the quality of your signage. If your bulbs are not producing enough UV light, the photopolymer may not harden correctly, leading to a weak structure of raised copy or braille, resulting in poor overall sign quality or, worse, a non-compliant sign.
Signs Your UV Bulbs Need to Be Replaced
Like regular household bulbs, UV bulbs dim over time due to constant usage. Many fabricators make the mistake of keeping their bulbs far too long, not realizing the impact this has on the quality of their signs. Worn-out bulbs can’t transfer all the intricate details your signage requires, leading to issues like lost text and Braille, which can render your signs non-compliant with ADA standards.
So, how do you know when it’s time to replace your UV bulbs? A good rule of thumb is to replace them every 300 hours of use or annually, depending on your production schedule. Factors like usage frequency, bulb age, and initial quality all play a role in determining the optimal replacement time.
Evaluating Bulb Effectiveness with the Stouffer Scale
To ensure your UV bulbs are functioning at their optimal output, it’s essential to regularly check their effectiveness using the Stouffer Scale. The Stouffer Scale measures light exposure during the photopolymer process, helping you gauge whether your bulbs are still performing adequately.
The scale uses numeric values to indicate the level of exposure, with specific ranges corresponding to different photopolymer materials. For instance, PT materials should read between 15 and 16 on the Stouffer Scale, while EX exterior-grade polymer substrate should read between 12 and 13. As your bulbs age, they will produce less light, increasing the exposure time needed to achieve the desired results. By regularly using the Stouffer Scale, you can monitor your bulbs’ performance and know exactly when it’s time to replace them.
Managing Your UV Bulbs for Optimal Signage Quality
To maintain high-quality signage, it’s crucial to implement a bulb quality check process. This involves regularly testing your bulbs with the Stouffer Scale, recording the results, and tracking changes over time. You can also identify failing or burned-out bulbs by positioning the Stouffer Scale in various locations within the exposure drawer.
Replacing your UV bulbs at the recommended intervals and keeping a consistent record of their performance will ensure compliance with ADA standards and improve your production cycle times. When your bulbs are in optimal condition, you can achieve 9-12 cycles per hour in your photopolymer processor, maintaining both quality and efficiency.
Key Takeaways
The quality of your ADA-compliant signage is closely tied to the condition of your UV bulbs. Regularly checking and replacing your bulbs is essential for maintaining the proper exposure times, ensuring compliance, and achieving consistent results. By integrating a routine bulb maintenance program into your workflow, you can avoid costly mistakes, reduce waste, and ultimately produce better signs.
At Nova Polymers, we understand the importance of every detail in the sign fabrication process. We’re here to help you identify and solve any bulb-related issues, ensuring your workflow runs smoothly and your signage meets the highest standards. Contact us today to learn more about how we can support your sign manufacturing needs.
