UVL manufactures conveyor UVC systems for treating exposed product surfaces, packaging materials, and production-line components. Each system is selected according to the conveyor width, line speed, available installation space, and required UVC dose.
The Facility
A large manufacturer in the Leningrad Region contacted us about adding UVC treatment to a production line for disposable hygienic underpads.
The high-speed line had the following operating parameters:
product web width: 450 mm;
maximum line speed: 250 m/min;
operating mode: continuous;
proposed treatment point: before packaging.
The product passes continuously through several processing stages. The manufacturer needed to add preventive UVC treatment without significantly changing the existing line configuration.
The Challenge
The main challenge was the high conveyor speed. At 250 m/min, the product passes through an 810 mm treatment zone in approximately 0.2 seconds. A sufficient UVC dose therefore had to be delivered across the entire product width within a very short exposure time.
The system also had to:
cover the full 450 mm product web;
provide the calculated dose at maximum line speed;
fit into a limited installation area;
preserve the existing production layout;
remain accessible for cleaning and lamp replacement;
operate reliably with several lamps installed close together.
A standard conveyor irradiator selected only by its external dimensions would not have been suitable. The configuration had to account for the conveyor speed, treatment-zone length, lamp-to-product distance, and available mounting space.
The Proposed Solution
UVL engineers reviewed photographs of the production line and the customer’s proposed installation areas. After confirming the dimensions and mounting conditions, three configurations were calculated:
VOZUF 810×4 — calculated dose of 11 mJ/cm² and total lamp power of 688 W;
VOZUF 810×8 — calculated dose of 22 mJ/cm² and total lamp power of 1,376 W;
VOZUF 810×12 — calculated dose of 33 mJ/cm² and total lamp power of 2,064 W.
The manufacturer selected the VOZUF 810×4 version with four germicidal lamps.
The purpose of the system was preventive treatment before packaging rather than the elimination of an identified microbiological problem. The four-lamp configuration therefore provided an appropriate balance between the required exposure, installed power, and project cost.
The stated dose applies to the agreed installation geometry. The dose delivered during operation will also depend on lamp-to-product distance, reflector condition, equipment cleanliness, lamp ageing, and actual conveyor speed.
Why UVL HOT Lamps Were Selected
In a multi-lamp conveyor irradiator, the lamps are installed relatively close to one another. This increases the temperature inside the housing compared with a single-lamp arrangement.
The output of a standard amalgam lamp depends on the temperature of the lamp tube. If the temperature moves outside its optimal range, the germicidal output may decrease.
For this reason, the system uses UVL HOT VOZUF lamps, which are designed to maintain stable output at the higher lamp temperatures typical of compact multi-lamp installations.
HOT lamps do not cool the equipment or remove the need for correct thermal design. Their advantage is that their operating characteristics are better suited to a dense lamp arrangement.
Scope of Supply
The delivery included:
VOZUF 810×4 conveyor irradiator;
AISI 304 stainless-steel housing;
four UVL HOT VOZUF germicidal lamps;
control cabinet;
four electronic ballasts;
ceramic connectors;
connection cables;
packaging and delivery to the facility.
The AISI 304 housing is suitable for production areas where equipment must withstand regular cleaning and remain easy to maintain.
The total contract value was RUB 243,500, including the irradiator, control cabinet, components, packaging, and delivery.
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Project Implementation
The project began with an assessment of the existing line. The customer supplied photographs of the production area and marked several possible mounting locations.
Using this information, UVL engineers confirmed the available dimensions, lamp-to-product distance, and maintenance access. The three system options were then calculated and presented to the customer.
After the four-lamp version was approved, the technical configuration, commercial proposal, and invoice were prepared. The manufacturing time was 15 working days.
The system was designed for integration without major changes to the production line. Installation and electrical connection should be completed during a scheduled shutdown, with appropriate shielding and safety measures to prevent personnel from being exposed to direct UVC radiation.
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Benefits for the Manufacturer
The selected configuration will allow the customer to:
add preventive UVC treatment immediately before packaging;
cover the full working width of the product;
retain the existing conveyor configuration;
avoid unnecessary installed power;
reduce the risk of microbiological contamination on exposed surfaces;
simplify operation through a separate control cabinet;
use equipment designed for a high-speed production line.
Conclusion
At high conveyor speeds, exposure time becomes extremely short. A suitable UVC system therefore cannot be selected only by housing width or individual lamp power.
Line speed, treatment-zone length, lamp-to-product distance, reflector geometry, and lamp operating temperature must all be considered.
For this production line, the VOZUF 810×4 provided the required preventive treatment without excessive power consumption or major modifications to the existing equipment.
UVL designs and manufactures conveyor UVC systems for specific production conditions—from compact single-lamp units to multi-lamp systems for high-speed industrial lines.
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