Have you ever wondered if your UV curing process is delivering consistent results, or if all parts of your assembly line are receiving the right dose of ultraviolet light? In industrial and engineering settings, UV exposure isn’t about sunburns, it’s about product quality, process reliability, and safety.
Today, let’s break down what “Safe” UV exposure means for your equipment and materials, how to spot early signs of UV-related damage, and the best ways to measure UV light in your workflow.
Why UV Exposure Matters for Industry
In manufacturing, electronics, printing, and packaging, UV light is a powerful tool. It’s used to cure adhesives, harden inks, sterilize surfaces, and more. But just like too much or too little heat can ruin a product, the wrong amount of UV can lead to incomplete curing, weak bonds, or even material degradation.
That’s why monitoring and controlling UV exposure is critical for quality control and process optimization.
What Happens When UV Exposure Goes Wrong?
Unlike visible light, UV rays can cause changes you might not notice right away. In plastics, for example, overexposure can lead to yellowing, cracking, or loss of strength. In electronics, uneven UV curing can cause delamination or adhesive failure. In food packaging, insufficient UV sterilization can compromise safety.
Common signs of UV-induced damage in industrial materials:
• Cracks or brittleness in plastics and polymers
• Discoloration or fading of surfaces
• Weakening of adhesive bonds
• Uneven curing or tacky surfaces in inks and coatings
• Unexpected product failures during testing or use
Catching these signs early can save you from costly downtime and product recalls. But how do you know what’s happening before the damage is visible?
How Much UV Exposure Is “Safe” for Materials and Processes?
There’s no universal “safe” UV level for all materials. The right dose depends on:
• The type of material (e.g., plastic, resin, metal, adhesive)
• The wavelength and intensity of the UV source (UVA, UVB, UVC)
• The application (curing, bonding, sterilization, etc.)
• The required performance or regulatory standards
For example, some plastics are highly sensitive to UV and degrade quickly, while others are UV-stabilized for outdoor use. In UV curing, manufacturers specify the required energy dose (in mJ/cm²) to achieve proper crosslinking or bonding.
Key point:
Safe UV exposure is about delivering the right amount of energy, evenly and consistently, to every part of your product or process.
How to Measure UV Exposure Accurately
To manage UV exposure, you need reliable measurement tools. Here’s how industry experts do it:
1. Visual Mapping with Fujifilm UVSCALE
Fujifilm UVSCALE is a thin, flexible film that changes color based on the amount of UV light it receives. It’s perfect for mapping UV distribution on surfaces, inside equipment, or in moving lines-places where a radiometer or meter can’t reach.
How it works:
• Cut the film to size and place it on the target surface.
• Run your process as usual.
• The film develops a color pattern showing how much UV each area received.
• Compare the color to the included chart for a quick, visual reading.
This makes it easy to spot uneven exposure, shadowed areas in a single test. If you need more precision, digital analysis is available just send your exposed film to Pressure Metrics for a detailed report.
2. Digital Measuring Tool for UV Light
For direct, real-time readings, a digital measuring tool (such as a UV radiometer) is used to measure UV intensity at specific points. This approach is ideal for:
• Spot-checking equipment
• Ensuring compliance with process standards
However, radiometers can’t always reach inside complex assemblies or moving parts. That’s where UV light measurement films like UVSCALE shine-they reveal the whole picture of light distribution in just one run.
3. Light Measurement Tool for Quality Control
A light measurement tool helps you track the performance of your UV systems over time. By regularly measuring and recording UV doses, you can:
• Detect degradation or reflector dirt before it affects quality
• Optimize lamp placement and process parameters
• Ensure consistent product quality and process repeatability
Step-by-Step: Using Fujifilm UVSCALE in Your Process
1. Cut the film to fit the area you want to measure.
2. Place the matte side facing the UV source.
3. Run your process under normal operating conditions.
4. Remove the film and compare the color to the standard chart for an instant readout.
For detailed analysis, use digital scanning or take advantage of Pressure Metrics free digital image analysis with your purchase.
Tip: UVSCALE can be used on flat, curved, or moving surfaces making it ideal for conveyor belts, rollers, or inside equipment where traditional meters can’t go.
Applications: Where Accurate UV Measurement Matters
• Printing & Packaging: Ensure UV inks and coatings cure fully for durability and appearance.
• Electronics Manufacturing: Achieve reliable bonding in LCD panels, hard drives, and circuit boards.
• Food & Beverage: Verify UV sterilization for safety and compliance.
• Medical Devices: Validate UV curing of adhesives and coatings.
• Automotive: Monitor UV curing in headlamp assembly, interior parts, and adhesives.
• Quality Control: Document and trace UV doses for audits and process validation.
If you’re interested in how other measurement films work, you might find it helpful to explore how color changes in heat mapping films can reveal temperature distribution in your process.
How to Interpret UVSCALE Film Results
After exposure, the color density on the film corresponds to the amount of UV energy received. Compare the film to the color correlation chart. Each shade matches a specific UV dose, so you can quickly see if your process is delivering the required energy everywhere.
If you need more detailed data, Pressure Metrics offers digital scanning and analysis, turning your film into a precise, shareable report. This is especially useful for process documentation or troubleshooting,
FAQs: UV Exposure in Industrial Settings
Q. How do I know if my UV curing process is working properly?
A. Use a light measurement tool or UVSCALE film to confirm that all areas are receiving the correct UV dose. Incomplete curing, tacky surfaces, or uneven color on the film are signs of insufficient exposure.
Q. Can UVSCALE film be used with all types of UV lamps?
A. Yes, UVSCALE works with high-pressure mercury, metal halide, low-pressure mercury, and UV-LED lamps. Choose the right type of film for your lamp’s intensity and wavelength.
Q. What’s the benefit of using UVSCALE over a digital meter?
A. UVSCALE maps the entire surface in one go, revealing shadows, uneven exposure, or lamp failures that a single-point meter might miss.
Q. How often should I check UV exposure in my process?
A. Regular checks (daily, weekly, or after maintenance) help catch problems early and ensure consistent quality. Store exposed films for traceability and audits.
Q. What if my film shows uneven color?
A. This indicates uneven UV exposure. Check for lamp misalignment, dirty reflectors, or obstructions in your system.
Q. Can I get digital analysis of my UVSCALE film?
A. Absolutely. With each purchase from Pressure Metrics, you can send in your exposed film for a free digital analysis and receive a detailed report by email.
Take the Next Step with Pressure Metrics
Ready to see UV in a whole new light? With UVSCALE films, you can accurately visualize and measure UV distribution across surfaces, detect hot spots or inconsistencies, and verify whether your UV system is delivering energy within optimal ranges.
Pressure Metrics are the experts in Fujifilm UVSCALE and other measurement films. Our team can help you choose the right film sensitivity, interpret results, and even digitize your data for advanced analysis.
Get in touch with Pressure Metrics today and take control of your UV processes with confidence and clarity.