42 Technology, a Cambridgeshire-based consultancy with expertise in solving complex engineering challenges across various industries, believes it has developed a more efficient method for drying water-based inks in digital printing. The company, based in St Ives near Cambridge, specializes in cross-sector innovation, leveraging its expertise in mechanical engineering, packaging, medtech, energy, and digital print. Dr. Peter Brown, the firm’s Chief Commercial Officer, describes 42 Technology as “generalists who specialize,” while Rowan Beale, a systems engineer, leads the company’s RF (radio frequency) dielectric drying development program.
Traditional drying methods, such as hot air and infrared, are inefficient and increasingly outdated. Hot air drying converts only about 5% of its energy into useful drying, with most of the heat lost to warming the surrounding air or equipment. Infrared drying is slightly more efficient at 15% but struggles with color variation—black inks absorb infrared well, while yellow inks do not. Additionally, both methods risk overheating substrates, particularly plastics.
RF dielectric drying, however, works differently. Instead of directly acting on water molecules like microwave or infrared drying, RF drying interacts with dissolved ions in the ink. These ions oscillate rapidly within the applied electric field, generating heat through friction as they collide with neighboring molecules. This internal heating efficiently dries the ink without affecting the substrate. Beale explains that this method is color-independent, highly energy-efficient, and safe for materials, making it a potential game-changer for the industry.
The efficiency gains with RF drying are dramatic. According to 42 Technology, RF drying can operate at up to 75% energy efficiency—15 times better than hot air systems. This not only reduces running costs but also enables printing on materials previously considered unsuitable, such as thin films or complex composites. Dr. Brown notes that the use of aqueous inks on plastic films, previously dismissed as impractical, could now become viable with RF drying.
Despite its potential, RF drying has long been dismissed by the industry due to legacy systems that were bulky, vacuum-tube-based, and poorly suited for fast-moving printed films. Additionally, technical explanations from RF system suppliers were often flawed, leading to skepticism. To address this, 42 Technology built a compact, solid-state RF drying demonstrator to prove its effectiveness. This tangible, repeatable process has helped overcome decades of technical doubt. Beale emphasizes that seeing the technology in action has convinced many industry players to consider adopting it.
The implications of RF drying extend beyond ink performance. Aqueous inks, viewed as more environmentally friendly than solvent- or UV-based alternatives, are gaining traction, particularly in packaging. Regulatory pressures, brand commitments, and consumer expectations are driving this trend. However, the inefficiency of traditional drying methods has been a bottleneck for aqueous inks. RF drying, if adopted at scale, could resolve this issue, making aqueous inks a more viable option.
Interest in RF drying is growing, and 42 Technology is in discussions with ink manufacturers, printhead developers, and OEMs. Brown highlights that the inability to dry aqueous inks efficiently has been a commercial barrier, and RF drying removes that obstacle. The consultancy is not looking to become an equipment manufacturer but operates on a fee-for-development-time model. It is now seeking development partners to co-fund the refinement and scaling of RF drying for specific applications.
While packaging is the initial focus, potential applications for RF drying are vast. In the food sector, it could improve shelf life by removing residual moisture. In medtech, it could enable non-contact drying in microfluidic systems. Beale notes that anywhere moisture needs to be removed quickly and precisely, RF drying has potential.
Developing compact, cost-effective RF systems posed significant challenges. Moving from expensive vacuum-tube technology to solid-state electronics and designing electrodes that maintain efficient energy transfer as ink dries were particularly tricky. However, these hurdles have largely been overcome. The greater challenge lies in changing industry perceptions. Brown explains that introducing RF drying is not just about new technology but also challenging long-held assumptions.
What 42 Technology has achieved is more than a technical breakthrough—it is a case study in innovation. By employing lateral thinking, patient engineering, and a willingness to ask uncomfortable questions, the company has demonstrated how transformative ideas can emerge from outside industry incumbents.
If RF drying takes hold, the impact will be significant, though it may not be headline-grabbing. The shift will be deeply felt in energy bills, substrate options, sustainability metrics, and beyond. This quiet but powerful change could redefine the future of industrial printing.
For more information or to connect with 42 Technology, contact Dr. Peter Brown at [email protected] or Rowan Beale at [email protected].
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