How do you calculate UV LED curing energy cost?

Multiply wall-plug power by runtime to get kWh, then multiply by your electricity rate. A 4.5 kW array running 7.5 hours uses 33.75 kWh, which at $0.14/kWh costs $4.73 per shift.

Is UV LED cheaper to run than mercury lamps?

Almost always. LED arrays draw far less wall-plug power for the same cure and switch instantly on and off, so idle time costs nothing. The same shift on a 16 kW mercury system can cost three to four times more in electricity alone.

What is the energy cost per part for UV LED curing?

It depends on throughput. At 2,400 parts per shift and $4.73 of energy, each part carries about $0.002 — small enough that LED energy is rarely the dominant cost on a high-volume line.

What is wall-plug power on a UV LED system?

It's the actual electrical draw at the outlet, including driver and cooling losses, not just the optical output. Always use wall-plug power for cost math; the radiant UV figure understates what you pay for.

How can I lower UV LED energy cost?

Run the array only when parts are present using conveyor interlocks, dial intensity to the minimum that achieves full cure, and keep optics clean so you don't over-drive power to compensate for output loss.

Does LED runtime equal shift length?

Not if you gate the array. Because LEDs switch instantly, smart lines energize them only during actual cure, so effective runtime is often well below the 7.5-hour shift, cutting cost further.

UV Curing calculator

UV LED Energy Cost Calculator

UV LED curing energy cost is the electricity your LED array consumes per shift, and per part, while curing inks, coatings, or adhesives. Process and finishing engineers track it because LED systems are sold on low running cost versus mercury arc lamps, and this is the number that proves it. Knowing your cost per part also lets you cost a job accurately and compare an LED retrofit's payback against the lamps it replaces. This calculator turns wall-plug power, runtime, and your blended rate into shift cost, energy used, and a per-part figure.

What this calculator does

Cost out a UV LED cure system per shift and per part using array wall-plug power, runtime, utility rate, and units cured.
Use it when costing a UV LED retrofit, building a job quote with energy as a line item, or reporting energy cost per part to operations.
It computes the electricity cost of running a UV LED curing array per shift, the kWh consumed, and the energy cost allocated to each part cured.

Formula used

Energy used (kWh) = wall-plug power × runtime
Shift energy cost = energy used × $/kWh
Energy cost per part = shift energy cost ÷ parts cured

Inputs explained

Array wall-plug power: Total electrical draw of the LED array(s) and driver electronics - not optical UV output.
Runtime per shift: Hours the array is actually energized - most lines idle the array between parts.
Blended electricity rate: Use the all-in rate from your utility bill including demand charges divided across kWh.
Parts cured per shift: Good cured units - exclude scrap so the per-part number is honest.

How to use the result

Use it when costing UV-cured jobs, building an LED-versus-mercury business case, or auditing finishing-line energy use.
It counts only the array's wall-plug draw — chillers, blowers, conveyors, and controls add real load that this figure excludes, so true line energy is higher.

Current U.S. benchmarks

As of Apr 2026, industrial electricity averages 8.7 cents per kWh across the U.S. (EIA), up 5.5% from a year earlier. State averages range widely, so plants should confirm against their own tariff.

Common questions

How do you calculate UV LED curing energy cost? Multiply wall-plug power by runtime to get kWh, then multiply by your electricity rate. A 4.5 kW array running 7.5 hours uses 33.75 kWh, which at $0.14/kWh costs $4.73 per shift.
Is UV LED cheaper to run than mercury lamps? Almost always. LED arrays draw far less wall-plug power for the same cure and switch instantly on and off, so idle time costs nothing. The same shift on a 16 kW mercury system can cost three to four times more in electricity alone.
What is the energy cost per part for UV LED curing? It depends on throughput. At 2,400 parts per shift and $4.73 of energy, each part carries about $0.002 — small enough that LED energy is rarely the dominant cost on a high-volume line.
What is wall-plug power on a UV LED system? It's the actual electrical draw at the outlet, including driver and cooling losses, not just the optical output. Always use wall-plug power for cost math; the radiant UV figure understates what you pay for.
How can I lower UV LED energy cost? Run the array only when parts are present using conveyor interlocks, dial intensity to the minimum that achieves full cure, and keep optics clean so you don't over-drive power to compensate for output loss.

Last reviewed 2026-05-12.