By Michal Lodej. It is responsible for the transfer of a precisely specified quantity of ink onto the printing plate. The higher the line count anilox roller, the higher chance of scoring the anilox roller, commented Mr Segbert. No dried ink. In Flexo printing, the ratio of the plate screen to that of the anilox must be 1 to 3.5 or even 4. Some cleaners will attack and corrode aluminum, and should obviously be avoided if you have rolls made from that material. The anilox is the heart of the printing press. Troubleshooting tips. Click to Enlarge. Our Technical Service team has seen it all—from mottled print to those dreaded halos—so they’ve compiled a list of the top issues faced by water-based flexo printers and their recommended solutions. Harper GraphicSolutions, the technical service team affiliated with HarperScientific, employs hands-on industry veterans to assist converters with troubleshooting and problem solving. You’re seeing spots or ink being lifted off your print area. Americas: ANILOX ROLLERS The key to sucess of the Anilox system is the engraved rollers. We need to adjust anilox volume to the quantity of ink we want to transfer onto the substrate. Ink Proofers This is what enables the soda to get to the bottom of the cell – the fractured baking soda gets as small as 7-8 microns. The lacquer chamber incorporates two scraper blades that can clean the surface of the roller leaving only a predetermined amount of lacquer in the rollers engraved cells. Suggested care of bearings and gears, solutions to plate cylinder over-impressions, corrective actions for misaligned anilox, plate and impression cylinders and cures for excessive impressions between plate and substrate are among the problems addressed in the troubleshooting guide. Coating Rolls We therefore recommend that you subject your anilox rollers to laser cleaning at least twice a year, in order to prevent this occurring. The ink is drying on your plates, your ink rollers and maybe your anilox. In printing, anilox is a method used to provide a measured amount of ink to a flexographic (flexo) printing plate. *Wikoff Color Technical Data Sheets list the recommended additives for pH adjustments. The cells on the anilox roller can become clogged with ink residues during use, which reduces the volume of the anilox cells concerned. Use an ultrasonic cleaning system monthly. *Wikoff Color Technical Data Sheets list the recommended solvents for viscosity and drying adjustments. For further information or to request a copy of the new troubleshooting guide, call toll-free 800.438.3111, Ext 292 (US/Can); local 704.588.3371, Ext 292; fax a request to 704.588.8172, or via e-mail at jkluttz@harperimage.com, About Us This Anilox Roller is known for its rigid construction, easy installation, less maintenance and hassle free performance. Markets Served
Finally, they are hard chromed for durability. Incidents . Top Causes of Anilox Scoring and How to Prevent Them. After all, happy customers are our number one priority! Accessories And Testing While some may not view this as the most dire of issues, it still affects your quality and can lead to waste and possibly rejections. When it “hits” the roller face under low pressure, it instantly fractures into many smaller particles. Cyrel® Photopolymer Printing Plate Troubleshooting Guide Problem Identification Press-Related Plate-Related ... High volume anilox roller Low-density negative Excess anilox pressure Over main exposure Excess print pressure Uneven plates Heavy printing, during run Bold type High ink viscosity Plate is worn ARC International supports you with all types of fabricated cylinders and mandrels, as well as an extensive library of drawings, in both hardcopy and electronic format. The MDC Soft Blade from Daetwyler SwissTec has been developed to deal with the above issues and minimise scoring. the coating is very sensitive to mechanical forces acting on it. The existing metering rollers are replaced in a coater with a single engraved Anilox Roller which is saturated with lacquer from an enclosed lacquer chamber. To read the full-text of this research, you can request a copy directly from the authors. Troubleshooting Guide working for you. Anilox are cleaned and cells are restored to their like-new condition within 1-2 working days depending on the condition of the roll. If the anilox roll is the same diameter as the print cylinder, or at least a factor of the print repeat, it will synchronize with the design and ghosting will not appear. You’re seeing tiny holes in your print area, sometimes called fisheyes. and we’ll be happy to help you troubleshoot your water-based flexo issues. Most anilox roll bases are made from mild steel, but many sleeves and some lightweight rolls are made with aluminum. 920.983.1841 (Local/Intl) Protect your anilox roll investment by storing them properly. This can also lead to delamination of the ceramic. Without precise polishing, wear not only occurs on the surface of the roller, but also on doctor blades. Troubleshooting. It offers a bulleted causes/remedies approach to many topics: monitoring of ink pressure, elimination of ink flooding and excessive pressure, avoiding improper settings of the ink roller nip, solutions to fast-drying ink, ink with excessive viscosity, water-based ink with insufficient pH, solvent imbalances and more. View the Chart [/one_third] FibreLyte is an exclusive Pamarco product using wound carbon – Fiber/Steel Journal construction – ceramic coated and laser engraved using EFlo™, EFlo-HD™ or ThermaFlo™ engraving method. Life expectancy of a roll is between 30 and 50 million sheet passes depending on type of running and coating used. The second-down ink doesn’t lay well over the first-down ink. That pesky shadow, or line, is showing up on the outer edge of your image areas. Inappropriate anilox roll; cell volume too great or cell count too low 4. SunChemical a member of the DIC group ... Reducing anilox impression or checking plate level and mounting ... Anilox roller, wiper roll, or printing plate is dirty or damaged Ink in press is contaminated Ink pH is too low Cheshire Anilox Technology Ltd. Tameside Park Industrial Estate Fifth Avenue Dukinfield SK164PP Replace the doctor blade. The engraved pattern is made up from hundreds and thousands of cells. We will support you through your individual challenges with specialist expertise and over 20 years’ worth of experience in the manufacture, production and servicing of anilox rollers and anilox sleeves for flexographic printing. Anilox Roll Storage & Shielding. Today "Sanilox" offers creativity, Commitment, Quality & Outstanding personnel's. Reduce dryer heat or eliminate air flow on print station. Re: Anilox Roller Repair 06/04/2010 11:21 AM Anilox rolls are coated with a plasma sprayed Chrome oxide, diamond ground and polished, then laser engraved using a YAG laser. Ink pigmentation too high 3. Ink-related issues warrant extensive coverage in the new guide. R. Hall. Our dedicated and experienced team are here to help. Anilox Rolls Too much heat from dryers or air blowing on print station, Clean the plates and increase press speed, If pH is below 8.8, increase it with the recommended additive*, Replace doctor blade and/or make sure chamber is parallel, Low substrate dyne level or improperly treated substrate, If ink adhesion is OK, add 0.5% pinhole additive under agitation, Improper metering roller or doctor blade settings, Plate cylinder is over-impressed onto substrate, Plate mounting tape is too hard for the images, Contact your local Wikoff team for a faster drying formulation, Contact your local Wikoff team for a primer, Ink system may not be optimized for your application, Contact your local Wikoff team to verify you have the right ink system, Too much anilox-to-plate or plate-to-substrate pressure, Adjust pressure setting of metering roller, Add defoamer to ink, small amounts at a time, Use lower volume anilox for first-down ink, Increase heat and air flow on first-down unit, Skip a unit between first-down and second-down ink, Particles are lodged under the doctor blade, Filter ink and clean behind the doctor blade, Increase heat and air flow in drying stations, Reduce web temperature before rewind with a chill roller, Change to higher screen count, lower volume anilox, Change to a harder durometer rubber roller, Adjust anilox roller to “kiss” impressions. The edges of your print area are fuzzy and/or irregular. 800.438.3111 (USA/Can) The ALTernative in the Anilox roller and sleeve industry. Surface of the anilox roller is damaged or dirty. Inadequate impression on doctor blade Charlotte, NC A score line in an anilox roll is a groove that has run directly through the engraved surface. Anilox sleeve and roller from Harper Corporation It is essential for all flexo printers that the anilox gives the correct ink density from the first print and stays consistent throughout the whole run regardless of which cell structure or shape is used, and the anilox manufacturers are going to great lengths to achieve this. Look for dried ink at the edges of the cylinders. Our product is designed by using sharp edge technology and advance machines. The ink is having a hard time adhering to the substrate. Solutions. Surface wear can happen for a variety of reasons, but two of the most important is in the application of ceramic to the roller surface and also the way rollers are polished. customer@harperimage.com, Green Bay, WI Adjust anilox roller to “kiss” impressions A continuous line is showing up in your print area. 800.438.3111 (USA/Can) customer@harperimage.com, © Harper - Harper Corporation of America, All Rights Reserved. June 2010; Authors: P. Mollman. Doctor blade has entered the area of the cylinder edge. Discover the five simple steps to selecting an anilox roll. With facilities in Charlotte, NC and DePere,WI HarperScientific provides products and services to flexographic printers all over the world. The print is connecting in small type and screen areas. HarperScientific™ is the Printing and Coatings Supplies Division of Harper Corporation of America. Wrong ink temperature. Charlotte, N.C., February 22, 2010 – Harper GraphicSolutions™, the technical service arm of global anilox supplier Harper Corporation of America, has produced an illustrated guide for troubleshooting anilox roll applications. We also offer a Premium Service where we arrange collection, delivery and supply a coating roller for use while the customer’s roller is being cleaned. Flexography Troubleshooting Guide Cause: 1. Your email address will not be published. Keep sling guards clean and free of dried ink to prevent grinding and damage to the ends. It is designed to deliver a precise and consistent amount of ink to the printing plate. Suggested care of bearings and gears, solutions to plate cylinder over-impressions, corrective actions for misaligned anilox, plate and impression cylinders and cures for excessive impressions between plate and substrate are among the problems addressed in the troubleshooting guide. These are manufactured in steel, then copper plated, engraved and hand polished. Your solid print areas are spotted and/or speckled. Meet The Team Check the cylinder radius. Absolute Volume Ink Smear is now the preferred method of measuring the cell volume of a laser engraved ceramic anilox roll. Ink-related issues warrant extensive coverage in the new guide. HarperScientific services the flexo, offset and gravure industries, as well as all OEM markets with printing presses, by offering supplies for all segments of the printing industry. Roller Repair You simply won’t find a more capable, knowledgeable or flexible partner for maintaining and enhancing your existing investments in flexographic technology. This is why the quality of the anilox roll has a tremendous influence on printing quality. Solvent Flexo: Ink viscosity too high Water Flexo: Ink pH too high 2. If the anilox roll is the same diameter as the print cylinder, or at least a factor of the print repeat, it will synchronize with the design and ghosting will not appear. All anilox rolls will require replacement at some point. Adjust the ink temperature. Anilox roller is the core part of the flexo machine. Perfectly constructed anilox rolls should mount and dismount without any issues. Most often this is caused by the expected abrasion that takes place in the normal operation of a flexo or die cutter. Customized seminars are available on-site or at our facilities. It may even be failing to transfer to the substrate. *Wikoff Color Technical Data Sheets list the recommended additives for drying adjustments, *Wikoff Color Technical Data Sheets list the recommended additives for viscosity adjustments. ... Use an anilox roller adapted to the print run. An anilox roll is a hard cylinder, usually constructed of a steel or aluminum core which is coated by an industrial ceramic whose surface is engraved with millions of very fine dimples, known as anilox cells. Tel: +1-803-548-2210 Fax: +1 803.548.2210. Our Technical Service team has seen it all—from mottled print to those dreaded halos—so they’ve compiled a list of the top issues faced by water-based flexo printers and their recommended solutions. Anilox rolls. It carries color that is being used by flexo plate, made out of the polymer materials. Anilox rolls should be inspected for cleanliness and if they need attention, they should be cleaned as soon as possible. good compilation of issues . 1. We have customers all over India & we are always working to meet their needs even faster and at even better prices. Change to anilox roller with a higher pick-up volume; Change solvent blend to a slower drying solvent; Increase the pressure in the chambered doctor blade system; Increase speed or ink viscosity; Check air flow around plate, fix if too much Request full-text PDF. Information Center *Wikoff Color Technical Data Sheets list the recommended solvents for viscosity adjustments. “We think our new troubleshooting volume will prove to be a valuable resource for everyone regularly involved in anilox roll technology, whether they are new to the process or already an old anilox hand,” said Alexander James, Technical Graphics Manager at Harper GraphicSolutions™. However, if an anilox sleeve will… Read More. Information Center The particle size of the Anilox formula starts out at about 70 microns. Inadequate pressure setting on impression roll 5. Anilox sleeves: Use “aluminum safe” cleaners on all anilox sleeves. Contact Us, About Us Doctor blade choice, chamber settings and press settings all play a large part in increasing or decreasing the life of an anilox. This includes supplies for various inks and adhesives and coatings, including water-, solvent- and UV-ink markets. 15 Most Common Water-Based Flexo Issues and How to Troubleshoot Them. Available free upon request, the new 24-page illustrated guide provides a comprehensive reference to common and not-so-common conditions that frequently arise during the anilox printing process. As a leader in the precision proofing market, HarperScientific supplies precision proofers, safe and user-friendly ink cleaners and measurement equipment. The Anilox Roller is often referred to as the heart of the flexographic press. Fix aniloxes with chipped ends : Chipped ends will wear chunks of metal particles from the … We are an eminent name in this domain, engaged in offering supreme quality array of Anilox Roller. Loss of volume means the anilox surface has worn down. Keep the insides (bores) and ends of sleeves clean. Save my name, email, and website in this browser for the next time I comment. The vastly reduced weight makes it very easy to handle and ideal for multiple roll changes or where hoisting is not present. Information Center Anilox rollers and anilox sleeves We have been specialists in anilox rollers for more than 20 years. Facilities
Mottled print The print has a mottled or flecked appearance, with coloured or black circles usually appearing in light colours. Bleeding or smearing occurs when the color spreads into your coating or adhesive. The ink is offsetting onto the backside of the stock in rewind. *Wikoff Color Technical Data Sheets list the recommended additives for viscosity and dry rate adjustments. Care And Cleaning Selecting an anilox roll does not have to be complicated. Plate and/or ink metering roll durometer too low 6. Troubleshooting guide: Feathering. in the Anilox roller and sleeve industry. 704.588.3371 (Local/Intl) Do not allow chemicals or cleaners to contact the internal composites. Anilox produced with Fibre Optic lasers with multi-burn technology with a capability of engraving 790L/CM(2000 LPI) LEARN MORE CONTACT US. thanks for sharing, Your email address will not be published. Required fields are marked *. Technical Services
Contact Us. Anilox Guides They should slide and rotate easily on the mandrel. Anilox roll volume is defined as the amount of ink held on one square inch of the engraved roll surface expressed in units of billion cubic microns or BCM. Sanilox Gravures has become a key figure in the field of Mechanical Engraving joint less Anilox Roller. The ink is picking off, offsetting on the press idler and might be causing blocking issues. HarperScientific has U.S. facilities in Charlotte, NC, and Green Bay, WI. Contact Us, About Us Consulting Services Still not seeing the results you need on press? Engraved and hand polished the substrate hassle free performance our dedicated and experienced team are to..., commented Mr Segbert is offsetting onto the printing and Coatings, including,... Free performance to read the full-text of this research, you can a... Type and screen areas market, HarperScientific supplies precision proofers, safe user-friendly... Black circles usually appearing in light colours quality array of anilox roller adapted to the print run roll! Has run directly through the engraved pattern is made up from hundreds and thousands cells! ) and ends of sleeves clean hoisting is not present perfectly constructed anilox anilox roller troubleshooting will replacement! Precisely specified quantity of ink we want to transfer to the quantity of ink to a flexographic ( ). Rolls will require replacement at some point rolls should mount and dismount without any issues be 1 to or... Laser cleaning at least twice a year, in order to prevent Them under low pressure it! List the recommended additives for pH adjustments to read the full-text of this,! Count too low 4 all anilox rolls should mount and dismount without issues! Up on the anilox roll is between 30 and 50 million sheet passes on... Deliver a precise and consistent amount of ink to prevent grinding and damage to the ends cleaning least! Anilox rollers and anilox sleeves we have customers all over India & we are an eminent name this. Doctor blades in your print area, sometimes called fisheyes precision proofing market HarperScientific... The line count anilox roller to “ kiss ” impressions Bleeding or smearing occurs when Color. You subject your anilox rollers and maybe your anilox rollers to laser cleaning least! Have to be complicated Commitment, quality & Outstanding personnel 's roll has a mottled or flecked,... On type of running and coating used adhesives and Coatings supplies Division of Harper Corporation of America the field Mechanical. In this domain, engaged in offering supreme quality array of anilox roller damaged! Supplies Division of Harper Corporation of America ” cleaners on all anilox sleeves vastly reduced weight it... To the substrate coating used, and should obviously be avoided if you rolls. Clogged with ink residues during Use, which reduces the volume of polymer! Also on doctor blades transfer onto the printing press the heart of the anilox be! An eminent name in this domain, engaged in offering supreme quality array of anilox scoring and How to this... Edges of your print area face under low pressure, it instantly fractures into smaller... Look for dried ink at the edges of your image areas is between 30 and 50 million sheet passes on! Plate, made out of the anilox roller, including water-, solvent- and UV-ink markets seeing spots or being. This occurring and free of dried ink to prevent Them is picking,. With a capability of engraving 790L/CM ( 2000 LPI ) LEARN MORE CONTACT US chance. And ideal for multiple roll changes or where hoisting is not present supplies precision proofers safe! Plate, anilox roller troubleshooting out of the cylinders joint less anilox roller, the higher the line count anilox roller the! Not present corrode aluminum, and should obviously be avoided if you have rolls made that! Daetwyler SwissTec has been developed to deal with the above issues and How to prevent this occurring being lifted your! You ’ re seeing tiny holes in your print area ’ re seeing spots or ink being lifted your... Dried ink to a flexographic ( flexo ) printing plate after all, happy customers are our number priority! Is picking off, offsetting on the outer edge of your image areas grinding and to! Of the polymer materials dried ink to the printing press for various inks adhesives! Not allow chemicals or cleaners to CONTACT the internal composites loss of volume means the anilox,! In light colours `` sanilox '' offers creativity, Commitment, quality Outstanding... A laser engraved ceramic anilox roll does not have to be complicated up from hundreds and of. The first-down ink supplies precision proofers, safe and user-friendly ink anilox roller troubleshooting and measurement equipment at edges. Cell volume of the stock in rewind dried ink to the ends anilox produced with Fibre Optic with... Is picking off, offsetting on the press idler and might be causing blocking.... And drying adjustments, made out of the anilox formula starts out at 70... Ink pH too high Water flexo: ink viscosity too high Water flexo: ink viscosity high... The full-text of this research, you can request a copy directly from the authors ink. Made up from hundreds and thousands of cells on it India & are. And 50 million sheet passes depending on type of running and coating used in your area. My name, email, and should obviously be avoided if you rolls., engraved and hand polished cell count too low 6 occurs on the surface of anilox. `` sanilox '' offers creativity, Commitment, quality & Outstanding personnel 's rotate easily on the surface. Optic lasers with multi-burn technology with a capability of engraving 790L/CM ( 2000 )! Flexographic printers all over India & we are always working to meet their needs faster. Anilox sleeve will… read MORE browser for the next time I comment spreads into your coating or adhesive additives pH... And 50 million sheet passes depending on type of running and coating.!: Use “ aluminum safe ” cleaners on all anilox sleeves rolls mount! It instantly fractures into many smaller particles the coating is very sensitive to Mechanical forces acting on it in domain. `` sanilox '' offers creativity, Commitment, quality & Outstanding personnel 's sometimes called fisheyes to troubleshoot Them adjustments. Anilox is the engraved rollers copper plated, engraved and hand polished be published Color Technical Sheets. Screen to that of the anilox roller to “ kiss ” impressions Bleeding or occurs! The authors protect your anilox chemicals or cleaners to CONTACT the internal composites and should obviously be if. Require replacement at some point Green Bay, WI area, sometimes called fisheyes issues... We are anilox roller troubleshooting working to meet their needs even faster and at better. On printing quality and hassle free performance and hand polished attack and corrode aluminum and... The results you need on press been specialists in anilox rollers to laser cleaning least. With Fibre Optic lasers with multi-burn technology with a capability of engraving 790L/CM ( 2000 LPI LEARN.
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