Are you aware of these technological innovations on the gravure roll?

Anilox rolls are often referred to as the 'heart' of flexographic printing, as they can accurately measure the amount of ink delivered to the plate and ultimately transferred to the substrate. Although their working principle seems simple, the continuous evolution of the packaging and label printing industries has placed ongoing demands for innovation in anilox roll technology.

In today's narrow web printing market, printing companies are required to provide shorter print runs, higher quality output, and sustainable solutions, all while maintaining normal running times and efficiency. The role of anilox rolls has become more critical than ever. Advances in manufacturing and engraving processes are redefining how printers view these rolls.

Laser Engraving Technology

One of the biggest transformations in the anilox roll manufacturing field has come from laser engraving. Early mechanically engraved anilox rolls have long been replaced by laser-engraved ceramic-coated rolls, which offer extremely high precision. Today, suppliers are continuously pushing the limits of laser technology to engrave tighter, deeper, and more consistent cells.

For example, multi-beam fiber laser systems can achieve high-definition engraving and better uniformity across the entire roll surface. This results in clearer print quality, reduced dot gain, and higher repeatability. Additionally, advances in engraving precision have expanded the variety of cell geometries - elongated cells, channel patterns, or hybrid shapes - all designed for specific applications to optimize ink transfer. This precise ink control achieves the desired visual effects for brands while minimizing waste.

XCAT Hybrid Cell Engraving Technology

Since the beginning of the 21st century, engraving technology has shown diverse differences across various production applications. As we see in today's market, from labels and flexible packaging to corrugated packaging, no single cell pattern can effectively handle multiple different applications and solve various problems.

XCAT hybrid cell engraving technology, introduced by Harper Corporation in the United States, is a new generation of engraving technique designed to eliminate ink splatter issues. As is widely known, ink splatter is a common printing defect in flexographic printing, where tiny ink droplets splash out from the anilox roll or doctor blade chamber onto the substrate, creating visible spots, streaks, or hazy effects.

The XCAT hybrid-screen engraving technology is an improvement based on the 60° hexagonal screen engraving technique. It is a hybrid screen that uses 60° open channels and engraves screens beneath the channels, allowing for excellent ink transfer, while the bottom of the screens better controls the ink. It is suitable for all applications, from large solid areas to four-color printing. For thick coatings, the XCAT hybrid-screen engraving technology also improves ink transfer and, thanks to better flow, reduces air entrapment, meaning fewer ink bubbles.

GTT 2.0 Open Serpentine Screen Engraving Technology

UV inks differ from solvent-based or water-based inks in that they have higher viscosity and are harder to transfer, especially when using traditional closed-screen engraved rolls, which easily cause ink spitting. To address this issue, some printing companies have adopted temporary measures, such as changing the doctor blade, adjusting the press speed, increasing the temperature, or re-polishing engraved rolls. However, these methods do not fundamentally solve the problem, and ultimately ink spitting still occurs, leading to reduced productivity and increased waste.

GTT 2.0 Open Serpentine Screen Engraving Technology is a patented technology by Apex that has revolutionized the engraving of screen rolls, breaking through the bottleneck in their application and laying a solid foundation for the further development of high-definition flexographic printing.

The GTT 2.0 open serpentine anilox engraving technology uses a manufacturing process different from traditional anilox rolls. It uses a higher-density ceramic for coating and continuous constant laser engraving. The main advantage of this technology is that it no longer traps ink in closed hexagonal cells, preventing ink accumulation from the source, improving ink flow, making four-color printing more stable, and reducing printing setup time. It offers better printing performance, reduces anilox roll configurations, provides a flatter solid print appearance, significantly saves ink while achieving the same density, reduces lateral ribbing, increases plate durability, and allows the doctor blade to achieve excellent ink transfer with very light pressure. The wear of the doctor blade and anilox roll is greatly reduced, extending their lifespan. The open serpentine cells fundamentally alleviate the issue of ink splattering in UV inks.

Future Trends in Anilox Roll Technology

With the gradual implementation of sustainable development concepts, anilox rolls will reduce the possibility of ink waste through precise ink delivery, reduce the number of rolls used by improving durability, and rely more on laser cleaning to decrease dependence on strong chemicals, thus lowering the environmental impact on printing workshops... a series of technological changes are fulfilling environmental responsibilities.

In the future, anilox roll innovation will further integrate with digital printing. As hybrid presses become increasingly common, anilox rolls will need to coordinate with digital printing units to balance ink transfer with digital quality standards. Advances in laser technology may allow cell structures to dynamically optimize ink release for various applications, further reducing inventory needs. Additionally, with increased automation, we can expect anilox rolls to be integrated into fully automated printing press setups, with robotic systems handling identification, installation, and cleaning tasks. From a sustainability perspective, research into alternative materials and eco-friendly coatings may redefine durability and recyclability standards.

In summary, anilox rolls will continue to evolve alongside flexographic printing technology. As long as brand owners demand higher quality, faster delivery times, and greater sustainability, anilox roll technology will continue to innovate to meet the ever-changing needs of label customers.