How to maximize the value of an anilox roll
Currently, many modern printing companies are seeking innovative methods, such as data and process control in the printing process, to further reduce production costs and increase profits. As a core component of flexographic printing, anilox rolls play a crucial role in printing quality and the performance of printing machines. At present, with the help of some new testing technologies, the quality and performance of anilox rolls can be measured, controlled, and optimized, thereby saving on ink, maintenance costs, and downtime.
However, because there are numerous measuring tools and technologies available on the market and a lack of industry-recognized standards for cell volume measurement, many companies do not realize the value and cost savings that precise anilox roll inspection can bring to their printing processes.
In this article, we will discuss how to use some new anilox roll inspection system portfolios to help printing companies achieve savings in the printing process, and how to improve printing quality and profitability with minimal investment.
What is anilox roll quality inspection?
To measure the quality of anilox rolls, a roller inspection microscope and integrated analysis software are required. It is important that the inspection system can quickly and accurately capture cavity volume, depth, line count, and angle measurements, and display the data in an easy-to-read format. With the Veritas inspection system, the operator simply places the Veritas instrument on the anilox roller and clicks to scan. The inspection system will record and display important acupoint measurements in less than 8 seconds. The operator will understand the impact of each anilox roll measurement on the printing process and select the most suitable roller for production.
By establishing an anilox roll inspection process, printers can detect roller damage and volume loss before loading them onto the press, saving downtime, ink usage, product waste, and more.
How can cost savings be achieved through inspection?
01
Save ink consumption
As the anilox cavity becomes clogged with ink or wears out due to scrapers, the cavity volume gradually decreases over time. This reduced screen volume reduces the amount of ink transferred to the plate, resulting in dull, faded prints. Businesses that do not test the quality of the anilox roll may not realize that the anilox roll is of poor quality and instead add more ink to the ink tank or even take a greater risk of reformulating the ink to achieve the desired coverage. Of course, this approach solves the printing problem, but at the cost of rising ink consumption.
On the other hand, operators inspecting anilox rolls before loading them onto the press can quickly assess the anilox volume and remove them for cleaning or re-engraving before they cause waste on the press. Using clean, high-quality anilox rollers will greatly save ink costs and reduce waste.
02
Reduce print waste
Not all anilox roll engraving shapes are the same. While cavity volume affects print quality, the shape and size of each cavity also have an impact. Therefore, even if the "numerical value" (i.e., load-bearing capacity) measurement of the cavity volume is accurate, different shapes of cavities can lead to different amounts of ink transfer because differences in cavity shape and wall thickness can lead to inconsistent printing. For example, there are two anilox rollers with the same cavity volume but completely different printing performance, one with a color density of 1.56 and the other with a color density of 1.79. This is clearly an unacceptable deviation and results in batch-to-lot color inconsistencies and customer returns.
With anilox roll inspection, operators can record the correct mesh cavity shape, volume, and size to select the correct anilox roll for each job run and reduce print waste.
03
Save on maintenance and downtime costs
Observing the condition of the microscopic anilox roller cavity allows operators to make decisions about cleaning, maintenance, and production. With accurate anilox roll measurements, operators can select the roller that best suits the job at hand and maximize time spent cleaning and maintaining rollers that only require maintenance. No more guessing whether anilox rolls are the cause of defects, thus avoiding downtime. With a consistent inspection process, maintenance, cleaning, re-engraving, and more can be predicted and optimized. Additionally, operators can reduce press setup time and keep the press running with the best-performing rollers.
04
Evaluate the ROI of anilox rolls
The anilox roll is not a small investment, and with an inspection system with a built-in database, it is possible to track the wear of the rollers over time and calculate the return on investment. How much work can a roller do before it needs to be cleaned, maintained, or re-engraved? Is there a roller or some kind of engraving that makes ink accumulation easier?
By detecting which cavity shapes or engraved patterns can save cleaning costs, eliminating inferior rollers and upgrading inventory with the best performing rollers for maximum uptime by detecting which cavity shapes or engraved patterns can lead to double cleaning costs. In addition, with objective data, Indian company leaders can make informed decisions about anilox investments and maximize operator time and anilox ROI.
How can cost savings be achieved through process control?
For anilox roll testing to truly be valuable, printing companies must incorporate testing into standard operating procedures. In order to obtain the best use effect of anilox rollers, it is recommended that printing enterprises follow the following points:
(1) Inspect the anilox rolls when they are received from the supplier, benchmark the standard volume and evaluate the quality of the rollers;
(2) Inspect anilox rolls before loading them onto the press to assess any cleaning needs or damage caused by storage and select the best quality rollers for production;
(3) Inspect the anilox roller after it is removed from the press to assess the ROI of the roller and maintenance needs;
(4) Inspection before regular cleaning to assess the current status of the anilox roll;
(5) Testing after regular cleaning to assess cleaning quality or re-engraving needs.