Whether you’re replacing a damaged roller or replacing your entire anilox printing system, a proper composite blade will increase the life span of your equipment. These high-performance components must meet the stringent requirements of the printing process to ensure a quality print. Properly applied coatings, engravings, and precise color transfer are just some of the requirements for this roller type. According to Michael Reuter, a product specialist at Esko, several aspects to consider for achieving a long service life. In addition to proper maintenance, professional care of these components can positively affect the life span of the roller.
Coated blades are an essential expense for anilox rolls. Anilox roll replacement and resurfacing isn’t a monthly expense, so plant personnel may be surprised to increase the cost. On the other hand, they might chalk it up to business or reach the end of their useful life. These blades could make your anilox rolls die-hard.
Made from specially treated carbides, this material offers superior wear resistance. They can reduce anilox wear.
Today’s box makers are asked to produce packaging that is functional for shipping and a visual display. This requires highly accurate graphic results and a consistent ink density to maintain brand consistency. The only material that could meet these demands was steel, but today, a new type of composite blade offers a continuous wear period and the best of both worlds. These features make the composite blade the perfect alternative for the anilox rollers in your printing process.
In addition to offering a longer life span, composite blades can be easily customized for the precise applications that require precision metering. These blades are a durable alternative to steel and extend the wear period of anilox rollers. Anilox cleaning brushes have a sturdy plastic handle to easily remove debris, while it is ideal for coarser anilox rolls and white decks.
Ink transfer changes over a wide range
The plastic blade is a common component of the printing system. The blade provides ink transfer by scraping the anilox roller along its length. This system is universally compatible and can be retrofitted onto any gravure coater or printer. In addition, the chamber doctor blade can be modified to accommodate a wide variety of anilox roll diameters.
Anilox rollers experience a range of wear over time, but the process is often unpredictable, and the cell walls rarely wear evenly. Ink transfer may also be uneven, depending on the washing method. To investigate the differences in ink transfer, we studied a Zecker GmbH anilox roller manufactured in 2012. The radial diagram was created with the same parameters as the measurements on the axis, but the values of ink transfer were much different.
Line screen distribution of anilox rollers
An anilox roll’s line screen distribution is determined by the amount of ink deposited per cell. Cells of an anilox roll typically have a global size of 10 to 80 mm in width and depth. Each cell has a corresponding ink volume, which corresponds to the amount of ink transferred from the roll to the substrate. These cells are arranged in a honeycomb-like structure. The distance between their center points determines the line screen of an anilox roll. This is often 100 lines per centimeter, but the higher-lined anilox rolls are better suited for printing details.
The structure of an anilox roll consists of a series of channel parts connected by a common wall. Because these channel parts have similar widths and depths, fluid is not disturbed locally. The resulting anilox roll is characterized by its unique features.