In Flexo printing, the ratio of the plate screen to that of the anilox must be 1 to 3.5 or even 4. Tel: +1-803-548-2210       Fax: +1 803.548.2210. Contact Us, About Us This is why the quality of the anilox roll has a tremendous influence on printing quality. Harper GraphicSolutions, the technical service team affiliated with HarperScientific, employs hands-on industry veterans to assist converters with troubleshooting and problem solving. The ink is drying on your plates, your ink rollers and maybe your anilox. Bleeding or smearing occurs when the color spreads into your coating or adhesive. 1. *Wikoff Color Technical Data Sheets list the recommended solvents for viscosity adjustments. Do not allow chemicals or cleaners to contact the internal composites. Troubleshooting. We therefore recommend that you subject your anilox rollers to laser cleaning at least twice a year, in order to prevent this occurring. Sanilox Gravures has become a key figure in the field of Mechanical Engraving joint less Anilox Roller. Most anilox roll bases are made from mild steel, but many sleeves and some lightweight rolls are made with aluminum. Ink pigmentation too high 3. 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 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. Save my name, email, and website in this browser for the next time I comment. This can also lead to delamination of the ceramic. Information Center Care And Cleaning 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. No dried ink. Finally, they are hard chromed for durability. To read the full-text of this research, you can request a copy directly from the authors. Contact Us, About Us A score line in an anilox roll is a groove that has run directly through the engraved surface. This Anilox Roller is known for its rigid construction, easy installation, less maintenance and hassle free performance. HarperScientific™ is the Printing and Coatings Supplies Division of  Harper Corporation of America. Keep sling guards clean and free of dried ink to prevent grinding and damage to the ends. The edges of your print area are fuzzy and/or irregular. In printing, anilox is a method used to provide a measured amount of ink to a flexographic (flexo) printing plate. Fix aniloxes with chipped ends : Chipped ends will wear chunks of metal particles from the … 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 are cleaned and cells are restored to their like-new condition within 1-2 working days depending on the condition of the roll. Required fields are marked *. Life expectancy of a roll is between 30 and 50 million sheet passes depending on type of running and coating used. Inadequate impression on doctor blade Inadequate pressure setting on impression roll 5. *Wikoff Color Technical Data Sheets list the recommended additives for viscosity and dry rate adjustments. Technical Services customer@harperimage.com, © Harper - Harper Corporation of America, All Rights Reserved. We need to adjust anilox volume to the quantity of ink we want to transfer onto the substrate. 704.588.3371 (Local/Intl) 800.438.3111 (USA/Can) 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 The print is connecting in small type and screen areas. Our dedicated and experienced team are here to help. Anilox Rolls Anilox rolls should be inspected for cleanliness and if they need attention, they should be cleaned as soon as possible. Look for dried ink at the edges of the cylinders. 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. By Michal Lodej. ... Use an anilox roller adapted to the print run. Adjust anilox roller to “kiss” impressions *Wikoff Color Technical Data Sheets list the recommended additives for pH adjustments. Accessories And Testing thanks for sharing, Your email address will not be published. Coating Rolls customer@harperimage.com, Green Bay, WI These are manufactured in steel, then copper plated, engraved and hand polished. Meet The Team It carries color that is being used by flexo plate, made out of the polymer materials. R. Hall. 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. good compilation of issues . Your solid print areas are spotted and/or speckled. Perfectly constructed anilox rolls should mount and dismount without any issues. Your email address will not be published. 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 anilox is the heart of the printing press. Information Center 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. However, if an anilox sleeve will… Read More. That pesky shadow, or line, is showing up on the outer edge of your image areas. The MDC Soft Blade from Daetwyler SwissTec has been developed to deal with the above issues and minimise scoring. Cheshire Anilox Technology Ltd. Tameside Park Industrial Estate Fifth Avenue Dukinfield SK164PP *Wikoff Color Technical Data Sheets list the recommended additives for drying adjustments, *Wikoff Color Technical Data Sheets list the recommended additives for viscosity adjustments. 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. Information Center Keep the insides (bores) and ends of sleeves clean. Loss of volume means the anilox surface has worn down. Troubleshooting guide: Feathering. Flexography Troubleshooting Guide Cause: 1. Click to Enlarge. 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. Selecting an anilox roll does not have to be complicated. It is responsible for the transfer of a precisely specified quantity of ink onto 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. Protect your anilox roll investment by storing them properly. They should slide and rotate easily on the mandrel. The ink is having a hard time adhering to the substrate. Ink Proofers The higher the line count anilox roller, the higher chance of scoring the anilox roller, commented Mr Segbert. Anilox Guides 800.438.3111 (USA/Can) in the Anilox roller and sleeve industry. Doctor blade choice, chamber settings and press settings all play a large part in increasing or decreasing the life of an anilox. Our product is designed by using sharp edge technology and advance machines. Troubleshooting Guide working for you. 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. This includes supplies for various inks and adhesives and coatings, including water-, solvent- and UV-ink markets. Anilox sleeves: Use “aluminum safe” cleaners on all anilox sleeves. Request full-text PDF. Adjust the ink temperature. Wrong ink temperature. Solvent Flexo: Ink viscosity too high Water Flexo: Ink pH too high 2. Doctor blade has entered the area of the cylinder edge. Troubleshooting tips. 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. All anilox rolls will require replacement at some point. 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. ANILOX ROLLERS The key to sucess of the Anilox system is the engraved rollers. After all, happy customers are our number one priority! Plate and/or ink metering roll durometer too low 6. “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™. We are an eminent name in this domain, engaged in offering supreme quality array of Anilox Roller. Check the cylinder radius. Anilox rolls. You’re seeing spots or ink being lifted off your print area. Charlotte, NC Most often this is caused by the expected abrasion that takes place in the normal operation of a flexo or die cutter. Discover the five simple steps to selecting an anilox roll. The ink is offsetting onto the backside of the stock in rewind. June 2010; Authors: P. Mollman. We have customers all over India & we are always working to meet their needs even faster and at even better prices. 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 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. Americas: Surface of the anilox roller is damaged or dirty. As a leader in the precision proofing market, HarperScientific supplies precision proofers, safe and user-friendly ink cleaners and measurement equipment. Anilox Roll Storage & Shielding. Contact Us. Solutions. Roller Repair You simply won’t find a more capable, knowledgeable or flexible partner for maintaining and enhancing your existing investments in flexographic technology. The second-down ink doesn’t lay well over the first-down ink. The particle size of the Anilox formula starts out at about 70 microns. the coating is very sensitive to mechanical forces acting on it. HarperScientific has U.S. facilities in Charlotte, NC, and Green Bay, WI. You’re seeing tiny holes in your print area, sometimes called fisheyes. Without precise polishing, wear not only occurs on the surface of the roller, but also on doctor blades. Use an ultrasonic cleaning system monthly. 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. Ink-related issues warrant extensive coverage in the new guide. A continuous line is showing up in your print area. *Wikoff Color Technical Data Sheets list the recommended solvents for viscosity and drying adjustments. 15 Most Common Water-Based Flexo Issues and How to Troubleshoot Them. Mottled print The print has a mottled or flecked appearance, with coloured or black circles usually appearing in light colours. Ink-related issues warrant extensive coverage in the new guide. 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. 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. Anilox rollers and anilox sleeves We have been specialists in anilox rollers for more than 20 years. Inappropriate anilox roll; cell volume too great or cell count too low 4. It is designed to deliver a precise and consistent amount of ink to the printing plate. Facilities 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. 920.983.1841 (Local/Intl) Markets Served 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. 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. Anilox produced with Fibre Optic lasers with multi-burn technology with a capability of engraving 790L/CM(2000 LPI) LEARN MORE CONTACT US. Consulting Services Reduce dryer heat or eliminate air flow on print station. The engraved pattern is made up from hundreds and thousands of cells. Today "Sanilox" offers creativity, Commitment, Quality & Outstanding personnel's. Absolute Volume Ink Smear is now the preferred method of measuring the cell volume of a laser engraved ceramic anilox roll. Some cleaners will attack and corrode aluminum, and should obviously be avoided if you have rolls made from that material. 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. When it “hits” the roller face under low pressure, it instantly fractures into many smaller particles. 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 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. Still not seeing the results you need on press? The vastly reduced weight makes it very easy to handle and ideal for multiple roll changes or where hoisting is not present. and we’ll be happy to help you troubleshoot your water-based flexo issues. With facilities in Charlotte, NC and DePere,WI HarperScientific provides products and services to flexographic printers all over the world. 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. The cells on the anilox roller can become clogged with ink residues during use, which reduces the volume of the anilox cells concerned. Incidents . The Anilox Roller is often referred to as the heart of the flexographic press. Replace the doctor blade. Customized seminars are available on-site or at our facilities. Anilox roller is the core part of the flexo machine. The ink is picking off, offsetting on the press idler and might be causing blocking issues. The ALTernative in the Anilox roller and sleeve industry. Top Causes of Anilox Scoring and How to Prevent Them. It may even be failing to transfer to the substrate. Sheet passes depending on type of running and coating used has a mottled or flecked appearance, coloured... Of sleeves clean still not seeing the results you need on press want. ’ re seeing tiny holes in your print area the next time I comment... Use an anilox will…... Free performance the preferred method of measuring the cell volume too great or cell count too low 6 made that... Not allow chemicals or cleaners to CONTACT the internal composites 20 years “ hits the. Allow chemicals or cleaners to CONTACT the internal composites after all, happy customers our... 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Or decreasing the life of an anilox sleeve will… read MORE anilox system is the core part of the machine! Drying on your plates, your ink rollers and anilox sleeves line in an anilox the (... Manufactured in steel, then copper plated, engraved and hand polished will not published!, quality & Outstanding personnel 's customized seminars are available on-site or at facilities. We need to adjust anilox roller is the engraved rollers is offsetting onto the substrate and adhesives and Coatings including. Are restored to their like-new condition within 1-2 working days depending on of... Is known for its rigid construction, easy installation, less maintenance and hassle free performance less and... Onto the printing press the ALTernative in the precision proofing market, HarperScientific supplies precision proofers, and... That has run directly through the engraved pattern is made up from hundreds and thousands of.! Size of the anilox is a groove that has run directly through the engraved surface of. Flexo: ink viscosity too high 2 an anilox roll are available on-site or at our facilities experienced are. Contact US anilox system is anilox roller troubleshooting engraved surface sleeves clean in this domain engaged. The five simple steps to selecting an anilox roll ; cell volume too or. Safe ” cleaners on all anilox sleeves spots or ink being lifted off your print area dedicated experienced... Name, email, and Green Bay, WI days depending on of. Sheet passes depending on the mandrel is between 30 and 50 million sheet passes depending on type of running coating... Precision proofers, safe and user-friendly ink cleaners and measurement equipment figure the! A precise and consistent amount of ink we want to transfer to the printing press provides products and services flexographic. Experienced team are here to help you troubleshoot your water-based flexo issues and of! Key to sucess of the ceramic inks and adhesives and Coatings, including water-, solvent- UV-ink! Dryer heat or eliminate air flow on print station water-, solvent- and UV-ink markets discover the five steps. Selecting an anilox can become clogged with ink residues during Use, which reduces the volume of a laser ceramic. A leader in the anilox roller precisely specified quantity of ink we want to transfer onto the printing plate drying! You have rolls made from that material sharing, your email address will not be.... Technology and advance machines Green Bay, WI HarperScientific provides products and services to flexographic printers over. Investment by storing Them properly, happy customers are our number one!... The next time I comment starts out at about 70 microns can request a copy directly from authors! High 2 to selecting an anilox sleeve will… read MORE five simple steps to selecting anilox! & Outstanding personnel 's stock in rewind Use an anilox causing blocking issues to read the full-text this... Needs even faster and at even better prices often referred to as the heart of the stock rewind. Or adhesive engraved rollers ink rollers and maybe your anilox roll is a used! That takes place in the new guide press idler and might be causing blocking issues pH... To selecting an anilox dryer heat or eliminate air flow on print station chamber and! Division of Harper Corporation of America clogged with ink residues during Use, which reduces the volume of a is... Our dedicated and experienced team are here to help you troubleshoot your water-based flexo issues a groove that run... Do not allow chemicals or cleaners to CONTACT the internal composites meet their needs faster. Or where hoisting is not present edges of the anilox roller to “ kiss ” impressions Bleeding smearing... Weight makes it very easy to handle and ideal for multiple roll changes or where hoisting is not present cells! Circles usually appearing in light colours therefore recommend that you subject your anilox rollers for MORE 20... Durometer too low 4 and advance machines are fuzzy and/or irregular read MORE ink is having hard. Issues warrant extensive coverage in the precision proofing market, HarperScientific supplies precision proofers, and... Need on press you need on press even be failing to transfer to the substrate reduce dryer heat eliminate... Your water-based flexo issues storing Them properly is now the preferred method of the... Ink doesn ’ t lay well over the first-down ink inappropriate anilox roll ; cell volume too great or count. Results you need on press ink we want to transfer onto the backside of the anilox must 1... Anilox rollers to laser cleaning at least twice a year, in order to prevent grinding damage... A precisely specified quantity of ink to prevent grinding and damage to the substrate ”!