Achieving stellar flexo print results with anilox and plate excellence

19 Sep 2024
Flexographic,Machine,For,Multicolor,Printing,On,Paper

At Creation Reprographics, we understand the challenges packaging and label printers face when it comes to achieving consistent, high-quality results. Part of that expertise is understanding the print processes that our customers use, be it digital, flexographic, offset or otherwise. One critical component that can make or break your flexo printing process is the anilox roll.

As an experienced and trusted reprographics partner and supplier of high-quality flexo plates, we recognise that to truly unlock the full potential of our plate technology, it’s crucial to understand and optimise every element of the printing process – including the anilox roll and plate selection.

Our expertise in flexo plate production gives us unique insight into how these two critical components work together. We know that to get the most performance, value, and quality from our advanced flexographic plates, such as the Fujifilm Flenex FW water-washable range, optimising your anilox setup is key. The interplay between anilox and plate is at the heart of exceptional print quality, and understanding this relationship can significantly enhance your printing results.

In this blog, we’ll explore the world of anilox rolls and how to ensure they work in perfect harmony with the high-performance plates we produce.

Looking to learn more about where a dedicated reprographics partner can lay the foundation for consistently excellent printing? Click here to get in touch today!

 

The key to flexo printing performance

The anilox roll plays a pivotal role in the flexographic printing process. Its purpose is to transfer a precise, consistent amount of ink to the printing plate – and there’s no room for error.

With countless microscopic anilox cells engraved on its surface, the anilox roll controls ink volume and distribution, directly impacting print quality. Usually constructed with a steel core coated with industrial ceramic, typically chromium oxide powder, these precision instruments are at the core of achieving exceptional print results.

 

Cell count and volume: Finding the right balance

When it comes to anilox rolls, cell count and volume are crucial factors that directly influence print quality. Cell count, measured in lines per inch (LPI) or lines per centimetre (LPC), determines the density of cells on the roll’s surface. Higher cell counts allow for finer detail but reduce ink volume, while lower counts provide more ink coverage but less precision.

The cell volume, measured in billion cubic microns per square inch (BCM) or cubic centimetres per square metre (cm³/m²), specifies the ink-carrying capacity of each cell. Finding the right balance between cell count and volume is essential for achieving optimal print results for different applications.

For instance, when printing finer intricate details or precise halftones, a higher cell count with lower volume may well be preferable, while solid areas or bold text might benefit from a lower cell count with higher volume.

 

The importance of maintenance

One of the most common issues affecting anilox roll performance is ink drying within the cells. This can lead to myriad problems, such as reduced ink transfer, inconsistent print quality, and even permanent damage to the roll if dried ink is left unchecked. Fortunately, it’s a problem that’s easily solved with a consistent cleaning schedule.

Daily cleaning after use should be standard practice, using appropriate cleaning solutions and soft brushes to remove ink residue without damaging the ceramic surface. Periodic deep cleaning, through technologies such as ultrasonic cleaning systems, can help remove ink buildup that’s hardened over time and restore the anilox roll to its optimal condition. Of course, no two printers at the same, so the frequency of required cleaning may vary depending on the specific printing environment, volume of print and ink types used.

 

Proper handling and storage: protecting your investment

Anilox rolls are precision instruments, and even minor damage can significantly impact print quality. Careful handling is essential to avoid physical damage. When removing an anilox roll from the press, always take care to use both hands or appropriate lifting equipment. Never allow the roll to come into contact with hard surfaces or other metal objects, as while they’re often heavy, the ceramic surface can be very delicate.

Proper storage is equally important. When not in use, anilox rolls should be stored in a clean, dry environment, ideally in protective sleeves or cases designed to prevent physical damage and contamination. A comprehensive inventory management system can help ensure that each anilox roll is properly tracked, maintained, and stored, maximising its lifespan.

 

Doctor blade selection and setup

The choice of doctor blade material and its proper setup can significantly impact anilox roll performance and longevity. While steel doctor blades have been the industry standard for many years, advances in materials science have led to the development of high-performance polymer and composite blades that can offer excellent metering capabilities while reducing wear and tear on ceramic-coated anilox rolls.

Blade angle and pressure are crucial to effective ink metering and minimising wear. Too much pressure can lead to premature wear of both the blade and the anilox roll, while insufficient pressure can result in poor ink metering and print quality issues.

 

Leveraging anilox optimisation with high-performance flexo plates

At Creation, we specialise in providing high-quality flexo plates that work in harmony with optimised anilox rolls.

Our Fujifilm Flenex FW water-washable plates, for instance, offer exceptional ink transfer and dot reproduction. These plates feature a unique rubber-based compound that allows for the creation of a 1% flat top dot, without the need for complex oxygen elimination systems.

When paired with a well-maintained anilox roll, these plates can help you achieve improved print quality with sharper details, vibrant colour and smoother gradients. The fantastic ink release properties of Flenex FW plates complement the precise ink metering of an optimised anilox roll, resulting in more consistent colour reproduction across print runs.

Moreover, the rapid processing time of Flenex FW plates – less than 40 minutes from imaging to press-ready – aligns well with the efficiency gains achieved through proper anilox roll management. This combination can lead to reduced setup times, less waste, and enhanced overall printing efficiency.

As printing technology continues to evolve, so too does anilox technology. We’re seeing exciting innovations in cell geometries, engraving techniques and coatings that promise even greater precision and efficiency.

At Creation, we stay at the forefront of these developments to ensure our plate solutions remain compatible with the latest anilox technologies. Our team is always ready to advise on how our plate solutions can complement your anilox setup for best results, taking into account the latest innovations in both plate and anilox technology.

By optimising your anilox rolls through proper selection, maintenance, and care, and pairing them with our high-quality flexo plates, you can achieve superior print results that will delight your customers and set you apart in a competitive market.

Whether it’s flexo plate production, colour management or design and origination services, as your prepress partner, we’re committed to helping you navigate the complexities of today’s printing market, ensuring that every element of your printing process is optimised for peak performance.

Want to learn? Get in touch with our team today to discuss your specific printing needs and discover how we can help you achieve printing excellence.

Questions?
Contact us on +44 (0) 1604 906000  or info@creation-repro.com
and we’ll be happy to help