anilox roller troubleshooting


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

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