Precautions for using ceramic anilox roller pattern

Ceramic anilox rollers, serving as excellent alternatives to chrome-plated metal anilox rollers, have become a vital component in the field of printing. They offer several unparalleled advantages, including precise ink transfer, uniform ink layers, and sharper dot printing. They also exhibit exceptional durability when used in conjunction with doctor blades. The quantitative ink-carrying capacity of these rollers is influenced by factors such as the mesh line count and the depth and opening-to-wall ratio of the cells.

To ensure the proper and efficient use of ceramic anilox rollers in daily production, it is essential for users to understand and master the correct cleaning and maintenance procedures. The following guidelines are specifically tailored for printing professionals:

I. Guidelines for Using Anilox Rollers:

1. Due to the high hardness of the ceramic layer, typically reaching up to HV1300, it is essential to avoid any hard or forceful impacts on the rollers. In the process, make sure to prevent items like wrenches or screws from falling between the anilox rollers and the ink metering roller. Once damaged, the entire anilox roller must be refurbished, as the ceramic layer and cell engraving are single-formed, making partial repairs impractical and resulting in uneven surfaces and ink leakage.

2. Prior to installation, inspect the roller surface for oil residues and any obstructions within the cells to ensure a clean surface that won't compromise ink transfer, impacting print quality.

3. During installation, avoid striking the bearings on the shaft, and consider using dedicated bearing disassembly tools. The precision of bearing installation directly affects the roller's operational accuracy. Many printing issues, such as uneven plate contact pressure, color inconsistencies, and uneven ink distribution, are linked to bearing installation precision, bearing damage, and lubrication quality.

4. When replacing an anilox roller, it is advisable to replace the doctor blade simultaneously. The doctor blade angle with the line of contact should typically be 30-40 degrees to maintain minimal contact pressure, with line pressures generally ranging from 2.8 to 5.6 g/cm. Under normal pressure, a thin ink film should exist between the blade and the roller's surface. Dry friction between the blade and the roller's surface is unacceptable. New doctor blades and anilox rollers should be allowed to run in for 2-3 hours upon installation.

5. The quality of water-based inks directly impacts the service life of anilox rollers. Dried resin particles can be detrimental to anilox rollers. Consider using mesh filtration to remove impurities.

6. The cleanliness of the factory's water supply is another critical factor affecting the anilox roller's lifespan. Incoming tap water to the workshop should be filtered through mesh screens, as impurities in the water supply can cause scratches in the ink metering system, resulting in roller damage.

7. Unclean cardboard surfaces, often containing abrasive metallic powders from blade sharpening in the cardboard production line, or the addition of sand in the paper mill to increase paper weight, can introduce abrasive particles. Despite dust removal brushes and dust control measures, the automated paper feeding system in most carton factories still carries hard particles. These particles, if not eliminated, can lead to scratches on the anilox roller.

II. Doctor Blade and Roller Pressures:

Ensure that doctor blade and roller pressures are maintained within the recommended operational range specified by the equipment manufacturer. Avoid increasing pressure arbitrarily to achieve specific goals.

III. Ink System Maintenance:

Ink inside the ink chamber should be cleaned promptly during idle periods to prevent drying. Doctor blades and doctor blade seals should be regularly cleaned with a cloth to prolong their service life. Pay special attention to the doctor blade seals as they are in direct contact with the anilox roller and any foreign particles trapped between the roller and the seal can cause continuous abrasion and scratching of the roller walls, leading to visible scratches on printed materials.

By adhering to these guidelines, users can maximize the performance and longevity of ceramic anilox rollers in their printing processes.