How to Choose Anilox Rollers？anilox roll selection guide

 

The selection of anilox rolls depends on the printing application, the substrate used, plate materials, and ink supply systems. Optimal anilox roll selection is crucial when it can consistently deliver even ink coverage on the printing plate and meet the client's color standards, especially in applications like tone printing or color printing.

Principles for choosing anilox rolls:

1. The majority of printing operations typically use a 60° engraving angle. While laser-engraved anilox rolls can be configured with 30° and 45° angles, the 60° anilox roll has demonstrated its advantages in ink transfer.

2. The selection of line screen is determined by the original on the printing press. For applying ink and varnish on the plate, anilox rolls with line screens between 85 to 200 lpi are recommended. For solid printing, line screens between 200 to 400 lpi are commonly used.

Let's delve into the selection criteria:

1. Choose based on graphic structure.

Anilox rolls:

For the same mesh engraving process, higher line screen counts result in less ink transfer, making them suitable for printing dots and small text. Conversely, lower line screen counts are better for printing large areas of color and bold fonts.

It is important to note that excessive ink transfer can lead to font blockages and blurry layouts, while insufficient ink transfer can cause issues like color deviations, solid whiteness, and uneven inking.

2. Choose based on substrate.

When the substrate surface is rough, and there is a high ink transfer requirement, it's advisable to use anilox rolls with fewer lines per inch. On the other hand, for smooth substrates, anilox rolls with more lines per inch, indicating lower ink transfer, are preferable.

3. Choose based on plate line screen.

To accurately reproduce the dot levels of each tone on the plate, it is essential to ensure that each dot receives the right amount of ink. Therefore, the opening area of the anilox roll should be smaller than the dot area on the plate, allowing for one or more ink cells to supply ink and prevent dots from falling into the cells, which could lead to dot enlargement on the printed product.

4. Choose based on different digital and analog devices.

In a double-roller inking system, it's crucial to ensure the proper matching of the line screen and hardness of the anilox roll with the doctor roll for smooth ink transfer. Reflective doctor blade systems, commonly used for fine products, require anilox rolls with a line screen of 220 lpi or above, and a pyramid-shaped cell configuration.

5. Choose based on different wear levels.

The lifespan of anilox rolls is generally limited to half of the cell volume. Prism-shaped anilox rolls exhibit higher wear resistance than pyramid-shaped ones, with the former having a lifespan 1.375 times longer than the latter. Therefore, pyramid-shaped anilox rolls are suitable for reactive blade inking systems.

In summary, considering these factors and aligning them with the specific requirements of the printing process will aid in the selection of an appropriate anilox roll, ensuring high-quality printing results. It is recommended to consult with professional printing equipment suppliers or technical support personnel before making a selection to ensure that the chosen anilox roll meets the specific requirements of the printing process.

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