Is Your Current Anilox Roller Suitable for Functional Coatings?

 

Functional coatings are no longer limited to decorative or protective layers. Today’s packaging and industrial applications require coatings that provide barrier properties, heat resistance, anti-fog effects, conductivity, adhesion enhancement, and more.

However, many converters are still using standard printing anilox rollers for these advanced coating applications — and this often leads to inconsistent coating weight, poor transfer efficiency, and unstable performance.

So, is your current anilox roller truly suitable for functional coatings?

Let’s break it down.

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What Are Functional Coatings?

Functional coatings are engineered layers designed to add performance features rather than visual appearance. They are widely used in:

• Flexible packaging films

• Paper and board packaging

• Labels

• Industrial films

• Electronics and specialty materials

Unlike standard varnish or aqueous coatings, functional coatings often have:

• Higher viscosity

• Larger particle size

• Higher solid content

• Stricter coating weight tolerance

• Stronger chemical reactivity

These characteristics require a specially designed coating anilox roller.

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Why Standard Printing Anilox Rollers Often Fail

Traditional flexo printing anilox rollers are optimized for ink transfer and image reproduction. When used for functional coatings, several problems may occur:

1. Insufficient Cell Volume

Functional coatings usually require higher coating weights. If your anilox cell volume is too low, transfer efficiency drops and coating thickness becomes inconsistent.

2. Incorrect Cell Geometry

Standard 60° hexagonal engraving works well for ink, but may not be ideal for heavy or high-solid coatings. Poor geometry leads to incomplete release and coating streaks.

3. Cell Plugging

High solid or particle-filled coatings easily block shallow cells, reducing effective volume and causing coating variation.

4. Surface Wear

Functional coatings can be more abrasive. If the ceramic layer quality is insufficient, wear occurs faster, directly affecting coating uniformity.

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Key Factors to Evaluate in Your Current Anilox Roller

If you are unsure whether your roller is suitable, review these four critical aspects:

✔ Cell Volume (BCM or cm³/m²)

Heavy barrier or adhesive coatings require higher volumes compared to standard varnish applications.

✔ Line Count (LPI or L/cm)

Lower line counts with higher volume are generally better for thick or high-viscosity coatings.

✔ Cell Geometry

Special geometries designed for coating applications improve release rate and reduce clogging.

✔ Ceramic Quality

High-density ceramic coating with precision laser engraving ensures long-term durability and stable transfer.

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When Should You Consider a Dedicated Coating Anilox Roller?

You should upgrade to a specialized coating anilox roller if you experience:

• Uneven coating weight

• Pinholes or streaks

• Low transfer efficiency

• Excessive cleaning frequency

• Fast wear of the ceramic surface

• Poor barrier or functional performance results

In many cases, changing the anilox specification improves coating consistency more effectively than adjusting machine settings.

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Ceramic Anilox Rollers for Functional Coatings

Modern laser-engraved ceramic anilox rollers are designed to handle demanding coating materials. Compared to standard rollers, they offer:

• Higher release rate

• Optimized cell depth-to-opening ratio

• Better resistance to abrasive particles

• Longer lifespan under heavy coating conditions

For advanced barrier coatings, heat-seal coatings, anti-fog coatings, or conductive coatings, customized cell design becomes essential.

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Printing Anilox vs Coating Anilox: What’s the Real Difference?

Using the wrong type may limit your coating performance without you realizing it.

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Conclusion: Your Anilox Roller Directly Impacts Functional Performance

Functional coatings demand precision, stability, and durability.

If your current anilox roller was originally designed for ink printing, it may not meet the technical requirements of modern coating applications.

Instead of adjusting viscosity or machine pressure repeatedly, evaluate whether your anilox specification truly matches your coating material.

The right coating anilox roller does more than transfer material — it defines coating weight control, release rate, and final product performance.