Optimising Print Quality with the Right Anilox Roll and Precision Inspection

In the dynamic world of flexographic printing, selecting the right anilox roller for each job is essential for achieving high-quality, consistent results. Different types of print work require unique anilox specifications, from line count to cell volume, to support proper ink transfer and coverage. As anilox manufacturers continue to innovate with new engraving types suited to specific applications, the demand for accurate inspection tools to maintain these rollers is increasing.

This article delves into the value of selecting tailored anilox rollers for distinct printing tasks, and how precision inspection systems like Troika Systems AniCAM HD? Plus, play a pivotal role in maintaining their performance over time.

Choosing the Right Anilox Roller for the Job

Anilox rollers are available in a variety of specifications, each suited to different types of print work. Manufacturers typically recommend rollers based on the line count, cell volume, and cell geometry that best support the desired ink transfer for each application. Here’s a look at how different roller types benefit specific printing needs:

1. High Line Count Anilox Rolls: Application: Ideal for fine detail work, such as in labels and high-resolution graphics. Characteristics: These rollers feature smaller cells with higher line counts, ensuring precise ink application for fine details and colour consistency.
2. Low Line Count, High Volume Rolls: Application: Often used in packaging, where vibrant colours and large areas of coverage are required. Characteristics: With larger cell volumes, these rollers ensure a thick, even ink layer, ideal for bold colours and high-opacity finishes.
3. Hybrid Anilox Rolls: Application: Suited for jobs that require both fine detail and high ink coverage, such as point-of-purchase displays. Characteristics: These rollers combine varied line counts and cell volumes to balance fine details with extensive coverage needs.

The Role of Precision Inspection: Tailoring Devices for Anilox Characteristics

With a range of anilox types in use, ensuring that each roller is operating at its peak is essential for maintaining print quality. Inspection systems like Troika Systems AniCAM HD? Plus provide precise data on cell volume, depth, and cell geometry, allowing print operators to proactively monitor roller condition and achieve consistent results across different print jobs.

1. Calibration and Tuning: Devices such as the AniCAM can be calibrated to specific anilox types. For example, operators can adjust the device’s settings to optimise measurements based on the roller’s line count and cell volume. This enables accurate readings for rollers with different specifications, ensuring the device captures data relevant to each roller’s unique design.
2. Predictive Maintenance for Each Roller Type: Since high line count rollers are prone to clogging, regular inspection ensures cells remain clear and effective. Conversely, low line count, high volume rollers benefit from monitoring to avoid cell wear that could impact ink distribution. With the AniCAM HD? Plus, operators can adjust inspection frequency based on roller type, helping extend each roller’s lifespan and reduce maintenance costs.
3. Custom Reporting and Data Analysis: Some inspection devices offer customisable software settings, enabling operators to focus on specific anilox characteristics such as cell depth or wall structure. By tailoring the inspection process to each roller’s specifications, devices like the AniCAM HD? Plus help users obtain a deeper understanding of each roller’s condition and performance, optimising ink transfer and print consistency.

Improving Operational Efficiency and Print Quality

Using anilox rollers tailored to specific applications, combined with precise inspection tools, enhances production efficiency and print quality. Here’s how:

• Reduced Downtime: By regularly inspecting and tuning each roller, operators can catch issues like cell wear or clogging before they impact production, reducing downtime for cleaning or replacement.
• Optimised Ink Usage: Precision inspection ensures that each roller is transferring the correct ink volume, reducing waste and ensuring consistency.
• Extended Roller Lifespan: Custom inspection schedules based on roller type help minimise unnecessary wear, maximising the lifespan of each anilox roller.

The Future of Anilox Inspection in Customised Printing

As the printing industry continues to push for higher-quality output and more efficient production methods, the need for tailored anilox solutions and adaptable inspection technology will grow. By combining specific anilox rollers with inspection systems that can be tuned for different characteristics, printers can maintain high standards and reduce costs—no matter the complexity of the print job.

With the right combination of customised anilox rollers and precision inspection tools, printers can look forward to a future of enhanced print quality, efficiency, and reduced waste.

Adrian Buratta is recognised worldwide for his deep expertise in surface metrology and has over 36 years of experience in the printing industry. Adrian leads the charge on Troika Systems sustainability initiatives across the globe. His extensive background in print quality and process optimisation has made him a trusted authority, shaping the future of sustainable practices and efficiency in printing worldwide.