Are you dealing with:

• Long make ready times
• Color variation

The anilox roll, which is often called the “heart” of the flexo press, has a primary job to deliver a precise, consistent film of ink to the printing plate. When maintenance slips, so does color control—the very thing brand-conscious clients demand.

The color density of your print is directly dictated by the cell volume (measured in BCM, or billion cubic microns) of the anilox roll and equates to the amount of ink delivered to the plate.

• Plugged Cells: When dried ink or debris fills even a small percentage of the cell, your color changes.
• Wear and Tear: The lifespan of an anilox isn’t infinity. Over time, friction from doctor blades and ink wears down the cell walls, reducing the roll’s ability to hold intended volume of ink.
• Inconsistency: Ink, Anilox, Practices – Who is the culprit? Dirty or worn rolls lead to “color shifting”, forcing operators to chase color by adjusting ink viscosity, strength or press speed, leading to unnecessary waste

To maintain perfect color, we can help you create the best multi-tiered maintenance strategy:

Daily Pressroom Practices

• Idle Ink leads to Unwanted Consequences: Never let ink sit idle. Always keep the anilox rotating and ink circulating, even during short breaks, to prevent solvent or aqueous inks from drying in the cells.
• Clean, Clean, Clean: Clean the roll immediately after a run ends while the ink is still wet. Establish your protocol to prioritize anilox and chamber cleaning.
• Proper Cleaning Products: Use the cleaning product that is designed for your specific ink system without corroding the ceramic or aluminum core.

Are your cleaning solutions working for or against you?  Some wash-ups leave microscopic residue behind and don’t penetrate the cells depth. Use these methods for a total reset:

• Chemical/Mechanical: Use stainless steel brushes (for ceramic rolls) or eraser sponges with appropriate cleaning solutions to scrub away stubborn deposits.  There are numerous options on the market to improve performance while still on press. Contact our Technical Solutions team for recommendations for your specific needs.
• Ultrasonic Cleaning: These units do a great job with proper chemicals in the tank. Let the soundwaves in the proper chemical bath do the work to vibrate dried ink out of the deepest cells.
• Laser Cleaning: These units are much safer for your rolls than when initially introduced. Discuss the pros and cons with your anilox manufacturer.

• Microscopic Inspection:There are several camera options and software programs to track the life of your anilox. Cameras will detect wear or the widening of cell walls vs. the loss of volume due to poor cleaning habits. Consult with your anilox manufacturer or ink company to perform on-site audits.

• Anilox Library / Volume Tracking: Regularly measure BCM and keep a “roll history” log. All rolls aren’t equal, used or new. Inspecting and creating a library to use the same roll, for the same colors, leads to quicker make-ready and consistency.
• Fingerprinting: Perform press characterization / fingerprinting to recalibrate how your anilox inventory interacts with your specific inks and substrates. FIRST provides an excellent step-by-step process for success.

• Doctor Blade Pressure / Selection: Use the proper blade for your press and job.  Keep minimum pressure to create optimum print performance. Excessive pressure is the leading cause of score lines and premature wear.
• Ink Filtration: Use magnets and ink filters to catch metal slivers or debris before they reach the anilox.

Adopt the practices above to avoid daily triage to your pressroom. Listen to your anilox and you will greatly improve performance and reduce waste.

Contact the Wikoff Color team at contact@wikoff.com and we will be happy to discuss best practices for your operation.