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Mike Huey of Harper Graphic Solutions cited several uses of ribbon anilox rollers in flexographic printing.
Ribbon anilox rollers have always been frequently used by printers, and its role is reflected in many aspects, such as determining the amount of ink for four-color printing, determining the optimal number of anilox rollers and cell volume for spot color printing and combination printing , Determine reasonable anilox roll inventory, etc. These are the most common applications of ribbon anilox rolls, and its use has now exceeded the above range and extended to other fields.
For example, it is used in certain occasions to determine the hardness of printing plates, the density of double-sided tape, and the ink supply system used. The use of belt-shaped anilox rollers can also determine the specific parameters of each process to ensure the quality of daily printing. These are very good methods.
Flexographic printing is both an art and a science, but in actual production and processing, we need to optimize the technological process to obtain maximum profits. As we all know, the anilox roller is a very critical component in flexographic printing and is called the "heart" of flexographic printing. In this article, I would like to introduce some common and uncommon uses of ribbon anilox rolls. No matter what market area you belong to, I hope that this article will help your business reduce production costs and increase profits.
Determine the optimal amount of ink for line draft, gradation draft printing and line image synthesis draft
Plan ahead:
We all know that in order to ensure the stability of the daily printing operation, we must determine various parameters and strive to adopt the best method to ensure the printing quality. These are very easy to achieve with the use of ribbon anilox rolls. But first of all, we should convene relevant personnel, suppliers of printing plates, inks, paste tapes and anilox rollers. Of course, printers must be involved. The printers should let the press operators and their supervisors, as well as a management People and project leaders are involved. This meeting should determine the parameters of the anilox roller used, the hardness of the various printing plates, and the type of ink and double-sided tape. All variables that need to be tested should be listed, the test plan should be determined and relevant data collected.
One thing to remember is that the ultimate goal is to determine the minimum ink volume for line drafts, four-color gradation drafts, and complex manuscripts to achieve the required solid density, and expand the range of tone reproduction. This means that in order to achieve the smoothest, thinnest and most stable solid density, a variety of different hardness plates and tapes are needed.
Test log:
The printing of any work is the same, pre-press preparation is to ensure that all materials are prepared before the start of the experiment. The approved test list should ensure the accuracy of each step, just like the daily printing operations, list the parameters to be tested, the samples to be saved, etc. in chronological order of the test. The printing press, ink, tension, temperature and all other control parameters should be the same as normal printing. If the usual ink viscosity is 24s (# 2 Zahn Cup), the test cannot be 28s. The quality standards for printing are the same as for normal printing operations. Normally, there are control belts at both ends of the anilox roller. The control belt means that the width of the anilox roller at both ends has the same screen line number and cell volume. It can print simple test items on both ends of the printing material to check whether the axial pressure of the anilox roller is balanced. Once it is determined that the pressure setting reaches normal operating conditions, all the equipment operating parameters can be recorded at this time, and the printed samples can be labeled / coded for future inspection and testing. Specific test parameters, such as marked samples and recorded printing conditions, are critical to the success of the test. Sample storage, parameter testing and chart display are as follows:
The number of network lines is 800lpi, and the density obtained when the network volume is 1.9bcm is closest to the requirement. Although the dot expansion is slightly larger than the anilox roller of 900 lpi and 1.7 bcm at this time, we still decided to use the anilox roller of 800 lpi and 1.9 bcm because the expansion of the dot can be solved by compensation. After the test is completed, the participating parties should discuss and determine specific standards, that is, the conditions necessary to achieve the desired results. The printing conditions for each type of work should include ink, anilox rollers, printing plates, and double-sided tape. Perhaps we also often participate in or implement this type of experiment. In fact, the key is to list all the data and determine the final cost / benefit ratio. It depends on your core business, customer needs and expectations, and then decide what kind of tape, printing plate, ink, etc. to meet the business requirements of both parties.
Ribbon anilox roller used for white ink printing test?
Above we briefly discussed the most common uses of ribbon anilox rollers. Through the standardization of the printing process, it helps printers improve the stability of print quality, reduce downtime, and minimize the impact of uncertainties. The printing of white ink using ribbon anilox rollers is not as common as the above-mentioned applications, but experiments have shown that it is indeed effective in determining the minimum ink layer thickness while reducing the cost of white ink, that is, meeting the opacity requirements. As with the above test, we also need to hold a team meeting to determine the various parameters. The key to this test is to determine the appropriate cell volume, and the corresponding hardness of the printing plate and double-sided tape to ensure a uniform, pinhole-free field. Based on years of experience, we know that the fewer pinholes, the more uniform the ink layer and the higher its opacity. I also know that many printers can reduce costs without testing opacity. Why don't we use an anilox roll with a volume of 7bcm, 8bcm or 9bcm to achieve the corresponding opacity? If we change the anilox roller of 9bcm to 8.5bcm, it means that we can save 5.5% ink cost. After a simple mathematical calculation, you can understand the impact on profit within a year, because all inks and prices depend on the amount and type of ink. For long-term cost considerations, the use of ribbon anilox rollers and other anilox rollers for white ink testing must be worthwhile. [next]
Whether it is narrow-format printing or wide-format printing, white ink is the most commonly used ink in printing plants, and it is also a part of higher cost. Although the application is different, there is no doubt that if handled properly, the production cost can be reduced, that is, the opacity required by the customer can be achieved, and the thickness of the white ink can be reduced. The cell volume of the anilox roller is not the only factor that determines the cost. Many related tests are still in progress or have passed the test, such as using double-sided tape and printing plates of different hardness to obtain the corresponding opacity. On a printed image, the opacity depends entirely on the number of pinholes. If the number of pinholes is reduced, the opacity can be increased accordingly.
The key to reducing costs is to optimize the printing elements: double-sided tape, printing plates, and anilox roller parameters (number of screen lines, cell volume, and cell shape) to achieve the best ink release and spreading in a given area, thereby avoiding Light passes through the ink layer. Introduced below is the use of anilox rollers with the same screen thread count, cell volume and cell shape, but the hardness of the printing plate and double-sided tape are different, and finally a completely different opacity is obtained.
Ribbon anilox roller used for coating test?
There is an occasion where ribbon anilox rollers are rarely used, but there is a possibility for the company to greatly reduce coating costs. Compared with the past, the application of coating in flexographic printing has been significantly reduced. Now there are more applications in special printing, for example, there are paints that change color with temperature, safety coatings and special coatings used in mobile phone batteries.
In fact, almost all imaginable prints require paint. UV, water-based and solvent-based adhesives have applications in almost every material. In short, if you do n’t have a special coating equipment, I believe you will buy it soon.
In order for the material to achieve the function required by the design, the coating amount of the paint must reach a specific thickness.
Most coating manufacturers have a recommended range, which is the amount of coating required for specific occasions, and the key to the problem is to find the minimum amount of coating that meets the requirements of customers. For example, if the recommended range of coating volume is 1.0-1.25 pounds / 3000 square feet, we should design a roller to achieve this range. According to the relevant calculation of the performance of the coating, the anilox volume of the anilox roller required to achieve this coating amount can be determined. Then, when we design the belt-shaped anilox roller, we can use an anilox roller that is slightly higher or slightly lower than this value to test to determine the optimal coating amount for a specific occasion. According to the test results, we can take some samples to test the specific performance required by the customer to determine the minimum "smallest" coating amount in the case of meeting the customer's requirements.
For example, 4.5bcm anilox roller is too small, and 5.5bcm is slightly higher, then 5.0bcm anilox roller should be the best choice. Relative to the use of 6.25bcm anilox rolls, 1.25 pounds / ream coating volume, the cost of the processor can be greatly reduced. Although the coating effect obtained by using an anilox roll of 6.25bcm can also reach the standard, why do we need to apply 20% more adhesive / coating? You should not feel that saving 20% ​​of adhesive is not worth paying attention to. This is a common example. On the premise of ensuring the performance of the coating, the belt-shaped anilox roller is used to reduce the coating amount. If other parameters change during actual printing, the printer is responsible for monitoring, testing and recording the coating amount to ensure that the reduction in coating amount will not cause quality problems and cause customer dissatisfaction.
Through the above introduction, we can see that the belt-shaped anilox roller is very widely used. It can be used to improve printing quality and standardize the printing process. Of course, the most important thing is to reduce costs and maintain competitiveness. The last thing to remind is that after the test is completed, the printer needs to take good care of the ribbon anilox roller. My recommendation is to clean it thoroughly and store it in a safe place. Ribbon anilox rollers may be frequently used, such as new printing plates, inks, double-sided tape, paint, etc. on the market, we can use ribbon anilox rollers for testing, and can also be used as quality control equipment to determine daily printing The performance of all materials is stable. If you find that some parameters are different, you can re-verify based on the data recorded during the test.
About the author: Mike is currently working for Mr. Harper GraphicSolutions company, it is the US Harper's subsidiary, has been established for five years. Mr. Mike is the printing technology manager of some western companies. His main responsibility is to provide technical support and advice to customers across the United States. Mr. Mike has 16 years of experience in the flexographic printing industry. He has worked as a production manager from a basic printing operator in a flexible packaging company. Main achievements: As a flexographic printing expert, he has obtained the National Skills Certification and has published many scientific articles. He has spoken at the 2005 and 2006 annual meeting of the American Flexographic Printing Association and actively participated in various exhibitions.
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