Anilox rollers are central components in the printing process, responsible for the precise transfer of ink to the print medium. To ensure consistently high print quality and maximize the service life of these rollers, regular inspection is essential.
Why regular inspections are crucial
During use, anilox rollers are exposed to various stress factors that can compromise their performance and printing quality. Regular inspections help to detect these issues early and ensure consistent high-quality results. Key reasons include:
Wear and mechanical damage:
Through continuous operation, anilox rollers are subject to friction, pressure, and possible contact with hard objects or misaligned doctor blades. Over time, this can result in gradual wear, scratches, dents, or even deformation of the roller surface. Such damage negatively impacts the uniformity of ink transfer and can lead to costly production downtimes.
Soiling and deposits:
Ink residues, varnishes and other contaminants can accumulate in the roller’s microscopic cells. These deposits reduce the effective cell volume, which directly decreases the amount of ink the roller can carry and transfer. This leads to inconsistent color application, reduced print quality, and may necessitate excessive cleaning efforts if not addressed early through routine checks.
Regular inspections allow such changes to be detected at an early stage, which enables preventative actions to be taken and avoids expensive downtime.
Anilox roller inspection methods
Zecher GmbH offers specialized methods for analysing the condition of anilox rollers:
VoluCheck method: The VoluCheck method involves determining the actual scoop volume of the anilox roller. A defined quantity of standardized test ink is applied to the roller surface using a laboratory pipette, followed by an application-oriented doctor blade process and the creation of an imprint of the measuring area. Special software then calculates the actual scoop volume by dividing the amount of liquid by the surface area. Several areas on the anilox roller surface can be tested at the same time. This method is closely aligned with the printing process and enables the measurement of up to one million cells, which minimizes statistical errors.
DotScope analysis: The DotScope analysis determines the geometric scoop volume of the anilox roller. During the process the device is placed on the anilox roller surface and takes up to 150 layered images of the engraving by varying the focus. An algorithm uses this to create a 3D depth model of the cell structure and calculates the geometric scoop volume of the cells. The process is repeated at various points on the anilox roller to calculate an average scoop volume. This process provides detailed information about the cell geometry and the condition of the engraving.
The two measuring systems differ in that one shows the actual scoop volume (VoluCheck) and the other the geometric scoop volume (DotScope). Due to different influencing factors, the two measuring systems and their results are not necessarily comparable.
Benefits of regular inspections
Continuous inspection of the anilox rollers results in several benefits:
Early detection of abrasion:
Through regular checks, even the smallest signs of abrasion or surface damage can be identified at an early stage. This allows for timely interventions such as reconditioning or replacement of affected rollers, which helps avoid costly downtimes, reduce the risk of defective prints and prevent damage to adjacent components.
Optimization of print quality:
Anilox rollers in optimal condition ensure consistent and precise ink transfer across the printing substrate. Clean cells and undamaged surfaces prevent issues such as streaks, color deviations, or uneven coverage, contributing to consistently high-quality print results and increased customer satisfaction.
Extension of service life:
By aligning cleaning and maintenance routines with inspection findings, abrasion can be reduced and critical damage avoided. This not only extends the operational life of the rollers but also enhances overall machine efficiency, reduces replacement frequency and lowers long-term operational costs.
Predictive maintenance with the Zecher App
To manage inspection results efficiently, the Zecher app offers a digital solution that supports companies in monitoring the condition of their anilox rollers. All inspection results – including those from external anilox rollers – can be stored and maintained in the app. A spreadsheet shows the current condition of the rollers at a glance, as well as the comparative values for previous inspections, so that potential abrasion or failure can be identified immediately.
The app is therefore based on the principle of predictive maintenance: By continuously recording and analysing measured values, companies can plan maintenance in advance and minimize unplanned downtime. This makes a significant contribution to increasing efficiency and reducing costs in the printing process.
Summary
Regular inspection of anilox rollers is an essential part of efficient printing operations. It not only enables high print quality to be maintained, but also makes a significant contribution to the cost-effectiveness and durability of the rollers used. We, at Zecher GmbH offer specialized procedures and services for this purpose, which enable precise condition analysis and subsequent optimization steps.
