How to choose the cleaning method for the mesh roller? I finally figured it out!

Mesh rollers are often referred to as the "heart" of flexographic printing by industry insiders, with their surface covered with small mesh holes that are used for precise storage and transmission of ink or paint, thereby affecting the color saturation, clarity, and uniformity of printed materials. However, during the printing process, pigments, resins, desiccants, etc. in the ink are prone to deposit inside the mesh, forming "ink scale" or "crust". If not cleaned in time, the ink output will decrease and the color will become lighter; Mesh blockage causes ink or line breakage in printing; Accelerate the wear of the mesh roller and shorten its service life.
Effective cleaning of the mesh roller is crucial for improving the productivity of flexographic printing. It can not only reduce downtime, material loss, and labor costs, but also ensure the quality and color stability of printed products. However, in the actual production process, cleaning the mesh roller is often a headache, and a lot of time is wasted on removing accumulated ink. Sometimes the surface appears to have been cleaned, but in reality it does not meet the requirements for use. So, what are the cleaning methods for mesh rollers? How should cleaning be standardized? Today, let's talk about the standard cleaning process and methods for mesh rollers.
PART.01
Common cleaning methods
At present, there are two commonly used methods for cleaning mesh rollers on the market: laser cleaning and chemical cleaning. Although these two methods are different, they can both achieve ideal results, reducing downtime and economic losses caused by dirty mesh rollers. In general, professional suppliers can be sought for assistance in selecting a reasonable cleaning plan according to actual needs.
01
Prerequisite factors
To make a reasonable choice, it is necessary to comprehensively consider the configuration of the enterprise's own mesh roller, printing workshop, and cleaning system. For example, the number of mesh rollers configured by the enterprise, the procurement period, the number of mesh rollers that need to be cleaned every day, whether the production cycle is tight, whether special inks or coating liquids are used for printing, and the expected cleaning costs.
02
Laser cleaning
Normally, if a company meets the requirement of cleaning no more than 30 mesh rollers per day and has a relatively complete set of configurations; The replacement frequency of the mesh roller is relatively low, and it stays on the printing machine for a long time; Special inks, adhesives, or coating liquids are used in printing; The enterprise site is restricted and unable to connect to the sewer or sewage system; Do not want any waste generated from cleaning; If you wish to waive three or more conditions such as subsequent cleaning fees, you can choose to use laser cleaning.

The advantages of using laser cleaning are very obvious, as its principle is to project highly focused energy onto the pollutants attached to the surface of the roller. This energy will excite molecular bonds within impurities, causing them to decompose and vaporize through a process called "ablation". This method has high selectivity and can remove excess residue without damaging the bottom surface of the roller. Laser cleaning can be performed on or off the machine.
The three synchronous processes of photothermal, photochemical, and optomechanical enable laser systems to clean a variety of materials, from hardened polymers to precision chromium oxide layers. Importantly, laser cleaning does not produce harmful waste and is a sustainable and environmentally friendly choice, especially effective for special ink and coating liquid printing on the mesh roller.
03
Liquid cleaning
Normally, if a company cleans more than 20 mesh rollers per day and the configuration quantity is relatively limited; Doubts about cleaning the bearing seat of the mesh roller with shaft; The production schedule is quite tight; The replacement frequency of mesh rollers is relatively high; Deep cleaning should be carried out every day; It is necessary to ensure that the cleaning is completed within 10-20 minutes; If the budget for cleaning equipment is limited, you can choose to use chemical cleaning solutions.
The advantage of liquid cleaning is its high cleaning efficiency, which can be completed in 10-20 minutes; Deep cleaning of the mesh roller can be carried out daily; Will not cause damage to the mesh roller; Fully automatic equipment is easy to operate.
PART.02
Other considerations
01
sustainability
The selection of cleaning methods should also take sustainability into consideration. Updated cleaning equipment can reduce the use of water and cleaning agents, and innovative cleaning solutions can help users improve printing quality, efficiency, and operational safety. The mesh roller that has been effectively cleaned can ensure the best working condition, reducing the waste of ink, materials, and time.

Due to the trend of reduced printing volume and zero inventory in the industry, the cleaning of mesh rollers must be thorough and fast in order for operators to obtain cleaned mesh rollers in the shortest possible time. Frequent shutdowns, ineffective manual cleaning, or equipment with low automation levels can cause a burden on practitioners, and highly automated cleaning equipment is becoming increasingly popular in the market.
02
Special ink
Some special inks or coating liquids are difficult to clean even if they have not completely dried out. The longer these inks stay in the mesh roller holes, the greater the difficulty of cleaning.
03
Cleaning timing
According to the length of the cleaning interval, the cleaning of the mesh roller can be divided into two types: daily cleaning and deep cleaning. Whether it is daily maintenance cleaning or deep cleaning, the appropriate cleaning method should be selected, but the basic principle of "not causing damage to the mesh roller" must be followed.
In order to improve the efficiency and service life of the mesh roller, it is generally necessary to clean it promptly after each printing job is completed; Regularly clean and maintain the mesh roller; The mesh roller should be cleaned immediately after being removed from the printing machine before being returned to the storage location; Always keep the mesh roller clean from the moment it arrives.
In short, nowadays the market competition is becoming increasingly fierce, and dirty mesh rollers cause fluctuations in printing quality, increase downtime and losses, which will have a negative impact on the competitiveness of enterprises. Therefore, developing good cleaning habits can not only improve the stability of printing quality, but also extend the service life of the mesh roller. With the continuous development of technology, automated cleaning equipment can effectively optimize the cleaning work of mesh rollers.