Improve anilox roller technology to improve printing quality
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For anilox rolls, there have been many new developments. However, only by making basic adjustments to the printing process can we see the good results of this new change.
Flexo printers want to have a certain advantage. Printer and accessory manufacturers have also been promoting the power of their new technology improvements. But if we don't pay attention to the basics, all these new technologies will not bring us the results we imagined.
Let's explain what is the basic work? That is, under what circumstances does the system need to be fine-tuned?
——This technique does not accurately control the thickness of the ink layer on the anilox roll when using a rubber nip rill instead of a squeegee.
——When the pH or ink viscosity (two key factors affecting ink flow) is not monitored, the color density shifts.
—— When the gears of the gears used are worn out, they can cause unstable ink transfer.
——The bearing becomes loose or worn, and the pressure between the dust plates is unstable.
——The phenomenon of elongation and deformation of the flexographic plate due to repeated loading and unloading.
——We can't think of an 800lpi anilox roll with 200 billion cubic micron meshes formed at an angle of 60 degrees, which will produce the same ink transfer performance as the 120 million cubic micron anilox rolls formed at 30 degrees. .
——The damaged and clogged anilox roller has the same ink transfer performance and clean and perfect anilox roller, even under the same engraving data, the ink transfer performance will be different.
All process variables must be correct so that we can see the benefits of new technologies when using new technologies. Moreover, the requirements for print quality must be matched with the cost and workload, otherwise there will be situations in which the staff adhere to their past experience.
FM network technology and hybrid screen technology (using traditional framed screens with FM to be widely used still requires a long process, so traditional screening technology still occupies a large proportion when used. At present, it is too early to consider the use of FM networks. However, if printers can use new technologies consciously and systematically, they will have a great advantage in the future competition.
Anilox roll manufacturers are always trying to develop higher number of engraving rolls. When the number of screen lines on the user's version reaches 150lpi or more (or even more than 200lpi), the minimum number of anilox lines established has reached 800lpi, and it is recommended that the use of 1000, 1100, 1200lpi anilox rolls may achieve better results. .
For 20 years, 800lpi has been the limit of laser technology and control technology, but in recent days, the limit of this number of engraving lines has been broken.
The benefits of the new engraving technology are obvious. The engraving rolls with higher line counts can support smaller and brighter plate points and reduce the occurrence of dipping. This dipping phenomenon means that the dots are smaller than the anilox roll mesh. When it is completely immersed in the mesh, the phenomenon of ink staining around the dots will result in unclear layout and large dot gain.
Although anilox roll production can currently produce more than 2000 lpi of products, few people buy anilox rolls of more than 1500 lpi. This anilox roller of more than 1500 lpi has a small mesh groove and a thin mesh wall. Although such a mesh can achieve high print quality, the excessively thin mesh wall structure is difficult to support the current cleaning methods such as ultrasonic and soda spray.
In addition to the consideration of cleaning and destruction issues, most printers do not have to meet the number of such people when they meet their users' requirements.
Generally, users who use 1500 lpi mesh rolls are few, and the trend of increasing demand is between 900 and 1200 lpi. But this range of orders comes from print shops for quality print jobs, mainly for narrow, medium and wide web presses. If an anilox roll of more than 800 lpi must be used, the optimization of the components of each ink delivery system is a critical factor.
The CO2 laser has been the standard laser generator for engraving in the industry for many years. YAG lasers are also very useful when producing fine engraving effects because their beams are narrower and can be focused on finer points; their energy is more concentrated, allowing for cleaner meshes in the case of finer mesh walls. . The basic engraving capability of this laser is 1200 Lpi; while the CO2 laser has a capacity of 700 lpi. Therefore, if the required ink dots are finer, the laser product can obtain a better color tone effect.
If the engraving technique is not considered, the thickness of the mesh wall decreases as the mesh line increases. If the 400 lpi mesh wall is twice as thick as the 800 lpi, the 400 lpi anilox roller will have a longer service life and will require less use.
For printers who want to use flexo printing to obtain offset quality, it is important to establish standards and monitor variables. The standard of the printing process includes the specification of the amount of anilox roller and the angle of the netting for each number of lines.
The interchangeability and estimation of the system must be strictly controlled. Once control is established, the integrity of the system is maintained. This is to properly maintain the various parts of the press. If we do this, we will see significant changes in print quality, and the work done is only the basic elements and control of the printing process.