The Flexographic print company was experiencing print issues which were incurring significant downtime, due to difficulty in achieving the correct colour density and laydown on the corrugated board.
This was resulting in high-levels of print rejects, production downtime and wasted materials and resource.
We were called in to help identify the problem and create a plan of action to resolve the issues.
Our technician attended site to review and undertake anilox and print process assessment. The findings would dictate the next course of action, which in these situations included an anilox roller deep clean treatment and recovery process.
On the initial inspection, it was noted that the anilox roller had score lines present across the surface, caused by dried ink forming in the inking system. Hardened dried ink particles form due to insufficient cleaning of the inking system and above the anilox roller, either due to the irregularity and or ineffective cleaning solutions being used.
Using our CellStore™ Anilox Inspection System our technician assessed the anilox rollers and quickly found that the cells were heavily contaminated. This prevents the correct delivery of ink to the printing plate.
The results were initially discussed, identifying the issues and explaining the actions to be taken. A full report was then generated to clearly show the anilox cell condition, both before and after our anilox recovery process.
The contaminated anilox roller and hardened ink particles within the inking system were all contributing to print quality issues on this press and increased print rejects.
From the anilox inspection and assessment findings, it was apparent that a full anilox recovery process was required.
This was scheduled and undertaken using Print Tech Solutions anilox recovery process, which included our anilox roller recovery solution CellGel. This is a deep clean anilox gel solution. This product is specifically formulated for anilox rollers that are heavily contaminated to remove dried ink particles.
Once this was completed, another anilox audit was carried out to illustrate the improvement achieved following the deep clean treatment.
A print run was then carried out, to review final print to checked for any print issues.
On inspection it was found that the print issues had been resolved. However, the anilox rollers with scoring damage required refurbishment.
Finished print illustrated:
- Improved colour consistency
- No marks on print
- Substantial reduction in print rejects
- A structed Anilox Care programme to be adopted on-site.
- Correct wash-down cycles for cleaning anilox rollers after change-over of jobs.
- Training of operators, to increase their knowledge of anilox rollers and correct care and maintenance.
- Aim to reduce the pump pressure / foaming of cleaning solution, to further aid the cleaning effectiveness.
The Added Value Gained
This has led the company to:
- Adopting a vastly improved cleaning regime
- Increased operator knowledge of the anilox rollers, leading to improved skills and confidence to undertake the correct care of anilox rollers.
- Anilox rollers maintained consistency, avoiding any reactive cleaning methods.
- Significantly improved print quality.
- Reduced print rejects.
- Reduced unscheduled print production downtime.
- Reduced waste of materials (inks, corrugated board etc.).
- Improved use of resource and time.
- Gained cost savings to the business.
We’re pleased to say the support provided, actions taken and beneficial outcome, has led to Print Tech Solution becoming the supplier of cleaning solutions and providing on-going technical support to the business.
It’s always rewarding to work through a problem and resolve it to a successful outcome for our customer.
J Scott, who initially invited Print Tech Solutions to site said, “We were unable to print even a simple reference on our rotary die cutter, so we called Print Tech Solutions to help us. Their technician arrived the next day (great service!) and undertook an anilox assessment. On checking both anilox rolls using his microscope inspection system he found both rollers were contaminated. He then carried out a deep clean on both rollers and restored cell volume to near full capacity and left instructions for future wash offs and cleaning.”
He added: “Both units are now printing as good as new. We are very happy with the service and the response from Print Tech Solutions and have purchased the recommended cleaning solutions and adopted a strict care and cleaning regime.”
To ensure your anilox rollers remain in top condition the need to monitor and maintain the correct cleaning and care is essential to reduce and avoid unnecessary print deterioration. Print Tech Solutions are here to help you. We will provide safe and effective cleaning solutions and support you maintain consistent high-quality print through training and technical support.
If you need help with your anilox roller and flexographic print care and maintenance, Contact our team now.
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