Anilox Roll Cleaning Methods

4.7 Correct Daily Cleaning and Maintenance Methods for Ink Transfer Anilox Roller:

(1) Daily cleaning with copper wire brush or steel wire brush

After each printing task, first rinse off the ink with water. Then prepare a special chemical cleaning agent according to the instructions, apply and soak it on the surface of the anilox roller (alternatively, put the prepared cleaning agent into the water-rinsed ink circulation system and run the equipment for circulating flushing; this method cleans the entire ink circulation system).For ceramic anilox rollers of 300 lines/inch and below, use a special stainless steel wire brush with a wire diameter of 0.07 mm to clean the cells (for metal anilox rollers with hard chrome electroplating, use a special copper wire brush). For those above 300 lines/inch, wipe with a special cleaning cloth, then rinse thoroughly with clean water and air-dry.

(2) Mechanical Cleaning with Anilox Roller Cleaning Plate

The anilox roller cleaning plate can be mounted on the printing cylinder just like a flexographic plate, then pressed against the anilox roller and run as in normal printing operation.During cleaning, the ink supply system is switched to supply cleaning solution. The cleaning of the cells is achieved by the combined squeezing and scouring effect of the cleaning plate and cleaning solution on the inner walls of the cells.

This is an effective mechanical cleaning method for daily maintenance of anilox rollers. Better results can be achieved if this method is applied from the early stage of anilox roller use.

                                                          Anilox Cleaning Plate                                                                                     Anilox Cleaning Plate Mounted for Cleaning

Usage of Anilox Cleaning Plate

Anilox Cleaning Plate is used for thorough cleaning of anilox rollers and ink supply systems after daily cleaning.It is mounted on the printing cylinder in the same way as a flexographic plate.With the cooperation of cleaning solution, automatic mechanical cleaning can be carried out by running the machine.This method features fast loading and unloading, convenient operation and obvious cleaning effect.

I. Cleaning Method

1.Install the cleaning plate

Mount the cleaning plate onto the plate cylinder using the standard plate-mounting method, then adjust the plate cylinder slot to a position under the ceramic anilox roller.

2.Prepare cleaning solution

Mix the powdered anilox roller cleaner with warm water at 50–70 °C at a ratio of 1:20.Pump the prepared solution from a clean water-ink bucket into the ink supply system and allow circulation.

3.Clean the anilox roller with cleaning solution

Run the press at a speed of 80–150 sheets per minute.Lower the anilox roller to normal printing position so that the cleaning plate and anilox roller continuously squeeze into the cells with the cleaning solution.Continue circulating cleaning for 30–40 minutes.If available, inspect the cells with a magnifier to confirm thorough cleaning.

4. Rinse the anilox roller with clean water

Recover and remove the cleaning solution from the ink supply system.Fill the system with clean water and circulate for a further 5–10 minutes.

5. Finish the operation

Recover and drain the clean water from the ink supply system.Separate the cleaning plate from the anilox roller, remove the cleaning plate, and wipe off water marks on the anilox roller with a clean cloth.

Notes

1. The actual cleaning time shall be adjusted according to the actual clogging condition of the anilox roller.

2. After each cleaning, use a magnifier to inspect and confirm that the cells are completely clean.

II. Storage Method of Cleaning Plate

After using the anilox roller cleaning plate, rinse it thoroughly with clean water, then store it on the plate rack in the same way as flexographic plates. Bending and placing under pressure are strictly prohibited.

III. Applicable Scope of Cleaning

1. This product is suitable for daily physical cleaning and maintenance of ceramic anilox rollers and metal anilox rollers from the initial stage of use, and can be reused.

2. This product is easy to use and adopts mechanical cleaning, which is one of the best daily physical maintenance methods for anilox rollers. Especially, better results can be achieved if it is used when the new anilox roller is put into operation.

3. After the anilox roller is severely clogged, chemical cleaning method must be used first to dissolve the dried ink resin, and then mechanical cleaning with the cleaning plate shall be carried out.

(3) Cleaning with Chemical Cleaning Agent

This is mainly periodic deep cleaning performed regularly or according to the degree of cell clogging, in accordance with the ink transfer anilox roller maintenance system.

⚫ Manual Cleaning (Solvent-based Anilox Roller Cleaning Fluid)

1. First clean the water-based ink on the anilox roller, doctor blade or rubber roller, then adjust the doctor blade or rubber roller away from the anilox roller.

2. Thoroughly dry the moisture on the anilox roller with a dry cotton cloth, and wait until it is completely dry before cleaning with this product.This cleaning agent is completely insoluble in water; otherwise, the cleaning effect will be affected.It is recommended to perform cleaning before the next operation.

3. Spray the cleaning agent onto a local surface of the anilox roller, wipe repeatedly with a clean cotton cloth for 3–5 minutes, and then clean other areas only after this section is clean.

4.After cleaning with the anilox roller cleaner, use anhydrous ethanol to clean once again using the same method. Once the anhydrous ethanol has dried completely, rinse with clean water and wipe dry.

5.Depending on the clogging condition and cleaning effect of the anilox roller, the above steps may be repeated until the cells are verified to be clean under a magnifying glass.

6.According to the operation condition of the printing press, regular cleaning and maintenance shall be carried out using the above method (recommended once a month).Cleaning shall be performed promptly if clogging is found. The longer the cells remain clogged, the longer the cleaning time required.

⚫ Soaking Cleaning

Use a special chemical cleaner for the cells of the ink transfer anilox roller.First soak the roller for 1–48 hours.Then spray the solution onto the rotating surface of the anilox roller via a high-pressure spray device moving axially along the roller(or scrub the roller surface with a special stainless steel wire brush of 0.07 mm wire diameter and a copper wire brush).

Remove the residual ink in the cells.For severe clogging, repeat the operation several times until the cells are verified clean under a cell microscope.Finally rinse with clean water and air-dry.

(4) Cleaning with Sodium Bicarbonate (Baking Soda) Dry Cleaning System

It is carried out by professional anilox roller cleaning equipment or online cleaning equipment.During cleaning, dried sodium bicarbonate (baking soda) powder is sprayed onto the surface of the anilox roller at low pressure to impact and break down the dried residual ink in the cells, thus achieving the purpose of cleaning the anilox roller.

(5) Ultrasonic Cleaning

Place the roller in the chemical cleaning solution of an ultrasonic cleaning tank and rotate it slowly.The ultrasonic generator vibrates the solution at high frequency, producing numerous micro-bubbles that impact the cells at high speed.These micro-bubbles collapse under pressure and strike the cell walls, removing residues and achieving thorough cleaning of the cells.

When using this method to clean anilox rollers,appropriate ultrasonic intensity, frequency, cleaning time and solution temperature must be adoptedto prevent damage to the anilox cells caused by excessive cleaning, especially for ceramic anilox rollers.

(6) Plastic Microbead Jet Cleaning Method

The plastic microbead jet cleaning method introduced abroad is regarded as a non-damaging cleaning method for the surface of ink transfer anilox rolls. Polyethylene plastic microbeads are jetted onto the surface of the anilox roll at a pressure of approximately 60 psi. These soft plastic particles with sharp edges deform and rebound when striking the roll surface and entering the cells. This process breaks up and removes residues from the inner surfaces of the cells, thereby achieving the purpose of cleaning the cells. The plastic microbeads are then recovered into the cleaning equipment for recycling.

(7) Laser Cleaning Method

In recent years, the laser cleaning method has been developed and applied both domestically and internationally. This method uses a laser beam with controllable energy to irradiate the surface of the ink transfer anilox roll. Without damaging the cells, the high-energy laser instantly gasifies dried ink, impurities and other residues inside the cells, thereby achieving thorough cleaning of the cells.

We DOYA is the only professional manufacturer in China producing laser cleaning machines for anilox rollers. Please contact us for any needs or inquiries.

(8) The following cleaning methods are strictly prohibited:

⚫ Steam jet cleaning

Steam jet cleaning will damage the engraved surface of the anilox roll and cause corrosion of the steel body.

⚫ Fire cleaning

High-temperature flame will severely damage the ceramic or hard chrome coating on the anilox roll surface, destroy the cells, cause thermal deformation of the roll, and leave marks on the roll surface.

⚫ Cleaning with acid or other highly corrosive chemical substitutes

This is the worst method attempted to clean the roller. Many acids and other highly corrosive compounds can severely damage the ceramic or hard chrome coating, destroy the cells, corrode the shaft heads and steel body, and also pose health risks to the operator.

There are no shortcuts to cleaning anilox rolls. Strict and routine cleaning must begin from the first use of a new roll and be performed in accordance with regulations and procedures.

Once water-based ink dries inside the cells, dissolving and removing the resin becomes an extremely difficult restoration process. It can only be achieved with great difficulty using a combination of chemical and physical methods, and this process can easily cause irreparable damage to the anilox roll.