The Magic of One
How important is it to have just one person in charge of cleaning, certifying, and inventorying anilox rolls? Very, according to experts.
"ONE" MAY BE the loneliest number, but it's also the magic number when it comes anilox roll cleaning. Regardless of the kind of cleaning system employed, the key to well and properly cleaned rolls is charging one, and only one, person with the responsibility.
Ask any roll cleaning system manufacturer. "The print quality of an anilox roll is only as good as the operator who's cleaning and maintaining it," said Dave Moulder, technical sales representative, Solutions Division, Pamarco Global Graphics.
Having one person to oversee the cleaning, inspection, and inventory of anilox rolls may seem meaningless but, in the long run, it will save money. Think about it—anilox rolls can make or break a print job, and keeping them spick and span will ensure today's necessary high-quality printing capabilities. "The anilox roller is the very heart of flexographic printing," said Mike Potter, president of Flexo Wash LLC. "If all other prepress conditions are perfect, but the anilox roller is not clean, you cannot produce consistent color and print quality. Keeping your anilox rollers clean after each job ensures the pressman's ability to produce repeat print jobs with consistent color and print quality in minutes rather than hours."
Benefits of "one"
Individuals have done great things alone. Albert Einstein discovered the theory of relativity. Galileo proved the Earth rotated around the sun. Marie Curie discovered radium. And, while not quite the same kind of feat, one person in charge of anilox roll cleaning will save thousands of dollars.
"We highly recommend a designated person to handle anilox roll cleaning," said Jim Harper, vice president of Harperscientific.com. "This person would also be in charge of inspection and maintenance of the rolls. After the press operator has cleaned the roll before taking it out of the press, we have found that the printers who have a designated person to oversee the inventory are much more efficient. This person inspects thoroughly, and cleans and certifies the roll press-ready. The companies that implement this method usually have anilox rolls that last longer and they save thousands of dollars because of less ordering of anilox rolls and decreased downtime due to loss of color as a result of dirty anilox rolls."
In addition to all of that, Bob Temple, president of Absolutely Micro*Clean International, said the operator should be proficient in recordkeeping to take full advantage of the cost savings afforded by a one capable person in charge of the anilox rolls.
"It is important at this point to stress that a good tracking system will save you thousands of dollars in anilox rolls and help reduce press downtime," explained Temple. "Having one person in charge of overseeing your anilox inventory greatly improves your productivity and bottom line."
As an example, Temple cited a Brazilian plant that's done just that. The plant has one employee whose specific role is to oversee the inventory of anilox rolls. The employee set up a computer-tracking program to record the original date of service and the specifications of each roll, including line screen, liquid volume, and the actual depth, width, and cell wall in microns. Whenever a rolls comes out of the press, it is inspected and all the information is recorded. If the employee finds the roll is dirty, it's put through the cleaning process and the final specifications are recorded.
"This helps them to tell the overall performance of the individual anilox, as well as the entire inventory. This is a great way to keep tabs on such an important investment," Temple said.
In the end, however, experience with rolls and the cleaning system used will also play a major role in keeping the rolls in shape. This is because every cleaning system has advantages and limitations that will either clean the rolls or do them harm. "Through your experience, you may find shorter cleaning times are possible or that longer soaking times are needed," explained Marty Cansler, national sales manager, Pressroom Products at Max Daetwyler Corp. "You may find that some ink types clean faster than others and some require a stronger mixture. You may find that adhesives, varnishes—especially with cross-linked resins—need longer cleaning times."
He added, "Each pressroom has different inks and coatings, as well as variations in anilox rollers and cylinders. Recommendations [by the manufacturer] will help you achieve good results, however, your best results will be derived through experience."
As for the actual anilox roll cleaning equipment, here's a look at available systems:
Soft-plastic media to clean rolls
Absolutely Micro*Clean International
www.microclean-int.com
The Micro*Clean Anilox Cleaning System uses soft-plastic media to clean anilox cells all the way to the bottom. The recyclable, nonabrasive material deep-cleans the geometrical valleys in anilox rollers, gently removing dried ink pigments and adhesives without eroding or impinging on the ceramic surface. Developed and manufactured by Temple Associates, the polyethylene beads can penetrate the 23 microns on a 1,000 line screen roller without damage, even after 400 cleanings.
"There is no cell damage associated with our cleaning system," Temple said. "Unique chemical properties make it impossible for the Micro*Clean beads to remove any ceramic particles or to alter the roller's molecular structure in any way. The porosity of the ceramic surface is not adversely affected."
Absolutely Micro*Clean offers three machines designed specifically for the narrow-web industry.
Clean anilox rolls, plates, or sleeves with one system
Flexo Wash LLC
www.flexowash.com
The Flexo Wash FW Series Anilox Cleaning System can double as a combination anilox and plate washing system with plate drum or plate sleeve adapters. This unique system has two tanks. Tank One is used with a mild solution for effectively cleaning plates or plate sleeves, and Tank Two uses Flexo Wash's normal cleaning solution.
The versatility of the Allen Bradley PLC allows operators to change the cleaning modes with the touch of an LCD screen. The computer automatically changes the cleaning parameters to gently and effectively switch from anilox cleaning to plate cleaning. The computer switches cleaning solution, wash cycle time, rotation speed, traverse speed, and water rinsing pressure to safely and effectively clean plates of all inks.
In addition, Potter said, it doesn't matter if the anilox roller is wet or dry, or if it's water-based, solvent, and/or UV inks, adhesives, glues, acrylics, polymers, lacquers, varnishes, laminates, etc. that need to be cleaned, together or separately. It's easy, Potter said. "Set the time. Close the lid and push the button," he said.
The systematic cleaning process is safe and harmless to the anilox rolls, employees, and the environment, and effectively restores anilox roll cell volume completely in minutes.
Ultrasonic roll cleaning using Alphasound from Alphasonics
Doyle Systems
www.doylesystems.com
Doyle Systems offers a full line of Ultrasonic Roll Cleaning Systems from Alphasonics. This technology's unique features include Alphasound "Variable Frequency" technology, which allows the operator to select the ideal frequency range for the rolls they will be cleaning. The low frequency is best for rolls below 700 lpi. The high frequency offers a much gentler cleaning action for many rolls over 700 lpi.
Doyle/Alphasonics systems offer a "cleaning station" approach with the ability to clean and rinse the rolls in the same unit. This minimizes the handling and potential for damaging the rolls while trying to move them to a second location for rinsing. These same models can be fully plumbed for a fresh water supply for rinsing and drainage.
Another unique and important feature is an integrated fluid filter for the cleaning solution tank. "This feature helps extend the life of the cleaning solution and remove impurities that impact roll surfaces," said Mark Gibis, vice president of sales at Doyle Systems.
All systems are custom designed for ease of use with no need to remove bearings or gears from the anilox rolls. The systems are available in 2-, 4- and 6-roll configurations up to 87˝ wide. The Doyle/Alphasonics Systems deliver the technology that is consistently effective, easy to operate, ecologically friendly, and adapts to today's and tomorrow's roll technology demands.
Remove inks, coatings with CeramCleanII
Harperscientific.com
www.harperscientific.com
Harperscientific.com's CeramCleanII™ is a water-based and UV ink cleaner, and cleans solvent-based inks in most cases as well. It is designed to effectively remove dried inks and coatings from the engraving without damaging cell structure and will also assist in the removal of tough stains that can develop on a roll. CeramClean II is also easy to use. It is applied by spreading the product over the roll with a damp rag or towel—wipe it on and then wipe it off.
"Utilizing a safe and effective cleaner that will not harm the anilox roll and keeps the cells within the anilox roll clean is the common goal of all printers," Harper said. "Developing a universal cleaner that cleans water- and solvent-based, and UV inks, as well as coatings and adhesives, was what our customers wanted. CeramCleanII, our largest selling product, is what we developed to do this. This cleaner does not have to be used with a brush and it works off the concept of micro scrubbing particles that pluck the ink out of the engraved cells while dissolving as it releases the cell cavities."
CeramClean II is environmentally friendly and safe to use.
Ultrasonic cleaning by Max Daetwyler
Max Daetwyler Corp.
www.daetwyler.com
The MDC Ultrasonic Cleaning system is most effective when the roller distance from the immersibles is constant, regardless of the diameter of the roller. With the push of a button, Daetwyler's new Power Dept Adjustment raises the cleaning tank with solution to the cylinder and automatically stops at the optimum distance.
Also, Daetwyler's new direct drive rotation provides constant rotation—no belts, chains, or slipping rollers. The anilox rests on idler rollers on each end. The anilox roller is attached to the drive shaft via a coupling, designed specifically for a printer's roller. This coupling is then connected to the flexible drive shaft of the direct drive motor. The roller is then lowered into the solution by the Power Dept Adjustment, meaning there's no need to continuously monitor the cleaning process.
The MDC Ultrasonic Cleaning system uses Crest Components, too. "Only Crest's Genesis generator delivers the constant power output necessary for generating the consistent cavitation intensity that promotes consistent cleaning," Cansler said. "Crest's exclusive Tru-sweep™ feature ensures uniform cleaning throughout the tank by sweeping the generator frequency +1 kHz, creating overlapping ultrasonic waves. That eliminates the risk of hot spots and dead zones."
C.A.R.E. by Pamarco
Pamarco Global Graphics
www.pamarcoglobal.com
Pamarco's C.A.R.E. program offers powerful and effective, yet safe cleaning solutions for every printing situation. We have specific cleaners for water-based, solvent-based, and even UV-based ink systems. Pamarco's cleaners fall well within the safe pH range, ensuring a healthy working environment.
The preventative maintenance cleaners are uniquely designed to be reused three or four times on average through an ink wash circulation system. This reuse can lead to significant water savings. These cleaners can be used in all aspects of the printing operation, including heavy-duty cleaning of the surrounding machinery.
Part of the C.A.R.E. program includes an entire service based on the printer's needs. Pamarco fully trains all personnel on proper roll and press management, and performs free audits for all anilox rolls on a regular schedule or by request.
by Kate Sharon
Associate Editor
