Total Anilox Management
The Best Practice of Anilox Inspection,
Management and Maintenance
Total Anilox Management
WARNING
This presentation may lead you to review your
anilox cleaning practices and equipment.
It will almost certainly lead you to having some
of your aniloxs refurbished or replaced
Total Anilox Management
Over the past decades we have seen higher and higher demands
come from the ‘BRANDS’ and other discerning customers to produce
more desirable print, with increased colour gamut, and more
importantly achieve density variations of better than 3ΔE.
To meet these requirements, printers of all types have had to adapt
QC procedures which enable them to achieve these targets
consistently, whilst remaining profitable and competitive.
Total Anilox Management
Many improvements have been achieved through:
a) New developments and improvements on Press and with
Press controls
b) Improved Inks and inking methods and controls
c) Plate developments which have enhanced colour gamut
significantly (mainly with flat topped dots and HD Flexo)
d) Aniloxs; improvements in design and production
With the exception of aniloxs, the above items are regularly checked
and maintained by print technicians and their managers.
Total Anilox Management
Since the development of ANILOX MANAGEMENT printers now have
QC tools that gives them empirical data that has proven to
enhance productivity, improve profitability and
competitiveness……
Having control has proven to make savings of
1 to 3 hours of set-up time per press per day
(time dependant on press process type.)
Total Anilox Management
IMPORTANT STATEMENT
# Using an anilox with 4 bands,
# run on a narrow web press,
# engraved with 0.1cm³/m² steps, and
# run on all 4 process colours.
Has led to the following regularly achieved guide-line:
0.4cm³/m² approximates to 3ΔE
Total Anilox Management
Deep Clean Anilox
See note 1
Note 1:
Deep cleaning typically should be
carried out every 2 to 6 weeks
dependant on ink type and usage, and
for new Aniloxs
Re-clean Anilox to ensure
cleaning process is optimised
With Anilox QC
Measure volume laterally.
Check for cracking & damage
See note 2
Compare volumes of rolls that
should be of equivalent value
using AMS
If greater than 0.4cm³/m² or
shows cracking
Refurbish
Note 2:
Lateral measurements are typically taken in:
2 places for label aniloxs,
3 places for wide web and
5 places for corrugated and coating rolls.
Total Anilox Management
In-house anilox
management
Anilox Management System
Showing the roll history
including images.
Shows the condition and
indicates when the roll
needs intense cleaning, or
refurbishing due to wear.
Total Anilox Management
Compare volumes of rolls
that should be of equivalent
value using AMS
Ensure difference
is less than
0.4cm³/m²
See note 3
Run Aniloxs on press
knowing set up time is
minimised
If greater than 0.4cm³/m²
refurbish lowest volume aniloxs
Note 3:
A difference of greater than 0.4cm³/m² has
been shown to display a visible difference in
print density of approximately 3ΔE.
Total Anilox Management
AMS Management Report
Management
Report
Showing the
inventory condition
and volumetric and
lateral differences
between aniloxs.
Identifies the
condition and
indicates when the
roll need
refurbishing .
Total Anilox Management
Deep Clean Anilox
See note 1
Note 1:
Deep cleaning typically should be
carried out every 2 to 6 weeks
dependant on ink type and usage.
Re-clean Anilox to ensure
cleaning process is optimised
With Anilox QC
Measure volume laterally.
Check for cracking & damage
See note 2
Compare volumes of rolls
that should be of equivalent
value using AMS
Ensure difference
is less than
0.4cm³/m²
See note 3
Run Aniloxs on press knowing
set up time is minimised
If greater than 0.4cm³/m²
or shows cracking
Refurbish
Note 2:
Lateral measurements are typically taken
in: 2 places for label aniloxs,
3 places for wide web and
5 places for corrugated and coating rolls.
If greater than 0.4cm³/m²
refurbish lowest volume aniloxs
Note 3:
A difference of greater than 0.4cm³/m² has
been shown to display a visible difference in
print density of approximately 3ΔE.
Total Anilox Management
How is in-house anilox management achieved?
AniCAM: 3D
scanning
microscope
Anilox QC
software
application
Anilox
Management
System
Total Anilox Management
How is in-house anilox management achieved?
AniCAM: 3D
scanning
microscope with
battery pack.
Used to capture the
stack of images for
3D analysis.
Total Anilox Management
How is in house anilox management achieved?
Anilox QC application showing the scanned image;
volume; average cell depth; screen count and angle.
Total Anilox Management
How is in house anilox management achieved?
AMS showing an inventory allowing the production
manager to monitor anilox condition , the efficiency
of the cleaning process and plan for refurbishment.
Total Anilox Management
CONSEQUENCES OF
ANILOX MANAGEMENT.
In exactly the same way that a printer who fails to meet the
demands of the BRANDS will not remain competitive. Some
engravers have lost significant business by failing to keep up
with modern engraving techniques and honouring their stated
volumetric tolerances.
Total Anilox Management
It is essential for printers to know their aniloxs are within an
agreed and workable specification; whether new or old.
Therefore, discuss with your anilox manufacturer what their
stated engraving tolerances are:
Some work in percentages:
±10% of a 3.6 cm³/m² engraving is from 4.0 down to 3.2 cm³/m²(too large)
±5% of a 3.6 cm³/m² engraving is from 3.8 down to 3.4 cm³/m² (acceptable)
Total Anilox Management
Cost saving examples of ANILOX MANAGEMENT when
used as part of the QC process:
Narrow web: proven time savings of 1 hour per press per day is frequent:
Narrow web press time is typically £250/hour
For 4 presses that is 28 hours additional production time or £7,000 per week
1,460 hours additional press time per year
Wide web: where proven time savings of over 2 hours / press / day:
Wide web press time is typically £500/hour
For 3 presses that is 42 hours additional production time or £21,000 per week
2100 hours additional press time per year
In almost every case the ROI is less than 4 weeks once
implemented and in process
Total Anilox Management
Thank you for listening

Phil Hall
Troika Systems Limited
www.troika-systems.com
+44 1793 766 355