Daily cleaning and maintenance of rubber rollers

The timely and correct daily maintenance of the anilox roller can effectively extend the service life, increase the usage, and bring greater benefits.

1. New roll running-in

Unless it is a last resort, do not use new rollers for proofing important orders. Although an anilox roll has undergone deburring, polishing and other processes before leaving the factory, and has been pre-run-in, it can effectively reduce the wear of the scraper during use, but this does not mean that the importance of running-in during the use of the new roll can be ignored Sex. When the new roll is just put on the machine, pay attention to it at the right time. If there are lines, stop and wipe the scraper in time. In general working conditions, the hardness of the particles is not enough to cause wear of the anilox roller, but it is not ruled out that some hard small particles impact the mesh wall under the action of the scraper to produce small ceramic chips that are clamped at the blade edge of the scraper, less than one. The shifts are enough to grind irreparable groove marks, and in severe cases, the roller body will be scrapped. This is also the reason why users often complain that new rollers are more prone to problems than old rollers. Generally, after 2-3 weeks of continuous running-in, relatively speaking, the screen wall is less sensitive to the impact of hard particles after being affected by the ink, doctor blade, and plate roller.

2. Shut down for production

If the machine stops for a short time, the anilox roller needs to keep rotating. When the machine is shut down for a long time, the anilox roller needs to separate the scraper in time, loosen the rubber pressure roller, and clean the floating ink, so as to avoid uneven ink supply in the horizontal direction or difficult to clean after the component ink is dried.

3. Scraper cooperation

High-quality scraper is an important factor to ensure the experience of using the anilox roll. The edge hardness of the scraper should be appropriate, not the harder the better. The shape of the cutting edge should be appropriate and pay attention to replacement.

4. Ink cleaning

Clean ink is of positive significance for preventing scratches on the anilox roller.

5. Ink loading detection of anilox roller

Although ceramic rollers have high hardness and long service life, they will also wear out as the use time increases. As a result, the ink-carrying capacity of the anilox roller gradually decreases with the increase of time. Therefore, if you want to conduct a more standardized and comprehensive management of the anilox roller, you need to regularly detect the actual ink capacity of the anilox roller.

Since the frequency of this work does not need to be too frequent, it is also a good choice to entrust this work to the anilox roll supplier.

Store

· The anilox roller should be stored in a dry place indoors to prevent it from being damaged by damp, rain or sun.

· When replacing the anilox roller, protect the roller surface to prevent collision damage. When storing, use a package made of natural fiber to wrap the roller.

· When storing, fix the roller on a special bracket, and don’t place the roller on the ground obliquely.

· When moving, it is necessary to pass the shaft heads at both ends of the roller instead of the roller surface to avoid friction and collision damage.

· After each printing or coating, the surface of the roller should be cleaned in time to avoid remaining ink or coating slurry left in the bottom of the mesh to dry and block.

· Frequently use a mesh microscope for inspection, and take corresponding measures if wear and blockage are found.

· Do not over-pressurize the scraper by adjusting the transfer amount, which will easily aggravate the abrasion of the anilox roller and the scraper.

· Do not rotate the dry anilox roll against the doctor blade.

· You need to reset the pressure of the scraper every time you update it, and the wrong pressure setting will cause scraper fragments.

· Stop using the scraper that has exceeded the maximum wear, establish a daily process for monitoring the wear of the scraper, and control the wear of the scraper stably.

· Keep the scraper parallel to the roller at all times, and calibrate it at regular intervals.

· Do not use inferior ink and coating slurry.

· Remove the dust on the surface of the printed product or coated substrate before printing to keep it clean.

· Use the correct mesh depth and opening ratio.

 

Common Problem

01. Scratch line

Reason analysis: The reason for the scratches on the surface of the ceramic anilox roller is that the hard small particles are mixed in the ink. When the doctor blade scrapes the ink, the small particles located between the doctor blade and the ink roller scratch the ceramic surface. Such small hard particles may come from metal particles shed by the doctor blade or the ink pump, dry solid ink particles, or impurity particles.

Solution:

Install a filter and a magnet block in the ink supply system to remove worn or chipped metal particles

Strengthen the cleaning of all parts of the ink supply system to prevent the generation of dry ink particles

· When using the chamber hanging ink knife, there should be enough ink to flow through the cavity, so that the scraper is fully lubricated and takes away the abraded script particles

 

02. Abnormal wear

Cause Analysis:

· The installation of the scraper is uneven and the force is uneven

· The scraper is over-stressed or insufficiently lubricated

· The quality of the ceramic layer is not up to standard

Solution:

·Install the squeegee carefully and set the squeegee before installation

Carefully clean the knife holder and lining knife

· Improve the quality of the ceramic layer

· Strengthen lubrication

 

03. Clogged mesh

Reason analysis: the cleaning work when the anilox roller is used up is not timely and incomplete

Solution:

· Observe the cleaning effect of the mesh with an appropriate magnification microscope

· Strengthen the cleaning of the anilox roller after printing

 

04. Physical damage

Cause Analysis:

· Direct collision with hard objects causes damage to the ceramic layer

· Improper cleaning method and selection of book collection may cause damage to the mesh wall

Solution:

· Strengthen the sense of responsibility to avoid mechanical collision accidents

· When off-machine storage, put on the protective cover of the pattern roller

· In-depth understanding of the characteristics of various cleaning methods, select a suitable cleaning method, give full play to the advantages of the method, and avoid the problems that may be caused by the method

· Read the instructions of cleaning equipment or cleaning materials in detail, and choose their operating parameters correctly

 

05. Corrosion and blistering

Analysis of the cause: This is caused by the corrosion of the base material of the anilox roller, which causes the surface of the anilox roller to bow, and in severe cases, it even causes local ceramics to fall off.

Solution:

· When ordering ceramic anilox rollers, please indicate the use environment of the anilox rollers. If it is a strong acid and strong alkali environment, the manufacturer needs to strengthen the anti-corrosion process measures.

· Use stainless steel as base roll material

· Avoid the use of strong acid and strong alkali chemical cleaning agents for cleaning the anilox roller

Cleaning method

The current methods of cleaning anilox rolls can be divided into the following categories:

1. Use special anilox roller cleaning agent, with steel brush or nano sponge for online cleaning.

2. Use an ultrasonic cleaning machine with special cleaning agent for cleaning.

3. High pressure water cleaning

4. Laser cleaning.

· Steel brush, nano sponge

Advantages: convenient cleaning, no disassembly and assembly, simple operation, thorough cleaning, no equipment, and low cost.

Disadvantages: Special alkaline cleaning solvent is required. For some stubborn inorganic substances, the effect is not as good as ultrasonic cleaning.

· High pressure water cleaning

Advantages: Relatively environmentally friendly and safe, with good cleaning effect.

Disadvantages: The price of equipment is high. In many cases, it is still necessary to use solvent to soak the ceramic anilox roller before turning on high-pressure water cleaning, and there are still consumables costs.

· Ultrasound

Advantages: No manual operation is required, and the effect on stubborn blockage is obvious.

Disadvantages: 1. The equipment is expensive, and cleaning solvents are still required in addition to the equipment;

2. The ultrasonic parameter control requires precision, and it is necessary to accurately evaluate the clogging of the anilox roller and prescribe the right medicine, otherwise it may cause damage to the anilox roller;

3. The use requires regular low frequency. Frequent use of ultrasonic cleaning of the anilox roller will damage the mesh wall and directly affect the life of the anilox roller.

· Laser cleaning

Advantages: The cleaning effect is the most clean and thorough, low energy consumption, no other consumables are required, no damage to the anilox roller, and can be cleaned online without disassembly of the anilox roller, especially suitable for cleaning large anilox rollers.

Disadvantages: The equipment is very expensive.

Each cleaning method has its advantages and disadvantages, and how to choose it needs to be determined by the printing company according to its own situation.

Regardless of the cleaning method, acidic cleaning agents and alternating temperature and humidity are two often overlooked details that cause the anilox roller to bulge. Compared with the alkaline environment, the acidic environment is more likely to corrode the substrate under the ceramic layer. Therefore, when the working condition is an acidic working environment, it must be specified in advance with the manufacturer when customizing, so that the corresponding level of anti-corrosion treatment can be done. In addition, experience has proved that in some workshop environments with high temperature and humidity and in workshop environments that use a lot of solvents, a layer of condensed water is easily formed on the surface of the anilox roll. It must be wiped in time during storage and stored after drying. The cleaned anilox roll should also be dried before entering the storage environment.


Post time: Apr-16-2021