Submitted By – Ankur Jha & Tanuj Soni
TABLE OF CONTENT
• PURPOSE OF PROJECT
• ANILOX ROLLERS
• ANILOX LASER CLEANING
• WORKING OF ANILOX LASER CLEANING
• CLASSIFICATION of anilox laser cleaning
• ADVANTAGES OF ANILOX LASER CLEANING
• SITEXCOLABEL L10 MACHINE INTRO.
• INDUSTRIAL VIST
• RESULT AND ANALYSIS
Executive Summary
There is a growing trend towards sustainable practices in the printing
industry. Methods like Anilox dry cleaning, which reduce chemical usage
and waste, are increasingly preferred. As printing technologies evolve, there
is a corresponding demand for maintenance methods that optimize
performance and reliability. Anilox dry cleaning fits this requirement by
ensuring consistent and efficient ink transfer.
To ensure successful adoption, we must conduct awareness campaigns and
demonstrations. Competitive pricing will be offered to emphasize long-term
cost savings. We will target major manufacturing hubs initially and identify
the best customers based on industry data.
INTRODUCTION
Purpose
The main purpose of this project is to introduce and find out the
effectiveness of a new advanced anilox laser drycleaning technology. Anilox
dry cleaning services can differentiate themselves by promoting
environmentally friendly practices and cost-effective solutions. Dry cleaning
methods typically require less downtime compared to wet cleaning
methods that involve drying time for solvents. This minimizes production
interruptions and increases operational efficiency. Gentle dry-cleaning
techniques help preserve the integrity of Anilox rolls, extending their
lifespan and reducing the frequency of replacements.
ANILOX ROLLERS
Anilox rollers are critical components in printing processes, particularly in
flexographic printing. Here's a detailed overview of Anilox rollers, their structure,
functions, and importance in the printing industry:
Structure and Design:
1. Cylindrical Shape: Anilox rollers are cylindrical in shape, typically made from
materials like steel, aluminum, or ceramic. The choice of material depends on
factors such as durability, wear resistance, and compatibility with different inks.
2. Engraved Surface: The surface of an Anilox roller is engraved with millions of
tiny cells or pits. These cells are arranged in a specific pattern across the roller’s
surface. The pattern and depth of these cells determine the volume of ink that can
be transferred to the substrate during printing.
3. Cell Configuration: Cell Shape: The cells can be hexagonal, quadrangular, or
other geometric shapes, depending on the printing requirements.
Cell Volume: Each cell has a specific volume, measured in BCM (billion cubic
microns), which indicates the amount of ink it can hold and transfer per unit area.
Functions:
1. Ink Transfer: Anilox rollers are responsible for transferring a precise amount of
ink from the ink fountain or supply system to the printing plate or directly onto the
substrate.
2. Uniform Ink Distribution: The uniform distribution of ink ensures consistent print
quality across the entire print run. The controlled release of ink from the Anilox
roller's cells contributes to sharp images, vibrant colors, and accurate detail in
printed materials.
3. Compatibility: Anilox rollers are used in various printing processes, including:
Flexographic Printing: Common in packaging industries for labels, corrugated
cardboard, and flexible packaging.
Offset Printing: Widely used in commercial printing for magazines, books, and
brochures.
Gravure Printing: Used for high-volume printing of publications and packaging.
Importance:
1. Print Quality: Anilox rollers play a crucial role in achieving high-resolution prints
with consistent ink coverage. They help maintain sharp text, fine lines, and vibrant
colors essential for quality printing.
2. Productivity: By ensuring efficient ink transfer and distribution, Anilox rollers
contribute to increased productivity and reduced waste in printing processes.
3. Versatility: Anilox rollers can be customized with different cell configurations
to meet specific printing requirements, such as different substrates, ink types, and
print designs.
Maintenance:
1. Cleaning: Regular cleaning of Anilox rollers is essential to remove dried ink
residues and contaminants from the cells. Cleaning methods include mechanical
brushing, ultrasonic cleaning, and advanced techniques like laser cleaning.
2. Inspection: Periodic inspection helps identify wear and tear on the roller's
surface or changes in cell volume, ensuring consistent print quality and extending
the roller's lifespan.
In conclusion, Anilox rollers are indispensable components in modern printing
technology, ensuring precise ink transfer and maintaining high print quality across
a variety of printing applications.
Their structured cell patterns and materialcompositions are tailored to optimize ink
management and enhance printing efficiency in diverse industries worldwide.
ANILOX LASER CLEANING
The Laser Anilox Cleaner uses cutting-edge technology to deep clean anilox
rolls with no waste and no need for a water source. It is very effective on all ink
types. This waste-free, completely safe and fully automatic method of cleaning is
a sustainable cleaning option for printers. The laser anilox cleaning system
removes the ink from inside the cylinder cells, extracting any type of ink, glue or
varnish.
WORKING OF ANILOX LASER CLEANING:
Anilox laser cleaning is an advanced method used to clean anilox rolls, which are crucial
components in printing and coating processes. This method utilizes laser technology to
remove ink, coatings, and other contaminants from the cells of anilox rolls. Here’s how
anilox laser cleaning generally works:
1. Laser Technology: Anilox laser cleaning systems use high-intensity laser beams,
typically generated by fiber lasers or CO2 lasers. These lasers emit focused pulses
of light energy that are precisely controlled.
2. Non-contact Process:Anilox laser cleaning is a non-contact process, meaning
there is no physical scraping or abrasion involved. This reduces the risk of damage
to the delicate cell structure of the anilox roll, which is crucial for maintaining
print quality.
3. Selective Absorption:The laser energy is selectively absorbed by the
contaminants on the surface of the anilox roll, such as dried ink or coating
residues. Different materials absorb laser energy differently, allowing the system
to target and break down the contaminants while minimizing impact on the anilox
roll itself.
4. Vaporization and Cleaning: When the laser energy is absorbed by the
contaminants, it heats them rapidly. This causes the contaminants to vaporize or
break down into smaller particles that can be easily removed from the surface of
the anilox roll.
5. Control and Precision:Laser cleaning systems are highly precise and controlled.
Operators can adjust parameters such as laser power, pulse duration, and
scanning speed to optimize cleaning effectiveness based on the type and
condition of the anilox roll.
6. Environmentally Friendly: Compared to traditional cleaning methods that may
involve harsh chemicals or abrasive materials, anilox laser cleaning is
environmentally friendly. It does not produce chemical waste or use solvents,
making it a sustainable cleaning solution.
7. Post-Cleaning Inspection:After laser cleaning, the anilox roll is typically
inspected to ensure all contaminants have been effectively removed. This
inspection ensures that the roll is ready for use in subsequent printing or coating
processes.
Anilox laser cleaning is particularly beneficial for industries where maintaining precise
and consistent print quality is essential. It offers advantages such as reduced downtime,
extended anilox roll life, and improved operational efficiency by minimizing the need
for manual cleaning and the associated risks of damage or inconsistency.
CLASSIFICATION OF ANILOX LASER CLEANING:
Anilox laser cleaning can be classified based on several factors that influence how the
process is executed and its effectiveness in cleaning anilox rolls:
Laser Type:
o Fiber Lasers: These are commonly used for anilox roll cleaning due to their
high efficiency and precision. Fiber lasers are suitable for both organic and
inorganic contaminants on the roll's surface.
o CO2 Lasers: These lasers are effective for removing organic contaminants
but may have limitations with certain types of inorganic materials.
Laser Parameters:
o Power: The laser power determines the intensity of the laser beam and its
ability to break down contaminants. Higher power lasers can handle tougher
cleaning jobs but must be carefully controlled to avoid damaging the anilox
roll.
o Pulse Duration: This parameter controls how long each pulse of laser
energy lasts. Shorter pulses can be more effective for precise cleaning
without heating the anilox roll excessively.
Cleaning Mechanism:
o Vaporization: Laser energy vaporizes contaminants on the surface of the
anilox roll, turning them into gas that is expelled from the roll's surface.
o Ablation: Some laser systems use controlled ablation, where the laser
removes contaminants layer by layer, ensuring thorough cleaning without
damaging the roll's surface.
Automation and Control:
o Manual Systems: In some setups, operators manually control the laser
cleaning process, adjusting parameters based on visual inspection of the
roll's condition.
o Automated Systems: Advanced laser cleaning systems may be fully
automated, with pre-programmed cleaning cycles and feedback
mechanisms to adjust parameters based on real-time monitoring of the
cleaning process.
Application Specificity:
o Printing vs. Coating: The specific requirements for cleaning anilox rolls
used in printing applications (e.g., flexographic printing) may differ from
those used in coating applications (e.g., applying varnishes or adhesives).
Overall, the classification of anilox laser cleaning methods considers the technical
specifications of the laser system, the cleaning mechanism employed, the degree of
automation, and the specific application requirements. Each classification helps in
understanding how laser cleaning technologies can be optimized for different industrial
needs while ensuring efficient and safe cleaning of anilox rolls.
ADVANTAGES OF ANILOX LASER CLEANING
Anilox laser cleaning is a specialized method used to clean and maintain anilox rollers,
which are critical components in printing and coating processes. The significance of
anilox laser cleaning can be understood through several key points:
1. Efficiency and Precision: Laser cleaning offers a highly efficient and precise
method for removing dried ink, coatings, and contaminants from the surface of anilox
rollers. It targets specific areas without causing damage to the roller itself, ensuring
that the engraved cells remain intact and functional.
2. Maintaining Print Quality: Clean anilox rollers are essential for maintaining
consistent print quality. Ink or coating buildup on the roller can lead to uneven ink
transfer, which affects print clarity, color consistency, and overall print quality. Laser
cleaning helps restore the roller's ability to meter and transfer ink uniformly.
3. Extended Roller Lifespan: Regular cleaning with laser technology helps extend
the lifespan of anilox rollers. Proper maintenance prevents the accumulation of
hardened residues that could otherwise degrade the roller surface over time, leading to
costly replacements or repairs.
4. Environmental Benefits: Laser cleaning is often chosen for its environmental
benefits compared to traditional cleaning methods using chemicals or abrasives. It
generates minimal waste and avoids the use of solvents or harsh chemicals, making it a
more sustainable option.
5. Operational Efficiency: By maintaining clean anilox rollers, printers can reduce
downtime associated with roller maintenance and cleaning. This improves overall
operational efficiency and productivity in printing processes.
6. Versatility: Laser cleaning can be applied to various types of anilox rollers, including
those with ceramic or chrome surfaces, and can effectively clean rollers of different
sizes and specifications used in flexographic, offset, gravure printing, and coating
applications.
In conclusion, anilox laser cleaning is significant because it offers a precise, efficient,
and environmentally friendly method for maintaining the performance and longevity
of anilox rollers, thereby ensuring consistent print quality and operational efficiency in
printing and coating processes.
SITEXCOLABEL L10 MACHINE
INTODUCTION
Eaglewood Technologies proudly introduces the Sitexco Label L10 Anilox Cleaning
System! This laser system is designed using the award-winning Sitexco technology and
is specifically for narrow web printers. Cleaning times are between 5 and 15 minutes
with no water or chemicals needed and no waste produced. It is a lightweight, desktop
machine that will deep clean any ink chemistry; water-based, energy curable (UV/LED),
solvent-based, adhesives, varnishes and coatings. It is cutting-edge technology in the
most economical package available.
The Sitexco Label L10 will support any sustainability initiative by using no chemicals,
producing no waste as well as improving print quality and thus production area
workflow.
INDUSTRIAL VISIT
1.Prakash Hitech pvt ltd – this company was a flexible substrate printing press which
consist of different types of flexography machines which was capable in printing flexible
substrates. This industry was having a total number of 118 anilox roller which were cleaned with
the help of ultra sonic cleaning process.
Different types of machines were as follows -
A. Novaflex A5 [2] – This was a type of flexography printing machine having several
specifications –
• Web width – 12 inches Circumference
• Speed -200m/min
• Ink type – UV based
• Dryer – UV LED CURING SYSTEM
• Unit – 8
• Inline Attachment – single unit gravure mechanism for lamination purpose
• Special attachment – 2 cameras for QC
B. NOVA SMART [1] – Specification of this flexography machine are –
• Web width – 12 inches Circumference
• Speed – 150m/min
• Ink type – UV based
• Dryer – UV based
• Unit – 8
• Special attachment – 6 cameras for QC
C. ANALOX CLEANING [ ani-clean] - This machine was an ultrasonic cleaning machine which was
capable of cleaning the anilox rollers used in flexography printing ink unit with the help of
ultra sonic waves. The specification of this machine is –
• 5kg solution with 15 L of water in a single tank
• Electrical power input 250V
• Electrical motor one phase 15AMP
• Time consumption 25 to 30 mins
• Cleaning capacity 2 rollers at a time
• Cleans at the temperature of 55 degree celsius
2. MARKS EMEBLAGE PVT LTD – This company was a flexible substrate printing
press which consist of different types of flexography machines which was capable in printing flexible
substrates This industry was having a total number of 69 anilox roller which were cleaned with the
help of ultra sonic cleaning process.
Different types of machines are as follows
A. GALAXY LABEL MASTER [2] - This is a type of flexography printing machine having several
specifications –
• Web width - 440 MM
• Speed 150 - 200/min
• Ink type - UV based
• Dryer - UV LED CURRING SYSTEM
• UNITS - 10
• Inline Attachment - Single unit gravure mechanism for lamination purpose and single unit of
pantack
B. ANALOX CLEANING [ Ani-clean]
This machine was an ultrasonic cleaning machine which was capable of cleaning the anilox roller
used in flexography machine. Specifications are as follows -
• Uses 5kg solution with 15 L of water in a tank
• Electrical power input 250V
• Electrical motor one phase 15AMP
• Time consumption 25 to 30 mins
• Cleaning capacity 2 rollers at a time
• Cleans at the temperature of 55 degree celsius
3. ARIHANT LABELS PVT LTD - This company was a flexible substrate printing press
which consist of different types of flexography machines which was capable in printing flexible
substrates .
Different types of machines are as follows -
A. Multitech Ecoflex – This is a type of flexography printing machine having several
specifications -
• Web width - 450 MM
• Speed - 150 meter per min
• Ink type - UV based
• Dryer - UV LED CURRING SYSTEM
• Units - 8
B. Alliance - This is a type of flexography printing machine having several specifications –
• Web width - 450 MM
• Speed - 150 meter per min
• Ink type - UV based
• Dryer - UV LED CURRING SYSTEM
• Units - 8
C. ANALOX CLEANING [ ani-clean] - This machine was an ultrasonic cleaning machine which was
capable of cleaning the anilox roller used in flexography machine with the help of ultra sound
waves. Specifications are as follows -
• Uses 5kg solution with 15 L of water in a tank
• Electrical power input 250V
• Electrical motor one phase 15AMP
• Time consumption 25 to 30 mins
• Cleaning capacity 2 rollers at a time
• Cleans at the temperature of 55 degree celsius
RESULT AND ANALYSIS
❖ In an era where environmental concequencious is a key driver of decision making, businesess
are poting towards sustainable practices. One significant stride in this direction is the wide
spread adoption of fast moving cleaning equiptments.
❖ By this training we learnt how fast and steady the anilox cleaning machines could be. There
are several cleaning devices/machines which are mandatory for the big firms for their never
ending and sustainable jobs and one is anilox laser cleaning machines.
❖ Anilox laser cleaning is the next big thing in the printing industries based is india because it
can make a boom with its fast, easy and deep cleaning. It is making a big impact in the
present growing industry with its capability of cleaning the flexography’s anilox roller with the
help of laser light in fast and convenient way. It eliminates traditional methods having varies
long techniques and complicated styles.
