Ceramic anilox roller development process!

In 1970, driven by the development of the thermal spray processing industry, it was proposed to make an anilox roll using a hard thermal spray ceramic layer. However, because the ceramic layer was too hard (up to HRC70, HV1100), the engraving was difficult, so it only stayed at that time. Theoretical stage. Only after the mature development and application of laser technology in 1984, ceramic anilox rolls were officially launched.

This process uses high-energy plasma thermal spraying to spray a layer of Cr2O3 metal oxide ceramic material on the surface of the metal roller, and then uses a precision grinding and polishing process to achieve a mirror effect on the roll ceramic layer, and then utilize the high energy of the laser beam. The ceramic layer is vaporized to complete the engraving of the textured shape.

Mysterious “Anilox”

Anilox roller, as the name implies, is straightforward, that is a roller with a "Anilox" on the roll surface. We can't see those "Anilox" with the naked eye, it doesn't mean they don't exist, just because they are too thin and too small, they need a magnifying glass, under the magnifying glass of 200 times or more, we can have a glimpse of the "Yushan True Face" of the net. The typical ceramic anilox roll mesh shape is shown below:

From left to right, they are 60° honeycomb, 30° honeycomb, 45° diamond, 1-89° diagonal (angle adjustable), and other mesh shapes can be engraved according to customer needs. 95% of the ceramic anilox rolls use a 60° honeycomb type mesh because it has the most compact arrangement, the largest amount of ink, and the ink release is also good, which can reduce the corner effect, because the cell boundary is not in the horizontal direction. On the top, it can also avoid the "channel effect" of the 30° engraving angle. 30° is another embodiment of the honeycomb type, which can reduce the “needle eye failure” in printing, and is mainly used in a small part of the coating industry. 45° and slanted ceramic anilox rolls, mostly used in the UV glazing and coating industries.

Experts say that ceramic anilox rolls are the future of anilox rolls

However, in actual production applications, there are many users who have such concerns or concerns about ceramic anilox rolls. They reflected that the ceramic anilox roller was too delicate. If it accidentally touched it, it would drop a piece of porcelain or a pit. It would cost thousands or even tens of thousands of dollars at a time, which was too expensive. So if it is not necessary to use ceramic anilox rolls, they would rather choose a cheaper metal anilox roll. In fact, for metal anilox rolls, they are not more "anti-collision" and "anti-cracking" than ceramic anilox rolls, and the surface hardness of the two is quite different. However, the cost of refurbishing the metal anilox roll after smashing is very low, giving the user a mentality: the ceramic anilox roll is too expensive! In fact, in terms of service life, ceramic anilox rolls are usually metal anilox rolls 5-10 times, and the price is only 3-5 times that of the metal anilox roller, especially the anilox roller using the doctor blade system; in terms of the uniformity of the inking (coating), the ceramic layer of the ceramic anilox roller has Capillary pores, which are hydrophilic, make the ink layer (coating) more uniform and finer, which can significantly improve the quality of the print. For some industries where the price of coatings is very expensive, although the use of ceramic anilox rolls increases the cost of the moment, in the long run, the material consumption will be greatly saved, the production speed will also increase, and the benefits will be obvious.