Inconsistent coating quality is often a result of anilox volume loss, which is caused by plugged anilox cells or a worn anilox surface in need of re-engraving. How can you tell if your anilox volume loss is a result of plugging or surface wear?
Examining your roll under a roll scope will provide you with clues to determine the cause of your volume loss. This information will then help you determine if it is time to re-engrave or if cleaning could return anilox cells to their original volume. Too often, rolls are returned to the manufacturer for expensive re-surfacing when a simple on-press cleaning is all that's needed.
Newly Engraved Surface
This is a picture of a newly engraved anilox surface. The cells have consistently thin walls and well-defined cell bottoms.
Anilox Cell Plugging
When anilox cells become plugged, dried coating residue diminishes the capacity of the cells and causes volume loss. In this case, you will notice that the thickness of the cell walls has not changed but the bottoms of the cells have far less definition. An on-press cleaning with a chemical cleaner and roll cleaning brush or an off-press mechanical deep cleaning should remove the debris and restore cell volume.
Anilox Surface Wear
As the anilox surface wears down, cell capacity is diminished and cells cannot carry the proper volume of coating. Under a roll scope, you can see that the cell walls are getting wider which indicates that the cells are becoming shallower. In this case, re-engraving is necessary to regain cell volume.
Using a roll scope to determine the cause of your anilox volume loss will help you decide on the best course of action to restore volume and may save you thousands of dollars in re-engraving costs.