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How to Prevent Anilox Roll Scoring

Anilox roll scoring has become a real challenge for offset printers applying coatings due to its devastating impact on the coated product and substantial cost to repair or replace the roll once scored.
 
A score in an anilox roll is a groove that has run directly through the engraved surface.  The score translates to a visible line in the coated product and is irreversible; once the surface is scored, the roll must be re-engraved or replaced.  For these reasons, it is crucial to prevent scoring whenever possible.

3-D Image of Anilox Roll Score Line
You can recognize a score mark as a thin, circumferential line on the surface of the anilox roll that appears to be darker than the rest of the roll.  The primary causes of score lines are slivers of steel doctor blades or ceramic pieces that break off and get lodged against the roll as it turns, contaminants in the coating system, misaligned chambers, and excessive doctor blade pressure.

Tips to Reduce Anilox Scoring:
1.  Keep anilox rolls clean of dried coating and contaminants.
2.  Repair any chipped ends of anilox rolls with a two-part epoxy.
3.  Check and ensure proper doctor blade pressure and chamber alignment.
4.  Install an in-line filter with a strong magnet that will trap contaminants.  Check and clean the filter regularly.
5.  When possible, wipe down the back of the doctor blade to remove any slivers or other contamination (wearing protective gloves).
6.  Use plastic or composite doctor blades in place of steel.
7.  Keep coating containers covered at all times so that foreign particles cannot make their way into the system.

Eliminating scoring altogether may not be possible.  However, minimizing scoring with a good internal preventative maintenance program will help prolong anilox life and preserve coating quality.

Learn about our UltraFlex composite doctor blade to reduce anilox scoring