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FLEXO Magazine : December 2011
it recognizes the unavoidable volume loss caused by plugging of cells and wear to the roll surface over time. An audit should include comments related to any physical damage to the engraved surface, such as: score lines, dings, scratches, chipped ends, blisters, etc. This data will not only be useful on the production floor but may identify need for ad- ditional training, highlight areas for improvement and assist with justification when budgeting for replacement rolls. With advancements in plate and ink technologies, it’s pos- sible for today ’s printer to meet the high level of quality that customers demand with fewer anilox engravings. Print quality that once required seven different engravings, can now be accomplished with four. Built on the foundation of known anilox volume and condition, the 60-degree hexagonal cell is still the preferred engraving to achieve the highest print quality based on trial after trial. That’s exactly why all anilox suppliers still offer it. Keep in mind, any anilox standardization program must certainly offer consistent, repeatable, and reliable measure- ments. If you are unable to measure it, how can you expect to control it, and how do you know what you are getting? READING RESULTS Upon receipt of roll audit results, the information needs to be reviewed and also made available to operators. While reviewing the results, make note of which rolls are plugged and In need of a thorough cleaning; worn, with wide posts and walls or damaged, with visible score lines, dings, or chipped ends. With the use of a hand-held, 200X or 400X magnification microscope, operators can easily view the condition of an anilox roll. This simple tool can greatly reduce time spent troubleshooting on press. With results in hand, printers must move out to avoid plug- ging of cells. This requires an evaluation of the effectiveness of current cleaning procedures. Steps must be taken to ensure all cleaning instructions are followed. Also, if an off-line cleaning system is being used, printers must be sure it is working prop- erly. They can refer to the manufacturer’s operation manual that recommends routine maintenance and then make sure it is performed by trained personnel. In the case of worn or damaged rolls, they should be removed from inventory to avoid having damage to the surface of the roll reflected in the print. Damaged anilox rolls can be sent out for reconditioning/resur- facing. Establish an ongo- ing system for tracking damaged anilox rolls, rather than being de- pendent on an outside source to supply you with a report. By doing so, you will increase your chance of determining possible causes. Preventative measures can then be put in place, resulting in less overall damage to inventory. (See chart) When tracking anilox roll damage, include the following data: • Press type or number—damage may only be seen on a specific press • Type of damage: score lines, impact damage (dings, scuffs, chipped ends, etc) • Location of damage—operator side, center, or drive side. Pictures may be helpful • Possible cause and preventative measures—include training or lack thereof: Awareness is key! Anyone who handles a roll has the potential to damage. All par- ties involved understand the need for proper care and handling. To help paint the picture, share the average cost per roll with your employees. It can be quite an eye opener. A hand-held microscope, available in 200 X or 400 X magnification, makes it possible for an operator to verify the condition of any anilox roll. Date Removed Mfg. Date Cust. Roll # Mfg. Roll # Press CPI Orig. Volume Current Volume OV/ETV% Comments / Reason Roll Removed from Inv. (Be very Specific) Possible Cause Determined Action Plan 02.02.11 08.15 .06 75 25432 2 600 3.00 2.32 77% unable to pull color Wear. Roll approx 3.5 yrs old. review audit reults. Results show wide posts and walls. 02.10.11 06.12 .09 26 36541 4 1000 1.80 1.72 96% score lines Excessive blade pressure. Contaminants in ink. 02.11.11 05.22 .09 45 35632 4 600 4.00 3.73 93% score lines Excessive blade pressure. Contaminants in ink. 02.18.11 07.15 .10 64 45672 4 800 3.00 2.82 94% score lines Excessive blade pressure. Contaminants in ink. 03.12.11 04.06 .10 52 43214 3 500 4.50 4.33 96% numerous dings (impact damage) on drive side. All wiithin 2 in. from roll end. Print cylinder gear coming in contact w/ anilox surface during installation / removal. 03.28.11 10.15.09 86 45952 3 600 3.00 2.82 94% numerous dings (impact damage) on drive side. All wiithin 2 in. from roll end. Print cylinder gear coming in contact w/ anilox surface during installation / removal. Anilox Remanufacture Log Conduct blade eval. Add filters and/or magnets. Training on proper blade instaltion. Cover anilox and raise print head prior to installing print cylinder. Create SOP. 62 FLEXO december 2011 www.flexography.org