As one of the top independent experts in thermal spray coatings, Alphatek Hyperformance Coatings offers comprehensive thermal spray coatings, metal spraying, fluoropolymer coating, and finishing services. We have provided these services to different sectors across multiple industries.

Thermal spray application coating methods have been embraced by many industries and the print and paper industry isn’t an exception to that. Keeping the printing and packing equipment well-maintained is important for the performance and efficiency of the equipment.

Roll Refurbishment

An anilox roll is sturdy and cylindrical, usually made from a steel or aluminium core and covered with an industrial-type ceramic. The surface of these rolls is covered completely in tiny bumps known as cells.

One aspect of roll refurbishment is the disassembly and reassembly of used roll assemblies. Doing this does have perks:

  • The ability to handle some of the largest roll assemblies with confidence.
  • When they’re handled during the refurbishing process, assemblies are protected.
  • Disassembly allows the roll assemblies to be cleaned more effectively which enhances product quality.
  • A quick turnaround time.
  • After reassembly, many rollers perform more effectively.

Anilox Rollers are quite often regarded as the beating heart of the print and paper industry. This is because these rollers can accurately transfer an exact and a consistent quantity of ink onto paper. Therefore, it’s essential that these rollers are kept in really good condition not just for the benefit of one country but in every country where printing happens.

How Anilox Rollers Work

Metering rolls, which are referred to as anilox rolls, work to supply a concisely measured volume of ink, varnish, or a coating onto the paper being printed.

Concise laser engravings, controlled by computers, of ceramic-covered steel rollers have essentially replaced the older techniques of mechanically engraving cells onto the surface of the roll. During this process, millions of microscopic cells are punched into the surface of the ceramic roll.

The surface technology and the surface tension of the plate, and the compatibility of the plate with the ink all have an impact on the ability to transfer ink. When it comes to anilox rollers, the receptivity of the ink and the delivery capacities are of greater relevancy.

Some of the contemporary anilox rollers are laser-engraved steel rollers which have been covered in a fine ceramic. Depending on the wear induced by blade contact, these specific ceramic rolls can endure for up to 10 years.

The Importance of Anti-Corrosion Coatings

Corrosion is a naturally occurring chemical reaction that takes place when the atoms of a metal surface are exposed to oxygen, causing them to oxidise. There are many metal elements that oxidise fairly easily due to losing electrons to oxygen. This loss of electrons affects the overall structure of the substrate, damaging the surface as a metal oxide is formed.

Once corroded, metal loses its purity. What this means is that metal can lose some of the properties that make it the material that it is. For instance, steel is a popular metal chosen for many infrastructures and machine parts across the country. But it loses its strength and tenacity when it begins to corrode as the corroded areas begin to weaken and crumble.

In serious cases of corrosion, this can lead to structural collapse.

Not only is the makeup of the metal element affected, but the appearance is, too. Metal that has undergone the process of corrosion can sport cracks, holes, and massive decolouration.

Substituting corrosive metals in structures with non-corrosive metals or coating corrosive metals with non-corrosive metals are common ways to prevent corrosion. This is why the core of anilox rollers is made from stainless steel or aluminium.

Alternatively, a layer of no particular substance can be fixed onto the surface of the metal, protecting it from contact with moisture and oxygen in the air. Then, no reaction can occur because there is a physical barrier between the metal component and the oxygen. This is how anti-corrosion coatings work.

Anti-Corrosion Coating Solutions for Roll Refurbishment

Thermal sprays extend the life of printing equipment, saving money over time. This is due to the fact that it reduces repair time while enhancing productivity.

As a result, it’s quite important that the spray coating solutions are long-lasting and dependable. Alphatek has a long history of supplying metal spraying solutions that improve efficiency in the print and paper industry.

Our HVOF and Fluoropolymer coatings deliver a level of protection against aggressive wear and corrosion that is unparalleled.

Roll Refurbishment

Process rollers can be refurbished in-house or at Alphatek’s purpose-built facility.

Ink is transferred to paper using engraver rolls. Ceramic coated rolls have excellent transfer acceptability because they are tougher and have a larger surface area for wetting. Plasma spray is more easily accepted and it provides greater corrosion resistance.

Draw rolls come in a variety of sizes and are constructed of hardened steel so they will wear, oxidise, and alter in dimension over time. With these rolls, there’s an increased amount of repairs and restorations.

Anilox Rolls

During the Thermal Spray Plasma (APS) process, anilox rolls are coated with a ceramic Ni-based sub layer and a Cr Oxide-based top coating.

Then, the rolls are diamond honed and laser engraves to establish a surface profile that offers a consistent level of ink to the printing paper.

Alphatek’s Solutions

Most of our coating solutions have been designed to meet the unique application needs of each of our clients. In general, they’ve been developed to extend component life by providing said component with a protective coating. The solutions we deliver can have specific resistance features – rust, corrosion, abrasion, wear, and friction resistance.

If you’re in need of or interested in our services, get in touch with the team. Email us with your enquiry details at postbox@alphatek.co.uk and we’ll respond to you as quickly as possible.

To speak directly to a member of the team, call us on 01706 821 021.

Fancy an in-person visit? Check our opening times before popping in but come along! We’re just 20 miles north of Manchester.