Anilox Rollers are frequently referred to as the beating heart of the print and paper industry. These rollers are intended to supply the printing plate with an exact and consistent quantity of ink.

So you can see the importance of keeping the rollers in excellent condition. Especially considering how much printing is done, not just in this country but worldwide.

What Are Anilox Rollers?

An anilox roll is a sturdy cylinder that is often made of a steel or aluminium core and covered with an industrial ceramic. The surface is covered in millions of tiny bumps which are called cells. For the best printing results, selecting the proper anilox roller is crucial.

How It Works

The accurate managed transference of a liquid ink, varnish, or coating is essential to the printing and coating process. A metering roll that regularly supplies a precise and measured volume of ink onto the paper being printed is known as the anilox roll.

Concise computer-controlled laser engravings of ceramic covered steel rollers has largely superseded older techniques of mechanically engraving cells into the surface of the roll. Millions of tiny cells are punched into the ceramic roll surface during this procedure.

The plate’s ability to transport ink is influenced by its surface technology, the surface tension of the plate and the ink, and plate compatibility with the ink. Ink receptivity and delivering capacities are of a much greater relevance when it comes to the anilox rolls.

Some of the more recent anilox rolls are laser engraved from a steel roller and covered in fine ceramic. Their cell counts have even been reaching 500 per every centimetre. And depending on the wear caused by contact with the blade, these ceramic rolls can actually last up to 10 years.

Roll Refurbishment

Disassembling and reassembling used roll assemblies is a part of roll refurbishing.

There are multiple benefits to this task:

  • Ability to confidently handle the largest roll assemblies.
  • Assemblies are protected when handled throughout the refurbishing process.
  • Effective cleaning enhances product quality by enabling better examination.
  • Quick turnaround time.
  • More effective performances from the rollers.

Print & Paper Thermal Spraying Services

For use in the Print & Paper Industry, Alphatek has a successful and long history of offering highly effective metal spraying solutions that save costs and increase productivity.

Our in-house developed HVOF and Fluoropolymer coatings provide the best defence against corrosive and abrasive wear, and demanding circumstances. We can supply both and on- and off- site solution, giving our clients the most flexibility, with the fewest interruptions and downtime.

Applications for metal spraying in the print and paper sector include:

  • Roll Refurbishment
  • Resistance to Corrosion
  • Bearing Seats
  • Resistance to Wear and Tear

Roll Refurbishment Solutions

Process rollers for the paper, printing, and steel industries can be repaired on site or at the specialised facility created by Alphatek.

To prepare for refurbishment, the rollers are grit blasted. Then coatings are applied which could be metal alloys or thermal spray carbides.

Anilox Rolls

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

The rolls are then diamond honed and laser engraved to create a surface profile that will provide a level, steady consistency of ink to the printing paper.

Bearings and Seats

The bearings of rubber-coated rollers in the printing sector can become clogged and damaged by various debris and ink deposits due to the hostile environment within which they work. This wear and damage affects both the bearing and the bearing sets.

Thermally sprayed coatings that are applied to the harmed bearings and bearing seats can significantly prolong life while restoring all function.

Contact Alphatek

The numerous advantages our customers receive are evidence of Alphatek’s on-site or in-situ performance coatings service’s expanding global reputation.

Built to last is something we value. Our customers depend on your high performance coatings and finishes to boost profitability, enhance production, decrease downtime, cut waste and environmental impact.

With a smile on their faces at all times, our highly skilled crew is dedicated to providing the highest standards of service and quality!

We are conveniently located less than 20 miles north of Manchester, and serviced by excellent arterial roads, railroads, and airports. So come over and see us – you’ll be welcomed!

Alternatively, you can drop us an email at postbox@alphatek.co.uk with your enquiry details and we’ll reply as soon as possible.

If it’s more convenient, then you can get in touch with us by phoning 01706 821 021.

Check out our blog for more information, guidance, and tips on thermal spraying services and the industries we work in!