New progress of flexo-printed ceramic anilox roller and sleeve technology

First, how to play the role of ceramic anilox roller

The performance of ceramic anilox rolls is determined by the following factors:

1. Anilox roller supplier

The performance of the roller base: including the processing of roller body dynamic balance to meet the requirements of high-speed operation of the printer, the roller shaft conditioning treatment to prolong the service life, and the precision of the roller base production.

The uniformity of the plasma spray coating and the uniformity of the engraving molding, the porosity of the ceramic layer should be small, the plasma spray gun should be able to spray a dense coating, and the roller surface net hole should be uniform from the beginning to the end.

The durability of the coating: The combination of the ceramic layer directly with the roller body will produce the result that the bonding force is not strong. If a protective layer is applied before the ceramic coating, the binding force will be greatly enhanced. Applying a protective layer will increase the 30% cost of anilox roll manufacturing. The sealing of the ceramic layer is also very important before or after engraving. Our extensive experience has demonstrated that the cost of adding a protective layer is of great significance for extending the life of the anilox roll.

2. Accuracy of anilox roller mesh

Mesh size accuracy and capacity specifications.

The accuracy specification depends on the anilox roller manufacturer you selected. Relatively speaking, high-quality printing has high requirements on the accuracy of the anilox roller, and of course the price is higher. The lower price of the anilox roll also has a greater change in accuracy.

Measure the mesh capacity. The WYKO Mesh Computer Measurement System is the only device that can accurately measure the mesh volume. Anilox roller makers should also pay attention to the depth and capacity of the mesh.

The geometry of the mesh will affect the transfer properties of the ink and the life of the mesh. The 60° hexagon is the preferred shape.

3. Printing operators

Concerned about how to clean the anilox roller, consider that you are using different cleaning methods such as SO CLEAN anilox roller cleaning system or ultrasonic cleaning system or laser cleaning system. Laser America’s US subsidiary has found that the ultrasonic cleaning system has a greater impact on the final ink transfer properties of the anilox roll.

Pay attention to the speed of the anilox roller on the printer. Sleeve Anilox rollers are lighter and easier to change, allowing larger anilox roller speed changes.

The latest progress in laser engraving is described below.

Simply look at the progress of modern laser engraving technology. First, look at the situation of CO2 (CO2) lasers. CO2 lasers use variable-wavelength beams. On longer anilox rollers (above 1200 mm), a slight change in mesh shape and capacity occurs (from the anilox roll This side to the other side). Single-beam engraving machines use a single beam and the resulting anilox roller mesh creates a cone.

This is the second laser installed by our company in 1992, and in 1996 it was part of the upgrade of the control circuit. This CO2 laser uses a fixed dual beam. Can be used for single or double light engraving. This double helix beam technique can produce two meshes in a single impact or double impacts on the same mesh with a single helix beam. The first impact creates a mesh shape, and the second impact expands the mesh and creates a sufficient depth. This is what we call the rapid prototyping mesh. This mesh can achieve higher ink transfer while maintaining a shallow depth, which is beneficial for ink transfer.

Pulsed YAG laser. This is our third laser and its number of engraving lines can reach 2000 lines/inch or more. Often referred to as pulse engraving. Its quality and precision can meet the most delicate printing requirements. The anilox roll made by YAG laser can achieve extremely fine prints. YAG lasers can also be enhanced by beam splitting and multi-impact modes. The multi-impact mode produces the smoothest common hole, but the engraving speed is greatly reduced, which means that the production cost increases.

Modulated YAG lasers are the latest process and require less energy than pulsed lasers. Compared with pulsed YAG lasers, when the laser is modulated in a continuous manner, the laser beam produces a perfect shape and a thin net wall. . Because low energy produces large sputter residue rather than complete evaporation, it helps to improve the porosity of the ceramic surface. The disadvantage is that this kind of mesh has slightly less abrasion resistance than the mesh produced by the pulsed laser, ie, the wear life is different. The greatest benefit of the modulated YAG laser is its higher production speed than the single pulse YAG mode.

Recent developments in modern technology have made YAG lasers suitable for engraving of high-line anilox rollers, while conventional dual-beam CO2 lasers are particularly effective for making anilox rollers below 600 LPI. Some anilox rollers that use older laser engraving may become less suitable as customer requirements for printing quality increase.

From the above explanation, it can be seen that in order to maximize the role of the anilox roll, accurate anilox roll characteristics are very important. The more precise anilox roller cores are made of steel, aluminum or synthetic materials. The use of quality control equipment to detect the mesh is an essential tool for anilox roller manufacturers.

Second, the application of sleeve technology in flexographic printing

The development of modern flexographic printing at an alarming rate has also led to the application of many new printing technologies and processes. Socket technology is accepted and applied in this situation.

The disadvantages of high cost and time-consuming change of the traditional roll have been unable to meet the rapid development of modern flexographic printing. So with the birth and application of the sleeve. From the perspective of the development of flexographic printing, sleeves have gradually replaced the trend of the traditional version of the roller. Why do you say this, let us first look at the characteristics of the sleeve:

*Low cost, high efficiency

* Easy loading and unloading

* Convenient storage and small footprint

* High degree of flexibility

* Reduced loading time

*long lasting

* High system accuracy

The sleeve system brings many benefits to flexo printing compared to conventional plate rollers. The sleeve can be handled by one person; the sleeve can be easily positioned on the air support roller; two or more sleeves can be installed on the same air lift roller as required, but the biggest advantage is that it can be reused and used at any time. Can print on the sleeve. The so-called repeated use is to affix the photosensitive resin plate to the sleeve, and the used plate can be conveniently peeled off from the sleeve for mounting other plates as required. With the sleeve system, you will be able to easily pre-plate the plates, saving plate loading time, increasing productivity, and achieving a high degree of flexibility. The sleeve costs less than the traditional plate rollers.

In general, the modern sleeve system allows the sleeve to be used in a printing perimeter of 150mm, sleeves with a minimum printing perimeter of 350mm to a maximum printing perimeter of 500mm, and only one gas-bearing roller is needed because of this The inner diameter of the sleeve within a printing perimeter is the same. Changing the printing perimeter, ie changing the circumference of the sleeve, only needs to change the wall thickness of the sleeve. Current advanced sleeve system printing perimeters allow print perimeters from 130mm to 2000mm; printing widths range from 100mm to 4500mm, which makes sleeve systems applicable to almost all flexo printing, down to label printing, Large-scale printing of corrugated cartons.

Air Support Rollers Nowadays, almost all flexographic printing machine manufacturers face the pressure of how to adopt the "quick change board" system in the machine design to meet the needs of flexographic printing development. This requires a device that uses a sleeve when designing the machine. Gas-bearing rollers are devices that fit sleeves. The air lift roller is similar in appearance to the plate roller. An air intake hole is provided on the air-bearing roller equipped with one end of the gear, and the air-blanket roller surface has some precise small holes. These small holes and the air inlet hole are through and the compressed air passes through the air inlet hole. Holes are evenly discharged. The inner diameter of the sleeve is generally smaller than the outer diameter of the air support roller to ensure its engagement. When the compressed air is input, the compressed air is evenly discharged from the small hole of the roller, forming a layer of “air cushion” between the sleeve and the air-bearing roller. This layer of air cushion expands the inner diameter of the sleeve and makes the sleeve light and convenient. Glide on the air support roller. When the compressed air is cut off, the sleeve immediately shrinks and is fastened with the air brace roll as one body. Then it can be installed and used on the printing press (the sleeve needs to be installed on the air-blanket roll loading base).

The following describes the classification and use of sleeves.

The material of the basic sleeve basic sleeve is mainly made of special multi-layer glass fiber reinforced plastic and coated with high-quality natural resin, and the surface of the sleeve is coated with rubber, poly-alkane or polyurethane, etc. It is used in the production of laser-engraving plate-making, seamless printing plates or glazing rollers. The high-precision and smooth sleeve inner diameter can be combined with the air-blanket roller. The outer diameter of the sleeve plus the frosted surface can be combined with any coating material, and has the characteristics of high temperature resistance and no deformation. By continuous engraving of laser-engraved rubber seamless printing plates, continuous pattern or wrapping paper with the same background color, cigarette filter tipping paper, wallpaper, etc. can be printed.

We have provided domestic users with hundreds of sets of wide-width and narrow-width laser-engraved rubber seamless printing plate series products, including the entire gas-support roller and supporting gears. The use of sleeve technology enables these companies to undertake seamless printing and improve the company's market competitiveness.

Sticker sleeve sleeve is specially designed for loading printing plates. The surface material of the sticker sleeve has the characteristics of high hardness, impact resistance and cutting resistance. The wall thickness of the sleeve can be arbitrarily chosen from 1.4mm to 25mm, which means that only one air support roller can be used to increase the printing perimeter by about 150mm. The use of double-sided adhesive tape or pad lining on the sleeve to mount the plate can replace the traditional plate sleeve. The use of a sticker sleeve has the advantages of easy handling, low cost, easy storage, and the like.

The surface material of the air bearing sleeve air cushion sleeve is an open, honeycomb, highly compressible polyurethane foam based on MDI. The combined application of air-cushioned sleeves and thin plates can not only achieve a high level of quality and standardization in flexo printing, but also reduce plate wear and extend the service life. Thin plates generally refer to photosensitive resin plates of 0.76 mm and 1.14 mm. Plates are bonded using double-sided adhesive tape. This thin double-sided adhesive tape is often used as a thin paste plate to replace PE tape. The foam material of the air cushion sleeve has higher hardness compared with the liner (standard application hardness is 65 degrees on Shore), because the hardness of the surface material of the air cushion sleeve is high, it is very favorable for printing full-field version; on the other hand, it accounts for about 80%. The volume of foam can be compressed, which means that the surface of the elastic cushion sleeve has a profound significance for printing fine dots and controlling dot gain. For example, fine products such as barcodes, thin lines, gradation, and halftones are printed.

Due to the use of air-cushion sleeves, it is possible to standardize flexo plates. You do not have to be busy with the choice of adhesive tape or pad to affix the plate. Standardization here refers to a standard thickness thin plate and air bearing sleeve.

Air cushion sleeve has the following advantages:

* Standardization of printing quality

* Dot gains are controlled

* Extended plate life

* Has good shock absorption performance

* High impact resistance and cut resistance

* Significantly improved print quality

* Can meet the level of color lines and field full-screen printing

MEGA super-lightweight sleeve This ultra-light MEGA plate sleeve is mainly designed for modern flexographic printing presses such as SOLOFLEX, COMEXI FP, FLEXOTECNICA TACHY'S, with a fixed air-bearing roll mounted on the press. The gas lift roller diameter is constant. Change the desired print perimeter by using a sleeve of the same inner diameter, different outer diameters. The wall thickness of the MEGA sleeve is between 10mm and 70mm, and the printing perimeter can be increased by nearly 400mm. This means that only one type of outer diameter air-bearing roll can meet the needs of different printing perimeters in a wide range. The MEGA ultra-lightweight sleeve uses special ultra-light-weight filling materials and processes to ensure the The sturdy and high precision of the tube.

In recent years, some advanced printing technologies have been applied to China's flexographic printing industry. Apart from Shanghai, Beijing, Shenzhen, Foshan, Dalian, Xiamen, and Suzhou, sleeve companies have adopted sleeve technology, and Yunnan, Jilin, Shandong, and other mainland enterprises have also adopted sleeve technology. Start the application. The speed and scale of sleeve technology development is only the beginning

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