Total Anilox Management The Best Practice of Anilox Inspection, Management and Maintenance

Total Anilox Management WARNING This presentation may lead you to review your anilox cleaning practices and equipment. It will almost certainly lead you to having some of your aniloxs refurbished or replaced

Total Anilox Management To meet these requirements, printers of all types have had to adapt QC procedures which enable them to achieve these targets consistently, whilst remaining profitable and competitive. Over the past decades we have seen higher and higher demands come from the ‘BRANDS’ and other discerning customers to produce more desirable print, with increased colour gamut, and more importantly achieve density variations of better than 3ΔE.

Total Anilox Management Many improvements have been achieved through: a) New developments and improvements on Press and with Press controls b) Improved Inks and inking methods and controls c) Plate developments which have enhanced colour gamut significantly (mainly with flat topped dots and HD Flexo) d) Aniloxs; improvements in design and production With the exception of aniloxs, the above items are regularly checked and maintained by print technicians and their managers.

Total Anilox Management Since the development of A NILOX M ANAGEMENT printers now have QC tools that gives them empirical data that has proven to enhance productivity, improve profitability and competitiveness…… Having control has proven to make savings of 1 to 3 hours of set-up time per press per day (time dependant on press process type.)

Total Anilox Management IMPORTANT STATEMENT # Using an anilox with 4 bands, # run on a narrow web press, # engraved with 0.1cm³/m² steps, and # run on all 4 process colours. Has led to the following regularly achieved guide-line: 0.4cm³/m² approximates to 3ΔE

Total Anilox Management Deep Clean Anilox See note 1 Note 1: Deep cleaning typically should be carried out every 2 to 6 weeks dependant on ink type and usage, and for new Aniloxs With Anilox QC Measure volume laterally. Check for cracking & damage See note 2 If greater than 0.4cm³/m² or shows cracking Refurbish Note 2: Lateral measurements are typically taken in: 2 places for label aniloxs, 3 places for wide web and 5 places for corrugated and coating rolls. Compare volumes of rolls that should be of equivalent value using AMS Re-clean Anilox to ensure cleaning process is optimised

Total Anilox Management In-house anilox management Anilox Management System Showing the roll history including images. Shows the condition and indicates when the roll needs intense cleaning, or refurbishing due to wear.

Total Anilox Management Run Aniloxs on press knowing set up time is minimised If greater than 0.4cm³/m² refurbish lowest volume aniloxs Note 3: A difference of greater than 0.4cm³/m² has been shown to display a visible difference in print density of approximately 3ΔE. Compare volumes of rolls that should be of equivalent value using AMS Ensure difference is less than 0.4cm³/m² See note 3

Total Anilox Management AMS Management Report Management Report Showing the inventory condition and volumetric and lateral differences between aniloxs. Identifies the condition and indicates when the roll need refurbishing.

Total Anilox Management Deep Clean Anilox See note 1 Note 1: Deep cleaning typically should be carried out every 2 to 6 weeks dependant on ink type and usage. With Anilox QC Measure volume laterally. Check for cracking & damage See note 2 If greater than 0.4cm³/m² or shows cracking Refurbish Note 2: Lateral measurements are typically taken in: 2 places for label aniloxs, 3 places for wide web and 5 places for corrugated and coating rolls. Compare volumes of rolls that should be of equivalent value using AMS Re-clean Anilox to ensure cleaning process is optimised Run Aniloxs on press knowing set up time is minimised If greater than 0.4cm³/m² refurbish lowest volume aniloxs Note 3: A difference of greater than 0.4cm³/m² has been shown to display a visible difference in print density of approximately 3ΔE. Ensure difference is less than 0.4cm³/m² See note 3

Total Anilox Management How is in-house anilox management achieved? AniCAM: 3D scanning microscope Anilox QC software application Anilox Management System

Total Anilox Management How is in-house anilox management achieved? AniCAM: 3D scanning microscope with battery pack. Used to capture the stack of images for 3D analysis.

Total Anilox Management How is in house anilox management achieved? Anilox QC application showing the scanned image; volume; average cell depth; screen count and angle.

Total Anilox Management How is in house anilox management achieved? AMS showing an inventory allowing the production manager to monitor anilox condition, the efficiency of the cleaning process and plan for refurbishment.

Total Anilox Management C ONSEQUENCES OF A NILOX M ANAGEMENT. In exactly the same way that a printer who fails to meet the demands of the BRANDS will not remain competitive. Some engravers have lost significant business by failing to keep up with modern engraving techniques and honouring their stated volumetric tolerances.

Total Anilox Management It is essential for printers to know their aniloxs are within an agreed and workable specification; whether new or old. Therefore, discuss with your anilox manufacturer what their stated engraving tolerances are: Some work in percentages: ±10% of a 3.6 cm³/m² engraving is from 4.0 down to 3.2 cm³/m²(too large) ±5% of a 3.6 cm³/m² engraving is from 3.8 down to 3.4 cm³/m² (acceptable)

Total Anilox Management Cost saving examples of A NILOX M ANAGEMENT when used as part of the QC process: Narrow web: proven time savings of 1 hour per press per day is frequent: Narrow web press time is typically £250/hour For 4 presses that is 28 hours additional production time or £7,000 per week 1,460 hours additional press time per year Wide web: where proven time savings of over 2 hours / press / day: Wide web press time is typically £500/hour For 3 presses that is 42 hours additional production time or £21,000 per week 2100 hours additional press time per year In almost every case the ROI is less than 4 weeks once implemented and in process

Total Anilox Management Thank you for listening Phil Hall Troika Systems Limited