2. Contents How can the Anilox improve your quality Anilox Parameters1
How can the Anilox improve your quality
Anilox Parameters
Screen Selection
Anilox volume & ink release
Best engravings for Fixed Palette
Care and maintenance

3. How can the Anilox improve your print quality?

6. Selecting the right specification will improve:
White opacity
Uniformity of solids
Print definition and clarity
Ink laydown
Gloss levels in varnish applications

7. Anilox Parameters

8. Engraving angle
The spacial orientation of cells in subsequent rows of engraving in relation to the horizontal axis of the Anilox roll. The placement of the cells determines the cell shape and more precisely, the orientation of the cell opening. When the cell opening is wider along the rotational axis, ink can flow out easier. When the cell opening is narrower, there is less turbulence in the ink flow and less pinholing.

9. Engraving angles 60° 45° 30° 75° 70°
30 and 60 degree angle engravings have 15.5% more cells
per square inch than 45 degree angle engravings
Angle determines the cell shape: hexagonal or diamond shape
These additional cells provide a more uniform distribution of ink to the plates.
In addition, there are no large land areas (which do not hold ink) between the cells as in the 45. Because of these large land areas, ink has farther to flow to fill the gaps for solid coverages.
The engraving angle is important because the placement of the cells determines the cell shape and more precisely, the orientation of the cell opening. When the cell opening is wider along the rotational axis, ink can flow out easier. When the cell opening is narrower along the rotation, there is less turbulence in the ink flow and less pinholing results in the print.
The other important aspect of engraving angle pertains to the efficiency of the cell placement. In a 45 degree pattern, excess wall naturally occurs rotationally between the cells. This wall takes up roll surface area that could otherwise be used for carrying ink.

10. Moire pattern To avoid moiré:
The difference between the screen angles of cyan, magenta and black should be 30°. The screen angle of yellow must differ by 15° from cyan or black
The screen angle must be 7.5° away from the Anilox screen angle.
The Anilox screen to plate ratio must be at least 5.5 ie. 100LPI plate/ 550LPI Anilox
Most common flexo angles
Most common offset angles

11. Line count Refers to the number of cells in a lineal inch/ centimetre
as measured along the engraving angle (because that is
where the cells line up in closest proximity to each other).
Cell diameter plus wall thickness equals the Pitch. By dividing 25,400 (the number of microns per inch) by the pitch, the result is the line count (the number of cells per inch).
Line screen is chosen in direct correlation to anilox volume.

12. Line count affects print quality
More cells means finer ink distribution
More uniform coverage on solids
Cleaner vignettes
Easier drying
The line count of an anilox roll is an important consideration. Line count determines the total number of ink dots that will be transferred to the plates. Higher line counts place more cells, closer together. This provides many benefits for the print quality.
For example, coverage on solid areas is more uniform. Smaller ink dots dry quicker allowing for faster press speeds. Because they dry faster, smaller dots tend to produce less dot gain. This allows for sharper edges on linework, and better image clarity for process jobs.

13. Finer ink distribution
Printed with 250LPI
Printed with 500LPI

14. Sharper edges
400LPI
600LPI

15. Dirty Print

16. Preventing Dirty print / Dot bridging Fault
Dot dipping
The Anilox screen should be 6 times the plate screen
Because line count affects ink distribution, it becomes a critical factor in the quality of the print job, particularly when printing process jobs. Smaller dots are closer together and produce more uniform solids.
The down side of higher line counts is that as the cell size is reduced, it becomes more challenging to deliver adequate cell volume to achieve desired colour densities and opacities

17. To prevent dot bridging the Anilox screen must be 5-6 times the plate screen
Dot supported by several cells
Effect of the dot size of a 200LPI Plate on a 900LPI /360LPC Anilox
25%
10%
Dot dips into the cell 2% 5%

18. Cell volume volume refers to the carrying capacity of
the cells in a square
inch or square
centimetre of roll
surface area
Cell opening
Cell depth
Remember you can use a lower volume anilox roll with a 60° cell because more cells fit into a square inch in this configuration.
However, a cell with too small of a volume will cause ink to dry before it can be transferred, unless there are sufficient drying inhibitors used. The goal is to specify an anilox roll that will deliver the colour strength and densities needed with the thinnest ink film possible.

19. We must differentiate Anilox volume which is the carrying capacity of the Anilox from the transferred volume.

20. Factors that effect transfer
Ink flow characteristics: viscosity, pigment load, and pH
Doctoring method: doctor blade, rubber nip roll, closed chamber system
Characteristics of the doctoring system: durometer of the rubber roll, thickness and type of blade material, nip or doctor blade pressure
Press speed
Surface tension of the plates and substrate
Absorption rate of the substrate

21. One main factor that will affect the ink transfer from the anilox cells, it is the cells themselves.
Cell shape and engraving geometry will affect the Anilox ink transfer properties.

22. Screen Selection
& engraving types

23. In order to achieve the best print quality a good rule of thumb it’s to specify the Anilox roll to the highest line count possible providing the cell volume is adequate to get the desired colour density or coat weight.

24. 60 degree hexagonal engraving

25. + 15.5% more cells per square inch than 45 degree angle engravings
45 degrees diamond engraving
60 degrees hexagonal engraving
+ 15.5% more cells per square inch than 45 degree angle engravings

26. The 60 degrees hexagonal pattern became the industry standard

27. 60 degree cell profile limitations:
Conical shape restricts
Ink release
Prone to plugging
Difficult to clean
Enclosed cells can cause micro foaming

28. New extended cell design
Ink Retention
New extended cell design
60 deg. cell
Up to 40%
10-15%

29. By increasing the cell volume without lowering the line count, the cell will be less efficient at releasing its volume and will retain more ink
30% retention
40-42% retention

30. New specifications can transfer on average 25% additional volume

31. Cell Shape & Ink Transfer
In order to increase the Anilox
line count without loss of ink coverage
The cell shape must be changed to
Improve ink transfer

32. The finer the line count, the better the print will be……
Providing we deliver the correct density

33. maxflo
Cell profiles is more efficient at transferring the ink, achieving up to 30% more compared to conventional engravings
Allows the use of higher line counts without the loss of volume

34. Fixed palette Printing
Fixed colour palette printing requires precise registration, consistent dots and minimal dot gain
In order to achieve this the Anilox consistency and efficiency at transferring the ink is critical.

35. Finer plate technology requires finer Anilox roll
60 degrees cell unsuitable due to poor release
Channel specifications could cause problems such as dot dipping/ bridging

36. Proflo Engraving hybrid of 60 degree and MaxFlo

37. Printed using same ink and print conditions
ProFlo Main Features & Benefits
Printed using same ink and print conditions
1000 LPI 3.8cm3/m2 Anilox 60 deg. hex
1300LPI x 3.5cm3/m2
ProFlo C
1.15
1.35 M
1.25
1.4 Y
0.90
1.0 K
1.50
ProFlo delivers up to 10% more ink than 60deg engravings
This allows the use of higher line counts without loss of colour densities
Higher ink densities are achieved. Increasing the density throughout the full tonal range widens the available range of colours and increases the process colour gamut.

38. flexo offset ProFlo Now you can print that looks like
EsKo Artwork HD Flexo Certified Vendor
ProFlo
for HD Flexo & ECG
Provides an improved ink lay down that delivers higher contrast, extended tonal range and better image definition at ultra fine line counts .
60 degrees standard engraving
ProFlo engraving
Now you
flexo
can print
that looks like
offset

39. MaxFlo+

40. MaxFlo+ 3D image

41. How does it work?
With closed-cell configuration air gets trapped causing foaming and uneven laydown of ink to the plate
Foaming will be seen as pin holing in the print
Maxflo+ is a channel engraving
Improves ink flow eliminating aeration of ink
Provides a more consistent, smoother and pin-hole free lay down of ink

42. Main benefits: No UV spitting Improved colour consistency
Higher print definition
Increased ink transfer of up to 30% compared to
conventional engravings
Cleaner vignettes & rich solids with one single Anilox
Designed to run at high press speeds (+ 600m/min ) 
Reduction of make ready times, as fewer changeovers
are necessary
Fast and easy clean-up
Recommended for Fixed Palette printing
Ink laydown with MaxFlo+ and hexagonal engraving

43. Achieving adequate colour density and reproducing it on each successive run is key to the success of Fixed Palette.

44. VOLUME CONTROL
Anilox rollers must be regularly monitored and their volume checked to ensure print consistency

45. ANILOX MAINTENANCE

46. Anilox Cleaning recommendations
As a standard practice, rollers should be always cleaned as soon as the roller is taken out of service with an adequate Anilox cleaner. After manual cleaning, engravings should be viewed under high-power magnification to ensure they are clean. If the cells are not plugged with ink, they should not be cleaned with off-press systems.
Never leave the ink to dry in the cells. It will makes it increasingly difficult to remove. This can be especially true with water-based inks.
Keep the rollers turning whenever there is ink in the system. Most presses are equipped with idling motors to accomplish this. If yours is not, it may be worth the investment for you.
Protect your Anilox rollers against air drafts. Keep them covered.
Regular cleaning will  make cleaning easier and faster

47. Anilox Sleeve Maintenance
Avoid using aggressive chemicals or
caustics as the aluminium cladding is
susceptible to corrosion
Keep the inner composite always dry
and free from any chemicals
Ensure inner bores are clean and
free from dried ink
Avoid rocking the sleeves up and down
during mounting
Preferably Store sleeves vertically

48. Thank You.