The Best Practice of Anilox I nspection, Management and Maintenance

1. The Best Practice of Anilox Inspection, Management and Maintenance

2. 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

3. 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. 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.

4. Many improvements have been achieved through:a) New developments and improvements on Press and with Press controlsb) Improved Inks and inking methods and controlsc) 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.

5. Since the development of Anilox Managementprinters 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.)

6. 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

7. 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 Re-clean Anilox to ensure cleaning process is optimised 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

8. 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.

9. Compare volumes of rolls that should be of equivalent value using AMS Ensure difference is less than 0.4cm³/m² See note 3 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. Run Aniloxs on press knowing set up time is minimised

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

11. 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. Re-clean Anilox to ensure cleaning process is optimised 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 Ensure difference is less than 0.4cm³/m² See note 3 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. Run Aniloxs on press knowing set up time is minimised

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

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

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

15. 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.

16. 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. Consequences of Anilox Management.

17. 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)

18. Cost saving examples of Anilox Management 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

19. Thank you for listening  Phil Hall Troika Systems Limited www.troika-systems.com +44 1793 766 355