Best way to clean an anilox roll

Fully automatic solution - Liquid cleaning

Automatic liquid cleaning systems clean anilox rolls without manual intervention, often using high-pressure washing and cleaning liquids. These systems are fully automatic, handling the entire wash cycle from washing to drying, delivering a clean and ready-to-use anilox.

Pros:

• Cleaning again & again: Liquid cleaning does not cause wear and tear on the anilox
• Consistent washing results: Liquid cleaning ensures even cleaning across the roll and does not cause tear on the anilox no matter how many times you wash it.
• Flexible & adjustable: The machines can be customized for your needs.

Cons:

• Ongoing liquids use: The automatic liquid cleaner has an ongoing liquid consumption.
• Maintenance required: Use of rinse water is required however the tank of rinse water can be reused for several washes.

Fully automatic solution - Laser cleaning

Laser cleaning uses focused beams to remove ink and contaminants. It is an eco-friendly alternative to high-pressure water or ultrasonic methods, with no chemicals or water required. Again, these systems are fully automatic and need no manual finishing.

Pros:

• Highly effective: Laser cleaning removes dried-on inks, but some inks that easily reflect can be difficult to remove.
• Environmentally friendly: No chemicals or water are required, reducing waste.

 Cons:

• High initial cost: The equipment can be expensive to install.
• Not suitable for all rolls: Some rolls may not be compatible with laser cleaning, depending on the material and condition, and will over time damage the roll.

Semi-automatic solution - Ultrasonic cleaning

Ultrasonic cleaning uses high-frequency sound waves transmitted through a solution to create microscopic bubbles that remove contaminants from the roll's surface. However, the roll must be manually rinsed and dried afterward.

Pros:

• Space area: Ultrasonic cleaning machines are smaller machines and fit in most productions.
• Adjustable: Able to adjust frequency to specific cleaning needs.

Cons:

• Manual handling: Improper use or prolonged exposure may potentially affect the roll's condition over time.
• Ongoing liquid & maintenance: Ongoing liquid use and manual rinse and drying are often required meaning more manual handling and risk of damaging the anilox.

Manual Cleaning – Brushes & pads

Manual cleaning could seem like the simplest method, involving brushes and cleaning liquids. In the short run, it is cost-effective, but it requires labor power, precision, and care to avoid damaging the delicate anilox cells.

Pros:

• Low cost: Minimal equipment is needed, making it a budget-friendly option.
• Immediate availability: No need to wait for cleaning equipment.

Cons:

• Manual handling: Improper scrubbing techniques can harm the roll’s surface. The quality of cleaning depends on the operator’s skill and diligence.
• Labor-intensive: Manual cleaning is time-consuming and requires significant effort.

Selecting the right cleaning method

Maintaining clean anilox rolls is important to achieving consistent print quality, and the method you choose will impact both the lifetime of your rolls and the efficiency of your printing process. While manual cleaning offers a budget-friendly option for quick or occasional cleanups, it requires precision and carries the risk of inconsistent results. Ultrasonic cleaning provides cell-level cleaning but requires careful handling and can involve more manual steps, making it less ideal for continuous production.

Laser cleaning, although highly effective and environmentally friendly, comes with a high initial investment and is not always suitable for all types of anilox rolls. However, automatic liquid cleaning stands out for its balance of thoroughness and convenience. It delivers consistent, even cleaning without causing wear on the rolls, making it a reliable choice for ongoing maintenance in high-production environments.

A combination of both laser and liquid cleaning is also preferred in larger productions where deep liquid cleaning is used daily and laser cleaning for example monthly to draw advance of each cleaning technique's excellent deep cleaning qualities.

By weighing the pros and cons of each cleaning method, you can select the most appropriate approach to keep your anilox rolls in optimal condition for the demands of your operation.