Why cleaning anilox with brushes increases downtime

The cleanliness of anilox rollers plays an important role in achieving high-quality prints. Many operators still rely on anilox roller cleaning brushes for manual cleaning, a method that can contribute to increased downtime and reduced print quality. However, automated solutions have become more accessible and effective than manual cleaning. For those who still prefer manual methods, cleaning liquids and brushes can still be used in this process. You can find tools and cleaning liquid for manual cleaning.

To learn more about what an anilox roller is and why its cleanliness is so crucial, check out our blog post: What is an anilox?

The limitations of anilox roller cleaning brushes

Anilox rollers are made with thousands of tiny cells that are responsible for holding and transferring ink. Using anilox roller cleaning brushes to clean these rollers can be challenging because the brushes often struggle to reach deep into the cells. This incomplete cleaning leaves behind dried ink, which can lead to inconsistent ink transfer. As a result, operators frequently must repeat the cleaning process or re-run print jobs, extending overall downtime.

Over time, anilox roller cleaning brushes may wear down the roller surface or cause damage to the cells. This damage not only reduces print quality but may also need expensive roller repairs or replacements, further increasing downtime and costs.

If you're dealing with anilox sleeves, there are specific cleaning techniques that can help. For more information on how to properly clean them, visit our blog post: How to clean anilox sleeves.

Flexo Wash manual cleaning solutions

Do you still prefer to stick with manual cleaning? We offer specialized cleaning liquids and brushes. Our cleaning liquids are formulated to break down and dissolve stubborn ink and other contaminants, allowing for a deeper clean without excessive scrubbing.

We also offer manual cleaning brushes for anilox rolls, with bristles that are gentle enough to avoid damaging the delicate cells while still providing a thorough clean. However, even with the best manual tools, the cleaning process can still be time-consuming and labor-intensive, which is why many printing companies are now choosing automated cleaning systems.

The advantages of choosing automated cleaning solutions

Automated cleaning systems provide various benefits that help minimize downtime, reduce labor costs, and extend the life of anilox rollers. Here are some key pros of choosing automated cleaning:

• Time efficiency: Automated cleaning systems clean anilox rollers much faster than manual methods. Instead of spending hours scrubbing rollers with anilox roller cleaning brushes, our automated systems can clean multiple rollers in just minutes.
• Consistent cleaning results: Automated systems provide consistent results. The cleaning process ensures that all ink residues and contaminants are thoroughly removed from the roller’s cells. This level of consistency is difficult to achieve with manual cleaning brushes.
• Reduced risk of damage: Automated cleaning systems are designed to clean the delicate cells of anilox rollers without causing damage. This contrasts with manual anilox roller cleaning brushes, which, over time, can wear down the roller’s surface or cause cell damage.
• Improved print quality: Clean anilox rollers lead to better ink transfer, resulting in higher-quality prints. Automated systems ensure that rollers are free from ink buildup, helping to maintain consistent print quality across production runs. This reduces the need for reprints or job adjustments, saving both time and money.
• Longer anilox roller lifespan: By reducing wear and tear on anilox rollers, automated systems extend the lifespan of these critical components. While anilox roller cleaning brushes can cause gradual damage over time, automated cleaning preserves the integrity of the roller, reducing the frequency of replacements.