Flawless Prints: The Crucial Role of Ultrasonic Anilox Roller Cleaning
In this article, we will show you the most effective method for the cleaning of flexo rollers or anilox rollers through innovative ultrasound technology.
If you're wondering how to keep your rollers in top condition for flawless prints, you've come to the right place.
Join us on this informative journey that will transform your approach to anilox roll cleaning.
Cleaning of anilox rings
Introduction
Developing effective cleaning methods for anilox rollers, tailored to the specific needs of the installation, should be an essential priority for any printing company.
When properly implemented, these actions will be reflected in a long life of the anilox rollers and optimised ink transferThe new system is designed to improve the stability and repeatability of the printing process.
This procedure is essential at the pre-press stage and is an integral part of an advanced quality management system.
It is relevant to address the following questions: Why invest considerable sums in new anilox rollers? How much production time and resources are lost due to improper settings? Why risk business reputation and print quality? What is the best anilox roller cleaning solution for my print shop?
Identifying the optimum anilox roller cleaning solution for the printing press is a crucial issue and here we will give you the keys.
What is an anilox roller and why does cleaning it change print quality?
The anilox is the ink “dispenser” in flexography: its cells record a volume (BCM/cm³) that determines how much ink reaches the plate.
When these cells become clogged with dried ink, pigments, or varnishes, lower the volume And you notice it right away: loss of density, gain in dot size, smudging, and more time spent correcting colour than printing.
On a day-to-day basis, the leap in stability provided by a clean anilox is remarkable: fewer machine adjustments, more consistent colours and fewer stoppages due to cross-contamination.
That is why cleaning is not “something I do when it breaks down”, but part of scheduled maintenance.
A detail that works: record the Anilox condition by LPI/BCM along with the ink from the print run; if the job is repeated, you already know what to expect and when a thorough cleaning is necessary.
Cells, BCM and ink transfer · Closed chamber and squeegee
BCM/cm³: theoretical volume; if the actual volume drops due to dirt, you will need to increase densities or open viscosity (bad for control).
Closed camera/scraperIf the anilox is dirty, pressures increase and premature wear occurs on both the doctor blades and the cylinder itself.
Colour stability: a clean cell transfers evenly throughout the print run.
What are the most common problems when cleaning anilox rollers?
Anilox rollers are key components in the printing process, but they can face several problems related to their cleaning.
Dry ink tanks
Dried ink and pigments can accumulate on the surface and cells of the anilox roller, reducing its ability to transfer ink.
Old ink residues
Old ink that has not been thoroughly cleaned can harden in the cells of the anilox roller.
Contamination with other fluids
If the anilox roller comes into contact with incompatible fluids or incorrect cleaning solutions, this can lead to contamination of the cells.
Obstruction of cells
The cells of the anilox roller can become clogged due to the accumulation of particles, debris or dried ink.
Surface corrosion or wear
Factors such as corrosion or surface wear can adversely affect the ability of the anilox roller to retain and transfer ink.
Problems of transfer uniformity
Lack of proper cleaning can result in uneven ink transfer along the anilox roller.
Reduced roller life
If not properly maintained, residue build-up can shorten the life of the anilox roll.
It is essential to address these problems through a regular cleaning routine and the use of effective methods, such as ultrasonic cleaning, to ensure optimum anilox roller performance and consistent print quality.
Signs that your anilox needs cleaning (typical symptoms and causes)
🔹 You need more past or increase speed to match colour.
🔹 Stripes or “ghosting” that disappears after an anilox change.
🔹 Point gain capricious between the beginning and end of the reel.
🔹 Extra time at decontaminate due to ink changes (especially with UV).
🔹 Volume measurement lower than historical (if you monitor actual BCM).
A tip: when you see variations in density that “dance” between posts with the same recipe, stop and check the anilox before blaming the ink. The usual trap: keep going and compensate with adjustments; this only masks the problem and wears out the system further.
The best method for cleaning anilox rolls
Imagine a cleaning process that goes beyond conventional limitations, a method that not only removes surface dirt, but also reaches the most intricate areas of your flexo rollers.
The ultrasonic cleaning has become the new standardrevolutionising the printing industry and raising the quality of your productions.
How the ultrasonic deep cleaning of flexo rollers works
Ultrasonic technology uses high-frequency sound waves to create micro-bubbles in a specific anilox cleaner fluid.
These bubbles collapse in a controlled manner, generating small explosions that detach and efficiently remove even the smallest particles from the anilox rollers.
This gentle but powerful approach guarantees a thorough and damage-free cleaning.
How is the ultrasonic cleaning process of anilox flexo rollers carried out?
When it comes to flexography, every detail counts. Anilox rollers are essential for precise ink transfer, and their efficiency is directly related to their cleanliness.
Here is a detailed guide to the process:
Preparation of the roller
Remove the anilox roller from the press and make sure it is clean of surface ink.
🔹 Identifies LPI/BCM and type of ink used (UV/solvent/water).
🔹 Protects gears and non-submersible areas.
🔹 Pre-rinse to remove fresh ink.
Select the appropriate anilox cleaner
A suitable anilox cleaner must be used for cleaning inks if ultrasonic cleaning is to be effective.
🔹 Use a compatible cleaner with the ink (avoid unusual combinations).
🔹 For UV, specific formulas; for solvent/aqueous, technical detergents.
At IBERKLEEN we have the right cleaners for perfect cleaning.
Immersion in the ultrasonic tank
Immerse the anilox roller in the ultrasonic tank filled with the cleaning fluid and make sure that the roller is completely submerged.
🔹 Place the anilox in the cradle/cylinder holder so that do not touch the bottom.
🔹 Time: between 20 and 30 minutes per cycle, depending on how dirty it is.
🔹 Temperature: according to instructions and stable; no “heating by eye”.
🔹 Frequency: set by the team.
Cleaning process
Start the ultrasonic cleaning process and wait 20 minutes.
The generated sound waves will create micro-bubbles in the liquid, which will implode on contact with each point on the surface of the anilox roll.
This action efficiently agitates and removes dried ink and other contaminants from the roller cells.
In 20-30 minutes the anilox roller is as good as new!
Post-rinse
After the ultrasonic cycle, the roller must be removed from the tank and rinsed to remove any remaining anilox cleaner.
Drying
Once dry, the roller is ready to return to the press as on the first day.
TIPif the anilox still appears “dull” in certain areas, repeat a short cycle (10–15 min) Instead of forcing a long one, I avoid unnecessary overexposure.
How often should you clean? Frequency depends on ink, print run and type of job.
🔹 Line maintenance: cleaning automatic watering system or light manual after each roll.
🔹 Deep ultrasound:
Inks UV: more prone to polymerisation; schedule each 1–2 weeks if there is high turnover.
Solvent: each 2–4 weeks.
Watery: each 3–6 weeks, depending on pigment load.
🔹 Colour changes problematic (opaque whites, dense blacks, varnishes): we recommend carrying out a deep clean if you notice a loss of density or contamination.
Rule of thumb: when the set-up time exceeds normal by more than 20–30% two rolls in a row, play ultrasound even if the calendar says otherwise.
DEMO of our specific machines for cleaning for anilox rolls
At IBERKLEEN we manufacture and design anilox roll cleaning machines according to your needs.
We customise sizes, vat dimensions, number of flexo rolls per cycle, etc.
We help you to make the cleaning of flexo rollers, not a problem but something very simple.
Demonstration video on how to clean anilox rolls
Why is ultrasonic cleaning of anilox rolls the best method?
The selection of an anilox roll cleaning technology should be based on the specific requirements of a given production process.
The key consideration should be an objective analysis of the advantages and disadvantages of specific cleaning methods in relation to the production profile and anilox roll inventory.
When evaluating aspects such as speed, efficiency, investment costs and environmental impact, the alternative that stands out as the most advantageous is the anilox roller ultrasonic cleaning system.
Other methods such as laser cleaning anilox rollers require very demanding parameters that very few machines can achieve.
Low-cost laser cleaning machines use a cutting laser source that damages the surface of the material and can cause permanent damage.
Moreover, the time, risk and uniform cleaning of the surface cannot be compared to ultrasonic cleaning, which reaches every point of the surface equally.
All this has made ultrasonic cleaning the standard for anilox roll cleaning.
Common mistakes that shorten the life of anilox rolls (and how to avoid them)
🔹 Laser without control: avoid low-cost equipment or untrained personnel.
🔹Harsh chemicals or improvised mixes: continue technical data sheets and ink compatibility.
🔹 Hard/abrasive brushes: they damage the ceramic; use specific tools.
🔹 Do not rinse/neutralise: the residues continue to “work” and attract dirt.
🔹 Keep dirty: the ink hardens; always pre-clean when finished.
A habit that saves hassle: a simple checklist stuck in the washing area and a quick photo of the anilox after cleaning. If a streak then appears, you will know whether or not it was already there.
An anilox clean and controlled is the basis of a stable flexo. The combination that performs best is: frequent water cleaning for everyday use + ultrasound scheduled every few weeks (or sooner if densities fall) and laser only in expert hands.
With the tips in the article, the 20–30 minute cycle With a good checklist, you reduce downtime, save ink, and extend the life of the cylinder.
Get ready to experience flawless flexo with the advanced cleaning your rollers deserve and contact us today!
At IBERKLEEN we advise you on the optimum parameters for the cleaning of anillox rollers
❓ Frequently asked questions about anilox roller cleaning
No, if you respect frequency, time and temperature and you use compatible chemicals. The damage comes from abuse or from “inventions” with unadvisable solutions.
When you have access to well-calibrated equipment and you need a swift recovery chemical-free. Avoid low-cost and ensure training and power control.
Lasers are very expensive equipment and require a significant investment.
UV: specific formulas with neutralisation.
Solvent: detergents compatible with dissolving resins without damaging the ceramic.
Watery: agents that release pigment/fillers without leaving a film.
As support, yes. As a sole strategy, no: it is inconsistent and ends up being more expensive in terms of density, starts and wear.