Happy new year to you all and welcome back to the Alphasonics Blog!  So the turkeys been eaten, all the good TV has finished and there are no more mince pies left.  We’re now in 2011.  Now is the time to take a look back on last year and think about how you’d change things.  Much like deciding to go to the gym or spending less time at the pub, many flexo printers will be thinking about how to improve on their production methods.  Maybe not in the same train of thought, but they will be thinking about it.  Trust me. 

Improving best practice methods are essential in ensuring print runs are perfect every time and at this early point in the year, most could say that there is never truly a ‘best best practice’ because there is always room for improvement.  Many think they have perfect procedures but you’d be surprised.  After visiting countless label and packaging printers both in the UK and overseas last year, I’ve learned that there is always room for improvement.  Where I’ve seen the need for this is time and time again the part of the flexo press which is arguably the most important, the anilox.  Many printers, in labels especially, have come to me asking why they aren’t getting the print results and nine times out of ten it is the condition of their anilox rolls. 

It’s unfortunate that the anilox isn’t always given the care and attention that is needed so I’ve decided that I’ll do my bit.  Below are five New Year’s resolutions that will keep your aniloxes clean, allow them to perform well and in turn, make the print production of your press undoubtedly improve. 

1)      Find a cleaning system that is appropriate for your aniloxes. 

Each different kind of anilox cleaning method has its own benefits.  Do your research and get it right.  Every single method has something to offer but there are always draw backs no matter what you may choose.  Look at the benefits and drawbacks to each method and think about the long term. 

If you’re looking to make a rushed decision based on price alone, you may as well take a hammer to your rolls and pour a few thousand pounds down the plug hole.  Consider your own printing capabilities, consider your press and your aniloxes, consider the facts, consider the long term benefits and consider how clean your aniloxes must be. 

The biggest lesson here is not to listen to hearsay or badmouthing that goes on between competitors.  Seek out the facts and you won’t regret it. 

2)      If you are going to bring in higher screen counts, ensure your current cleaning system is compatible.

When you purchased your cleaning system, you would’ve ideally considered your future plans.  If you are looking to move to higher screens, you need to ask a very simple question: Is this good enough to move on with us?  If you have single frequency ultrasonics or a blasting system, you have to take the possibility of roll damage into consideration.  Most methods incur a high consumables costs.  If you have a system that won’t grow with you as a business then it’s back to the drawing board.  If you fail to plan, you plan to fail. 

3)     To derive the greatest benefits from higher screen counts, you need a regime.

Regular and effective roll cleaning is quite simply essential.  There is no other way to say it.  When you’re considering a cleaning system, you need to take into account whether it will allow you to clean as and when you want.  If there is complexity and a long set up time, then I would suggest you give it a miss.  You need a system that will allow you to draw up a detailed roll cleaning plan and stick to it.  The sticking to it is the important bit and is down to you but one thing is for sure, you will not regret it.  It will certainly reflect in your print quality and the awards you pick up because of it.  

4)     Clean between ink changes to avoid layering. 

We spoke about regime in the last point.  A good idea is to clean between every ink change as you can otherwise coat your rolls in a contamination that is extremely difficult to shift.  The range and complexity of today’s inks mean we are finding more and more that traditional roll cleaning methods are struggling at first.  

The reason for this is a kind of cross contamination that occurs when different inks are used on the same anilox without adequate cleaning in between.  We are seeing UV, water based (both filmic and thermal) and in some cases even solvent based inks being run on the same anilox and what we've come across is a layering of contamination that is difficult to shift in one go.  One chemistry may break through one layer but struggle with the next and vice versa.  Luckily, we have Alphaclean 10 which is a chemistry that can tackle this but unless you have products such as this at your disposal it will be difficult.    It is critical that the anilox is cleaned at least between every ink change as thoroughly as possible and you must have a system that will allow you to do this every single time.  Unless you have 100% cleaning 100% of the time, you’re doomed to struggle. 

5)     Finally, share your advice. 

As I mentioned in my last blog entry, the community that is forming across label printing, packaging and all industries utilising flexographic printing is one of the main reasons that this year will be successful.  We’re starting to emerge from a troubled couple of years and I feel that the relationships that are being formed between organisations and experts both online and at trade shows can be credited with helping this to happen.  Also, read publications, blogs and tweets and get the top tips from the industry gurus.  Share your tips and help and in turn you can help bring everyone forward together. This can even start by commenting below.    

Whether you think you’ve got it right or not, there is always room for improvement.  My tips are based on what I’ve seen in the past year and probably the five biggest tips that I’ve been dishing out to printers.  You can be a huge printing outfit or you could be running one tiny press, it all works the same.  Once you get the condition of your anilox right, the rest will follow.  You’ve got to use it or you’ll lose it.