Few components of a flexo pressroom are as essential as the anilox roll. Often called the “heart” of flexographic printing, the anilox roll meters a precise amount of ink to the plate, and ultimately to the substrate. Its job sounds straightforward, but the evolution of packaging, labels, and converting has demanded continuous innovation from anilox suppliers.

In today’s narrow web marketplace – where converters are asked to deliver shorter runs, higher quality graphics, and sustainable solutions – all while maintaining uptime and efficiency, the role of the anilox roll has never been more critical. Advancements in manufacturing and engraving are redefining how printers think about their anilox inventory.

The surface of an anilox roll is engraved with millions of microscopic cells, each designed to carry and transfer a precise amount of ink. Historically, the geometry of those cells – measured in lines per inch (lpi) and volume (billion cubic microns per square inch, or BCM) – defined how well a job would print.

It has always been a delicate balance. Coarse engravings deliver more ink but less detail. Finer engravings deliver greater resolution but can compromise density. In the flexo industry, anilox innovation aims to give converters the best of both worlds – detail and density, repeatable and reliable.

One of the biggest changes in anilox manufacturing has come from laser engraving. Early generations of mechanically engraved aniloxes have long since given way to ceramic-coated rolls laser-engraved with extraordinary precision. Suppliers today are pushing the limits of laser technology to engrave tighter, deeper, and more consistent cells.

For example, multi-beam fiber laser systems allow for high-definition engravings with improved uniformity across the roll surface. This translates to sharper print quality, reduced dot gain, and greater repeatability. The leap in engraving precision also enables advanced geometries – elongated cells, channel patterns, or hybrid shapes – engineered to optimize ink release for specific applications.

Label and packaging converters now have access to engravings tailored not only for process work and solids but also for specialized coatings, adhesives, and opaque whites. The ability to control ink laydown at this level of precision helps brands achieve the visual impact they demand while minimizing waste.

Introducing Harper’s XCAT

Harper Corporation of America is widely regarded as a pioneer in anilox roll innovation, offering both ceramic-coated and engravings engineered with HarperScientific’s proprietary surface technologies.  Richard Hernandez, technical manager for Harper, discusses the essential role the anilox plays within the flexo printing process, as well its place in a rapidly evolving industry. 

 “It has been said that the anilox is the heartbeat of the press,” Hernandez says. “And it makes sense – good engravings with clean cells will produce sharp, clean, and vibrant color. Whereas worn and dirty cells, combined with inconsistent ink release, will produce ink waste, downtime and inconsistency in job repeatability. But with all the developments in plate technology, ink system improvements, and advancements in press operation, when does the role of the anilox come into play? Can the workhorse engraving still compete with the advancements in our industry? Or is it time for the next generation of anilox to be introduced and take our printing customers and partners into the next generation? I believe it is time.”

Harper Corporation recently introduced its XCAT engraving, a next-generation technology that Hernandez says is one of a kind. “Our 60º Hex engraving has been the proven industry leader for decades. So instead of changing what works, we improved upon it,” he explains. “The XCAT channeled application technology combines a channeled engraving with a consistent pocket structure. This allows us to have a measurable, precise CPI and BCM like no other channel engraving.”  

Harper began developing the XCAT geometry to help with the issue of ink spitting. In flexographic printing, ink spitting is a defect where tiny droplets or streaks of ink are ejected unpredictably from the anilox roll or the doctor blade chamber and land on the substrate. Instead of transferring clean, controlled dots, the ink splatters, resulting in visible specks, streaks, or haze on the printed material. 

“Understanding the basis behind spitting, we knew that flow would help with reducing the buildup of ink behind the doctor blade, but a channeled engraving does not allow control of consistent, measurable ink release across the web,” says Hernandez. “Without this control, repeatability and make-ready times will be increased. In creating a pocketed channel, we reduced spitting by a significant amount and found that we also ended trail edge voids, reduced the downtime in both in-press and off-line cleaning, reduced blade wear, and improved ink solubility at high speeds. 

“When it comes to heavy coatings, the XCAT has improved transfer. And because of improved flow, it has reduced air entrapment, which means less foaming,” says Hernandez.

When Harper first developed its 60º Hex, the company’s experts found that it did not interfere with plate angles or customers did not have a moiré pattern when printing. “So, in keeping with tradition, we kept this 60º angle so that our customers will achieve optimum dot support in process/screen and combo printing, rich – solid ink densities across the web when printing solids and achieved higher white ink opacities due to less pin holing. With all these added benefits, we found that the XCAT will work with all ink systems and substrates.”

Hernandez continues, “The next generation of anilox is here. With XCAT, Harper has designed an engraving to deliver multiple application needs in a single geometry. Harper developed this engraving to be designed for high definition process images, expanded gamut printing, combination work, screen tones/vignettes, spot colors, opacities, metallics, and OPV/specialty coatings.

“One geometry for all applications – sounds great, doesn’t it? At Harper, we pride ourselves on staying in touch with our customers’ needs and demands,” Hernandez adds. “With over 200 years of combined flexography experience, we know what it is like on the production floor. Having conversations about what slows down production, and understanding how those issues create a bottleneck, allows us to come back and develop solutions for all customers. This is what sets us apart from our competitors. We have always strived to develop solutions, not a band aid, to provide for our customers and build relationships that will move this industry into the next new horizons.”

Solving UV Ink Spitting with Apex

Apex International, touted as the world’s largest anilox and metering roll manufacturer, is known for its GTT 2.0 open slalom ink channel engraving, a patented technology designed to replace conventional cell structures. GTT anilox rolls deliver a controlled ink flow that reduces issues like dot gain, mottling, and excessive ink consumption. By standardizing ink transfer, converters achieve predictable color density and faster setups, which is especially valuable for short-run and repeat jobs. 

Nick Harvey, technical director at Apex, discusses the anilox roll’s importance. He says, “In label printing, the anilox roller is more than just another component. It is the heartbeat of flexo. Every label, vignette, and vibrant color depends on how well the anilox meters and delivers ink. When performance slips, the entire workflow feels it. Printers face inconsistent density, wasted material, and costly downtime from recurring print defects.”

Harvey points out that one of the most frustrating and persistent issues affecting flexo printing has been UV ink spitting – a problem that has shaped anilox development for more than a decade.

“UV inks behave differently than solvent or water-based inks,” he explains. “Their higher viscosity makes them harder to transfer consistently, especially with traditional closed-cell engravings. As the anilox struggles to replenish and release ink, hydraulic pressure builds beneath the doctor blade. The result is ink spitting, where tiny drops are flung onto the substrate and leave behind spots, streaks, or dirty print.”

Printers have long fought this battle with temporary fixes such as swapping doctor blades, tweaking press speeds, raising temperatures, or re-polishing rollers, Harvey says. He adds, “These approaches may help for a short time, but they do not solve the root problem. Eventually, the spitting returns along with lost productivity and additional waste.”

Over the last decade, according to Harvey, engravings have been adjusted in an effort to keep UV spitting under control. He explains, “Traditional 60° engravings (H60) were once the gold standard, offering sharp print and strong transfer. With UV inks, however, the closed cells trapped pressure and spitting followed. 30° engravings with shallower angles and channel-like structures relieved some pressure but sacrificed ink transfer, color strength, and fine-screen performance. In addition, lightly polished H60 created micro-gaps for ink flow, which reduced spitting in the short term. Over time, the raised hex corners wore quickly, the problem returned, and rollers became more vulnerable to scorelines and early wear.

“These adjustments offered improvement, but none provided a complete solution,” Harvey says. “Printers were still managing problems instead of eliminating them.”

The breakthrough that solved these problems, Harvey says, is open-channel engravings. He states, “The real leap forward came with engineered open-channel engravings such as GTT. Instead of trapping ink in closed hexagonal cells, GTT channels are designed to relieve pressure under the doctor blade and stop hydraulic build-up at the source; improve flow so even high-viscosity UV inks replenish and release consistently; and balance transfer by optimizing flow resistance and release for smooth, predictable ink laydown.

“With this approach, printers no longer must choose between controlling spitting and achieving print quality. Open-channel engravings deliver clean vignettes, sharper detail, vibrant solids, and faster press speeds with fewer interruptions,” Harvey says.

For converters under constant pressure to do more with less, the benefits of GTT are clear. They include a dramatic reduction in UV ink spitting, resulting in less rework and fewer rejects; higher press speeds, which maximize output per shift without loss of quality; superior print quality with smoother gradients, brighter colors and sharper images; less downtime and waste thanks to fewer plate washes and roller swaps; longer roller life, since precision engravings resist wear and scorelines; and future-ready performance that adapts to new inks and substrates.

“Instead of fighting the same battle over and over, printers can now remove the problem from the process,” Harvey says, emphasizing how addressing print issues has evolved from troubleshooting to true productivity. “It is possible to keep adjusting doctor blades, reformulating inks, or changing temperatures,” he says. “The problem is that each fix adds time, cost, and unpredictability. Addressing the root cause through engraving design allows printers to break free from that cycle.

“The anilox has always been the heartbeat of flexo,” Harvey concludes. “With today’s open-channel engravings, it is no longer just a metering tool. It has become a competitive advantage. For label printers, the message is simple – solving UV ink spitting is not about patching problems. It is about choosing the right technology at the source and unlocking new levels of speed, quality, and reliability.”Sustainability and the future of Anilox

Sustainability and the future of Anilox

As the label and packaging industry embraces sustainability, the anilox roll plays a surprisingly central role. By delivering precise ink volumes, anilox technology directly impacts waste, energy use, and recyclability.

High-efficiency engravings can reduce the need for multiple ink hits, saving both material and energy during curing. Improved durability means fewer rolls are manufactured, refurbished, or disposed of over time. Laser cleaning reduces the reliance on harsh chemicals, lowering environmental impact in the pressroom.

For converters, these sustainability benefits aren’t just good PR – they align with the demands of brand owners who expect their packaging supply chain to demonstrate measurable environmental responsibility.

What does the future hold for anilox innovation? Several trends are emerging such as further integration with digital printing. As hybrid presses become more common, anilox rolls will need to harmonize with digital print units, balancing ink laydown with digital quality standards. Advances in laser technology could enable cell structures that dynamically optimize ink release for multiple applications, further reducing inventory needs. Plus, with more automation, we can expect to see anilox rolls integrated into fully automated press setups with robotic systems handling identification, mounting, and cleaning. And from a sustainability standpoint, research into alternative materials and eco-friendly coatings may redefine durability and recyclability standards.

The anilox roll will continue to evolve in tandem with the flexographic printing process. And as long as brand owners require higher quality, faster turnaround times, and greater sustainability, anilox roll suppliers will keep innovating to meet the evolving demands of their label converter customers.