With flexography still serving as the backbone of the label printing industry, product evolution remains critical. Such is the case with the anilox roll. The newest enhancements to anilox design can make or break a print run.

One of the most significant areas of innovation in anilox technology has been the development of hybrid and channeled engraving formats, too. The latest engineering has been designed to overcome the limitations of conventional 60° geometries.

“Traditional 60° engravings can create parabolic cell structures at higher line counts and volumes, where the cell narrows as it deepens,” remarks Jake Roberts, sales director, Sandon Global. “While these cells may theoretically hold the required ink volume, they often struggle to release it efficiently on press. This can result in common print defects such as UV ink spitting, ghosting, reduced optical density, and drying-in, particularly as press speeds increase and graphics become more complex.   

“Hybrid engravings combine open channel structures with shallower cells, enabling more efficient ink collection and release, allowing higher line counts and usable volumes to coexist without compromising transfer performance,” Roberts continues. “The result is more predictable ink flow, improved print consistency, and reduced downtime associated with cleaning and troubleshooting.”

Providing flexibility

According to Roberts, line count and volume alone do not define performance. Two anilox rolls with identical specifications can behave very differently depending on cell geometry, wall structure, and depth. Hybrid engravings provide converters with greater flexibility to optimize ink transfer based on the specific application, rather than being constrained by traditional resolution-volume trade-offs.

“In the US narrow web market, we have seen strong adoption of our hybrid technologies,” states Roberts. “Many converters have successfully transitioned from conventional 60° engravings to hybrid formats such as Fluid UV (combination solid and tonal print) and Fluid Hex (process and solid 60°), with some standardizing their entire anilox inventories around these solutions to improve consistency and efficiency.”

Overcoming challenges

When print runs are comprised, suppliers often suggest an analysis of the anilox roll. A key challenge for converters is selecting the correct anilox specification for a particular application.

“As flexographic printing has advanced, the interaction between the anilox, plate, ink system, and substrate has become more complex,” notes Roberts. “There is still a tendency to focus on line count as a primary specification. However, this can be misleading. Volume is the critical parameter. It determines how much ink is delivered to the plate and, ultimately, to the substrate. Selecting an anilox based on line count alone can lead to insufficient or excessive ink transfer, affecting print quality, color strength, and consistency. The optimal solution is an engraving that balances volume, cell geometry, and plate resolution, aligned with the specific ink and substrate combination.”

In addition, consistency of volume control is equally important. Even small variations in engraved volume can result in visible color shifts, increased Delta E, and longer make-ready time.

“Controlled volumes, consistent geometries and robust, durable coatings together ensure the tightest tolerances needed to achieve the level of print quality expected by brand owners today,” says Roberts. “Maintaining tight tolerances during manufacturing, combined with regular inspection and volume verification on press, is essential for repeatable, high-quality print. Across multi-station presses, this level of control prevents cumulative density imbalances that even advanced color systems struggle to correct.”

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Coating quality

Coating quality is another critical factor that is often overlooked. The hardness and porosity of the ceramic layer directly influence wear resistance, ink release, and long-term performance. Without monitoring these properties at every single stage, it is impossible for anilox suppliers to guarantee coating consistency.

“Inconsistent coatings compromise engraving precision, cell formation and lead to variability in ink transfer – a challenge for any converter,” comments Roberts. “Robust coating quality control, supported by advanced materials analysis and inspection, is therefore necessary to ensure coating integrity and durability over time.

“At Sandon Global, an on-site metallurgical laboratory supports coating consistency through advanced materials analysis and inspection,” he adds. “Advanced instrumentation includes a scanning electron microscope (SEM) capable of magnifications up to 150,000x, allowing detailed inspection of surface topography, porosity, and microstructure.”

Cleaning and handling

Handling and storage also contribute to anilox damage. Even minor impacts can damage the engraved surface and affect performance.

“Implementing proper handling procedures, protective covers, and appropriate storage systems are essential to extending anilox life and maintaining consistency,” states Roberts.

Cleaning is fundamental to anilox performance, as well. However, cleaning can present its own challenges.

“Inadequate or inconsistent cleaning leads to ink and coating residues building up in the cells, reducing effective volume and causing print variability,” explains Roberts. “At the same time, the incorrect use of cleaning systems can damage the anilox surface, particularly if coating quality is not sufficiently robust. A structured cleaning and inspection regime is essential.

“Regular cleaning, ideally on a scheduled weekly basis, combined with post-clean inspection and periodic volume measurement, helps maintain performance and detect issues early,” he continues. “Selecting the correct cleaning method should also consider coating properties, ink chemistry, and operational requirements.”