The anilox roll has often been called the “heart” of flexographic printing. Synonymous with flexo, the role the anilox plays cannot be understated in the success of a label converter’s print run. Despite the emergence of digital printing in recent years, flexo will continue to remain a dominant label
printing process.

In a new report from Smithers, the global value of flexographic printing in 2024 was $230.5 billion, and that figure is projected to increase at a 3.0% CAGR through to 2029. Data from its newly published market report, “The Future of Flexographic Printing Markets to 2029” shows this will yield a total value of $267.2 billion in 2029 – at constant 2023 pricing. The report illustrates that flexo output is growing across most applications, with packaging emerging as a standout. 

Given that anilox and flexo printing go hand in hand, L&NW recently sat down with Juan Bermudez, executive vice president, Sales & Technical Services, Harper Corporation of America, to learn about the newest flexo trends and how the anilox roll will drive converter success in this pivotal printing segment.

L&NW: What are the latest trends in flexo label printing, and how vital is the anilox roll?

JB: Sustainability, automation, innovations in plate materials and screen technologies, customization, and developments in color management are significant trends in the flexo label industry. All are impacting flexo label printing in diverse ways.  

The anilox roll interacts fluently with these trends by ensuring accurate ink transfer and maintaining color consistency that directly contributes with the production of more detailed images, seamless tone transitions, and vibrant colors by accurately managing ink transfer and using finer screen patterns. 

As a precision ink transfer device, its effectiveness is directly tied to the quality of its coating, engraving consistency, and repeatability. Selecting the correct cell shape, volume, line screen, and screen angle is essential for achieving the expected ink transfer, color results, and overall print quality.

L&NW: How has anilox technology evolved and improved in recent years?

JB: Anilox roll technology has undergone rapid evolution since the introduction of ceramic surface coatings, laser-engraved technologies, and high-line screen count engravings. The consistency and repeatability of the engraved surface are without precedent, as well as the ink transfer control and efficiency. This has been a game-changer for color reproduction and reducing dot gain.

L&NW: When troubleshooting issues on-press, what’s important to know about the anilox?

JB: There are a number of factors to keep in mind. For starters, the engraving specifications, such as volume, line screen count, cell shape, and engraving angle, are critical. Plus, the current condition of the engraved surface is vital. Is the roll clean, worn, in good working condition? The mechanical performance and structural integrity of the core should not be overlooked, either. You should also check for dimensional stability and accuracy.   

L&NW: What’s important for customers to know when selecting an anilox roll? 

JB: Label converters should be cognizant of the engraving specifications of the anilox rolls for the type of work they plan to print, the kind of printing applications they intend to achieve or for the printing issues they want to overcome. These include volume, line screen, cell shape, and angle.

L&NW: How does Harper collaborate with customers to ensure they’re getting a tailor-made solution for their specific needs?

JB: Through our Technical Solutions Division, Harper works with our customers to identify their printing and/or coating application needs/objectives, and gathers all technical information required to provide a tailor-made anilox solution to meet their specific needs.