Ceramic anilox rollers are an indispensable and important equipment in industrial production and are widely used in many industries such as flexographic printing, coating, and packaging. In these fields, the main function of ceramic anilox rollers is to store and accurately transfer liquids through the small holes or grid structure on their surface, thereby ensuring that materials such as printing inks and coatings can be evenly attached to the surface of the substrate. A key performance indicator of anilox rollers is their mesh volume, which directly affects the amount of liquid transferred and the coating quality. Therefore, understanding the mesh volume range of ceramic anilox rollers is crucial for selecting suitable equipment.

This article will explore the mesh volume range of ceramic anilox rollers, their role in different applications, and how to choose the appropriate mesh volume according to specific needs.

What is the mesh structure of ceramic anilox rollers?

Basic principles of mesh design

The surface of ceramic anilox rollers is engraved with regularly arranged tiny mesh holes that can hold liquids and transfer them evenly to the substrate during rotation. The size, depth, shape and arrangement of the mesh determine the roller's liquid storage capacity, which in turn affects the efficiency and quality of liquid transfer.

The volume of the mesh is usually expressed in cubic centimeters per square inch (cm³/in²). Specifically, the larger the mesh volume, the more liquid it can store; conversely, the smaller the mesh volume, the less liquid it can store. This characteristic has a direct impact on the precision and quality of different processes.

Mesh volume and mesh line count

The mesh volume is closely related to the mesh line count. The mesh line count refers to the number of meshes arranged horizontally per inch of length, usually expressed in lines per inch (LPI). The higher the line count, the greater the density of the mesh and the smaller the aperture. Therefore, anilox rollers with high line counts are suitable for fine printing, while anilox rollers with low line counts are used for thick layer coating or large amounts of liquid transfer.

For example, an anilox roller commonly used for high-precision flexographic printing can have a line count of more than 1000 LPI, while a low-precision anilox roller used to apply thick layers of ink may have a line count of around 200 LPI. The mesh line count and volume together determine the final transfer effect of the liquid.

What is the mesh volume range of ceramic anilox rollers?

The mesh volume range of ceramic anilox rollers varies depending on the application scenario, usually between 1.0 cm³/in² and 20.0 cm³/in². Here is a detailed description of the different mesh volume ranges and their corresponding application scenarios:

Small volume mesh: 1.0 cm³/in² to 5.0 cm³/in²

Anilox rollers with smaller mesh volumes are usually used for high-precision printing processes, such as high-detail image transfer in flexographic printing. These anilox rollers usually have a higher mesh line count, smaller pore size, and relatively less liquid transfer, but can ensure the fineness and uniformity of the image.

Main applications of small mesh volume:

● High-precision flexographic printing: When printing high-resolution images, small mesh volume can ensure uniform transfer and precise control of ink, avoiding the problem of excessive or insufficient ink.

● Thin film coating: When coating thin layers of liquid, the use of anilox rollers with small mesh volume can ensure the uniformity of the thin layer, which is suitable for processes with strict requirements on coating thickness.

Advantages of small mesh volume:

● High liquid transfer accuracy, suitable for fine printing and high-demand coating processes;

● Effectively control liquid usage and reduce material waste.

Medium mesh volume: 5.0 cm³/in² to 10.0 cm³/in²

Anilox rollers with medium mesh volume are suitable for printing and coating medium-thick liquids. This type of anilox roller balances the amount of liquid transferred and the fineness of the image, and is suitable for coating and printing needs in general industrial applications.

Main applications of medium volume mesh:

● Packaging printing: When printing patterns on packaging materials, medium volume mesh is usually required to ensure color saturation and print clarity.

● Industrial coating: When manufacturing industrial coatings, medium volume anilox rollers can provide suitable coating thickness and liquid transfer volume, suitable for conventional processes.

Advantages of medium volume mesh:

● It takes into account the requirements of liquid transfer volume and accuracy, and has a wide range of applications;

● It can handle medium-thick coating or printing tasks.

Large volume mesh: 10.0 cm³/in² to 20.0 cm³/in²

Large volume anilox rollers are used for processes with high liquid demand, such as heavy coating or large-area image printing. This type of anilox roller has a lower mesh line count and a larger aperture, which is suitable for transferring large amounts of liquid and is usually used in more extensive coating processes.

Main applications of large mesh volume:

● Large area coating: When a thick coating is required on the substrate, an anilox roller with a larger mesh volume can ensure sufficient liquid supply to meet the process requirements.

● Extensive printing: When used for printing large area color blocks or patterns, an anilox roller with a large mesh volume can quickly and effectively transfer a large amount of ink to ensure the printing effect.

Advantages of large mesh volume:

● Large liquid transfer volume, which can meet the process with high liquid demand;

● Suitable for coating and printing processes with lower requirements, which can effectively improve production efficiency.

How to choose the right mesh volume?

Choosing the right mesh volume is crucial to ensure the smooth progress of the production process. The viscosity and fluidity of the liquid are one of the main factors affecting the selection of mesh volume. For low-viscosity liquids, a smaller mesh volume can already provide sufficient transfer volume; while for high-viscosity liquids, a larger mesh volume is required to ensure that the liquid can be effectively transferred. If the process has high requirements for coating thickness or fineness of the printed pattern, a smaller mesh volume should be selected to ensure precise control of the liquid. On the contrary, in situations where high precision is not required, a larger mesh can be selected to improve production efficiency.

In addition, the surface characteristics of the substrate will also affect the selection of mesh volume. For example, for a smoother surface, the liquid absorption capacity is limited, so a smaller mesh should be selected to avoid excessive accumulation of liquid. For a rougher substrate surface, a larger mesh can be used to ensure sufficient liquid coverage.

How to maintain and adjust the mesh volume?

In actual production, the mesh volume of the anilox roller may change with the increase of usage time, especially when dealing with corrosive or abrasive liquids, the surface of the mesh may be eroded or worn, resulting in a decrease in volume. Therefore, it is important to clean and maintain the anilox roller regularly.

Cleaning the mesh

Liquid residues and solidified substances may clog the mesh and affect the transfer ability of the liquid. Therefore, it is recommended to use special cleaning equipment and chemical cleaning agents regularly to clean the surface of the anilox roller to ensure that the mesh remains unobstructed.

Check and measure the mesh volume

Check the mesh volume of the anilox roller regularly to ensure that it is consistent with the process requirements. The mesh volume can be accurately measured using specialized measuring instruments, allowing any wear or deformation to be discovered and repaired promptly.

JH Machinery has been delivering exceptional industrial rolls to global buyers since 2001. Based in China, our ISO9001-certified factory manufactures rolls such as ceramic-coated rolls, polyurethane rolls, and heating rolls. Industries like packaging, automotive, and mining trust our products for their durability and performance. We offer customizable solutions, competitive prices, and wholesale options to suit your needs. Experience reliable service and quality with JH Machinery.