As an important part of the printing and coating industry, the anilox roller bears the heavy responsibility of accurately controlling and transferring liquid materials during the production process. Its core role is to ensure the uniform distribution of ink or coating in industrial processes such as printing and coating, so as to obtain high-quality production results. The structure of the anilox roller has a direct impact on its performance. Its design should not only consider materials and coatings, but also pay attention to mesh structure, roller shaft, surface treatment and other aspects.

Before deeply understanding the structure of the anilox roller, it is necessary to clarify the specific function of the anilox roller in the industry. It is mainly used to control the amount of liquid transferred and accurately deliver ink or coating through the tiny mesh structure on the surface. Therefore, the accuracy, uniformity and durability of the anilox roller are closely related to its structure. This article will analyze the structure of the anilox roller in detail from the aspects of materials, mesh, roller shaft, surface treatment, etc.

What is the structure of the anilox roller?

The anilox roller is mainly composed of the following key parts: roller shaft, substrate, mesh structure and surface coating. Each part plays an important role in the overall performance of the anilox roller.

Shaft

One of the core structures of the anilox roller is its shaft. The material and design of the shaft affect the stability and durability of the anilox roller. The shaft is usually made of steel, aluminum or alloy materials to ensure sufficient rigidity to withstand the pressure and mechanical forces generated during printing or coating.

The diameter and length of the shaft depend on the specific application requirements. A larger shaft can improve stability and avoid bending or deformation under high pressure. In addition, the mounting structure at both ends of the shaft is critical to the precise operation of the anilox roller. It needs to be precisely connected to the mechanical equipment and remain stable at high speeds.

Base Material

The base material of the anilox roller is its main supporting part and is usually made of steel, aluminum alloy or carbon fiber. Different base materials will affect the weight, durability and cost of the anilox roller.

● Steel base material: Steel, as the base material of the anilox roller, has high hardness and wear resistance and is suitable for industrial environments that require high strength. However, steel anilox rollers are heavy and may increase mechanical loads on high-speed production lines.

● Aluminum alloy substrate: Compared with steel, aluminum alloy is lighter and suitable for high-speed production lines. Although slightly less hard than steel, aluminum alloy still provides sufficient strength and is easy to process and install.

● Carbon fiber substrate: Carbon fiber is a lightweight and high-strength material. Its use is becoming more and more common in industrial environments that require high precision and high speed.

Mesh structure (Anilox Cells)

The mesh structure of the anilox roller is its most critical part. The mesh is a tiny groove precisely carved on the surface of the anilox roller, usually distributed in a certain pattern over the entire surface of the roller. The shape, depth and density of these meshes determine the amount of liquid (ink, paint, etc.) transferred. The structural types of meshes are usually hexagonal, diamond, linear, etc.

● Hexagonal mesh: The hexagonal structure is the most common mesh shape because this design can maximize the carrying capacity of the liquid and ensure uniform liquid transfer.

● Diamond mesh: Diamond mesh is often used in processes that require a large coating amount because its design can increase the depth and volume of the mesh.

● Straight mesh: This mesh design is more suitable for some special applications, such as coating transfer that requires greater fluidity.

Each mesh structure design has a specific application, and choosing the right mesh shape can greatly improve production efficiency and product quality.

Surface Coating

The coating on the surface of the anilox roller not only determines its durability, but also affects its corrosion resistance and wear resistance. The most common types of coatings include ceramic coatings and chrome coatings.

● Ceramic coating: The coating of the ceramic anilox roller has high hardness and can withstand long-term mechanical friction and liquid erosion. At the same time, ceramic coatings have good corrosion resistance, so they are very popular in the printing and coating industry.

● Chrome coating: Chrome coating also provides excellent wear resistance and corrosion resistance, and is suitable for applications in environments that require high hardness. However, chrome coatings may be slightly inferior to ceramic coatings in durability and service life.

What is the processing technology of the anilox roller?

The mesh engraving and surface treatment of the anilox roller need to be completed through precise processing technology. Generally, there are two main mesh engraving technologies: laser engraving and mechanical engraving.

Laser engraving technology

Laser engraving is a high-precision processing technology that uses a high-energy laser beam to ablate tiny mesh holes on the surface of the anilox roller. The advantage of this technology is that it can achieve extremely fine mesh structures, and the engraving speed is fast and the precision is high. Laser engraving is often used in the manufacture of high-quality ceramic anilox rollers.

Mechanical engraving technology

Mechanical engraving technology uses diamond tools to carve mesh holes on the surface of the anilox roller. This traditional engraving method is low-cost, but the processing accuracy and efficiency are not as good as laser engraving. Mechanical engraving is mostly used for chrome-plated anilox rollers or other occasions with less demanding requirements.

What are the characteristics of anilox rollers?

The structure of the anilox roller determines its application characteristics in different industrial occasions. Here are some important characteristics:

High wear resistance

The ceramic coating has a very high hardness and can withstand the friction of high-speed operation for a long time, so it has high durability on coating and printing production lines. Although the chrome coating is slightly less hard, it also has good wear resistance.

Controllability of coating amount

The mesh structure on the surface of the anilox roller determines the amount of coating. Meshes of different shapes and depths can flexibly adjust the transfer amount of ink, coating or other liquids to meet different production needs.

Corrosion resistance

Since the anilox roller usually needs to come into contact with chemical solvents, the corrosion resistance of the surface is particularly important. Ceramic coatings are outstanding in this regard, while chrome coatings need to be optimized according to the specific chemical environment.

What are the application scenarios of anilox rollers?

Anilox rollers are widely used in industries such as flexographic printing, gravure printing, coating processes, and label printing. In each application scenario, anilox rollers play a key role in accurately controlling the distribution of liquids.

Flexographic printing

Flexographic printing relies on anilox rollers to control the amount of ink to ensure the clarity of the printed pattern and the uniformity of the color. The choice of anilox rollers is crucial in flexographic printing because it determines the amount of ink transferred and the printing quality.

Coating process

In the coating process, anilox rollers are used to control the thickness and uniformity of the coating. The depth and shape of the mesh determine the thickness of the coating, which affects the final performance of the product.

Label Printing

Label printing requires extremely high precision and quality control. The anilox roller ensures even distribution of ink on the label through its precise mesh structure, avoiding problems such as uneven or blurred colors.

Since 2001, Jiangsu Jinhang Machinery Manufacturing Co., Ltd. (JH Machinery) has been a reliable source for high-quality rolls at factory-direct prices. Our 13,000-square-meter facility is equipped with state-of-the-art machinery, allowing us to manufacture products such as chrome-plated rolls, ceramic anilox rolls, and cooling rolls. We cater to industries including lithium battery production, mining, and packaging, offering customized solutions to meet unique needs. Contact us now for wholesale opportunities and affordable prices.