CASE STUDY
Anilox Wear - Improving the Life of Anilox Rollers
Dear Customer,
We visited your facility to investigate the roll wear concerns and gain understanding of pressroom practices. We were very impressed with the level of dedication and commitment of your staff. The open-minded attitude will allow us to work as partners in resolving your anilox concerns. Below is a list of opportunities we feel will greatly decrease the level of wear and scoring.
Action Plan Current
Doctor Blades
Determine blade type, i.e. radius and thickness, based on the documented trial below. Flxon has agreed to orchestrate the follow up with the trial results and future blade evaluation. Other opportunities discussed; currently using .006”, suggest .008” blades specifically for the white and the more viscous materials. The containment blades are .025” in thickness and could possibly be decreased in thickness. Eliminating the use of poly blades all together will require further investigation. I have added to the list of future actions to complete. The reason for possible elimination of the poly blades would be if it is determined that steel is in-fact in-bedded in the blade.
IDC Trial: Production Person in charge of the data and samples to send to Flxon upon trial completion.
- 19 Y 800 625 .006 / Radius Neoprene
- 20 M 800 610 .006 / Beveled Felt
- 21 C 800 625 .008 / Radius Neoprene
- K 800 Standard Benton Foam
Stainless Steel Dead Bands/ Roll Covers
The reasoning behind the stainless steel dead bands is to prevent edge damage on the Comco and the IDC presses. After reviewing the press configuration on the IDC, we agreed to the following actions for the IDC press. First, ship customer a thin roll cover to test in the press. The goal is to leave the roll cover on the roll at all times including installation and removal of anilox from the press. The roll cover will be an inch and a half longer on each side of the roll face. Customer to add the 1/8” thick white foam 3 inches in on each side of the cover to the inside of the roll cover for this particular test. The thought is if the roll is covered it will greatly decrease the opportunity of damaging the edges and the face of the roll. Upon success of the anilox cover test we can then eliminate the stainless steel dead bands on the IDC press. Further investigation is required on the Comco press and is added to the list of future actions. Harper to complete this action and has agreed to a date of 06/15/01 to have one roll cover.
The un-engraved area on the edge of the anilox roll will be increased to 1” on each side.
End Seals
The end seals on the IDC press may be the key to increasing roll life, in my opinion. The observation of the older of the 2 chamber assemblies pose the most concern. The seal height and thickness create the doctor blade to raise approximately 1/8” on the outside edges. Unfortunately the felt seals shipped to you for that particular chamber assembly were also too tall and thick and did not work. The concern from a scoring standpoint is the seals cause the doctor blade to contact the anilox roll too soon. The end of the blade in some cases has extorted the stainless steel. The extorted particles of steel could in fact be adding to the scoring of the anilox rolls. I understand the reasoning for the oversized white foam seals and agree that is important to not create another problem such as leaking by removing the white foam. The rigid felt seal is one distinct advantage over the Neoprene and white foam. Harper will work with HarperScientific, our supplies division, to modify the felt seals.
End Bracket for End Seals
An observation of the wear on the stainless steel dead bands prompted further investigations during the visit. Possible cause is the end brackets come very close to the anilox roll after extended time in the press. Customer has addressed by have all new modified brackets manufactured. When the chamber is out of position the result is uneven blade wear, which causes premature blade wear and premature leaking. When the chamber starts leaking some of the operators will add more pressure to stop the leaking versus stopping the press and correcting the problem. The distance from the anilox roll to the bracket on the chamber that holds the end seal is less than ¼” away. When press operators add pressure they may have a 1/16” of movement when the chamber is skewed before coming in contact with the anilox roll.
Other Opportunities
Determine if we can locate sleeves for the rare earth magnets existing at customer. Harper will investigate and report back to customer by 06/15/01.
Schedule a visit for Bill Applegate and I to continue the investigation on the Comco press, incorporate training for all shifts and review open projects.
Next visit determine team members for GET. Create a check list to assist in determining streaks on press. I will create and issue by 06/15/01.
Workshop
When adjusting the chambers in the operators must reset at start up
Operator not resetting chamber at start up after new system
Care and Maintenance program
Roll cover use and reasons
for cleaning magnets more frequently
Consistent re-setting of chambers
The above issues are, in fact, impacting the life of the anilox roll. In order to correct the scoring issue we need your help. Press side care and maintenance is an important factor impacting scoring and can be addressed through the G.E.T. program.
Future Actions
Plastic on anilox rack to prevent edge damage
The possibility of eliminating the use of poly blades all together
Investigate all the above concerns / opportunities on the Comco press.
To summarize, Harper Corporation appreciates the opportunity for your business and will continue to do whatever we can to keep this relationship strong. If you have any questions please feel free to contact me at 800-627-4784, Ext. 104. Otherwise, I look forward to meeting with you in the near future.
Best Regards,
David L. Brewer
Midwest Service Manager
Harper Corporation
© 2005-2006, Harper Corp. of America; All Rights Reserved 
Terms & Conditions of Use
|
