Category: Cleaning Routine | Packaging & Print
Reading time: about 5 minutes
Target audience: Operators and technical managers in the flexography industry
Do you wait to maintain your grid roller until something goes wrong? You’re not alone, but it’s definitely the most expensive approach. In this article, we explain when maintenance is necessary, how you can spot issues early on, and how a good cleaning routine can save you money and reduce downtime.
What exactly does a grid roller do?
The anilox roller is the heart of every flexographic printing process. The roller transfers ink to the printing plate through thousands of microscopic cells. The size, depth, and volume of these cells determine how much ink is transferred per print run and thus directly affect the quality of your printed material.
When those cells become clogged with ink residue, they shrink. And smaller cells mean reduced ink transfer, color variations, and blurry prints. What starts as a subtle quality issue quickly escalates into customer complaints, reprints, and downtime.
The wrong signal: waiting for printing problems
The most common answer to the question “When should we clean?” is: “When the pressure is off.” That’s understandable, but it’s too late.
By the time you notice clogging issues, the cells are already so clogged that daily or periodic cleaning is no longer enough. You’ll need a deep clean: more intensive, more time-consuming, and more expensive. And in the meantime, your machine is idle.
Waiting for problems to arise is a reactive approach. What you want is a predictable approach.
Volume measurement: the objective benchmark
The key to predictable maintenance is **volume measurement**. By regularly measuring the cell volume of your anilox roller, you can get an objective picture of the roller’s condition before printing problems arise.
How does it work?
Using the **AniCAM from Troika Systems**, a specialized anilox scanner, we measure the volume per cell in BCM (Billion Cubic Microns) or cm³/m². The scanner maps both the cell volume and the clogging percentage. You can compare this figure with the roll’s original specifications and track it over time using the Troika TMS software.
What do you do with that measurement?
Set a threshold: the minimum volume at which your roller still produces acceptable print results. As soon as the measurement falls below that threshold, schedule a routine cleaning. Not as an emergency measure, but as part of your regular maintenance routine. A measurement taken after the cleaning will objectively confirm how effective the cleaning was and how much cell volume has been restored.
**Clean Solutions Group partners with Troika Systems** to offer exactly this: a closed-loop system in which cleaning and measurement reinforce each other. CSG removes contamination and restores cell volume, while Troika validates the results and monitors the condition of your rollers over time. Together, we don’t just provide a service—we deliver demonstrable results.
The three levels of cleaning
A good skincare routine works in layers. Each step has a different frequency and purpose:
1. Daily cleaning
After each production run, remove fresh ink residue before it has a chance to harden. This is the most effective way to slow down cell volume loss. A good daily cleaner dissolves ink without damaging the cell or the chrome surface. Done properly, this significantly delays the need for deep cleaning.
2. Regular cleaning
Once a week or every two weeks, use a periodic cleaning agent, for example in combination with a Heating Bucket. This removes caked-on residue that daily cleaning cannot reach. A cycle takes about an hour and serves as the bridge between daily maintenance and deep cleaning.
3. Deep cleaning
When volume measurements indicate that the cell has deteriorated too much, or when stubborn contamination (such as cured UV ink or limescale) does not respond to routine cleaning, deep cleaning is required. This is performed using specialized machines such as the Jet-Flow, BioJet Cabinet, or BioJet In-Press and requires more time and preparation. That is precisely why you want to make this as predictable as possible and not treat it as a crisis response.
What are the benefits of a good routine?
For the operator: less hassle at the machine, fewer rush jobs, and better control over your production process.
For the technical manager: longer service life of the anilox rolls (which are a significant investment), fewer unplanned downtimes, more consistent print quality, and fewer defects. The cost of a structured cleaning routine is a fraction of the cost of a single unexpected replacement or a night of production downtime.
Getting Started
Establishing a cleaning routine that works for your specific situation, your inks, machines, and production speed starts with an on-site analysis. The specialists at Clean Solutions Group will visit your production site, collect samples for laboratory analysis, and recommend an approach tailored to your specific needs—not a one-size-fits-all plan.
Summary
- Don’t wait for printing problems to arise—check the cell volume of your anilox roller regularly using the AniCAM from Troika Systems.
- Set a threshold and schedule a deep clean as soon as that threshold is reached.
- Daily and periodic cleaning is your most important tool: it delays the need for deep cleaning and extends the life of your roller.
- A good routine saves money, time, and headaches.
Want to know how your skincare routine is doing right now?
Our experts will analyze your production facility and provide concrete advice—with no obligation and by appointment.
Schedule a consultation with our specialists
Clean Solutions Group: The leading platform for cleaning solutions in the industrial, packaging, and printing sectors.