Category: Cleaning Machines | Packaging & Print
Reading time: approx. 6 minutes
Target audience: Operators & technical managers in flexography
Calcium is one of the biggest challenges worldwide when it comes to cleaning anilox rolls in the corrugated cardboard and flexo industries. Traditional cleaning methods only partially remove calcium and cannot fully restore the cell volume without risking damage to the cells.
The DeepWave does offer the solution. Using advanced cleaning technology, the machine completely and safely removes calcium and restores the original cell volume without damaging the anilox roller. Anilox rollers cleaned up to 100%, with consistent results and no pre-treatment required.
How does the DeepWave work?
The DeepWave cleans using two liquids, each with a specific purpose. An alkaline cleaning agent dissolves the ink particles; an acid removes calcium and varnishes. Both liquids are heated and applied to the anilox roller in a controlled manner via a 3D spray head with a PTFE front seal. They are then sprayed deep into the cells at high pressure (100 to 210 bar), loosening contamination from the inside without damaging the roller.
Cleaning and rinsing are performed in a single automatic cycle. There is no mist formation thanks to the built-in extraction system, and no spray issues occur because the machine operates at low pressure, with all moisture being immediately extracted.
The average cleaning time is approximately 35 minutes, including cleaning and high-pressure rinsing. For heavily soiled anilox rolls, it may be necessary to repeat the cycle.
The Sinner’s Circle: Four Factors That Determine Purification
Why does DeepWave work where other methods fall short? This can be understood through Sinner’s Circle: the principle that four factors together determine the cleaning result: chemistry, mechanical force, time, and temperature.
- Chemistry: the concentration and pH of the cleaning agent. The DeepWave uses both a strongly alkaline agent (for ink) and an acidic agent (for calcium and varnishes). Both have been specially developed and tailored to this cleaning process in the Clean Solutions Group’s in-house laboratory.
- Mechanical force: The high-pressure water jet (100–210 bar), combined with the PTFE seal, creates a mechanical action that manual cleaning can never match.
- Temperature: Heated liquids work faster and more effectively. The DeepWave heats both cleaning agents before they are applied.
- Time: By optimizing the combination of the three factors listed above, the required cleaning time is at least approximately 35 minutes per cycle.
None of these factors operates in isolation. If you increase the mechanical force, you need less chemical. If you increase the temperature, the cleaning time is shorter. The DeepWave is designed to make optimal use of all four factors.
Online or offline: the choice is yours
The DeepWave can be used both inline and offline, which is a significant practical advantage.
- In inline operation, the anilox roller runs at the standard rotational speed of the printing unit. The DeepWave cleaning head is manually adjusted to the correct spread. This allows you to clean the roller without removing it from the machine, minimizing production downtime.
- When using the machine offline, you manually adjust the rotation speed using a control panel, depending on the size and diameter of the roll. This allows production to continue while you clean the rolls outside the machine.
The machine is compatible with anilox rolls ranging from 600 mm to 9000 mm—virtually every size found in practice. You can use the DeepWave to clean both anilox and coating rolls.
The two-product system
The DeepWave always uses two products in combination. Both have been specially developed for this cleaning process:
DeepWave Cleaner (item no. 92250) dissolves ink residues and opens the nozzles. Suitable for water-based, UV, and solvent-based inks.
DeepWave Descaler (item no. 92260) removes the limescale residue left behind after using the Cleaner. This is the step that makes all the difference: calcium builds up invisibly inside the cells and reduces their volume without immediately causing visible pressure issues. Skipping the Descaler means the cleaning process is only half done.
Always use them together—that’s the system.
When is the DeepWave the right choice?
For limescale buildup in water-based environments. Calcium is the biggest hidden problem in water-based environments. Daily and standard periodic cleaning don’t solve it. DeepWave does.
When you want to clean inline without stopping production. With the DeepWave, the roll doesn’t need to be removed from the machine. This allows you to keep production running.
As an alternative to outsourced cleaning. Printing companies that send dirty anilox rolls to third parties for cleaning can use the DeepWave to bring that process in-house, with full control over the frequency and results.
DeepWave vs. Jet-Flow: What's the Difference?
You should use the DeepWave regularly as part of your routine, scheduled cleaning routine.
The Jet-Flow is a deep-cleaning machine designed for more intensive cleaning. You should use this machine when regular cleaning is no longer sufficient to restore the cell volume.
Both machines have a place in a comprehensive cleaning routine: the DeepWave for periodic use, and the Jet-Flow for deep cleaning based on volume measurement.
Want to learn more or see the DeepWave?
Check out the DeepWave in action on the product page, which includes a video, or schedule an on-site visit. Our specialists will assess whether the DeepWave is compatible with your machinery and roll stock and provide tailored advice.
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WordPress Installation Instructions
Title: What is the DeepWave and when should you use it?
Slug: deepwave-cleaning-machine
Category: Cleaning Machines
Tags: DeepWave, cleaning machine, anilox, limescale, calcium, periodic cleaning, flexography, Jet-Flow, Sinner’s Circle
Featured image: photo of the DeepWave machine in use (available at jet-cleaning.com/deepwave/)
Video: https://www.youtube.com/watch?v=AHKfBi_bQFs — embed as a YouTube block in Elementor
Meta description: The DeepWave completely removes calcium from anilox cells — inline or offline, in approximately 30 minutes. Read how the machine works and when to use it.
Internal links: Cleaning Machines page, Flexoclean products, Blog on anilox maintenance, Contact Packaging Print