The influence of the number of mesh roller lines on printing quality
Date: Apr 03 2025 From: Star Color
The anilox roll is one of the core components in flexographic printing. It plays a crucial role in evenly transferring ink to the printing plate. The line count of the anilox roll, as an important parameter, has an extremely significant impact on the quality of flexographic printing.
What is Anilox Roll Line Count?
The line count of an anilox roll refers to the number of ink cells within a unit length on the surface of the anilox roll. Common units are "lines per centimeter (l/cm)" and "lines per inch (lpi)". The conversion relationship between the two is 1l/cm = 2.54lpi. On the surface of the anilox roll, there are numerous uniformly shaped tiny concave holes, namely "ink cells". These ink cells are engraved at a 45° angle to the axis and are responsible for storing, homogenizing, and quantitatively transferring ink.
For anilox rolls with different line counts, there are differences in the size and number of ink cells. An anilox roll with a low line count has relatively larger ink cells and fewer in number; while an anilox roll with a high line count has smaller ink cells and a large number. This difference directly determines the ink transfer performance of the anilox roll.
The Impact of Anilox Roll Line Count on Ink Transfer
Ink Transfer VolumeGenerally speaking, the line count of the anilox roll is negatively correlated with the ink transfer volume. The higher the line count, the smaller the ink cells, the less ink storage capacity of a single ink cell, and thus the smaller the ink transfer volume. Conversely, the lower the line count, the larger the ink cells and the greater the ink transfer volume. When printing large solid color blocks, more ink is needed for filling, and at this time, an anilox roll with a low line count (such as around 360 lines per inch) is used. When printing fine images or small text and lines, a high - line - count anilox roll should be used to accurately control the ink transfer volume.
Ink UniformityA high - line - count anilox roll can make the ink distribution on the printing plate more uniform during the ink transfer process due to the large number and dense distribution of ink cells. This is crucial for printing high - quality and color - uniform images. On the contrary, an anilox roll with a low line count has larger ink cells, and uneven ink volume may occur during the ink transfer process, especially when printing large solid screens, it is easy to produce inconsistent ink color shades.
The Impact of Anilox Roll Line Count on Printing Definition
Dot ReproductionIn flexographic printing, dot reproduction accuracy is one of the key indicators for measuring printing quality. The line count of the printing plate is related to the requirements of the printed pattern. The more exquisite the pattern, the higher the line count of the printing plate. The selection principle of the anilox roll line count is usually 4 - 7 times the line count of the printing plate. This is because the smallest printing plate dot should be larger than the opening of the anilox roll cell to avoid the printing plate dot falling into the cell during the printing process, causing ink accumulation at the dot edge and resulting in dot gain problems.
| Printing Plate Line Count (lpi) |
Dot to be Reproduced |
Printing Plate Dot Diameter (μm) |
Suitable Anilox Roll Line Count (lpi) |
Dot Reproduction Effect |
| 120 |
3% |
41.3 |
550 |
Clear dot reproduction |
| 133 |
1% |
21.5 |
1000 |
Accurate reproduction of fine dots |
Clarity of Text and LinesWhen printing small text and lines, a high - line - count anilox roll can provide more accurate ink volume control, ensuring clear text edges and fine lines. An anilox roll with a low line count has a large ink transfer volume, which is likely to make text strokes thicker and lines blurred, affecting reading and visual effects. For example, when printing tiny text instructions on labels or high - precision line patterns, a high - line - count anilox roll must be used to meet the requirements.
Comprehensive Considerations for Selecting Anilox Roll Line Count
Types of Printed ProductsDifferent types of printed products have very different requirements for the line count of anilox rolls. In packaging printing, when printing large solid products such as cartons, a low - line - count anilox roll can be selected; while when printing fine labels, high - end cartons and other products with high requirements for pattern accuracy, a high - line - count anilox roll is required. In publication printing, color albums, art books, etc. need high - line - count anilox rolls to present delicate images and text; while for some ordinary newspaper printing, the requirements for printing accuracy are relatively low, and a low - line - count anilox roll can be used to improve production efficiency and reduce costs.
| Types of Printed Products |
Suggested Anilox Roll Line Count |
Reason |
| Large solid products such as cartons |
Low line count (such as 300 - 400lpi) |
Require a large amount of ink filling, and low - line - count anilox rolls have a large ink transfer volume |
| Fine labels, high - end cartons |
High line count (800 - 1200lpi) |
High requirements for pattern accuracy, and high - line - count anilox rolls can accurately control the ink |
| Color albums, art books |
High line count (800 - 1200lpi) |
Present delicate images and text, and require accurate ink control |
| Ordinary newspapers |
Low line count (300 - 500lpi) |
Low requirements for accuracy, and low - line - count anilox rolls can improve efficiency and reduce costs |
Characteristics of Substrate MaterialsThe surface roughness, ink absorption and other characteristics of the substrate materials also affect the selection of the anilox roll line count. Materials with a rough surface and strong ink absorption, such as corrugated cardboard, require more ink to cover, and a low - line - count anilox roll is suitable; while materials with a smooth surface and weak ink absorption, such as plastic film, using a high - line - count anilox roll can better control the ink volume, prevent ink diffusion, and ensure printing quality.
Printing CostThe higher the line count of the anilox roll, the greater the processing difficulty and cost. At the same time, the service life of a high - line - count anilox roll is relatively short because the thickness of the cell wall becomes thinner and the strength decreases, making it easy to be damaged by factors such as scraper wear during the printing process. Therefore, when selecting the anilox roll line count, it is necessary to comprehensively consider the printing quality requirements and cost factors, and select a cost - effective anilox roll under the premise of meeting the quality requirements.
The line count of the anilox roll is a key factor affecting the quality of flexographic printing. It plays a decisive role in ink transfer and printing definition. In actual production, printing enterprises should reasonably select the anilox roll line count according to various factors such as the type of printed products, the characteristics of substrate materials, and printing costs, in order to achieve the best printing effect and economic benefits.
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