Technician performing routine flexographic printing maintenance to ensure optimal print quality and machine efficiency.

Optimizing Efficiency with Proper Flexographic Printing Maintenance

Your shop floor, from prepress to production to shipping, is packed with essential tools and equipment you rely on daily. These machines are carefully selected to help produce high-quality labels and packaging. But is your operation as efficient as it could be? Are there weak links in your production process that could be improved with better flexographic printing maintenance?

Are You Overlooking Flexographic Printing Maintenance?

Even the best-run shops may overlook critical details that can make a big difference in the quality of their output. Some of the most important components in your operation are less visible, which means they might be ignored or undervalued, impacting overall productivity.

The Importance of Filters and Magnets?

Ink system components, including filters and magnets, should be inspected as part of regular flexographic printing maintenance to prevent contamination and ensure smooth operation.

One often overlooked aspect of flexographic printing maintenance is your ink system. Deep inside your ink tanks are filters that ensure your inks remain clean and free from contaminants. In high-volume shops, where presses run non-stop, or in environments where anilox roll cleanliness isn’t always a top priority, these filters play a vital role.

Ideally, filters should be replaced at least once a week. However, press operators, in a rush to complete scheduled maintenance, may overlook this task. Neglecting filter replacement can make it harder to achieve accurate colors, increase production costs, and shorten the lifespan of your anilox rolls. Instituting a consistent filter replacement routine as part of your flexographic printing maintenance plan is a simple, low-cost way to avoid these issues.

Another “out of sight, out of mind” component is the magnet in your ink system. Its job is to capture stray metal particles that could otherwise lodge between a doctor blade and an anilox roll, potentially causing scoring or streaks in the print. Metal debris often comes from damaged doctor blades, and while filters catch some of these particles, magnets are essential for capturing what the filters miss. Although magnets last a long time, they are sometimes removed during maintenance and not replaced. Make sure to include magnet checks in your regular flexographic printing maintenance schedule.

Don’t Forget the Pumps: An Essential Component

Pumps are another critical part of your ink system that often doesn’t receive the attention they deserve. These durable components keep ink circulating and flowing through your filters and over the magnets, ensuring smooth operation. Like the fuel pump in your vehicle, you probably don’t think about your pumps until one fails, but when it does, productivity comes to a halt.

Part of your flexographic printing maintenance strategy should be assessing how often your pumps need replacement based on usage. Consult with your Anderson & Vreeland representative to determine whether you should keep extra pumps in stock or replace them on a set schedule. Being prepared can prevent costly downtime due to pump failure.

Anilox Roll Cleaning: A Vital Part of Flexographic Printing Maintenance

In addition to filters, magnets, and pumps, maintaining clean anilox rolls is crucial for print quality. Many shops overlook the importance of in-house anilox roll cleaning systems, relying on external services instead. However, chemical, water wash, or ultrasonic cleaning systems are available for in-house use and can extend the life of your rolls while saving you time and money. Adding an anilox cleaning system to your flexographic printing maintenance routine can significantly improve efficiency.

Prepress Color Management: Getting It Right the First Time

As demands for accurate color grow, particularly from retail clients who expect perfect brand color consistency on store shelves, flexographic printing maintenance needs to include prepress color management. Advanced color and workflow management software can help, but nothing replaces the human eye for ensuring color accuracy. Investing in a high-quality printer for proofs and a color-correct viewing booth in your prepress room can help catch color issues before they make it to the press, saving you time, money, and potential client dissatisfaction.

Flexographic Printing Maintenance is Key to Success

Proper flexographic printing maintenance is essential for keeping your operations running smoothly and ensuring the highest quality output. From regularly replacing filters and checking magnets to maintaining pumps and cleaning anilox rolls, attention to these often-overlooked details can greatly enhance your efficiency and profitability.

Make sure your flexographic printing maintenance plan is robust and comprehensive to avoid costly downtime and ensure that your presses deliver the best possible results. Contact Anderson & Vreeland to discuss how we can help you improve your maintenance practices and keep your production line running at peak performance.

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