It is widely believed that many flexible packaging companies have faced similar challenges. The semi-finished film products, which are usually well-processed during the lamination process, often lead to disappointing results. Most companies tend to blame the operators for such issues, but in reality, the problem may lie with the anilox roller on the laminating machine.
1. When a dry lamination machine is purchased by a flexible packaging factory, the original gumming anilox rollers typically come with 80–120 lines. However, if the goal is to produce high-quality composite bags, it's essential to carefully select the anilox roller and determine the appropriate line count to enhance the overall quality of the final product.
2. There are various types of anilox rollers, but in the context of dry lamination machines used for flexible packaging, there are generally two main types: tapered (such as the quadrangular pyramid or prism type). Most dry laminators currently used in flexible packaging applications employ the quadrangular pyramid type. However, the cell depth of these rollers also plays a critical role. A deeper cell allows for more adhesive transfer, but it also reduces the roller’s lifespan. Therefore, when selecting an anilox roller, it's important to consider the depth of the cells, and it's always advisable to consult the manufacturer for guidance.
3. The production methods of anilox rollers can be broadly divided into two categories: one is electric carving, and the OTHER is extrusion using specialized equipment. Depending on the method, the mesh structure and performance of the roller may vary. In machines that use a doctor blade, the blade angle must be precisely adjusted to control the amount of adhesive applied. Most manufacturers today use extrusion techniques. The line count of the anilox roller should be selected based on the specific quality requirements of the composite packaging bag.
4. The selection process can be summarized as follows: for standard composite bags using single-component adhesives, an anilox roller with 80–120 lines is typically sufficient. For two-component adhesives, a roller with 120–160 lines is commonly used. For high-end packaging bags with stricter lamination requirements, an engraved roller with 160–200 lines is recommended, especially when using two-component polyurethane adhesives.
In conclusion, reputable companies should keep a variety of anilox rollers with different line counts available. After use, it's crucial to clean the mesh holes thoroughly to avoid blockage. If the roller is not used for an extended period, it should be cleaned repeatedly with a brush and ethyl ester, and finally wiped dry with a clean cloth to maintain its performance and longevity.
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