Baking Soda
An Effective Eco-Friendly
Cleaning Compound for Anilox Rolls
By Jeff Paduano, President, Anilox Roll Cleaning Systems, Inc.
Flexographic customers demand sharp, consistent color densities that can only be supplied by clean Anilox rolls or expensive, time-consuming ink reformulations. Today's printers need to be concerned with not only quality output, but also the regulatory issues surrounding use of chemicals when used for roll maintenance purposes. A comprehensive roll maintenance program that includes use of eco-friendly cleaning agents such as Baking Soda can provide a strategic advantage in today's marketplace.
Everyone knows when rolls are not clean they cannot print repetitive colors for the same customer at different times. If roll volumes (BCM) change, one way to correct the problem of color matching is to adjust the density of the ink. This costs more money for extra ink consumed and causes expensive downtime of the printing press.
A good roll maintenance program includes regular volume monitoring through either roll audits by the manufacturer or by using Capatch, an easy to use test strip which provides on-the-spot volume analysis. Capatch is a disposable volume tester that is used in-house to provide an instant and reliable method of testing rolls to determine the current ink volume in cells.
A proper testing schedule can easily be implemented at a facility. The best method is to track each individual roll so that all key variables are taken into account. These include the line screen count of the roll, wear and age of the roll, power outages, high profile customer demands, incompatible inks, colors used on the roll, and efficiency of daily cleaning.
As the roll log captures the above data along with periodic BCM test results, patterns begin to develop that can assist in heading off a problem before it occurs. Reviewing these logs on a regular basis enables plants to schedule downtime in order to perform the maintenance required to bring a roll "back to life".
Baking Soda: Natural and Inorganic
The higher quality printing presently being done by Flexographic printers requires using higher line screen rolls with lower volume cells. The very nature of the roll design requires more stringent volume control in the cells, which have become harder to clean. No longer can mere hand-scrubbing with a stainless steel brush provide the level of cleanliness required to produce the sharpness and color densities presently required.
Baking soda (aka Sodium Bicarbonate) is a natural, inorganic compound. Its crystalline structure makes it a very effective yet mild cleaning agent. The soft, friable crystals shatter upon contact with the roll, resulting in a gentle cleaning process that reaches the bottom of each cell without causing damage to the cells or cell walls. Baking Soda easily removes titanium ink, glue, and other adhesives, compounds which always present a challenge for other cleaning methods.
Baking Soda is also water-soluble, nontoxic, and nonhazardous - as defined by the Environmental Protection Agency (EPA) and the Occupational Safety and Health Administration (OSHA). This allows for any residue to be completely removed from the roll surface with just water and eliminates many of the safety and environmental disposal hazards associated with other methods using hard abrasives or chemical cleaners.
Another unique fact about Baking soda is that it is USDA approved and can be used in conjunction with any direct contact food applications.
Cleaning Method
The Baking Soda cleaning process can achieve precise, uniform cleaning in various ways. Larger Anilox rolls can be cleaned directly On Press, something not possible with any other cleaning method. Smaller rolls can be cleaned in minutes Off Press. Most Baking Soda cleaning contractors can also clean Anilox rolls at their own facilities as well. This is becoming more common as companies have learned to properly handle and ship their rolls. However, most roll manufacturers would agree that whenever possible, it's best to leave rolls in their respective presses.
The equipment used to apply the Baking Soda onto the Anilox Roll is called a Sani-Blaster. The system is portable, and can be taken from press to press. The printing facility only needs to provide compressed air and electricity. The Baking Soda is metered through a precise nozzle that ensures a consistent and constant flow of Baking Soda is applied at the correct pressure. The equipment can adapt to any size roll, and automatically traverses the roll without operator involvement.
Actual cleaning time varies between one and two inches per minute depending on the diameter of the roll. Usually, one pass is all that is needed in order to return the roll back to its original volume. Complete containment is achieved using a powerful vacuum head which is attached to the cleaning nozzle, allowing for a dust-free operation.
Summary
Cleaning an Anilox Roll using Baking soda can literally restore it to the original volume levels specified when the roll was purchased and also overcome the government restraints imposed in order to comply with pollution and safety regulations.
A good contractor will personally visit your facility to evaluate your roll conditions, survey the plant layout, provide references upon request, and offer post-sale and service support.
About Anilox Roll Cleaning Systems, Inc. (ARCS)
ARCS was founded 20 years ago and pioneered the use of Baking Soda as a way to effectively and safely clean Anilox Rolls. Since then, ARCS has successfully cleaned well over 10,000 rolls for hundreds of clients. ARCS can provide turn-key cleaning services at a client facility either On or Off press. They also offer the convenience of roll cleaning at either one of their facilities near Philadelphia, PA or Charlotte, NC. ARCS can be reached at 800-699-3722 or visit their website www.aniloxrollclean.com for more information.
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