Laser cleaning systems for anilox rolls: Innovations and insights

By Jeff Paduano, owner and president, Anilox Roll Cleaning Systems (ARCS)

Laser cleaning systems offer a highly precise and sustainable solution for maintaining anilox rolls in the converting industry. This article examines the fundamentals of laser cleaning technology, its advantages over traditional methods and critical innovations, such as circular scanning and tunability, based on insights presented at a recent industry conference.

Clean anilox rolls are critical to achieving consistent, high-quality results in printing and coating applications. As roll maintenance technologies have evolved, laser cleaning has emerged as a better and more powerful alternative to traditional methods such as media blasting, jet washing and ultrasonic systems. On average, a laser-cleaned roll will increase roll volume by 10-15% compared to other deep cleaning methods. This article explores the principles, benefits and advanced features of laser cleaning systems, offering practical insights for industry professionals.

Figure 1. Image of an off-press laser cleaning using a roll cart.

Principles of laser cleaning

Laser cleaning operates by directing highly focused energy onto contaminants adhered to the roll surface. This energy excites molecular bonds within the debris, causing them to break apart and vaporize through a process known as ablation. The method is highly selective, removing unwanted residues without damaging the underlying roll surface. It can be performed on-press or off-press (see Figures 1 and 2).

Three simultaneous processes – photothermal, photochemical and photomechanical – enable laser systems to clean a broad range of materials, from hardened polymers to delicate chromium oxide layers. Importantly, laser cleaning generates no hazardous waste, making it a sustainable and environmentally friendly choice.

Key innovations in laser technology

Recent advancements in laser cleaning systems have focused on addressing the challenges of roll damage, cleaning speed and energy efficiency. Two critical areas of innovation include scanning technology and system tunability.

Figure 2. Image of on-press laser cleaning

Scanning technology: Traditional linear scanning systems are effective but can produce “hot spots” due to uneven energy distribution, increasing the risk of roll damage. Circular scanning technology eliminates these hot spots by evenly dispersing energy across the surface, preserving roll integrity while enhancing cleaning speed (see Figure 3). This approach allows for efficient, precise cleaning of intricate roll geometries, reducing thermal stress and improving outcomes.

System tunability: Modern laser cleaning systems allow for precise control over parameters such as wattage, pulse frequency and scanning speed. This tunability ensures compatibility with a wide range of roll materials and contaminants. For example, lower pulse frequencies maximize photothermal energy for tough residues, while higher frequencies are used for more delicate cleaning tasks. Striking the right balance between these parameters is key to achieving optimal results.

Safety considerations

Laser cleaning systems, particularly those classified as Class IV, require robust safety protocols. These include protective eyewear, training for operators and physical containment measures to prevent accidental exposure to laser light. Portable containment partitions, advanced filtration systems and automated shut-off features further enhance operational safety, ensuring compliance with regulatory standards.

Comparing laser cleaning with traditional methods

Figure 3. Image of a circular laser in action

While traditional cleaning methods (soda blasting, jet washing and ultrasonic systems) remain widely used, each has its limitations:

Soda blasting: effective and low-cost but requires skilled operators and consumable media.
Jet washing: automated and efficient but generates hazardous waste and relies on strong chemicals.
Ultrasonic cleaning: compact and thorough but also generates waste and poses risks to sensitive engravings.

Laser systems stand out by addressing many of these challenges, offering a non-contact, chemical-free solution with low operating costs and minimal environmental impact.

Conclusion

Laser cleaning systems represent an advancement in anilox roll maintenance, combining precision, safety and sustainability. By leveraging innovations in circular scanning and tunability, these systems provide a versatile and effective solution for the challenges faced by modern converting operations. As the industry continues to evolve, leaders in laser cleaning technology are setting new standards for performance and efficiency, ensuring that anilox roll maintenance meets the demands of both today and the future.

Jeff Paduano is the owner and president of Anilox Roll Cleaning Systems (ARCS), a company that has been pioneering deep-cleaning solutions for anilox rolls for nearly 30 years. Under Paduano’s leadership, ARCS has expanded its operations to three key markets: Hatfield, PA; Greensboro, NC; and Grand Rapids, MI, serving as both a premier service provider and a trusted systems supplier in the industry. Paduano holds a Bachelor of Science degree from SUNY Geneseo. He is actively involved in industry associations focused on printing and converting technologies, continuously contributing to best practices in roll maintenance and sustainability. Paduano can be reached at (800) 699-3722, email: jeff@aniloxrollclean.com, www.aniloxrollclean.com.