Author: Christine Duggan

Steel Doctor Blades Cause Anilox Roll Scoring and Injuries
Steel doctor blades are often the cause of anilox roll scoring and severe personal injuries. Switching to nonmetallic blades can not only ensure print quality and minimize waste, but also prolong the life of anilox rolls and reduce the risk of lost-time accidents.

Anilox Roll Scoring from Steel Doctor Blades

Score line on an anilox roll

Steel doctor blades are the cause of many anilox roll scoring incidents. Improper blade installation and excessive blade pressure can cause small fragments of the metal blade to break away, become lodged against the roll and destroy rows of anilox cells as the roll turns. The damaged area or “score line” appears as a thin band which runs around the circumference of the roll. The corresponding area of print will either show a dark or light streak depending on the depth and severity of the score line. Either way, the roll has to be resurfaced or replaced at a significant cost to the printer.

To reduce anilox roll scoring from steel doctor blades:
- Ensure the roll’s engraving is smooth when received from the anilox supplier
- Filter inks using current magnet technology
- Maintain a good anilox cleaning regimen
- Ensure proper chamber alignment and blade installation
- Change blades and end seals frequently
Injuries from Steel Doctor Blades

Steel doctor blades can also be blamed for a large number of pressroom injuries. As steel blades wear, their edges become honed through contact with the anilox roll. This leaves razor-sharp tips that pose a significant cut hazard. Press operators always need to be cautious when handling steel blades but especially careful when removing the worn blades from the press for this reason. There are substantial costs associated with accidents that occur on the job in addition to the emotional impact of a workplace injury. The cost of lost-time accidents from a steel doctor blade ranges from an increase in insurance rates and workman’s compensation claims to medical bills, labor replacement expenses and press downtime.

When it comes to the pressroom, safety is everyone’s concern. To reduce the risk of injury and eliminate the risk of anilox roll scoring, consider switching to non-metallic blades instead.
Carton Craft Supply to Feature the TruPoint™ QuikWash™ System at PRINT13

Carton Craft Supply will proudly feature the TruPoint™ QuikWash™ System at this year’s PRINT13 show in Chicago September 8-12. Staff will be on hand in the company’s booth #3936 to provide demonstrations and answer any questions about the revolutionary wash-up system.

Released to the market in 2012, the QuikWash System is a retrofit blade clamp that attaches to the printer’s existing wash-up tray and holds a TruPoint plastic wash-up blade. The TruPoint blade is constructed from a durable, rigid material that allows it to achieve and maintain a fine contact area with the roller. The fine contact point results in more efficient wiping and cuts wash-up times and solvent consumption in half. The blade is also extremely resistant to chemical breakdown and ideal for use with UV inks and aggressive press washes.

An exclusive reseller of the QuikWash product, Carton Craft prides itself on providing new and innovative products to the die cutting, die making and converting industries. For more information about QuikWash, visit Carton Craft’s booth #3936 at the show or contact Flexo Concepts™ at 508.830.9506. Information is also available at www.flexoconcepts.com/quikwash.

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades, the TruPoint™ QuikWash™ System and wash-up blades, and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
Mark Andy to Feature the New TruPoint Orange Doctor Blade at PRINT13

The TruPoint™ Orange™ doctor blade by Flexo Concepts™ will be on display among several featured products offered by the new Mark Andy Print Products supplies division at this year’s PRINT13 show in Chicago September 8-12. Other highlights include Mark Andy’s latest press offerings, the Versa Max in-line flexo press for mid-web and the technology award-winning Performance Series for narrow web flexo.

Released to the market earlier this year, the TruPoint Orange blade was recently selected to join the Mark Andy Print Products line of blade offerings to provide customers with a solution to UV ink spitting, anilox scoring and insufficient blade life. Orange combines a next generation polymer with a unique MicroTip™ designed to produce a fine contact area that meters consistently on a full range of anilox line screens.

Most TruPoint Orange blade sizes are stocked and available for same day shipping from Mark Andy Print Products in Des Plaines, IL. In addition, Orange is shipping with all new Mark Andy Performance Series installations to provide customers with a blade that will deliver maximum performance.

Staff will be on hand in Mark Andy’s booth #1273 to hand out blade samples and to answer any questions about this revolutionary new product. For more information, call Flexo Concepts at 508.830.9506 or visit www.flexoconcepts.com.

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades, the TruPoint™ QuikWash™ System and wash-up blades, and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
3 Steps to Ensure Proper Doctor Blade Alignment
Proper alignment of your doctor blades(s) to the anilox roll (or any roll being wiped or cleaned) is critical to the performance of any ink or coating metering system. This alignment plays a pivotal role in preventing premature doctor blade and anilox roll wear, reducing leaks, and minimizing downtime. Let’s dive into the key aspects of blade alignment to optimize the performance of your process.

Doctor Blade Functionality

Doctor blades are designed to remove excess ink from the surface of the anilox roll. To achieve this, it’s imperative to maintain consistent, light contact between the doctor blade and the anilox roll along its entire face. Variation from this ideal contact can lead to problems including inconsistent transfer of ink or coating to the substrate and premature anilox roll wear.

Causes of Incorrect Contact

Several factors contribute to inconsistent contact between the doctor blade and the anilox roll:

Blade / Blade Holder Alignment: Ensure the blade is not skewed, offset, or misaligned with the centerline of the anilox roll.

Poor Blade Installation: Properly seat the blade in the holder and avoid overtightening to eliminate ripples or buckling of the blade.

Inconsistent Pressure: Maintain even pressure across the blade holder to prevent variations in blade contact.

Consequences of Incorrect Alignment

Deviation from proper alignment often shows up as uneven ink or coating thickness. Frequently operators try to overcome this problem by increasing blade pressure to compensate for the underlying issue.

This quick fix may temporarily address ink or coating problems but will eventually cause accelerated wear of both the doctor blade and anilox roll. Accelerated blade wear means more frequent blade changes and increased downtime. Accelerated wear of the anilox roll can lead to uneven or inconsistent ink or coating density.

How to Check Doctor Blade Alignment

Start with a clean blade doctor blade chamber (dual blade) or doctor blade holder (single blade) and make sure blades are installed firmly against stops, with no buckling.

Slowly engage the blades against the anilox roll, and verify the blade-to-anilox contact occurs simultaneously across the blade face.

For dual-blade systems, there are (4) checkpoints; top and bottom blades at both ends of the doctor blade chamber.

For single-blade systems, there are (2) checkpoints at the left and right ends of the blade holder.

The goal is to make sure all checkpoints contact the anilox or coating roll at the same time.

Adjust if necessary to achieve uniform simultaneous contact.

Pro tips: When aligning a doctor blade chamber (dual blade), remove end seals to create an unobstructed view of blade and anilox contact.

A feeler gauge (or business card!) is a great tool to help compare blade to anilox pressure.

Maintaining proper doctor blade to roller alignment is fundamental to optimizing your ink or coating metering system. Avoid the temptation to increase blade pressure to overcome misalignment as this can lead to shortened blade life and accelerated anilox roll wear.

By investing a few minutes in checking your setup, you’ll reap long-term benefits in terms of time, cost savings, and reduced waste. Remember, a well-aligned chamber ensures your doctor blade performs at its best, delivering exceptional results.

For detailed instructions on doctor blade installation and visual guides, download our 3 Keys to Success Infographic.

Download Infographic
Doctor Blade Installation: Correct Angle and Pressure are Needed for Consistent Performance

The anilox roll and doctor blades are designed to work together to deliver a precise amount of ink to the plate. It is important to take time during a doctor blade installation in order to ensure print quality.

A doctor blade that’s installed correctly will have uniform, balanced contact with the anilox roll and remove ink consistently across its surface. Blade positioning, orientation, angle and pressure will aﬀect the delivery of a precise amount of ink to the plate, and proper installation will give the printer control over consistent, repeatable print quality.

3 Keys To Doctor Blade Installation Success
1. Handling
It’s essential to handle the doctor blade with care to prevent damage. Additionally, make sure to clean the surface of the doctor blade holder before inserting the blade.

2. Orientation
It is essential that the metering and containment blades be positioned correctly when they are installed. Depending on the rotation of the anilox roll, the metering blade could be positioned on the top or the bottom of the chamber. Keep in mind that the metering blade is always the last blade to contact the roll before the ink transfers to the plate. The containment blade is installed in the opposite location. If the two blades are installed in reverse, the metering blade will not achieve the appropriate point of contact with the roll and remove the correct amount of ink before transfer. It is important to remember that the MicroTip or bevel should point away from the roll or towards the chamber to prevent streaking.

The angle at which the blade comes into contact with the anilox roll is also crucial to proper doctor blade installation and optimum blade performance. Ideally, the contact angle should be 30° tangent to the anilox roll circumference. In reverse angle and chamber blade applications, the doctor blade angle should be between 28° and 32°. If the blade angle drops below 28°, a larger part of the blade’s edge will come into contact with the roll. When this happens, the contact area is too big to meter eﬀectively and the blade may allow ink to pass underneath or “hydroplane” at high speeds. If the angle exceeds 32°, it will result in faster wear on the blade.

3. Pressure
When a doctor blade chamber is properly aligned, light pressure between the anilox roll and doctor blade is all that’s needed to produce a clean wiping action. In fact, applying the lightest possible pressure necessary to maintain sealing and metering will produce the best results. Excess pressure can cause a deterioration in print quality, wasted ink and substrate, and accelerated.

blade and anilox wear. A good way to tell if you’re using the correct amount of doctor blade pressure is to look at the roll once it’s inked. Before increasing pressure, the anilox roll will appear glossy. This is a sign that too much ink is remaining on the surface. Pressure should be increased gradually until a satin ﬁnish appears on the surface of the roll. A satin ﬁnish is a good indication that the correct amount of pressure has been achieved and the doctor blade is eﬀectively shearing the excess ink from the roll. If pressure is increased beyond this point, the doctor blade edge will bend and hydroplane. The roll will again begin to look glossy because it is ﬂooded with too much ink.

The doctor blade plays a key role in the performance of the anilox roll and the printer’s control over print quality. Take the time to double-check blade positioning, orientation, pressure and angle during doctor blade installation to guarantee that the anilox roll delivers the precise volume of ink for which it was designed.

Download Now: Free 3 Keys to Success Installation Infographic
Flexo Concepts™ Celebrates 25 Years of Success with TruPoint™ Doctor Blade Line

This year marks 25 years in business for doctor blade manufacturer, Flexo Concepts. Since introducing its first TruPoint blade to the printing industry in 1988, the company has become the world’s leading producer of non-metallic doctor blades serving the flexographic and sheetfed offset markets.

The company opened its doors a quarter-century ago with a limited line of doctor blades for corrugated and newspaper printers. Over the years, the line grew to include multiple materials and a range of tips and thicknesses for a wide variety of flexographic and sheetfed offset printing applications. The company added a line of anilox cleaning equipment and service through the acquisition of MicroClean™ in 2005.

By achieving market leadership with a number of exclusive products, the company has developed a reputation for cutting-edge technology. Its trademark orange logo color, introduced in 2006, has become an icon of innovation that is well-recognized throughout the industry.

Most recently, Flexo Concepts began marketing its revolutionary new product, the TruPoint Orange™ doctor blade,, to the international flexible packaging and label market. After successful testing and a U.S. launch in 2012, Orange has been proven as a long-life replacement for steel with added safety benefits in a full range of wide web and narrow web applications. While the company had traditionally maintained a niche-market approach, this product gives it access to a broad industry sector where steel has historically been the only option due to high print quality requirements. Flexo Concepts is confident that Orange will achieve market dominance throughout the industry over the next several years based on sales to date.

Three years ago, driven by organic growth in the core consumables business overseas, Flexo Concepts relocated its manufacturing operation and corporate offices to a significantly larger facility in Plymouth, Massachusetts to consolidate all aspects of production under one roof. Recent additions to the sales, marketing, customer service, engineering and accounting teams are a sign of the company’s optimism about success with the Orange product.

Current owner and president, Kevin McLaughlin reflects, “I am proud of the growth we have achieved over the past 25 years. We owe our success to our customers, both those who have been with us from the start as well as the new ones we welcome every day, and the hard work and dedication of our committed staff. I am excited to see what the next 25 years will bring.”

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades, the TruPoint™ QuikWash™ System and wash-up blades, and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
Flexo Concepts™ to Feature New TruPoint™ Doctor Blade Technology at Info*Flex 2013

Flexo Concepts™ announced plans today to exhibit at Info*Flex 2013 April 29-30 in San Diego. The show will be combined with the annual FTA Forum which offers attendees a variety of informative sessions focused on helping printers stay on top of industry trends. Search for suppliers of similar products in the Packaging Network.

At the event, Flexo Concepts™ will introduce its newest TruPoint™ Orange™ doctor blade technology that joins innovations in polymer materials with advancements in tip design. The result is a long-life blade that can deliver the metering ability of steel with the safety benefits of a non-metallic blade in a wide variety of flexographic printing applications. The company’s TruPoint™ DuraPoint™ blade, a next generation UHMW with 30% longer blade life in corrugated applications, will also be featured. Information about the company’s MicroClean™ dry media anilox cleaning equipment as well as other TruPoint™ blades and samples will be available at booth #306.

Hosted by the FTA, Info*Flex is considered the largest trade event of the year serving the packaging, printing and converting industries. Flexo Concepts™ will be one of over 200 exhibitors showcasing new products and technologies to an expected audience of 1,600+ visitors. Running concurrently, the conference program promises lively “dialog, discussion and debates” about hot issues facing the industry today. Visit Flexo Concepts™ in booth #306 or online at www.flexoconcepts.com for more information about the company and its TruPoint™ and MicroClean™ product lines. For regular updates, follow Flexo Concepts™ on Facebook and Twitter.

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades, the TruPoint™ QuikWash™ System and wash-up blades, and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
Flexo Concepts™ to Feature New TruPoint™ Doctor Blade Technology at ICE Europe

Flexo Concepts™ announced plans today to exhibit at ICE Europe 2013. The international converting show will take place on March 19-21 at the Munich Trade Fair Center in Germany.

At the event, Flexo Concepts™ will introduce its newest TruPoint™ doctor blade technology that combines innovations in polymer materials with advancements in tip design. The result is a blade that can deliver the metering ability of steel with the safety benefits of a non-metallic blade in flexible packaging applications. The company will also feature its MicroClean™ eco-friendly anilox cleaning equipment for the coating & laminating market.

To accommodate visitors from the neighboring CCE corrugated and carton exhibition, Flexo Concepts™ will promote its TruPoint™ DuraPoint™ doctor blade. DuraPoint™ is engineered from a next generation UHMW material to last up to 25% longer than standard UHMW.

ICE Europe draws converting specialists from around the world and will include 400 exhibitors from 19 countries this year. The show displays a wide variety of equipment and accessories used for the converting of flexible web materials such as paper, film, foil and nonwovens.

Visit hall A5, Stand 722 or www.flexoconcepts.com for more information about Flexo Concepts™ and its TruPoint™ and MicroClean™ product lines.

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades, the TruPoint™ QuikWash™ System and wash-up blades, and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
Coating Supplier Henkel Endorses TruPoint™ Doctor Blades for Specialty Coating Applications

TruPoint™ doctor blades by Flexo Concepts™ received a strong endorsement from worldwide leader in adhesive technologies, Henkel, for use with its specialty coatings. TruPoint™ blades are the company’s number one recommendation to customers using special coating formulas to decorate their packages.

Founded in 1876, German-based Henkel is a global producer of top brands across the laundry and home care, cosmetics and adhesive technologies industries. The company is the leading supplier of UV coatings to the package printing market along with a full range of overprint finishing and coating products used to enhance consumer product packaging.

Dennis Drummond, Senior Key Account Manager and John Bervoets, Business Development Manager for Henkel, promote the use of TruPoint™ doctor blades in a wide variety of coating applications in the package printing market.“TruPoint™ is our number one recommendation to customers looking to apply not only standard gloss and matte finishes but also special coating effects to their packaging.” Henkel insists converters use TruPoint™ blades with its raised, textured, MBoss, glitter and pearlescent coatings.

Mr. Drummond and Mr. Bervoets maintain that TruPoint™ products are superior to other doctor blades in terms of their ability to effectively meter the anilox coating roller and deliver exceptional results. “TruPoint™ blades are able to effectively wipe and contain high viscosity coatings with no spitting or slinging.” UV chemistries, common in specialty coating applications, have a viscosity of 5-7 times that of water and solvent-based formulas. This thicker consistency applies excessive pressure to the metering blade, often resulting in hydroplaning or “spitting” and contamination of the finished piece. Coatings like Henkel’s MiraFoil® is a heavier viscosity than most coating technologies but can be applied in an extremely thin layer with TruPoint™ blades to optimize coating consumption and minimize waste. According to Drummond, “The TruPoint™ blades do a remarkable job of wiping the cylinder and containing the MiraFoil® at high press speeds. Other blade technologies allow the coatings to push under the blades at high speeds.”

Finishes such as glitter, metallics and pearlescents contain larger particulates, and a customized blade solution is often necessary to meter these chemistries and control the volume of coating applied to the blanket. TruPoint™ blades can be engineered to a full range of size and profile combinations to meet the precise needs of the printer. In addition to standard coatings, the TruPoint™ blade’s thickness and tip can be modified to improve its metering performance with the higher viscosity and large particulate formulas. Drummond and Bervoets appreciate that Flexo Concepts™ can customize its blades for any situation: “We have always been impressed with the company’s ability to deliver the correct solution with the proper blade composition and thickness for all special applications.”

Drummond and Bervoets continued, “Compared to other blades on the market, the TruPoint™ blades not only perform better, but also last longer and are easier to install.” The blades are compatible with all coating types and resistant to aggressive chemistries. Other benefits include safety to the anilox roller and a lower risk of injury to the operator handling the blade. TruPoint™ blades are suitable for work and turn, complex spot and high-end coating applications. To learn more about the TruPoint™ doctor blades please visit www.flexoconcepts.com or email [email protected].

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
QuikWash™ System Draws Strong Interest From Distributors at Drupa

Flexo Concepts™ QuikWash™ System drew a lot of attention at Drupa from distributors around the world wanting to represent the product. Given its remarkable benefits and low up-front investment, the retrofit technology is attractive to printers who want to reduce wash-up times, use UV ink or harsh solvents, or are environmentally conscious.

By combining a special clamp with the company’s TruPoint™ DeltaFlex™ plastic wash-up blade, the system cuts wash-up times in half by maintaining a fine contact area with the roller for more effective wash-ups. The resulting increase in press uptime and reduction in solvent consumption have been sources of excitement in the industry. Another strong selling point is that DeltaFlex is compatible with UV solvents and resistant to aggressive press wash, making it a good solution for printers who have experienced blade swelling due to chemical incompatibility.

While Flexo Concepts had previously gone to market with QuikWash in limited geographic locations, the company used Drupa as the official launch site to introduce its exclusive technology to a global audience. The resounding response from prospective distributors at the show confirms the product’s viability in the offset market.

“We are very happy with our results from the show,” said Chris Nolin, Flexo Concepts’ Vice President of Sales. “Our objective was to grow our reseller base for QuikWash and there was a great amount of interest from people all around the world interested in selling the product.”

The QuikWash System was also touted as a tool to help reduce VOCs in the pressroom. By cutting solvent use and disposal, the wash-up system helps printers meet growing pressure to shrink their carbon footprint. These environmental benefits were highlighted in an article in the DrupaReportDaily entitled, “European suppliers keen on QuikWash.“

To learn more about QuikWash, visit https://www.flexoconcepts.com/quikwash.

About Flexo Concepts™
Headquartered in Plymouth, Massachusetts, Flexo Concepts™ manufactures TruPoint™ doctor blades, the TruPoint™ QuikWash™ System and wash-up blades, and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts™ maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit www.flexoconcepts.com.
Flexo Concepts® Takes Home FEFCO Sustainability Award for MicroClean™ System

Plymouth, MA, May 4, 2011. Flexo Concepts took home the FEFCO Sustainability Award from this year’s show in Munich for its MicroClean™ anilox cleaning equipment. The technology was recognized for its eco-friendly features including non-hazardous waste stream, non-use of water or chemicals and recyclability of the plastic media.

Best known in the industry for its value in helping high graphics corrugated printers control ink densities and coating weights, the MicroClean System has also earned a reputation for its green benefits. Many plants have adopted this technology for anilox roll cleaning in response to growing legislation mandating a reduction in VOC use.

According to Dave Burgess, VP of Sales for Flexo Concepts, “Corrugated boxmakers, like all printers, are under pressure to reduce their carbon footprint. Yet, until recently, hand cleaning with high pH solvents was the best option for cleaning.”

High-board line presses with quick-change anilox capabilities have made off-line cleaning a viable option, however. With the new press design, rolls are more easily removed and can be cleaned off-line to reduce downtime. “The market has embraced MicroClean,” continued Burgess. “It not only helps plant managers maintain ink densities, but in a way that eliminates VOCs and disposal concerns. We are happy to be able to meet the needs of our corrugated customers on multiple levels.”

Instead of using harsh solvents or even water like many other methods, MicroClean is a mechanical cleaning process that uses plastic media particles to remove ink and coating deposits from the anilox engraving. Throughout the cleaning cycle, the machine separates the reusable particles from the spent media and circulates them back through the system. The waste stream is non-hazardous and does not require special handling or disposal.

In addition to operating without water or chemicals, MicroClean has no energy requirements when not running unlike some off-line cleaning systems. The cleaning process is entirely contained within the cabinet and the area around the machine remains dust-free during and after use.

There are currently 14 machines in operation in corrugated plants in the U.S., two in Europe and one in Australasia. To learn more about the benefits of MicroClean for corrugated applications, visit www.micro-clean.com or call 1.508.830.9506.

About Flexo Concepts

Headquartered in Plymouth, Massachusetts, Flexo Concepts manufactures TruPoint® doctor blades and wash-up blades and MicroClean™ dry media anilox cleaning systems. All products are designed to improve print quality and reduce operational costs for flexographic and offset printers. Flexo Concepts maintains distribution locations in North America, South America, Europe, Asia, Africa and Australia. For more information about the company and its products visit https://www.flexoconcepts.com/. For regular updates, follow Flexo Concepts on Facebook and Twitter.