Developing The Next Generation Of Anilox Rolls

A new generation of printing rollers aims to cut waste and boost speed by replacing their porous ceramic surface with a custom-engineered coating. The rollers, called anilox rolls, transfer precise amounts of ink onto printing plates in high-speed packaging and label production. Current ceramic coatings wear down over time, forcing printers to slow machines or replace rolls frequently. This project builds on a recent Knowledge Transfer Partnership that developed a bespoke coating material with unique properties in porosity, density, and hardness. The research now focuses on using short-pulse lasers and beam manipulation to etch that coating into a functional roller surface. If successful, the new rollers would improve print quality, allow faster running speeds, resist wear longer, and reduce material waste. For manufacturers of food packaging, pharmaceuticals, and consumer goods, that means fewer production stoppages, lower costs, and less discarded substrate. The project is applied industrial research with a clear commercial endpoint—there is no fundamental science component here. The outcome would be a tangible upgrade to a piece of equipment that quietly underpins much of the printed packaging people handle every day.