Anilox Roll Cleaning

How to Protect Cell Volume, Prevent Plugging, and Maintain Print Quality

Cell plugging is the most common, and most preventable, cause of anilox roll

performance degradation. When dried ink, coating residue, or contaminants accumulate

inside anilox cells, they reduce the effective cell volume. Less cell volume means less ink

transfer to the plate, which shows up on the printed product as weaker color density,

uneven solid coverage, and inconsistent print quality across color decks.

The damage is progressive and often invisible. A roll losing 2 to 3% of its cell volume per

month doesn't trigger an obvious quality alarm until cumulative loss reaches 15 to 20%,  at

which point the press can no longer produce the target density regardless of ink formulation

or plate condition. By then, aggressive deep cleaning or resurfacing may be the only option.

Proper cleaning prevents that cycle. This article covers the principles of effective anilox

cleaning, the products PRS (through ARC International) provides for each market, and the best practices

that extend roll life and maintain print consistency.

Why Anilox Rolls Plug — And Why It Matters

Cell plugging occurs when ink or coating material dries inside the engraved cells before it can be cleaned out. The most common causes:

• Delayed cleaning after press stops. This is the single biggest contributor. When a press stops and the anilox roll sits with wet ink in the cells, that ink begins drying immediately.

• Water-based inks in corrugated and wide web environments are particularly prone to fast drying. Every minute between press stop and cleaning makes removal harder.

• Inadequate cleaning chemistry. Using a cleaning solution that doesn't match the ink chemistry — or using water alone — leaves residue in the deepest part of the cell where mechanical action (brushing) can't reach. Over repeated press runs, that residue builds layer by layer until cell volume is measurably reduced.

• High line count rolls. Cells on high line count rolls (800+ cpi) have smaller openings and shallower depths. There is less space for cleaning solution to penetrate and less margin for residue accumulation before performance is affected. High line count rolls require more diligent cleaning protocols than low line count rolls.

• Ink chemistry changes. Switching ink systems (water-based to UV, or changing ink suppliers) can leave incompatible residue if the previous ink isn't fully cleaned before the new chemistry is introduced. Cross-contamination between ink systems accelerates cell plugging.

The cost of plugging is real and measurable: reduced print quality, increased ink consumption (operators compensate for low cell volume by increasing ink feed, which causes other problems), shorter roll life, and ultimately premature resurfacing or replacement.

ARC International Cleaning Products

ARC engineers cleaning solutions for specific market environments, because the cleaning challenge in a corrugated plant running water-based inks is different from a narrow web operation running UV inks. Using the right product for your application produces better results with less effort.

Cleaning Solutions

ProARC™ Cleaner

ARC's most versatile cleaning solution. Effective across corrugated, wide web, and narrow web applications. Works particularly well on high line count anilox rolls where chemical penetration matters more than mechanical action. ProARC™ is the recommended starting point for plants that run multiple ink systems or need a single solution that handles a range of cleaning challenges.

Opticlean™ Powder

Engineered specifically for the corrugated industry. Powder format dissolves into cleaning solution at the point of use. Formulated for the starch-based adhesives and water-based inks common in corrugated environments.

Optiwash™ Cleaner

Corrugated-specific cleaner available in 275-gallon tote quantity for high-volume plants. The bulk format reduces per-unit cost and ensures cleaning supply doesn't run short during production campaigns.

triClean Cleaner

Designed for use with cleaning blankets and print plates. Effective for routine maintenance cleaning between jobs without removing the roll from the press.

On-Press Cleaning

Anilox Cleaning Pad

Mounts on the press in place of the printing plate. Cleans the anilox roll and ink system as the press runs, no production stop required. The pad works with the press's existing ink delivery system to circulate cleaning solution through the cells during operation. This is one of the most effective tools for preventing plugging buildup between deep cleans, because it can be used during production without scheduling dedicated cleaning time.

Brushes

Plastic, wood, and stainless steel brushes — for manual cleaning of anilox rolls. Brushing physically dislodges dried ink from cells, restoring cell volume. Available in materials matched to the cleaning situation: plastic for routine maintenance (gentlest), stainless steel for heavy buildup (most aggressive). Proper brush selection prevents ceramic surface damage while maximizing cleaning effectiveness.

Important: brushes are effective on lower line count rolls (under ~600 cpi) where the bristles can reach the cell bottom. On high line count rolls (800+ cpi), chemical cleaning is more effective because the cells are too small for brush bristles to fully penetrate.

Measurement & Auditing Tools

You can't manage anilox performance without measuring it. ARC provides tools for both quick on-press checks and comprehensive inventory auditing:

Capatch Strip — on-press measurement of anilox roller and sleeve cell volumes. Quick and practical — apply the strip, read the result, compare to the roll's original specification. Capatch strips are the fastest way to check whether a roll is still performing to spec without removing it from the press.

Roll Audit Kit — complete materials and instructions for on-site auditing of your entire anilox roller inventory. Includes everything needed to measure cell volume across every roll in your plant and document current condition versus original specification. The audit results tell you exactly which rolls need cleaning, which need resurfacing, and which are still performing to spec.

Pi Tape — direct reading of roller diameter by circumference measurement. Quick and accurate verification of roll dimensions.

Durometer Gauge — manual hardness tester for rubber roller components. Essential for verifying rubber wiper roller and feed roller condition.

Press-O-Film — profile measurement for impression and nip analysis across various thickness ranges.

Cleaning Best Practices

The Single Most Important Rule

Clean immediately after the press stops. Wet ink is easy to remove. Dry ink is exponentially harder. The difference between cleaning 5 minutes after a press stop and 30 minutes after a press stop can be the difference between routine maintenance and an aggressive deep clean. Build immediate post-run cleaning into your standard operating procedure — not as a suggestion, but as a required step before the operator leaves the press.

Match Chemistry to Chemistry

Use a cleaning solution designed for the ink system you're running. Water-based ink residue requires different chemistry than UV ink residue. Using a corrugated-optimized cleaner (Opticlean™, Optiwash™) on corrugated water-based systems, or a versatile cleaner (ProARC™) on mixed systems, produces better results than generic solvents or water alone. 

Don't Use Metal Scrapers or Abrasive Tools on the Ceramic Surface

The plasma-coated ceramic surface of a laser-engraved anilox roll is hard and durable, but it can be damaged by aggressive mechanical tools — metal scrapers, wire wheels, or abrasive pads used directly on the engraved surface. Damage to the ceramic creates irregularities in ink transfer and can accelerate cell wall deterioration. Use ARC recommended brushes and cleaning pads designed for ceramic surfaces.

Prioritize High Line Count Rolls

Rolls above 800 cpi are the most vulnerable to plugging and the hardest to clean once plugged, because the cells are small enough that mechanical brushing alone can't reach the bottom. For these rolls, chemical soak cleaning is essential — and prevention (frequent cleaning, proper chemistry, on-press cleaning pads) is far more effective than remediation.

Document and Track

Measure cell volume periodically using Capatch strips or a full roll audit. Record the measurements and track trends over time. A roll showing steady volume decline despite regular cleaning may have subsurface plugging that requires professional deep cleaning or resurfacing. Catching the trend early gives you time to plan service — waiting until print quality degrades forces reactive scheduling.

Establish a Cleaning Schedule

Don't rely on operators remembering to clean. Create a documented cleaning schedule that specifies what product to use, how to apply it, how long to soak, and what measurement to take afterward. Post it at the press. Make it part of the standard operating procedure. The plants that maintain the best anilox performance are the ones that treat cleaning as a process step, not an afterthought.

When Cleaning Isn't Enough: Resurfacing and Refurbishment

If a roll has been neglected long enough that chemical cleaning and brushing can no longer restore cell volume to acceptable levels, ARC resurfacing or full refurbishment is the next step. Resurfacing strips the existing ceramic coating, applies a new plasma-coated surface, and re-engraves the cell pattern to specification — restoring the roll to new-roll performance.

ARC refurbishment routinely delivers 3–5x roll life extension at a fraction of new fabrication cost. Typical timelines: resurfacing ~10 days, refurbishment ~7 days, expedited available. 

Professional Auditing Services

For plants that want an expert assessment of their entire anilox inventory, ARC offers two levels of service:

On-Site Roll Audits & Press Evaluations

ARC technicians visit your plant, measure every anilox roll in your inventory, and provide a written report with condition assessment, volume degradation data, and recommendations for cleaning, resurfacing, or replacement. The report gives you a complete picture of your roller program's health and a prioritized action plan.

Glue Roll Audits — dedicated on-site analysis for corrugated plants, focused on single facer and glue machine applicator rollers. If you're seeing bonding inconsistency, glue waste, or warp problems, a glue roll audit often identifies the root cause.

Frequently Asked Questions

How often should I clean my anilox rolls?

After every press run. Ideally within minutes of the press stopping. In addition to post-run cleaning, using on-press cleaning pads (Anilox Cleaning Pad) during production provides continuous maintenance without stopping the press. Deep chemical cleaning should be performed on a regular schedule based on your production volume and ink system; weekly or bi-weekly is common for high-utilization presses.

Can I use the same cleaning product for water-based and UV inks?

ProARC™ Cleaner is formulated to work across multiple ink systems. However, dedicated products (Opticlean™ for corrugated water-based, for example) are optimized for specific chemistries and typically deliver better results in those applications. If you run a single ink system, use the product designed for it. If you run multiple systems, ProARC™ is the versatile option.

How do I know if my anilox rolls are plugged?

The most reliable method is measurement. Use a Capatch strip for a quick on-press check, or conduct a full roll audit. Compare the measured cell volume to the roll's original specification. A difference of more than 10% indicates meaningful plugging. Visual inspection can sometimes reveal severe plugging (cells that appear shiny or reflective rather than matte), but measurement is always more reliable than visual assessment.

Will brushing damage the ceramic surface?

ARC-recommended brushes (plastic, wood, or stainless steel) are designed to clean cells without damaging the ceramic coating when used properly. Do not use wire wheels, metal scrapers, or abrasive pads directly on the ceramic surface. For high line count rolls (800+ cpi), chemical cleaning is preferred over brushing because the small cell openings limit brush effectiveness.

Can severely plugged rolls be saved, or do they need replacement?

In most cases, severely plugged rolls can be restored through ARC resurfacing; stripping the ceramic, applying a new plasma coat, and re-engraving. Replacement is only necessary when the roll body itself (journals, core) has structural damage.

Contact ARC at 800-526-4569 to evaluate your specific situation.

Order Cleaning Products or Schedule an Audit

ARC International: 800-526-4569 | info@arcinternational.com | View All Cleaning Products

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