Flexo Technology
Anilox technology in a high-resolution world:
Why cell geometry matters By Stuart Mitchell, technical director print, Sandon Global
HYBRID GEOMETRY AS AN ALTERNATIVE SOLUTION
Hybrid engravings have been developed by anilox manufacturers like Sandon Global as a solution to this challenge. Rather than relying on a single parabolic shape, hybrids can combine open channels with shallower cells, improving the collection and transfer of ink.
F
or decades, fl exo printers have specifi ed anilox primarily by line count. The assumption was simple: more cells per centimetre meant higher print quality. While this logic once held, modern fl exo has moved beyond line count alone. Print stability, ink effi ciency and consistency are now governed less by the number of cells, and more by volume and how those cells are engineered. At the heart of this evolution is anilox cell geometry, the shape and angle of the engraving that controls ink fl ow, release effi ciency and wall strength. Cell geometry aff ects the volume an anilox can hold and, critically, how eff ectively that ink is transferred to the printing plate.
THE ROLE OF 60° HEX ENGRAVINGS The 60-degree hexagonal engraving remains widely used, and for good reason. Developed in the 1980s, its regular, repeating structure off ered a reliable way to distribute ink evenly. Advances in laser engraving have since improved precision, wall strength and achievable resolution. When carefully specifi ed and maintained, a 60° anilox can deliver excellent results. For many printers using established inks and conventional screening, it continues to provide a stable and predictable foundation. However, high resolution in conjunction with high volume can prove to be problematic.
PARABOLIC CELLS AND INK TRANSFER LIMITS
Conventional 60° engravings can create parabolic cells when manufactured at high resolution and
This allows higher line counts and usable volumes to coexist without sacrifi cing ink release. Ink fl ows more predictably, reducing ghosting and pinholing, whilst also reducing downtime and the need to clean the anilox. Hybrid engravings are not necessarily a replacement for classic 60° designs, but an alternative solution for printers who need to push beyond the traditional resolution-volume trade-off . The key is reviewing, assessing and selecting the geometry that best suits each print application.
OPTIMISING GEOMETRY FOR DIFFERENT APPLICATIONS
high volume. This is because these cells narrow as they deepen.
This is often where print issues arise. Faster presses and complex graphics lead printers to increase line count or volume without considering how these changes aff ect ink collection and ink evacuation. Cells may theoretically hold the right amount of ink but struggle to empty cleanly on press, resulting in a variety of diff erent print defects such as ghosting, loss of optical density and drying-in issues. The challenge lies not in the 60° engraving itself, but in the constraints of its parabolic geometry.
Line count tells us how many cells exist; volume tells us how much ink they hold. Neither indicates how eff ectively ink will transfer. Two anilox with the same cm³/m² (centimetre cubed per metre squared) and line count can behave diff erently because of cell opening, volume, wall shape and depth control ink fl ow. For example: 120 l/cm (lines per centimetre) x 10.00 cm³/m² (60° Classic Hex) compared to 200 l/cm x 10.00 cm³/m² (60° Classic Hex) – it is the latter engraving that would create a parabolic cell.
Process CMYK, spot colours, white inks and coatings all place diff erent demands on an anilox. Some require fi ne, stable dots, while others demand heavy, uniform ink laydown. No single geometry optimises all requirements.
What matters is how the cell is engineered to deliver the required volume at the required resolution with clean, repeatable release. That might mean a well- optimised 60° engraving in one application and a hybrid cell structure in another. The key is understanding the benefi ts of the various engraving formats available and knowing where, and how, to apply them correctly, considering today’s inks, plates and press speeds.
UNDERSTANDING ADVANCED ANILOX TECHNOLOGY Modern fl exo demands consistency, effi ciency and process control. Achieving this starts with understanding how anilox line count, volume and geometry interact.
Anilox technology has evolved, just like every other part of the fl exo process. Printers who take the time to review and optimise engraving choices, rather than relying on inherited specifi cations, are better positioned to meet the quality and productivity expectations of today’s market.
26
February 2026
www.convertermag.com
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