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Engraving matters: choosing the right anilox spec for your wide web printing applications

Flexographic printing has advanced significantly in the past decade. Innovations in plate technology, inks, press design and of course the anilox itself have pushed the boundaries of print quality and press efficiency. But with increased capability comes greater complexity, especially when selecting the right anilox specification for wide web print applications. 

Understanding how various print components interact is critical to achieving consistent, high-quality results. In particular, the relationship between the anilox and the printing plate is key, especially as plate resolution continues to rise. Selecting the appropriate anilox for each type of job is no longer just a best practice, it’s a competitive advantage. 

Why dot shape matters 

Traditional bullet-shaped dots are being replaced with flatter, wider dots on the plate surface. These modern flat top dots enable improved ink transfer to the substrate and contribute to greater print consistency. As a result, the plate itself now does more of the work, meaning high ink volumes from the anilox are no longer necessary. 

With reduced ink volume and shallower cells, the anilox becomes more efficient. Add hybrid engraving into the mix and this efficiency is taken even further. Hybrid engravings use shallow cells that maintain excellent release characteristics, giving printers the ability to achieve solid and tonal areas on the same plate with improved accuracy. This versatility helps deliver the high-resolution, vibrant graphics that are now a mainstay of wide web printing. 

Matching the right anilox to the right job 

There is no one-size-fits-all anilox specification. At Sandon Global, we’ve identified five key areas in flexographic printing, each with its own requirements: 

⬡ Process/CMYK printing 

⬡ Intermediate printing 

⬡ Spot colour/PMS printing  

⬡ White ink 

⬡ Coatings/Overvarnish 

Every application demands a different approach to ink volume, cell geometry and line count. The ideal goal is simple: achieve optimal coverage with the lowest possible volume, using an engraving that ensures consistent ink transfer and minimises waste. 

From conventional to advanced engraving technologies 

In today’s print and packaging market, cost reduction is essential, and companies must identify how they can become more competitive, more efficient, and reduce waste. Yet, despite the many benefits, hybrid and channelled engraving formats are still often overlooked by some flexo printers in favour of conventional 60° engravings.  

At Sandon Global, we’ve developed a range of unique engravings for wide web printing, including XPRO, High Volume Process (HVP), Fluid FP and GMX Anilox®, that offer proven performance advantages across various applications, including the five key areas mentioned above.  

By understanding how anilox specification impacts your business, and looking beyond standard cell engraving, common print issues that arise with some conventional engravings can be overcome with the adoption of advanced hybrid engraving technologies. 

Making better-informed choices 

Choosing a high line count anilox doesn’t automatically mean better print. While line count is still part of the specification, it should not be the focus. Instead, the most important consideration is volume – how much ink the cell can hold and release, and whether this is suited to the application. 

At Sandon Global, we continue to advocate for engravings that are fit for purpose. That means engravings that balance cell depth and opening size, suit the plate resolution, and match the ink system and a specific substrate. Flexo printing is more capable and complex than ever before. Press speeds are increasing, designs are becoming more sophisticated, and the demand for embellishments and speciality finishes is rising. The anilox must evolve in parallel. 

The right anilox engraving does more than deliver print quality. It improves press efficiency, reduces waste, and ultimately protects your bottom line. Selecting the best possible anilox specification for the job should be a straightforward decision based on facts, not tradition. And, at Sandon Global, we’re here to help you make that decision easier. 

About the author 

Stuart Mitchell is Technical Director – Print at Sandon Global. With more than three decades of technical experience in flexographic print technologies, Stuart supports packaging converters around the world in optimising their print processes through anilox specification and print process guidance. He works closely with Sandon Global’s R&D and production teams to ensure that the company’s advanced engraving technologies continue to meet the demands of today’s ever-evolving print market. 

To discover how Sandon Global can help YOU choose the right anilox engraving to optimise your wide web flexographic printing process, get in touch today!