At the Flexo Forward Conference in Ahmedabad (5 June 2026), jointly organized by apex International, Miraclon, Bobst and Polymount, Mahesh Mense, sales manager – Indian Peninsula, apex International, highlighted how effective anilox management can significantly improve print consistency, operational efficiency and profitability in flexographic printing.
Mense began by pointing out that although flexo technology has evolved considerably, converters continue to face challenges arising from multiple variables on press, including plates, inks, substrates, anilox rolls and doctor blades. The growing number of SKUs, shorter run lengths and increasing quality expectations from brand owners further complicate production.
“One of the most critical challenges in flexo is maintaining consistent ink transfer,” he said. According to Mense, inconsistency often stems from large inventories of consumables sourced from multiple suppliers, leading to longer setup times, increased waste and greater maintenance requirements.
Central to the discussion was the role of the anilox roll, which transfers ink to the printing plate. “Anilox has a direct impact on print quality, efficiency and profitability,” Mense emphasized, noting that cell geometry and volume directly influence colour density and repeatability.
To optimize performance, apex advocates a five-pillar approach: standardizing anilox inventories, adopting advanced engraving technologies, implementing proper cleaning and maintenance routines, ensuring correct storage and handling, and conducting regular anilox audits.
Mense stressed that many converters maintain more anilox rolls than necessary. Instead, he recommended grouping jobs according to application requirements and creating standardized anilox libraries. “It is important to have the minimum but sufficient set of aniloxes required for production,” he said. Standardizing specifications across multiple presses can further improve consistency throughout a plant.
Discussing conventional 60-degree hexagonal engraving technology, Mense acknowledged its popularity and versatility but highlighted its limitations. Different print applications and plate resolutions often require different anilox specifications, resulting in larger inventories, higher investment costs and frequent roll changes.
“Achieving standardization becomes very challenging when multiple anilox changes are required to run different jobs,” he said.
Maintenance emerged as another key theme. Mense warned that allowing ink to dry in anilox cells can severely affect performance and advocated structured cleaning procedures. “Daily cleaning, periodic deep cleaning and preventive maintenance are essential for maintaining consistent ink transfer,” he said. He also advised the use of anilox-safe cleaning chemicals and regular monitoring of cell-volume degradation.
Mense also encouraged converters to conduct annual anilox audits. These audits measure actual cell volume and engraving characteristics against original specifications, enabling printers to identify wear before it affects print quality.
Summing up his presentation, Mense argued that successful flexo operations increasingly depend on process control rather than simply press speed. “Profitability is no longer driven by speed alone,” he said. “It is driven by process control, standardization and intelligent ink transfer that can be achieved with the right anilox solution.”
