4 Problems Caused By Low Quality Rollers

Posted by Andrea Wilson on Sep 9, 2021 5:01:46 PM

Problems Caused By Low Quality Print Rollers

Think packaging is easy? Think again! There are multiple hurdles to navigate, and one of these is quality. At any stage of a project, quality matters. Sometimes it only matters slightly, and sometimes it matters a lot. A 0.001 mm difference in a deep hole volume might mean nothing on a pushbike but might result in catastrophe for a plane.

For example, if your business is printing, having an ineffective roller is the equivalent of having a vehicle without a wheel. Here are some of the problems that low-quality rollers can cause, and how you can avoid them.

1. Ghosting

Ghosting is when an image appears unexpectedly and unnecessarily. Ghosts can either be due to low ink quality (a ‘chemical’ ghost), or a bad roller (a ‘mechanical’ ghost). A combination of low quality ink and a bad roller results in a big mess.

Even with the best ink, a poorly honed roller will cause mechanical ghosting. This results in profit reduction, loss of time, and lowered productivity.

To avoid this catalogue of problems, precision engineering of the roller is vital. Maintenance can avoid plate wear, and accurate roller settings can prevent uneven distribution. Ask your manufacturer about the ideal mechanical settings for your roller.

2. The Wrong Roller

In a precision engineering industry, this one should be obvious. However, the majority of roller problems are caused by bad technical drawings.

Precision boring and honing is an art that requires pin-point accuracy. Printing presses require equal levels of accuracy. This is a demand that has increased incrementally as HD print quality and substrate variance has continued to raise the bar for the new ‘norm’ in visual perfection.

In the case of print rollers, there is no ‘one-size-fits-all’ answer. They are bespoke products that need to be engineered to individual specifications. Don’t order the wrong roller. Bring your technical drawings to us, and let us take a look.

3. False Economy

Applying economic rules to something like a print roller can be a challenge.

The main areas of quantification are time, productivity, and reliability. A quality print roller is likely to increase all of these. However, the real benefit is in predictability. Knowing that a print run can be finished on time and to a guaranteed standard, and knowing that new ideas can be tried and launched within predictable windows, can make a lot of difference.

This means that investing in a quality product can offer predictable, long-term, quantifiable returns. Opting for a short-term saving can easily end up costing more. Asking about prices (with the right technical drawings!) might result in a surprisingly wallet-friendly long-term outcome.

4. Cost Effective Precision Rollers

When it comes to print rollers, it pays to do the homework. Getting it right now can guarantee quality in the future.

At Hone All, we’ve got decades of experience in the precision engineering of rollers, and we’re one of the only companies in the UK that has invested in the right machines to make them. If you’re interested in learning more, we’re here to talk. You can call us on 0845 5555 111, or use the chat bubble to speak to an expert online.

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Topics: Precision Rollers, Printing Rollers, print press rollers

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