Why Can We Always Ensure Excellent Quality

Quality Control

Quality control in the production of ceramic anilox rollers is the key to ensuring their performance and service life. In our company, the quality control system runs through the entire process of anilox roller production. Quality control covers all key links such as raw material procurement, production process monitoring and finished product testing.

1. Raw material control

• Ceramic powder: Use high-purity, uniform-size powder to ensure coating quality.

Check the particle size distribution, purity, chemical composition and other indicators of the ceramic powder to ensure that it meets the production requirements. For example, the purity of alumina ceramic powder should be above 95%, the particle size distribution should be uniform, and the D50 particle size should be within the appropriate range. At the same time, check the properties of the binder, such as viscosity and curing time, to ensure that it can be well combined with the ceramic powder.

• Substrate: The substrate must have high strength and good thermal expansion coefficient matching.

The material, hardness, roundness, cylindricity, etc. of the metal roller core are strictly inspected. The material should have sufficient strength and toughness. For example, if 45 steel is selected, its hardness must reach HRC28 - 32. The roundness and cylindricity errors should be controlled within ±0.02mm, and the surface roughness Ra should not be greater than 0.8μm to ensure the bonding quality with the ceramic coating.

2. Quality control of production process

• Roller core treatment

Surface treatment: The surface of the substrate needs to be cleaned and roughened to enhance the adhesion of the coating.

Geometric accuracy control

Diameter and length: Ensure that the dimensions meet the design requirements and the error is controlled within the allowable range.
Concentricity and straightness: Ensure that the roller rotates smoothly and avoids vibration.

• Spraying process

Plasma spraying is used to control the temperature, speed and spraying distance to ensure uniform coating.

• Reticulation Processing

Engraving Parameters: Use ALE laser engraving to process the reticulation, and precisely control the engraving depth, angle, number of lines and other parameters.

Anilox shape and depth: Ensure that the anilox shape and depth are consistent to meet printing requirements.

3. Finished product quality inspection

• Appearance inspection:

Use visual inspection and optical microscope to check whether there are cracks, pores, peeling and other defects on the surface of the ceramic anilox roller. The surface should be smooth, without obvious scratches and impurities, and the anilox pattern should be clear and complete.

• Dimensional accuracy inspection:

Use measuring tools such as calipers, micrometers, roundness gauges, and cylindricity gauges to detect the diameter, length, roundness, cylindricity and other dimensional parameters of the roller to ensure that they meet the design requirements. The diameter tolerance is controlled within ±0.05mm and the length deviation is within ±1mm.

• Hardness inspection:

Use a hardness tester to test the hardness of the ceramic coating, such as Rockwell hardness or Vickers hardness, to ensure that the hardness value is within the specified range, such as the hardness of the alumina ceramic coating should reach HRA85-92.

4. Records and traceability

• Production records: record the process parameters and test results of each link in detail.
• Traceability system: establish a traceability mechanism to facilitate problem tracking and improvement.
• Data analysis: regularly analyze production data and optimize the process.
• Feedback mechanism: collect customer feedback and continuously improve product quality.

5. Provide quality inspection report