Corrugated rolls are essential components in the production of corrugated cardboard, serving as the molds that shape the fluted structure. As one of the most expensive and critical parts on a single-faced corrugating machine, their performance directly impacts the quality and strength of the final product. The height of the corrugated teeth determines the thickness and structural integrity of the cardboard, making it crucial for the corrugated roller to maintain high wear resistance and dimensional stability over time. In the past, traditional repair methods involved hard chrome plating, which, while common, lacked sufficient durability and often led to frequent maintenance and downtime.
To address these challenges, an innovative coating technology has been developed: silicon carbide-chromium nano-ceramic coatings applied to the working surface of corrugated rollers. This advanced coating is composed of three distinct layers, with a total thickness ranging from 0.08 to 0.10 mm. The first layer forms a strong ion diffusion bond with the base material, the second acts as a transitional layer, and the third is the outermost nano-ceramic layer, offering exceptional hardness and wear resistance. Compared to conventional hard chrome-plated rollers, this new technology provides up to three times greater durability, significantly extending the service life of the roller and reducing the frequency of maintenance. This not only lowers operational costs but also minimizes machine downtime, improving overall efficiency in the production process.
In addition to corrugated rollers, anilox rollers play a vital role in flexographic printing, where their performance directly affects print quality. Traditional anilox rollers made from low carbon steel or copper are typically engraved with a 45° pyramid-shaped ink cell structure and then chrome-plated. However, due to the thinness of the coating, these rollers are prone to wear, especially when used with scraper-type ink systems. Over time, this wear reduces the capacity of the ink cells, leading to inconsistent ink distribution and lower print quality.
To overcome these limitations, laser-engraved nano-ceramic anilox rollers have emerged as a superior alternative. Made from high-performance ceramic materials, these rollers exhibit remarkable strength, toughness, and wear resistance. Their enhanced properties make them ideal for high-speed printing applications, where consistent ink transfer is critical. As a result, they are increasingly replacing traditional metal anilox rollers in flexographic presses. The use of nano-ceramics not only meets the demand for harder, more durable surfaces but also ensures reliable performance, contributing to higher-quality printed cartons and better long-term cost efficiency.
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