Corrugated rolls are essential components in single-sided corrugating machines, and they represent one of the most costly and critical parts. The height of the corrugated flutes directly affects the thickness and structural strength of the corrugated cardboard. Therefore, for the final product to meet quality standards, the corrugated roll must be highly wear-resistant and resistant to deformation. Traditionally, when the surface of a corrugated roll became worn, the common repair method was to apply hard chrome plating. However, this technique offered limited wear resistance and did not provide long-term durability.
To address these challenges, an innovative coating technology has been developed: silicon carbide-chromium nano-ceramic coatings applied to the working surface of corrugated rolls. This coating is approximately 0.08–0.10 mm thick and consists of three distinct layers. The first layer forms an ion diffusion bond with the base material, ensuring strong adhesion. The second layer acts as a transition between the first and the outermost ceramic layer, while the third layer is a high-performance silicon carbide-chromium nano-ceramic coating that provides exceptional wear resistance. Compared to traditional hard chrome-plated rolls, this new type of corrugated roll offers about three times better wear resistance. As a result, it significantly extends the service life of the roll, reduces machine downtime, and lowers maintenance costs.
In addition to corrugated rolls, anilox rollers are also crucial components in flexographic printing presses. Their performance plays a vital role in determining the print quality of the final product. Conventional anilox rollers are typically made from low-carbon steel or copper, which are then engraved with a 45° pyramid-shaped ink cell structure and coated with chromium. However, due to the thinness of the coating, these rollers tend to wear out quickly—especially when used with scraper-type ink delivery systems. This wear can reduce the volume of the ink cells, leading to poor ink distribution and lower print quality.
To overcome these issues, laser-engraved nano-ceramic anilox rollers have emerged as a superior alternative. These rollers are made from advanced nano-ceramic materials, offering enhanced strength, toughness, and wear resistance. Their improved properties make them ideal for high-speed flexographic printing applications. As a result, they are increasingly replacing traditional metal anilox rollers in modern printing operations. The use of nano-ceramics ensures that the anilox roller maintains its structural integrity and ink transfer efficiency over time, providing a reliable technical solution that enhances print quality and production efficiency.
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