Six Key Points for Proper Use and Maintenance of Ink Rollers

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Introduction: Ink rollers play a critical role in the printing process by transferring ink. They typically come in three forms: ink supply, ink distribution, and ink diversion. Ideally, ink rollers should exhibit excellent ink absorption and transfer capabilities while being resistant to chemical solvents such as organic solvents, gasoline, and kerosene. Proper daily maintenance directly affects their service life.

Since ink rollers are made of rubber, they are susceptible to issues such as swelling, deformation, surface drying, aging, and cracking, which can impair ink transfer and disrupt production. Therefore, proper usage and maintenance are essential. The following six key points should be emphasized:

1. Prevent deformation of the ink roller under pressure.

During normal operation, the pressure applied to the ink roller is uniform, preventing localized depressions or protrusions. However, after prolonged inactivity, localized compression may cause indentation.

Therefore, when ink rollers are not in use for extended periods, they should be removed and stored on designated racks, not on the floor or workbench, to avoid pressure-induced deformation.

2. Avoid scratching or crushing the ink roller with debris or the ink scraper.

In production, tools should never be placed haphazardly. When adjusting pressure between the ink roller and the plate or between ink rollers, use a thickness gauge for measurement and minimize insertions to prevent surface damage.

3. Regularly remove oxidation films formed on the ink roller surface.

In offset printing, glossy fast-drying resin inks containing drying agents and dispersants are commonly used. These components can penetrate the ink roller surface over time, forming a sealed oxide film that reduces ink absorption and transfer performance.

Therefore, the film layer should be manually or mechanically removed regularly. However, care must be taken not to excessively reduce the roller diameter, as this may affect ink transfer.

4. Prevent ink loss on the ink roller.

In offset printing, water usage can lead to ink emulsification, forming a hydrophilic layer on the smooth ink roller surface, causing ink rejection.

To resolve this, emulsified ink should be removed, and the hydrophilic layer should be stripped using a mixture of 5% sodium hydroxide solution and pumice powder. This restores the roller's lipophilic properties.

Additionally, the water fountain solution formulation should be carefully controlled, including its pH value. The minimum necessary amount of water should be used during printing to avoid plate scumming and reduce emulsification. The addition of gum arabic and surfactants should also be moderate.

5. Store ink rollers in a dry, clean, and shaded environment.

Avoid exposing them to excessive humidity or heat. Ink rollers should be stored horizontally at both ends, ensuring their surfaces do not come into contact with each other or other objects.

6. Perform daily cleaning of ink rollers.

After each workday or printing session, thoroughly clean the ink rollers to prevent oxidation and the formation of a hard, glossy film on the surface caused by ink pigments and resins. Cleaning typically involves using kerosene followed by gasoline. Since kerosene evaporates slowly while gasoline evaporates quickly, this two-step process helps maintain clean and dry ink rollers, ensuring their longevity.