Understanding Anilox Scoring: Causes, Signs & How to Prevent It 

Anilox scoring remains one of the most frustrating and costly challenges in the flexographic and gravure printing world. Despite the wide awareness of its effects, many printers still struggle to pinpoint its root causes and prevent recurrence. 

As strategic partners to the print and packaging industry, we believe proactive education and process optimization are essential to overcoming these production pitfalls. Here’s what you need to know about identifying, preventing, and addressing anilox scoring.

What Is Anilox Scoring? 

Anilox scoring refers to the breakdown of the engraved cell walls on an anilox roll, often forming a continuous gouge or line along the roll’s circumference. Instead of discrete, intact cells that meter ink evenly, the affected area becomes compromised leading to visible lines in the print, reduced ink transfer, and long-term press damage if left unaddressed. 

How to Spot Scoring vs. Plug Lines 

Lighter Lines 

Subtle, lighter lines often indicate minor damage caused by polished or plugged cells. In these cases, the tops of the cells may have been worn smooth or blocked with debris, preventing them from holding and releasing ink properly. These are sometimes called “plug lines” and can usually be resolved with thorough cleaning. 

Darker Lines 

Darker, more prominent lines signal more severe damage, a physical gouge in the roll. These scores disrupt ink flow significantly and cannot be reversed. At this stage, recoating or replacing the anilox roll is typically required. 

What Causes Anilox Scoring? 

Through hands-on evaluations and vendor collaboration, several key culprits emerge consistently: 

• Doctor Blade Issues 
  Misaligned or improperly seated blades can scrape across the roll surface, especially under excess pressure, creating score lines over time. 

• Ink Contamination 
  Poorly milled inks may contain oversized particles that wedge between the blade and roll, contributing to both scoring and cell plugging. 

• Pressroom Debris 
  Dust, substrate fragments, or foreign material can enter the chamber and embed between the blade and roll, causing surface damage. 

• Anilox Manufacturing Defects 
  Flaws like slag, recast, or irregular engraving patterns, especially in low-LPI rolls, can predispose the roll to early scoring or uneven wear. 

Proven Ways to Prevent Anilox Scoring 

While scoring may be common, it’s not inevitable. Here are best practices we recommend building into any high-performance pressroom: 

• Operator Training & Blade Alignment 
  Establish detailed SOPs and audit protocols to ensure proper blade installation, seating, and chamber alignment. 

• Use Magnetic & Filtration Systems 
  Add rare-earth magnets to ink lines and install filtration systems to capture metal particles or hardened ink debris before they reach the blade. 

• Inspect Anilox Rolls Upon Arrival 
  Don’t assume perfection. Validate every new roll against spec before putting it into production. 

• Reinforce Cleaning Standards 
  Consistent cleaning of press components and surrounding environments helps prevent debris buildup that leads to scoring. 

• Leverage Vendor Support 
  Work closely with trusted suppliers (like Provident) who understand the full print ecosystem, from blades and seals to anilox rolls and pressroom chemistry. Their insight can save time, money, and headaches. 

Final Thoughts 

Anilox scoring isn’t just a maintenance issue, it’s a production risk that directly impacts print quality and operational efficiency. But with the right mix of education, process control, and vendor alignment, it can be significantly reduced, if not avoided entirely. 

Looking to troubleshoot a scoring issue or elevate your pressroom performance? Let’s talk. Whether you need technical insight, product guidance, or a full process review, we’re here to help solve problems before they disrupt your production.