Flexographic printing companies across the industry are turning to disposable “quick change” ink pan liners to streamline operations, reduce cleanup time, and eliminate unnecessary mess. At DIPCO, we’ve engineered our liners for peak efficiency—but like any great tool, they perform best when used properly. Here are some proven best practices to help your pressroom get the most out of your ink pan liners.

1. Start with the Right Ink Viscosity

Maintaining correct ink viscosity is key to quality print results and liner longevity. If your ink is too thick, it may not flow properly, creating uneven coverage or premature liner wear. If it’s too thin, it can splash or cause color swings. Use a Zahn cup or digital viscometer to regularly check ink viscosity—especially at the start of a run or after extended pauses. Most water-based inks perform best between 25–35 seconds in a #3 Zahn cup but always follow your ink supplier’s specs.

2. Clean Rollers Mean Cleaner Results

Before installing and filling liners, make sure your anilox and metering rollers are free from dried ink and debris. Dirty rollers can cause inconsistent laydown, roller scoring, and ink buildup around the liner edges. A clean setup reduces wear on rollers and liners and ensures a smooth start to your run.

3. Don’t Overfill (or Underfill!) the Liner

Overfilling the ink pan liner is a common mistake that can lead to leaks and spills. Underfilling is just as bad. Liners with too little ink can cause irreparable damage to both metering and anilox rollers. Our liners are engineered to mimic your press’s OEM pan capacity. All paperboard flexo liners feature built-in score lines marking the minimum and maximum ink fill level. For best results, fill within these markings to ensure worry free operation. Pro tip: Use Ink Level Clips to ensure you never overfill when adding ink during a run.

4. Use Drain Hoses and Plugs Properly

Many DIPCO liner models include drains to make end-of-run cleanup even faster. Always attach drain hose before installing the system in the press. To eliminate damage to the drain flange, always support the drain on the inside of the liner with one hand while pushing the hose onto the drain spout. After installation, don’t forget to plug your drain with a rubber stopper before filling the liner with ink.

5. Install WC2000 Wipers with Precision

For presses using the plastic WC2000 wipers, proper alignment during installation is critical. These wipers are designed to fit snugly within the ink pan liner system to create a consistent seal and guide ink flow efficiently. Ensure each wiper is securely clipped into the stainless steel retainer, with the flexible fins resting lightly against the sides of the metering and anilox rollers. There should be approximately a 1/8” gap between the rollers and the solid block section of the wiper. Wipers are designed as a disposable wear component—reusing them can lead to damaged rollers and ink spitting during operation.

6. Replace Liners After Every Run

It may be tempting to reuse a liner or simply rinse out a drain hose between runs to “save money.” But in reality, that defeats the entire purpose of a liner system. DIPCO liners are designed to be fully disposable—everything from the liner itself to the hose and wipers (keep the steel retainers and drain plugs though!). Reusing liners risks cross-contamination from dried ink flakes, dust particles, and metal shavings from doctor blades. Even a small amount of residue can affect print quality, damage rollers, print plates, or cause extended press downtime. The true savings come from reduced labor and faster changeovers—not from cutting corners. Replacing all disposable components after every run ensures consistency, minimizes defects, and reinforces good 5S practices across the pressroom.

Conclusion

DIPCO’s ink pan liners are designed to simplify your flexo operation—but the key to maximum performance lies in proper setup and consistent usage. By managing viscosity, keeping rollers clean, avoiding overfilling, draining correctly, using fresh components every run, and ensuring proper fit and wiper alignment, your team will experience cleaner print, faster turnarounds, and longer equipment life.

Ready to reduce downtime and improve your process? Contact us to request a sample or speak with a DIPCO rep today.