ZRE: Bringing Chamber-Anilox Coating to a New Generation of Printers

Digital printing has changed the expectations around finishing. Shorter runs, faster turnaround times, and tighter margins mean printers need coating systems that are reliable, efficient, and easy to run.

For many printers entering the coating market, the first option they encounter is often a lower-cost roller coater. These systems may appear attractive at first, but they rely on decades-old technology that can introduce inconsistency, higher labor demands, and limitations in coating performance.

Harris & Bruno is developing a new platform designed to offer a better alternative. The upcoming ZRE system brings our world renowned chamber-anilox coating technology into a compact flood coater built specifically for printers who want professional coating results, but don’t need full automation.

Where Roller Coaters Fall Short

Roller coaters apply coating by compressing it between rollers before transferring it to the sheet. This process often requires constant adjustment to maintain the correct coating thickness and coverage.

Because the coating is squeezed between rollers, operators frequently encounter uneven laydown across the sheet and throughout the job. High spots can waste coating and create visual defects, while low spots can leave areas under-protected or inconsistent in appearance. This variability means operators often need to adjust pressures and settings throughout a run, increasing labor requirements and slowing production.

Another common challenge is coating compatibility. Many roller coaters are primarily designed to run UV coatings, which can limit flexibility and increase operational costs. For printers looking to run more environmentally friendly aqueous coatings, this can become a significant limitation.

Introducing particulates such as soft touch or matte brings its own set of challenges. While the first few sheets may come out smooth, the particulates will find their way into the nip, and start to collect. When this happens the particulates never make it to the sheet, and the operator is faced with a big mess to clean up.

The Superior Chamber-Anilox System

Chamber-anilox systems approach coating in a completely different way. Instead of squeezing coating between rollers, the system meters a precise amount of coating through an engraved anilox roll before transferring it to the sheet.

This controlled metering delivers a uniform coating weight across the sheet and eliminates much of the guesswork involved in roller-based systems. The first sheet looks the same as the thousandth sheet, creating predictable and repeatable results. Because the coating is measured rather than compressed, chamber-anilox systems also require fewer manual adjustments. This reduces operator intervention and helps printers lower labor demands on the finishing floor.

Another major advantage is coating flexibility. Chamber-anilox systems can run both UV and aqueous coatings with ease, as well as particulates such as soft touch, glitter, and grit. This allows printers to meet the growing demand for AQ coatings that provide a more economical and environmentally friendly alternative to lamination, as well as open up the possibilities of specialty coatings.

Introducing the ZRE Platform

The ZRE platform is currently being developed to deliver these chamber-anilox advantages in a compact offline flood coating system built specifically for B2 and A3 digital print environments. Even though it is a streamlined system, the ZRE maintains the same chamber-anilox metering technology that Harris & Bruno systems are known for. The heart of the system is the same that you will find on offset coating towers, and our offline and inline ZR and ZRW units.

The system supports aqueous, UV, and priming coating applications while handling a wide range of substrates and sheet sizes. One area where the ZRE truly stands apart from many entry-level coaters is its ability to reliably handle specialty coatings. Because chamber-anilox systems meter coating precisely, they can run coatings that contain particulates such as soft touch, grit, or textured finishes that are often difficult to run on roller coaters.

This opens the door to more premium applications while maintaining consistent coating performance, all while minimizing operator intervention.

A Smarter Entry into Coating

The ZRE platform is designed for printers who want to add coating without sacrificing quality or operational efficiency.

By combining the simplicity of a compact flood coater with the precision of chamber-anilox technology, the ZRE provides consistent coating results, reduced labor requirements, and the flexibility to run both UV and aqueous coatings.

If you’re ready to move beyond the limitations of roller coaters reach out to our team. We would love to show you how the chamber-anilox system brings modern coating technology to a broader range of production environments and delivers the performance that today’s print applications demand.

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