Assessor Resource

ICPPRN413
Set up for complex flexographic printing

Assessment tool

Version 1.0
Issue Date: December 2018


This unit describes the skills and knowledge required to set up machines for non-routine flexographic printing. It includes the ability to conduct a proof run and adjust settings to ensure production speeds are attained.

It applies to individuals working as print machinists in the printing and graphic arts industry. They prepare material, set up, monitor and operate equipment and machinery, apply solutions to a defined range of problems associated with the print medium, and analyse and evaluate information from a variety of sources. They may also provide leadership and guidance to others with some limited responsibility for the output of others.

Mounting and demounting plates is covered in ICPPRN411 Mount and demount flexographic plates for complex printing.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1. Confirm non-routine job specifications

1.1 Job requirements are read and interpreted from job documentation or production control system

1.2 Set up is planned and carried out correctly in minimum time with minimum wastage

1.3 Availability of all job related components is checked

1.4 Proofed job is checked for conformance with job specifications

2. Set up reel transportation and delivery system on web-fed machine

2.1 Reels are checked for treatment levels, coatings and printing side, and age of product

2.2 Unwind reels are secured on reel shaft

2.3 Reels are correctly positioned on unwind stand

2.4 Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications

2.5 Edge guide is centred and set to non-routine job specifications

2.6 Unwind tension is set to suit substrate

2.7 Rewind tension is set to suit substrate

2.8 Positively Infinitely Variable (PIV) drive is set for appropriate tensioning of substrate

3. Select and prepare inks and solvents

3.1 Inks and solvents are selected according to job specifications and end-user requirements

3.2 Quality and suitability of inks and solvents are checked and appropriate action is taken

3.3 Inks and solvents are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions with suitable precautions to minimise waste

3.4 Correct colour and weight/volume of ink are mixed and viscosities checked and modified according to press requirements and non-routine job specifications

3.5 Ink formula and approved colour draw-downs are appropriately recorded

3.6 Inks and solvents are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions and relevant hazardous liquids storage regulations

4. Set up machine for complex flexographic printing

4.1 Flexographic plate cylinders are installed, and register adjustments centred

OR

4.2 Sleeves are installed in press and register adjustments made

OR

4.3 Plate mounting sheets are mounted on cylinders in press and register adjustments made

4.4 Plate cylinders are gauged up or pre-set to impression

4.5 Anilox rollers are selected to suit individual colour and plate reproduction requirements for each unit

4.6 Appropriate ink metering system is selected for each unit

4.7 Inking system is set up and roller nips/blades are set correctly

4.8 Ink circulation is maintained at correct level and flow for machine

4.9 Viscosities are adjusted according to job specifications

4.10 Air volume and drier temperatures curing units are selected to suit inks, substrate, solvents and, according to job specifications

4.11 Air volume is adjusted between colours to maximise drying and minimise air overspill

5. Set up in-line units for basic process/es

5.1 Minor in-line printing/converting/binding units are set up for basic process/es and adjusted according to machine requirements and job specifications

5.2 Assistance is given in set-up of major in-line printing/converting/binding units

6. Conduct proof run

6.1 Material to be used for proof is organised correctly

6.2 Press is set up and operated according to WHS guidelines

6.3 Print impressions are set to minimum kiss impression

6.4 Web tensions are correctly set at unwind, between stations and rewind

6.5 Drying is checked as sufficient to key ink to the substrate

6.6 Viscosities are adjusted to obtain correct colour at proof speed and checked against colour matching system

6.7 Substrate is checked against job specifications

7. Organise proof inspection and/or testing

7.1 Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

7.2 Production does not commence without client approval or authority where appropriate

8. Readjust settings to production speed

8.1 Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings

8.2 Adjustments are made according to product specifications and press performance

8.3 Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals

8.4 Press settings are documented and samples are retained

Evidence of the ability to:

set up flexographic printing machines for non-routine print jobs, conduct a proof run and adjust settings to ensure production speeds are attained

demonstrate use of computerised control, monitoring and data entry systems if available and appropriate

set up a flexographic printing machine for a complex job on TWO occasions (if possible using different substrates and if possible including at least two in-line processes) according to manufacturer’s and job specifications, and enterprise procedures.

Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.

To complete the unit requirements safely and effectively, the individual must:

describe production problems that could be created by not reading or understanding the job specifications

list work health and safety (WHS) factors to consider when mounting and proofing flexographic plates

describe the most common cause of photopolymer plates crazing on the image side

explain the importance of printing plate resiliency

list main advantages of using thin photopolymer plates in process printing

outline faults that may be detected on new plates

identify types of solvents used on photopolymer plates

describe benefits of optical mounting

explain the purpose of binding plates after mounting

outline possible print faults that could be eliminated by using a cushion mount

list WHS factors to consider when installing printing cylinders or sleeves

describe precautions to ensure the plates and cylinders or sleeves are not damaged during installation

explain what to check to ensure plates and cylinders or sleeves have been installed correctly

list WHS precautions to be observed when webbing up the machine

explain how to determine position of the reel

demonstrate how the substrate is pulled into the machine

outline consequences of insufficient unwind tension

describe consequences of excessive unwind tens

outline the function of the ‘Dancer’ roller on a web machine

explain the function of the PIV unit

demonstrate knowledge of how to make adjustments to the PIV

describe the function of the lay-on roller

outline effects of excessive lay-on roller pressure

describe what can happen if the web is not spliced correctly

explain how the particular web viewing device works

list WHS precautions for setting up the delivery

explain how the web is controlled in the rewind unit

describe the result of incorrect rewind tension

outline remedial steps if there is a possibility of ink marking in the rewind

explain the function the air blast plays in the delivery of sheets

list WHS precautions for preparing inks and additives

identify details to check an ink’s suitability for the printing process

outline special end-use requirements that may be necessary

describe the main functions of a pigmented extender used in flexographic printing

explain the purpose of adding plasticisers to flexographic inks

list additives used in flexographic inks

outline the range, in seconds, for zahn cup measurements

describe the effect foaming has in a zahn cup when measuring ink viscosity

identify recommended pH range when printing with aqueous inks

list precautions to observe to minimise waste when preparing ink

describe how to determine shelf life of most inks

outline conditions relevant to storing inks and additives

list conventions for labelling mixed ink

list WHS factors to consider when setting up the machine

identify advantages of centring all machine controls

describe checks to be made on cylinders and gears

outline checks to do prior to cylinder or sleeve installation

identify the angle chamber blades should be set at

outline the main advantage of gauging up and dry register prior to printing a job

describe the cell count of the anilox roller used when printing solids

explain why water treatment additives should be used in a central impression drum and chill roller coolant system

list advantages of laser engraved ceramic anilox rollers

demonstrate knowledge of the anilox roller and what it measures

list possible reasons for anilox wear

describe the type of job printed using a hexagonal cell configuration

identify the recommended web temperature when printing polypropylene film

explain the method of drying used when printing on polythene by the flexographic process

list factors affecting drying rate of liquid inks

list factors affecting drying of aqueous inks

identify the operating range of UV lamps

list WHS precautions to be observed when slitting on the machine

explain how a cold seal is formed

outline reasons for a printed product to be punched

describe what to consider when setting hole punching in relation to repeat length

outline consequences of excessive pressure on the slitters

describe why is it necessary to graduate drying speeds of each progressive colour, so first-down colours dry faster the subsequent colours

explain why, in flexographic printing, that as press speed increases so does colour strength

list causes of a decrease in web tension

outline consequences of increasing rewind tension after the roll has been partially rewound

identify the major cause of a telescopic roll

describe print characteristics related to excessive printing pressure

list causes of picking when printing multicoloured work

identify print faults from using an over-reduced ink

outline problems that can cause lateral streaks in uneven printing

describe causes of moire patterns when printing by the flexographic process

outline consequences of air being trapped under mounted plates

name the instrument used to identify retained solvent trapped in the print

explain the purpose of taking Dyne readings

explain the purpose of the crinkle test when testing an ink

outline consequences if an excessive final drying temperature was used when printing polypropylene film

identify the ink property that can be adjusted to reduce dot gain

demonstrate understanding of correctly checking ink viscosity while using ink pumps

identify problems resulting from excessive use of slow solvents

explain why laminating inks, once printed, appear dull and become easy to scratch

outline the result of excessive print area tension

list some of the problems the printer may associate with cold seals

locate machine manuals, safety and other documentation relevant to this task, and outline information included in these documents.

Gather evidence to demonstrate consistent performance in conditions that are safe and replicate the workplace. Noise levels, production flow, interruptions and time variances must be typical of those experienced in the printing field of work and include access to special purpose tools, equipment and materials, including a narrow flexographic press.

Assessors must satisfy NVR/AQTF assessor requirements.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1. Confirm non-routine job specifications

1.1 Job requirements are read and interpreted from job documentation or production control system

1.2 Set up is planned and carried out correctly in minimum time with minimum wastage

1.3 Availability of all job related components is checked

1.4 Proofed job is checked for conformance with job specifications

2. Set up reel transportation and delivery system on web-fed machine

2.1 Reels are checked for treatment levels, coatings and printing side, and age of product

2.2 Unwind reels are secured on reel shaft

2.3 Reels are correctly positioned on unwind stand

2.4 Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications

2.5 Edge guide is centred and set to non-routine job specifications

2.6 Unwind tension is set to suit substrate

2.7 Rewind tension is set to suit substrate

2.8 Positively Infinitely Variable (PIV) drive is set for appropriate tensioning of substrate

3. Select and prepare inks and solvents

3.1 Inks and solvents are selected according to job specifications and end-user requirements

3.2 Quality and suitability of inks and solvents are checked and appropriate action is taken

3.3 Inks and solvents are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions with suitable precautions to minimise waste

3.4 Correct colour and weight/volume of ink are mixed and viscosities checked and modified according to press requirements and non-routine job specifications

3.5 Ink formula and approved colour draw-downs are appropriately recorded

3.6 Inks and solvents are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions and relevant hazardous liquids storage regulations

4. Set up machine for complex flexographic printing

4.1 Flexographic plate cylinders are installed, and register adjustments centred

OR

4.2 Sleeves are installed in press and register adjustments made

OR

4.3 Plate mounting sheets are mounted on cylinders in press and register adjustments made

4.4 Plate cylinders are gauged up or pre-set to impression

4.5 Anilox rollers are selected to suit individual colour and plate reproduction requirements for each unit

4.6 Appropriate ink metering system is selected for each unit

4.7 Inking system is set up and roller nips/blades are set correctly

4.8 Ink circulation is maintained at correct level and flow for machine

4.9 Viscosities are adjusted according to job specifications

4.10 Air volume and drier temperatures curing units are selected to suit inks, substrate, solvents and, according to job specifications

4.11 Air volume is adjusted between colours to maximise drying and minimise air overspill

5. Set up in-line units for basic process/es

5.1 Minor in-line printing/converting/binding units are set up for basic process/es and adjusted according to machine requirements and job specifications

5.2 Assistance is given in set-up of major in-line printing/converting/binding units

6. Conduct proof run

6.1 Material to be used for proof is organised correctly

6.2 Press is set up and operated according to WHS guidelines

6.3 Print impressions are set to minimum kiss impression

6.4 Web tensions are correctly set at unwind, between stations and rewind

6.5 Drying is checked as sufficient to key ink to the substrate

6.6 Viscosities are adjusted to obtain correct colour at proof speed and checked against colour matching system

6.7 Substrate is checked against job specifications

7. Organise proof inspection and/or testing

7.1 Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

7.2 Production does not commence without client approval or authority where appropriate

8. Readjust settings to production speed

8.1 Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings

8.2 Adjustments are made according to product specifications and press performance

8.3 Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals

8.4 Press settings are documented and samples are retained

Evidence of the ability to:

set up flexographic printing machines for non-routine print jobs, conduct a proof run and adjust settings to ensure production speeds are attained

demonstrate use of computerised control, monitoring and data entry systems if available and appropriate

set up a flexographic printing machine for a complex job on TWO occasions (if possible using different substrates and if possible including at least two in-line processes) according to manufacturer’s and job specifications, and enterprise procedures.

Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.

To complete the unit requirements safely and effectively, the individual must:

describe production problems that could be created by not reading or understanding the job specifications

list work health and safety (WHS) factors to consider when mounting and proofing flexographic plates

describe the most common cause of photopolymer plates crazing on the image side

explain the importance of printing plate resiliency

list main advantages of using thin photopolymer plates in process printing

outline faults that may be detected on new plates

identify types of solvents used on photopolymer plates

describe benefits of optical mounting

explain the purpose of binding plates after mounting

outline possible print faults that could be eliminated by using a cushion mount

list WHS factors to consider when installing printing cylinders or sleeves

describe precautions to ensure the plates and cylinders or sleeves are not damaged during installation

explain what to check to ensure plates and cylinders or sleeves have been installed correctly

list WHS precautions to be observed when webbing up the machine

explain how to determine position of the reel

demonstrate how the substrate is pulled into the machine

outline consequences of insufficient unwind tension

describe consequences of excessive unwind tens

outline the function of the ‘Dancer’ roller on a web machine

explain the function of the PIV unit

demonstrate knowledge of how to make adjustments to the PIV

describe the function of the lay-on roller

outline effects of excessive lay-on roller pressure

describe what can happen if the web is not spliced correctly

explain how the particular web viewing device works

list WHS precautions for setting up the delivery

explain how the web is controlled in the rewind unit

describe the result of incorrect rewind tension

outline remedial steps if there is a possibility of ink marking in the rewind

explain the function the air blast plays in the delivery of sheets

list WHS precautions for preparing inks and additives

identify details to check an ink’s suitability for the printing process

outline special end-use requirements that may be necessary

describe the main functions of a pigmented extender used in flexographic printing

explain the purpose of adding plasticisers to flexographic inks

list additives used in flexographic inks

outline the range, in seconds, for zahn cup measurements

describe the effect foaming has in a zahn cup when measuring ink viscosity

identify recommended pH range when printing with aqueous inks

list precautions to observe to minimise waste when preparing ink

describe how to determine shelf life of most inks

outline conditions relevant to storing inks and additives

list conventions for labelling mixed ink

list WHS factors to consider when setting up the machine

identify advantages of centring all machine controls

describe checks to be made on cylinders and gears

outline checks to do prior to cylinder or sleeve installation

identify the angle chamber blades should be set at

outline the main advantage of gauging up and dry register prior to printing a job

describe the cell count of the anilox roller used when printing solids

explain why water treatment additives should be used in a central impression drum and chill roller coolant system

list advantages of laser engraved ceramic anilox rollers

demonstrate knowledge of the anilox roller and what it measures

list possible reasons for anilox wear

describe the type of job printed using a hexagonal cell configuration

identify the recommended web temperature when printing polypropylene film

explain the method of drying used when printing on polythene by the flexographic process

list factors affecting drying rate of liquid inks

list factors affecting drying of aqueous inks

identify the operating range of UV lamps

list WHS precautions to be observed when slitting on the machine

explain how a cold seal is formed

outline reasons for a printed product to be punched

describe what to consider when setting hole punching in relation to repeat length

outline consequences of excessive pressure on the slitters

describe why is it necessary to graduate drying speeds of each progressive colour, so first-down colours dry faster the subsequent colours

explain why, in flexographic printing, that as press speed increases so does colour strength

list causes of a decrease in web tension

outline consequences of increasing rewind tension after the roll has been partially rewound

identify the major cause of a telescopic roll

describe print characteristics related to excessive printing pressure

list causes of picking when printing multicoloured work

identify print faults from using an over-reduced ink

outline problems that can cause lateral streaks in uneven printing

describe causes of moire patterns when printing by the flexographic process

outline consequences of air being trapped under mounted plates

name the instrument used to identify retained solvent trapped in the print

explain the purpose of taking Dyne readings

explain the purpose of the crinkle test when testing an ink

outline consequences if an excessive final drying temperature was used when printing polypropylene film

identify the ink property that can be adjusted to reduce dot gain

demonstrate understanding of correctly checking ink viscosity while using ink pumps

identify problems resulting from excessive use of slow solvents

explain why laminating inks, once printed, appear dull and become easy to scratch

outline the result of excessive print area tension

list some of the problems the printer may associate with cold seals

locate machine manuals, safety and other documentation relevant to this task, and outline information included in these documents.

Gather evidence to demonstrate consistent performance in conditions that are safe and replicate the workplace. Noise levels, production flow, interruptions and time variances must be typical of those experienced in the printing field of work and include access to special purpose tools, equipment and materials, including a narrow flexographic press.

Assessors must satisfy NVR/AQTF assessor requirements.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are read and interpreted from job documentation or production control system 
Set up is planned and carried out correctly in minimum time with minimum wastage 
Availability of all job related components is checked 
Proofed job is checked for conformance with job specifications 
Reels are checked for treatment levels, coatings and printing side, and age of product 
Unwind reels are secured on reel shaft 
Reels are correctly positioned on unwind stand 
Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications 
Edge guide is centred and set to non-routine job specifications 
Unwind tension is set to suit substrate 
Rewind tension is set to suit substrate 
Positively Infinitely Variable (PIV) drive is set for appropriate tensioning of substrate 
Inks and solvents are selected according to job specifications and end-user requirements 
Quality and suitability of inks and solvents are checked and appropriate action is taken 
Inks and solvents are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions with suitable precautions to minimise waste 
Correct colour and weight/volume of ink are mixed and viscosities checked and modified according to press requirements and non-routine job specifications 
Ink formula and approved colour draw-downs are appropriately recorded 
Inks and solvents are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions and relevant hazardous liquids storage regulations 
Flexographic plate cylinders are installed, and register adjustments centred 
Sleeves are installed in press and register adjustments made 
Minor in-line printing/converting/binding units are set up for basic process/es and adjusted according to machine requirements and job specifications 
Assistance is given in set-up of major in-line printing/converting/binding units 
Material to be used for proof is organised correctly 
Press is set up and operated according to WHS guidelines 
Print impressions are set to minimum kiss impression 
Web tensions are correctly set at unwind, between stations and rewind 
Drying is checked as sufficient to key ink to the substrate 
Viscosities are adjusted to obtain correct colour at proof speed and checked against colour matching system 
Substrate is checked against job specifications 
Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures 
Production does not commence without client approval or authority where appropriate 
Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings 
Adjustments are made according to product specifications and press performance 
Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals 
Press settings are documented and samples are retained 

Forms

Assessment Cover Sheet

ICPPRN413 - Set up for complex flexographic printing
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

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Assessment Record Sheet

ICPPRN413 - Set up for complex flexographic printing

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: