Assessor Resource

ICPPRN513
Set up for specialised flexographic printing

Assessment tool

Version 1.0
Issue Date: April 2024


This unit describes the skills and knowledge required to set up machines for specialised flexographic printing.

It applies to individuals required to set up for specialised colour jobs and who have a good knowledge of substrates and press settings.

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. Select and prepare inks and solvents for non-routine job

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

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

2.3 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

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

2.5 Ink formula and approved colour draw downs are appropriately recorded

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

3. Set up machine for specialised flexographic printing

3.1 Flexographic plate cylinders are installed and register adjustments centred

OR

3.2 Sleeves are installed in press and register adjustments made

OR

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

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

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

3.6 Appropriate ink metering system is selected for each unit

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

3.8 Ink circulation is maintained at correct level

3.9 Viscosities are adjusted according to job specifications

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

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

4. Conduct proof run

4.1 Material to be used for proof is organised correctly

4.2 Press is set up and operated according to WHS guidelines

4.3 Print impressions are set to minimum kiss impression

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

4.5 Print is checked for register

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

4.7 Viscosities are adjusted to obtain the correct colour at proof speed

5. Organise proof inspection and/or testing

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

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

6. Troubleshoot machinery and material problems

6.1 Corrective or preventive action is recommended and implemented where appropriate

6.2 Changes are communicated to relevant personnel in a logical and easily understood manner

6.3 Changes are monitored to confirm improvement to production efficiency

Evidence of the ability to:

correctly set up a flexographic printing machine for a specialised job on TWO occasions using different substrates and including at least two in-line processes) according to the manufacturer’s and job specifications, enterprise procedures and performance criteria

safely conduct a proof run and adjust settings to ensure production speeds are attained

find and use information relevant to the task from a variety of information sources.

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:

outline production problems that can eventuate if job specifications are not read and/or understood

identify the person to discuss production problems with

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

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

explain the importance of printing plate resiliency

describe the main advantage of using thin photopolymer plates in process printing

list faults that may be found on new plates

describe the type of solvents to use on photopolymer plates

explain what V-block mounting is

describe how V-block mounting is achieved

list benefits of optical mounting

outline the purpose of binding plates after mounting

explain possible print faults that can be eliminated by using cushion mount

explain any WHS factors to be considered when installing printing cylinders or sleeves

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

outline checks to ensure plates and cylinders or sleeves have been installed correctly

discuss WHS precautions for webbing up the machine

explain how to determine position of the reel

describe how the substrate is pulled into the machine

explain the result of insufficient unwind tension

discuss the result of excessive unwind tension

describe the function of the ‘dancer’ roller on a web machine

explain the function of the positive input ventilation (PIV) unit

discuss the result of adjustments to the positive input ventilation (PIV) unit

describe the function of the lay-on roller

discuss the effect of excessive lay-on roller pressure

describe the effect of the web not being spliced correctly

explain how the particular web viewing device functions

outline WHS precautions for setting up the delivery

explain how the web is controlled in the rewind unit

outline the result of incorrect rewind tension

discuss remedial steps to take if there is a possibility of the ink marking in the rewind

explain the use of air blast play in the delivery of sheets

discuss WHS precautions for preparing inks and additives

outline how to determine an ink’s suitability for the printing process

explain special end-use requirements that may be necessary

outline the main function of a pigmented extender used in flexographic printing

describe the effect of adding plasticisers to flexographic inks

explain why other additives are used in flexographic inks

explain the range, in seconds, for zahn cup measurements

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

explain the recommended ph range when printing with aqueous inks

outline precautions to minimise waste when preparing ink

explain the shelf life of most inks

identify conditions relevant to storage of inks and additives

describe conventions for labelling mixed inks

list WHS factors to consider when setting up the machine

explain the advantage of centring all machine controls

list checks to make on cylinders and gears

outline checks to perform prior to cylinder or sleeve installation

explain the angle chamber blades should be set at

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

discuss cell count of the anilox roller for printing solids

outline 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

describe three things relating to the anilox roller that a roller scope measures

explain possible reasons for anilox wear

outline the type of job that is printed using a hexagonal cell configuration

describe 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 the drying rate of liquid inks

identify factors that affect drying of aqueous inks

explain the operating range of UV lamps

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

explain why in flexographic printing, the colour strength increases as the press speed increases

identify possible causes of a decrease in web tension

describe the result of increasing rewind tension after the roll has been partially rewound

explain the major cause of a telescopic roll

list print characteristics related to excessive printing pressure

outline causes of picking when printing multicoloured work

explain print faults from using an over-reduced ink

discuss problems that can cause lateral streaks showing up in uneven printing

describe causes of moire patterns when printing by the flexographic process

explain what happens when air is trapped under mounted plates

describe which instrument is 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 the result if an excessive final drying temperature was used when printing polypropylene film

explain what ink property can be adjusted to reduce dot gain

discuss the effect of using the ink returning from the ink fountain when checking viscosity for ink while using ink pumps

list problems that result from excessive use of slow solvents

explain the effect of the ‘yield value’ of ink on the ink transfer of halftone dots

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

explain the result of excessive print area tension

identify some of the problems associated with cold seals

identify the location of machine manuals, safety and other documentation that are relevant to this task, where they are kept, and describe the information included in them.

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 a 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. Select and prepare inks and solvents for non-routine job

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

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

2.3 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

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

2.5 Ink formula and approved colour draw downs are appropriately recorded

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

3. Set up machine for specialised flexographic printing

3.1 Flexographic plate cylinders are installed and register adjustments centred

OR

3.2 Sleeves are installed in press and register adjustments made

OR

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

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

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

3.6 Appropriate ink metering system is selected for each unit

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

3.8 Ink circulation is maintained at correct level

3.9 Viscosities are adjusted according to job specifications

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

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

4. Conduct proof run

4.1 Material to be used for proof is organised correctly

4.2 Press is set up and operated according to WHS guidelines

4.3 Print impressions are set to minimum kiss impression

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

4.5 Print is checked for register

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

4.7 Viscosities are adjusted to obtain the correct colour at proof speed

5. Organise proof inspection and/or testing

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

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

6. Troubleshoot machinery and material problems

6.1 Corrective or preventive action is recommended and implemented where appropriate

6.2 Changes are communicated to relevant personnel in a logical and easily understood manner

6.3 Changes are monitored to confirm improvement to production efficiency

Evidence of the ability to:

correctly set up a flexographic printing machine for a specialised job on TWO occasions using different substrates and including at least two in-line processes) according to the manufacturer’s and job specifications, enterprise procedures and performance criteria

safely conduct a proof run and adjust settings to ensure production speeds are attained

find and use information relevant to the task from a variety of information sources.

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:

outline production problems that can eventuate if job specifications are not read and/or understood

identify the person to discuss production problems with

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

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

explain the importance of printing plate resiliency

describe the main advantage of using thin photopolymer plates in process printing

list faults that may be found on new plates

describe the type of solvents to use on photopolymer plates

explain what V-block mounting is

describe how V-block mounting is achieved

list benefits of optical mounting

outline the purpose of binding plates after mounting

explain possible print faults that can be eliminated by using cushion mount

explain any WHS factors to be considered when installing printing cylinders or sleeves

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

outline checks to ensure plates and cylinders or sleeves have been installed correctly

discuss WHS precautions for webbing up the machine

explain how to determine position of the reel

describe how the substrate is pulled into the machine

explain the result of insufficient unwind tension

discuss the result of excessive unwind tension

describe the function of the ‘dancer’ roller on a web machine

explain the function of the positive input ventilation (PIV) unit

discuss the result of adjustments to the positive input ventilation (PIV) unit

describe the function of the lay-on roller

discuss the effect of excessive lay-on roller pressure

describe the effect of the web not being spliced correctly

explain how the particular web viewing device functions

outline WHS precautions for setting up the delivery

explain how the web is controlled in the rewind unit

outline the result of incorrect rewind tension

discuss remedial steps to take if there is a possibility of the ink marking in the rewind

explain the use of air blast play in the delivery of sheets

discuss WHS precautions for preparing inks and additives

outline how to determine an ink’s suitability for the printing process

explain special end-use requirements that may be necessary

outline the main function of a pigmented extender used in flexographic printing

describe the effect of adding plasticisers to flexographic inks

explain why other additives are used in flexographic inks

explain the range, in seconds, for zahn cup measurements

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

explain the recommended ph range when printing with aqueous inks

outline precautions to minimise waste when preparing ink

explain the shelf life of most inks

identify conditions relevant to storage of inks and additives

describe conventions for labelling mixed inks

list WHS factors to consider when setting up the machine

explain the advantage of centring all machine controls

list checks to make on cylinders and gears

outline checks to perform prior to cylinder or sleeve installation

explain the angle chamber blades should be set at

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

discuss cell count of the anilox roller for printing solids

outline 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

describe three things relating to the anilox roller that a roller scope measures

explain possible reasons for anilox wear

outline the type of job that is printed using a hexagonal cell configuration

describe 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 the drying rate of liquid inks

identify factors that affect drying of aqueous inks

explain the operating range of UV lamps

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

explain why in flexographic printing, the colour strength increases as the press speed increases

identify possible causes of a decrease in web tension

describe the result of increasing rewind tension after the roll has been partially rewound

explain the major cause of a telescopic roll

list print characteristics related to excessive printing pressure

outline causes of picking when printing multicoloured work

explain print faults from using an over-reduced ink

discuss problems that can cause lateral streaks showing up in uneven printing

describe causes of moire patterns when printing by the flexographic process

explain what happens when air is trapped under mounted plates

describe which instrument is 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 the result if an excessive final drying temperature was used when printing polypropylene film

explain what ink property can be adjusted to reduce dot gain

discuss the effect of using the ink returning from the ink fountain when checking viscosity for ink while using ink pumps

list problems that result from excessive use of slow solvents

explain the effect of the ‘yield value’ of ink on the ink transfer of halftone dots

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

explain the result of excessive print area tension

identify some of the problems associated with cold seals

identify the location of machine manuals, safety and other documentation that are relevant to this task, where they are kept, and describe the information included in them.

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 a 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 
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 
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 
Print is checked for register 
Drying is checked as sufficient to key ink to the substrate 
Viscosities are adjusted to obtain the correct colour at proof speed 
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 
Corrective or preventive action is recommended and implemented where appropriate 
Changes are communicated to relevant personnel in a logical and easily understood manner 
Changes are monitored to confirm improvement to production efficiency 

Forms

Assessment Cover Sheet

ICPPRN513 - Set up for specialised 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

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Assessment Record Sheet

ICPPRN513 - Set up for specialised 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

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