Assessor Resource

ICPPRN521
Set up for specialised gravure printing

Assessment tool

Version 1.0
Issue Date: April 2024


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

It applies to individuals who work outside standard job routines and who have the skills to experiment and make on-the-job adjustments to 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 specialised 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

2. Plan and carry out specialised set up

2.1 Specialised job specifications are identified and analysed

2.2 Special set up requirements are determined

2.3 Specialised set up is completed in minimum time with minimum wastage

3. Set up reels

3.1 Unwind and rewind reels are set up and adjusted according to job specifications

3.2 Webbing procedures are carried out according to job specifications

3.3 Web-control system is set up, evaluated and adjusted according to job specifications

3.4 Reels are spliced/joined according to job specifications

3.5 Printed web viewing devices are set up, evaluated and adjusted according to job specifications

3.6 Folder and sheeter are set up, evaluated and adjusted according to job specifications

3.7 Set off / marking prevention devices are set up, evaluated and adjusted according to job specifications

4. Select and prepare inks and additives

4.1 Inks, dyes or additives are evaluated with reference to specialised requirements

4.2 Inks, dyes or additives are selected according to job specifications

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

4.4 Correct colour and weight/volume of ink are mixed and prepared according to job specifications and the printing process

4.5 Formulation of ink, colour match and approved colour are appropriately recorded

4.6 Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life

5. Set up machine for specialised gravure printing

5.1 Gravure cylinders are selected, installed, set up and adjusted according to job specifications

5.2 Impression roller is set up and adjusted according to job specifications

5.3 Inking system/doctor blade is set up and adjusted according to the gravure process and job specifications

5.4 Drying system is set up and adjusted according to job specifications

6. Conduct specialised proof run

6.1 Material to be used for proof is organised correctly

6.2 Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specified proof

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

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

6.5 Results are interpreted and evaluated with adjustments carried out according to product and machine specifications

7. Troubleshoot machinery and material problems

7.1 Corrective or preventive action is recommended and implemented where appropriate

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

7.3 Changes are monitored to confirm improvement in production efficiency

7.4 Ongoing problems are reported according to enterprise procedures

Evidence of the ability to:

safely set up a gravure printing machine for a specialised job on TWO occasions using different substrates according to manufacturer’s specifications, enterprise procedures and the performance criteria

complete 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:

explain why it is important that job specifications are read and properly understood

discuss production problems that could eventuate if job specifications are not read and properly understood

identify who to discuss any production problems with

list work health and safety (WHS) precautions for installing printing cylinders on the machine

explain how to determine the optimum print sequence

identify the visual aid on the cylinder that shows the colour of ink to be used

list precautions to ensure cylinders are not damaged during installation

discuss WHS precautions for webbing up the machine

describe how to determine the position of the reel

explain what happens if brake tension is not set correctly

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

explain what happens if the web is not spliced correctly

describe how the particular web viewing device works

explain the principle of electrostatic assist (ESA) roller operation on the gravure printing machine

identify the type of substrate to use on the ESA roller

list WHS precautions for setting up delivery

explain how the web is controlled in the rewind unit

describe the outcome of incorrect rewind tension

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

list problems attributable to a blunt knife when sheeting

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

list WHS precautions for preparing inks and additives

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

explain why additives are used in gravure inks

discuss the range, in seconds, for zahn cup measurements

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

explain why pigmented ink is brought to operating temperature before correcting viscosity

list advantages of using automatic viscosity controllers

explain precautions to minimise waste when preparing ink

discuss shelf life of most inks

describe conditions relevant to storage of inks and additives

explain conventions for labelling mixed inks

list WHS factors for setting up the machine

describe the function of chill rollers on a machine

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

discuss the result of excess printing pressure

explain how to determine pressure to be applied to the doctor blade

outline possible print faults that caused by excessive overspill of air from the inter-colour drier

discuss the recommended air ratio for efficient inter-colour drying

list advantages of using high-velocity air in the drying system

explain the cause of doctor blade wear on a gravure printing unit

outline possible options for reducing doctor blade wear

describe how to determine optimum make ready speed for the job

explain how to communicate steps involved in make ready to other team members

discuss the need to grade drying speeds of each progressive colour, so that first-down colours dry faster than subsequent colours

explain the cause of a decrease in web tension

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

discuss the major cause of a telescopic roll

explain how to test metallised film to find out the correct side to print on

describe how to measure the metallised surface for coating thickness

explain the effect of annealing on aluminium foil

discuss the purpose of using thermal imaging face stocks

explain how substrates are metallised

list client requirements for bar codes

describe print characteristics related to excessive printing pressure

explain what causes picking when printing multi-coloured work

describe possible print faults that result from using an over-reduced ink

list causes of moire patterns when printing by the gravure process

describe the instrument to be 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

describe print faults that result from a worn doctor blade

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

outline problems that result from excessive use of slow solvents

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

describe the result of excessive print area tension

identify problems the printer may associate with cold seals

identify who has responsibility for the final say in the OK of the job

identify machine manuals, safety and other documentation relevant to this task, and where they are kept and discuss the information 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 gravure printing machine.

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 specialised 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

2. Plan and carry out specialised set up

2.1 Specialised job specifications are identified and analysed

2.2 Special set up requirements are determined

2.3 Specialised set up is completed in minimum time with minimum wastage

3. Set up reels

3.1 Unwind and rewind reels are set up and adjusted according to job specifications

3.2 Webbing procedures are carried out according to job specifications

3.3 Web-control system is set up, evaluated and adjusted according to job specifications

3.4 Reels are spliced/joined according to job specifications

3.5 Printed web viewing devices are set up, evaluated and adjusted according to job specifications

3.6 Folder and sheeter are set up, evaluated and adjusted according to job specifications

3.7 Set off / marking prevention devices are set up, evaluated and adjusted according to job specifications

4. Select and prepare inks and additives

4.1 Inks, dyes or additives are evaluated with reference to specialised requirements

4.2 Inks, dyes or additives are selected according to job specifications

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

4.4 Correct colour and weight/volume of ink are mixed and prepared according to job specifications and the printing process

4.5 Formulation of ink, colour match and approved colour are appropriately recorded

4.6 Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life

5. Set up machine for specialised gravure printing

5.1 Gravure cylinders are selected, installed, set up and adjusted according to job specifications

5.2 Impression roller is set up and adjusted according to job specifications

5.3 Inking system/doctor blade is set up and adjusted according to the gravure process and job specifications

5.4 Drying system is set up and adjusted according to job specifications

6. Conduct specialised proof run

6.1 Material to be used for proof is organised correctly

6.2 Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specified proof

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

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

6.5 Results are interpreted and evaluated with adjustments carried out according to product and machine specifications

7. Troubleshoot machinery and material problems

7.1 Corrective or preventive action is recommended and implemented where appropriate

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

7.3 Changes are monitored to confirm improvement in production efficiency

7.4 Ongoing problems are reported according to enterprise procedures

Evidence of the ability to:

safely set up a gravure printing machine for a specialised job on TWO occasions using different substrates according to manufacturer’s specifications, enterprise procedures and the performance criteria

complete 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:

explain why it is important that job specifications are read and properly understood

discuss production problems that could eventuate if job specifications are not read and properly understood

identify who to discuss any production problems with

list work health and safety (WHS) precautions for installing printing cylinders on the machine

explain how to determine the optimum print sequence

identify the visual aid on the cylinder that shows the colour of ink to be used

list precautions to ensure cylinders are not damaged during installation

discuss WHS precautions for webbing up the machine

describe how to determine the position of the reel

explain what happens if brake tension is not set correctly

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

explain what happens if the web is not spliced correctly

describe how the particular web viewing device works

explain the principle of electrostatic assist (ESA) roller operation on the gravure printing machine

identify the type of substrate to use on the ESA roller

list WHS precautions for setting up delivery

explain how the web is controlled in the rewind unit

describe the outcome of incorrect rewind tension

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

list problems attributable to a blunt knife when sheeting

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

list WHS precautions for preparing inks and additives

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

explain why additives are used in gravure inks

discuss the range, in seconds, for zahn cup measurements

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

explain why pigmented ink is brought to operating temperature before correcting viscosity

list advantages of using automatic viscosity controllers

explain precautions to minimise waste when preparing ink

discuss shelf life of most inks

describe conditions relevant to storage of inks and additives

explain conventions for labelling mixed inks

list WHS factors for setting up the machine

describe the function of chill rollers on a machine

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

discuss the result of excess printing pressure

explain how to determine pressure to be applied to the doctor blade

outline possible print faults that caused by excessive overspill of air from the inter-colour drier

discuss the recommended air ratio for efficient inter-colour drying

list advantages of using high-velocity air in the drying system

explain the cause of doctor blade wear on a gravure printing unit

outline possible options for reducing doctor blade wear

describe how to determine optimum make ready speed for the job

explain how to communicate steps involved in make ready to other team members

discuss the need to grade drying speeds of each progressive colour, so that first-down colours dry faster than subsequent colours

explain the cause of a decrease in web tension

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

discuss the major cause of a telescopic roll

explain how to test metallised film to find out the correct side to print on

describe how to measure the metallised surface for coating thickness

explain the effect of annealing on aluminium foil

discuss the purpose of using thermal imaging face stocks

explain how substrates are metallised

list client requirements for bar codes

describe print characteristics related to excessive printing pressure

explain what causes picking when printing multi-coloured work

describe possible print faults that result from using an over-reduced ink

list causes of moire patterns when printing by the gravure process

describe the instrument to be 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

describe print faults that result from a worn doctor blade

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

outline problems that result from excessive use of slow solvents

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

describe the result of excessive print area tension

identify problems the printer may associate with cold seals

identify who has responsibility for the final say in the OK of the job

identify machine manuals, safety and other documentation relevant to this task, and where they are kept and discuss the information 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 gravure printing machine.

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 
Specialised job specifications are identified and analysed 
Special set up requirements are determined 
Specialised set up is completed in minimum time with minimum wastage 
Unwind and rewind reels are set up and adjusted according to job specifications 
Webbing procedures are carried out according to job specifications 
Web-control system is set up, evaluated and adjusted according to job specifications 
Reels are spliced/joined according to job specifications 
Printed web viewing devices are set up, evaluated and adjusted according to job specifications 
Folder and sheeter are set up, evaluated and adjusted according to job specifications 
Set off / marking prevention devices are set up, evaluated and adjusted according to job specifications 
Inks, dyes or additives are evaluated with reference to specialised requirements 
Inks, dyes or additives are selected according to job specifications 
Inks, dyes and additives 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 prepared according to job specifications and the printing process 
Formulation of ink, colour match and approved colour are appropriately recorded 
Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life 
Gravure cylinders are selected, installed, set up and adjusted according to job specifications 
Impression roller is set up and adjusted according to job specifications 
Inking system/doctor blade is set up and adjusted according to the gravure process and job specifications 
Drying system is set up and adjusted according to job specifications 
Material to be used for proof is organised correctly 
Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specified proof 
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 
Results are interpreted and evaluated with adjustments carried out according to product and machine specifications 
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 in production efficiency 
Ongoing problems are reported according to enterprise procedures 

Forms

Assessment Cover Sheet

ICPPRN521 - Set up for specialised gravure 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:

Signature:

Date:

Assessment Record Sheet

ICPPRN521 - Set up for specialised gravure 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: