Google Links

Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

  1. Confirm non-routine job specifications
  2. Set up reel transportation and delivery system on web-fed machine
  3. Select and prepare inks and solvents
  4. Set up machine for complex flexographic printing
  5. Set up in-line units for basic process(es)
  6. Conduct proof run
  7. Organise proof inspection and/or testing
  8. Readjust settings to production speed

Required Skills

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication of ideas and information by interpreting the job brief and advising the client internal or external about options and limitations

collecting analysing and organising information by collecting and analysing data about printing process machine specifications and performance to calculate appropriate adjustments for the job

planning and organising activities by providing information about time and materials requirements for production scheduling

teamwork when cooperating with other workers and coordinating the production unit to ensure efficient operation

mathematical ideas and techniques by calculating substrate requirements and pressures

problemsolving skills by recognising proofing faults and calculating adjustments necessary to meet job specifications

use of technology by using monitoring equipment and computerised production records

Required knowledge

interpreting complex job specifications

production problems that could eventuate by not reading and understanding the job specifications

mounting and proofing flexographic plates

OHS factors needing to be considered when mounting and proofing flexographic plates

most common cause of photopolymer plates crazing on the image side

resiliency of the printing plate

main advantage of using thin photopolymer plates in process printing

faults that may be detected on new plates

types of solvents that should be used on photopolymer plates

benefits of optical mounting

purpose of binding plates after mounting

possible print faults that could be eliminated by using cushion mount

installation of printing cylinders or sleeves

OHS factors that need to be considered when installing printing cylinders or sleeves

precautions that should be undertaken to ensure that the plates and cylinders or sleeves are not damaged during installation

checking to ensure plates and cylinders or sleeves have been installed correctly

reel transportation system

OHS precautions to be observed when webbing up the machine

position of the reel

how the substrate pulled into the machine

result of insufficient unwind tension

result of excessive unwind tens

function of the Dancer roller on a web machine

function of the PIV unit

adjustments to the PIV

function of the layon roller

what will be the effect of excessive layon roller pressure

what can happen if the web is not spliced correctly

how does the particular web viewing device work

delivery system

OHS precautions that must be observed when setting up the delivery

how web controlled in the rewind unit

result of incorrect rewind tension

remedial steps that can be taken if there is a possibility of the ink marking in the rewind

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

preparing inks and additives

OHS precautions that must be observed when preparing inks and additives

necessary checks to test an inks suitability for the printing process

special enduse requirements that may be necessary

main functions of a pigmented extender used in flexographic printing

purpose of plasticisers added to flexographic inks

additives used in flexographic inks

range in seconds for zahn cup measurements

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

recommended pH range when printing with aqueous inks

precautions to observe to minimise waste when preparing the ink

shelf life of most inks

conditions are that relevant to the storage of inks and additives

conventions that should be adhered to when labelling mixed ink

complex machine set up

OHS factors that need to be considered when setting up the machine

advantage of centring all machine controls

checks that should be made on cylinders and gears

checks that should be performed prior to cylinder or sleeve installation

angle that should the chamber blades be set at

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

cell count of the anilox roller is used when printing solids

water treatment additives used in a central impression drum and chill roller coolant system

advantages of laser engraved ceramic anilox rollers

things relating to the anilox roller that a roller scope will measure

reasons for anilox wear

type of job would be printed using a hexagonal cell configuration

recommended web temperature when printing polypropylene film

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

factors affecting the drying rate of liquid inks

factors affecting the drying of aqueous inks

operating range of UV lamps

inline processes

OHS precaution to be observed when slitting on the machine

how is a cold seal formed

reasons for a printed product to be punched

setting hole punching in relation to repeat length

result of excessive pressure on the slitters

problem solving proofing and adjustment

why is it necessary to graduate the drying speeds of each progressive colour so that firstdown colours dry faster the subsequent colours

why is it that in flexographic printing as the press speed increases so does the colour strength

decrease in web tension

increasing rewind tension after the roll has been partially rewound

major cause of a telescopic roll

print characteristics related to excessive printing pressure

causes of picking when printing multicoloured work

print faults from using an overreduced ink

problems that can cause lateral streaks showing up in uneven printing

causes of moire patterns when printing by the flexographic process

result of air being trapped under mounted plates

instrument used to identify retained solvent trapped in the print

purpose of taking Dyne readings

purpose of the crinkle test when testing an ink

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

property of ink that can be adjusted to reduce dot gain

when checking the viscosity for ink whilst using ink pumps why should the ink returning from the ink fountain not be used

problems resulting from the excessive use of slow solvents

why do laminating inks once printed appear dull and easy to scratch

result of excessive print area tension

problems that the printer may associate with cold seals

machine manuals safety and other documentation are relevant to this task and where are they kept and information is included in these documents

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the ability to

set up flexographic printing machines for nonroutine print jobs The individual will 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

demonstrate an ability to find and use information relevant to the task from a variety of information sources

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 inline processes according to manufacturers and job specifications enterprise procedures and the Performance Criteria

evidence for assessment may be gathered from assessment of the unit of competency alone or through an integrated assessment activity

Context of and specific resources for assessment

Assessment must ensure

assessment may take place on the job off the job or a combination of these Off the job assessment must be undertaken in a closely simulated workplace environment

a wide or narrow flexographic press

Method of assessment

A range of assessment methods should be used to assess practical skills and knowledge The following examples are appropriate for this unit

direct questioning combined with review of portfolios of evidence and third party workplace reports of onthejob performance by the candidate

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector workplace and job role is recommended for example

ICPPRC Produce complex flexographic printed product

ICPPR314C Produce complex flexographic printed product

ICPPRC Mount and demount flexographic plates for complex printing

ICPPR411C Mount and demount flexographic plates for complex printing.

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Non-routine may include:

non-routine within this context relates to the set up and production of print runs. The set up of equipment and production involves a significant amount of deviation from using standard equipment settings. It also involves significant problem solving and the development of new criteria and procedures for performing current practices. It does not refer to a job that an individual does only occasionally.

Substrate handling may include:

wide and narrow reel delivery systems.

Inks/coatings may include:

range of inks commonly used in 4 or more colour printing, including standard and special colours.

Machines may include:

range of stack, in-line and central impression flexographic printing machines with manual, semi-automated, fully automated or computerised process control.

Substrate types may include:

range of substrates within the major categories of paper, pressure sensitive material, board, corrugated board, plastics and related films, or metal.

In-line processes may include:

minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, date coding, slitting that do not in themselves constitute another defined unit of competency. Where a major in-line process is defined as a separate competency (eg flat-bed cutting, folding) it should be assessed as such.

Design may include:

4 or more colours, complex graphics and text. Critical "tight" registration, fit and position, registration should be at least that required for four-colour process work.