Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

ICPPR551C Mapping and Delivery Guide
Set up for specialised relief printing

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency ICPPR551C - Set up for specialised relief printing
Description This unit describes the performance outcomes, skills and knowledge required to set up for specialised relief printing that requires a certain amount of problem solving and experimentation with the substrate and press settings.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit requires the individual to set up reel- or sheet-fed plate, cylinder or rotary printing machines for specialised print jobs. The individual will conduct a proof run and adjust settings to ensure production speeds are attained.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field Printing
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities
Slides
PPT
Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Confirm specialised job specifications
  • Job requirements are read and interpreted from job documentation or production control system
  • Availability of all job related components is checked
       
Element: Plan and carry out specialised set up
  • Specialised job specifications are identified and analysed
  • Specialised set up requirements are determined
  • Specialised set up is completed in minimum time with minimum wastage
       
Element: Set up reel system (OR Element 3)
  • Unwind and rewind reels are set up, evaluated and adjusted according to job specifications
  • Webbing procedures are carried out and 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 sheeters 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
       
Element: Set up sheet system (OR Element 2)
  • Feeder and delivery sections are set up, evaluated and adjusted according to job specifications
  • Sheet pick-up and transportation system is set up, evaluated and adjusted according to job specifications
  • Transfer and control systems are set up, evaluated and adjusted according to job specifications
  • Substrate is added to and removed from process according to job specifications
  • Set off/marking prevention devices are set up, evaluated and adjusted according to job specifications
       
Element: Evaluate, select and prepare inks and additives
  • Inks, dyes or additives are evaluated according to end-user requirements and job specifications
  • Inks, dyes and additives are selected according to end-user requirements and job specifications
  • Inks, dyes and additives are prepared according to OHS 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 the requirements of the printing process and job specifications
  • Formulation of the ink, colour match and the 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 prolong shelf life
       
Element: Set up machine for specialised relief printing
  • Appropriate relief plates are selected and secured to the machine
  • Relief polymer plates/forme are set up and adjusted according to job specifications (platen)
  • Relief polymer cylinders are set up and adjusted according to job specifications (platen)
  • Impression is set up and adjusted according to job specifications (platen and rotary)
  • Inking system is set up and adjusted according to the requirements of the relief process and job specifications (platen and rotary)
  • Drying system is set up and adjusted according to job specifications
       
Element: Conduct specialised proof run
  • Material to be used for specialised proof is organised correctly
  • Machine is operated according to manufacturer's specifications and enterprise procedures to produce a specialised proof
  • Specialised 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 adjustment changes are carried out according to product and machine specifications
       
Element: Troubleshoot machinery and material problems
  • 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
  • Ongoing problems are reported according to enterprise procedures
       


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.

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 reel- or sheet-fed platen, cylinder or rotary printing machines for specialised 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 relief printing machine for specialised printing 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, 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

reel- or sheet-fed platen, cylinder or rotary printing machine.

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 on-the-job 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:

ICPPR352C Produce complex relief printed product

ICPPR451C Set up for complex relief printing.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, 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.

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 providing advice to clients 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 job

planning and organising activities by evaluating the special job specifications when determining production scheduling

teamwork when maintaining the production process in association with others

mathematical ideas and techniques by calculating substrate requirements, plate position and pressures

problem-solving skills by recognising proofing faults and determining adjustments to meet job specifications

use of technology by using monitoring equipment and making adjustments

Required knowledge

need to ensure that the job specifications are read and properly understood

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

responsible person todiscuss any production problems

importance of the hardness of the printing plate

faults that may be detected on new plates

type of solvents that should be used on photopolymer plates

meaning of the term V-block mounting

V-block mounting

the purpose of binding plates after mounting

checks that are performed prior to cylinder installation

importance of keeping machine frames and unit slides cleaned

OHS precaution that must be observed when installing printing cylinders in the machine

optimum print sequence

visual aid on the plate that identifies the colour of ink to be used

precautions that were taken to ensure that the plate/cylinders were not damaged during installation

OHS precaution that must be observed when webbing up the machine

determining the position of the reel

effect if the brake tension is not set correctly

function of the "Dancer" roller on a web machine

function of nip rollers

effect if the web is not spiced correctly

major OHS concerns when setting up the sheet transportation system

cause of more than one sheet to pick up in the feeder

essential accurate feeder set up

position of the sheet prior to being transferred to the printing unit

determining which front lays to use

type of substrate that would require additional front lays to be engaged

need for additional front lays when printing this type of substrate

OHS precaution that must be observed when setting up the delivery

control of the in the rewind unit

function of a slitter on a web machine

problems that could be attributed to a blunt knife when sheeting

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

OHS precaution that must be observed when removing sheets from the delivery

cause of sheets to be delivered incorrectly

adjustments that would be necessary if changing from lightweight to heavyweight stocks

sheet release into the delivery

problems resulting from the excessive use of anti set off spray powder

cause of printed sheets to set off in the delivery

reducing the possibility of set off in the delivery

air blast assistance to sheet delivery

OHS precautions that must be observed when preparing inks and additives

details that are necessary to check an ink's suitability for the printing process

special end-use requirements that may be necessary

additives and their use in inks

use of a spectrophotometer to assess the colour of an ink

formula for calculating the correct quantity of lithographic ink

print fault that will occur if excessive driers are mixed into the ink

precautions that you observe to minimise waste when preparing the ink

shelf life of most inks

conditions that are relevant to the storage of inks and additives

conventions that should be adhered to when labelling mixed inks

major OHS concerns when setting up the machine

level of packing required in the tympan

amount of printing pressure required

ideal condition of the tympan

achieving the correct top sheet tension when fitting a new tympan

print faults that can occur if the tympan is not tensioned correctly

order eccentric or concentric roller adjustments should be made

width of the contact stripe between two rollers when setting the rollers

ink duct setting

ideal ink duct sweep setting

recommended degrees shore hardness for forme rollers

main reason for blistering on a heatset machine

types of ink drying/curing systems

curing the ink using the drying unit

operation of the true inch function fitted to some machines

problems that may cause the machine to keep stopping

checks that are necessary prior to engaging the impression

checks that are performed when running the machine

the effect the position of certain guards has on the operation of the machine

communicating the steps involved in operating the machine to other team members

aids that are available for the testing of the machine proof

tests that are necessary for this job

testing location

function of a polarisation filter in a densitometer

ideal conditions for inspecting the proof

need to use visual aids on the printed sheets

cause of a halo effect on the image

methods that are available to check and adjust ink colour and consistency

adjustments that may have caused mis-register

adjustments that are made to position the image laterally

adjustments that are made to position the image circumferentially

effect of changing the colour sequence on the final colour cast

procedure to lengthen the print length on this type of press

procedure to shorten the print length on this type of press

difference between mechanical and optical dot gain

cause of excessive mechanical dot gain

responsibility for the final say in the "OK" of the job

in-line processes that can be used in specialised pad printing

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

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.

Specialised may include:

specialised within this context relates to the set up and production of print runs that involve new products, or a new mix of substrates and inks that requires a certain amount of problem solving and experimentation with the substrate and press settings. The set up of equipment and production involves the development of new set up and production approaches based on solving technical problems arising from new product or equipment combinations.

Substrate handling may include:

wide and narrow reel, and large and small sheet handling systems.

Inks/coatings may include:

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

Colour matching systems may include:

use of densitometers and spectrophotometry.

Machines may include:

range of platen, cylinder and rotary machines with manual, semi-automated, fully automated or computerised process control.

Design may include:

3 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.

Substrate types may include:

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

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 
Availability of all job related components is checked 
Specialised job specifications are identified and analysed 
Specialised set up requirements are determined 
Specialised set up is completed in minimum time with minimum wastage 
Unwind and rewind reels are set up, evaluated and adjusted according to job specifications 
Webbing procedures are carried out and 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 sheeters 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 
Feeder and delivery sections are set up, evaluated and adjusted according to job specifications 
Sheet pick-up and transportation system is set up, evaluated and adjusted according to job specifications 
Transfer and control systems are set up, evaluated and adjusted according to job specifications 
Substrate is added to and removed from process 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 according to end-user requirements and job specifications 
Inks, dyes and additives are selected according to end-user requirements and job specifications 
Inks, dyes and additives are prepared according to OHS 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 the requirements of the printing process and job specifications 
Formulation of the ink, colour match and the 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 prolong shelf life 
Appropriate relief plates are selected and secured to the machine 
Relief polymer plates/forme are set up and adjusted according to job specifications (platen) 
Relief polymer cylinders are set up and adjusted according to job specifications (platen) 
Impression is set up and adjusted according to job specifications (platen and rotary) 
Inking system is set up and adjusted according to the requirements of the relief process and job specifications (platen and rotary) 
Drying system is set up and adjusted according to job specifications 
Material to be used for specialised proof is organised correctly 
Machine is operated according to manufacturer's specifications and enterprise procedures to produce a specialised proof 
Specialised 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 adjustment changes are 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 to production efficiency 
Ongoing problems are reported according to enterprise procedures 

Forms

Assessment Cover Sheet

ICPPR551C - Set up for specialised relief 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

ICPPR551C - Set up for specialised relief 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: