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

ICPPRN313 Mapping and Delivery Guide
Set up for basic flexographic printing

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPPRN313 - Set up for basic flexographic printing
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to set up machines for routine flexographic printing.It applies to individuals who work as print machinists and prepare material, and monitor and run equipment and machinery, and apply solutions to printing difficulties as they arise.No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

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

a range of standard inks and substrates

a variety of stack, in-line and central impression flexographic printing machines.

Assessors of this unit must satisfy the requirements for assessors in applicable vocational education and training legislation, frameworks and/or standards.
Prerequisites/co-requisites
Competency Field
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 routine job specifications
  • Job requirements are read and interpreted from job documentation or production control system
  • Set up is carried out correctly in minimum time with minimum wastage
  • Availability of all job-related components are checked
  • Proofed job is checked for conformance with job specifications
       
Element: Set up delivery systems
  • Delivery systems are correctly set up and adjusted according to job specifications
  • Substrate is added to and removed from process according to job specifications
       
Element: Select and prepare inks and solvents
  • Inks and solvents are selected according to routine job specifications and end-user requirements
  • Quality and suitability of inks and solvents are checked and appropriate action 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 routine job specifications
  • Ink formula and approved colour drawdowns 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
       
Element: Set up machine for basic flexographic printing
  • Flexographic plate cylinders are installed and register adjustments centred
       
Element: OR
  • Sleeves are installed in press and register adjustments made
       
Element: Set up in-line units for basic process(es)
  • Minor in-line printing/converting/binding units are set up for basic process(es) and adjusted to suit machine requirements and job specifications
  • Assistance is given in set-up of major in-line printing/converting/binding units.
       
Element: Conduct print run
  • Material to be used for print 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 correct colour at proof speed and checked against colour matching system
  • Substrate is checked against job specifications
       
Element: Organise print inspection and/or testing
  • Print is visually inspected and/or tested, or laboratory testing is organised according to enterprise procedures
  • Production does not commence without client OK where appropriate
       
Element: Readjust settings to production speed
  • 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 where applicable
  • Press setting is documented and samples are retained
       


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 routine job specifications

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

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

1.3 Availability of all job-related components are checked

1.4 Proofed job is checked for conformance with job specifications

2. Set up delivery systems

2.1 Delivery systems are correctly set up and adjusted according to job specifications

2.2 Substrate is added to and removed from process according to job specifications

3. Select and prepare inks and solvents

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

3.2 Quality and suitability of inks and solvents are checked and appropriate action 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 routine job specifications

3.5 Ink formula and approved colour drawdowns 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 basic 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 Inking system is set up and roller nips/blades are set correctly

4.6 Ink circulation is maintained at correct level and flow for machine requirements

4.7 Viscosities are adjusted according to job specifications

4.8 Air volume and drier temperatures or curing systems are selected to suit inks, substrate, solvents and according to job specifications

4.9 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 to suit machine requirements and job specifications

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

6. Conduct print run

6.1 Material to be used for print 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 Print is checked for register

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

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

6.8 Substrate is checked against job specifications

7. Organise print inspection and/or testing

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

7.2 Production does not commence without client OK 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 where applicable

8.4 Press setting is documented and samples are retained

Evidence of the ability to:

demonstrate all safety devices on the machine

demonstrate use of control, monitoring and data entry systems

set up a press on TWO occasions for basic flexographic printing (if possible including at least ONE in-line process), according to manufacturer’s specifications and enterprise procedures. The individual will also conduct a proof run and adjust settings to ensure production speeds are attained.

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:

Job requirements

describe what to do if vital information is missing from the job ticket

ensure all required materials are available prior to set up

Flexographic printing plates and cylinders or sleeves OR plate mounting sheets

identify precautions to avoid damaging plates and cylinders

For reel systems only

Reel in-feed

explain work health and safety (WHS) factors to consider when operating the reel in-feed and delivery system

explain how to correctly select printing side of the material

describe the effect of low web tension on the print

name types of web splices that could be used appropriately for the job

Reel delivery system

describe effect of excessive web tension at the rewind of the machine

discuss how to minimise three risks associated with the rewind

For sheet systems only

Sheet in-feed

explain WHS factors to consider when operating the sheet in-feed and delivery system

describe why the sheet is normally set up in the middle of the machine

describe effect side-lay selection has on the job

describe how appropriate front lays should be selected

describe what determines position of the sheet before it is transported to the printing unit

explain how a register check is carried out

discuss why a two-sheet cut is used on most feeders

discuss how the machine recognises if a sheet is missing or late

Sheet delivery system

describe why application of spray powder is sometimes advisable

discuss effects of too much spray powder

show how slowdown devices may be used in delivery

identify effect of excessive jogging on the stack

Selection and preparation of inks and additives

name major environmental and WHS concerns with regard to inks and additives

describe how ink suitability is matched to a particular job

describe implications if ink is too viscose

describe how an ink that is slightly light can be modified to meet the job needs

identify methods to check ink for correct colour

name the person who passes the colour prior to running the job

Machine set-up

discuss all WHS factors to consider when setting up the machine

show how machine specifications are determined, relating to a specific job

discuss steps to ensure the inking system is adjusted correctly

describe why inking system ink level is maintained at a certain level

list necessary precautions when handling doctor/chamber blades

identify optimum make-ready-speed for the job

explain basic in-line processes

list steps to incorporate the in-line processes into the make-ready

describe how equipment used in in-line processing is protected against damage during set-up

list precautions to take if uv drying is utilised to dry the ink film

Proofing and adjustment

identify methods to minimise waste during make-ready

list procedures required to have the print approved

describe quality control measurements to apply to the proof to test against known standards

outline how to check on initial print prior to running

describe how setting adjustments are determined

identify processes to plot success of the machine adjustment

describe how final results are recorded for future reference

Relevant test procedures

identify and describe tests for scuffing and coefficient of friction

show circumstances in which these tests should be applied

Leaching

discuss leaching

Information sources

identify machine manuals, safety and other documentation relevant to this task and where are they kept, and information contained.

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.

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

1. Confirm routine job specifications

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

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

1.3 Availability of all job-related components are checked

1.4 Proofed job is checked for conformance with job specifications

2. Set up delivery systems

2.1 Delivery systems are correctly set up and adjusted according to job specifications

2.2 Substrate is added to and removed from process according to job specifications

3. Select and prepare inks and solvents

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

3.2 Quality and suitability of inks and solvents are checked and appropriate action 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 routine job specifications

3.5 Ink formula and approved colour drawdowns 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 basic 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 Inking system is set up and roller nips/blades are set correctly

4.6 Ink circulation is maintained at correct level and flow for machine requirements

4.7 Viscosities are adjusted according to job specifications

4.8 Air volume and drier temperatures or curing systems are selected to suit inks, substrate, solvents and according to job specifications

4.9 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 to suit machine requirements and job specifications

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

6. Conduct print run

6.1 Material to be used for print 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 Print is checked for register

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

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

6.8 Substrate is checked against job specifications

7. Organise print inspection and/or testing

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

7.2 Production does not commence without client OK 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 where applicable

8.4 Press setting is documented and samples are retained

This section specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Delivery systems MUST include EITHER:

reel

OR

sheet

Setting up and adjusting MUST include EITHER:

checking reels for treatment levels, coatings, printing side and age of product

securing reels on reel shaft

correctly positioning reels on unwind stand

positioning and mounting correctly cut cores on rewind shafts

centring and setting edge guide

setting unwind and rewind tension to suit substrate

setting nip rollers

OR

feeder

sheet pick-up and transportation system

transfer system

delivery

sheet transfer and control system

set off / marking prevention devices

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 carried out correctly in minimum time with minimum wastage 
Availability of all job-related components are checked 
Proofed job is checked for conformance with job specifications 
Delivery systems are correctly set up and adjusted according to job specifications 
Substrate is added to and removed from process according to job specifications 
Inks and solvents are selected according to routine job specifications and end-user requirements 
Quality and suitability of inks and solvents are checked and appropriate action 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 routine job specifications 
Ink formula and approved colour drawdowns 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 to suit machine requirements and job specifications 
Assistance is given in set-up of major in-line printing/converting/binding units. 
Material to be used for print 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 correct colour at proof speed and checked against colour matching system 
Substrate is checked against job specifications 
Print is visually inspected and/or tested, or laboratory testing is organised according to enterprise procedures 
Production does not commence without client OK 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 where applicable 
Press setting is documented and samples are retained 

Forms

Assessment Cover Sheet

ICPPRN313 - Set up for basic 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:

Signature:

Date:

Assessment Record Sheet

ICPPRN313 - Set up for basic 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: