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

ICPPRN421 Mapping and Delivery Guide
Set up for complex gravure printing

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPPRN421 - Set up for complex gravure printing
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to set up non-routine gravure printing machines for non-routine print jobs. It includes the ability to conduct a proof run and adjust settings to ensure production speeds are attained.It applies to individuals working as print machinists in the printing and graphic arts industry. They prepare material, set up, monitor and operate equipment and machinery, apply solutions to a defined range of problems associated with the print medium and analyse and evaluate information from a variety of sources. They may also provide leadership and guidance to others with some limited responsibility for the output of others.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, including a gravure printing machine.

Assessors must satisfy NVR/AQTF assessor requirements.
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 non-routine job specifications
  • 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
       
Element: Set up reels
  • Unwind and rewind reels are set up and adjusted according to job specifications
  • Webbing procedures are carried out according to non-routine job specifications
  • Web-control system is set up and adjusted according to job specifications
  • Reels are spliced/joined according to job specifications
  • Printed web viewing devices are set up and adjusted according to job specifications
  • Folder and sheeter are set up and adjusted according to job specifications
  • Set off / marking prevention devices are set up and adjusted according to job specifications
       
Element: Select and prepare inks and additives
  • Inks, dyes or additives are selected according to job specifications and end-user requirements
  • Quality and suitability of inks, dyes or additives are checked and appropriate action is taken
  • Inks, dyes and additives are prepared according to 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 to match requirements of the printing process and job specifications
  • 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
       
Element: Set up machine for complex gravure printing
  • 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
       
Element: Conduct proof run
  • Material to be used for proof is organised correctly
  • Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof
  • Production does not commence without client approval or authority where appropriate
  • Results are interpreted and adjustments are carried out according to product and machine specifications to determine adjustment requirements
       


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

2. Set up reels

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

2.2 Webbing procedures are carried out according to non-routine job specifications

2.3 Web-control system is set up and adjusted according to job specifications

2.4 Reels are spliced/joined according to job specifications

2.5 Printed web viewing devices are set up and adjusted according to job specifications

2.6 Folder and sheeter are set up and adjusted according to job specifications

2.7 Set off / marking prevention devices are set up and adjusted according to job specifications

3. Select and prepare inks and additives

3.1 Inks, dyes or additives are selected according to job specifications and end-user requirements

3.2 Quality and suitability of inks, dyes or additives are checked and appropriate action is taken

3.3 Inks, dyes and additives are prepared according to 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 prepared to match requirements of the printing process and job specifications

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

3.6 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

4. Set up machine for complex gravure printing

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

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

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

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

5. Conduct proof run

5.1 Material to be used for proof is organised correctly

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

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

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

5.5 Results are interpreted and adjustments are carried out according to product and machine specifications to determine adjustment requirements

Evidence of the ability to:

set up a gravure printing machine for a complex job on TWO occasions (if possible using different substrates and, if possible, including at least two in-line processes) according to manufacturer’s specifications and enterprise procedures

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

demonstrate use of control, monitoring and data entry systems.

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 necessary to ensure job specifications are read and properly understood

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

identify who production problems should be discussed with

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

demonstrate knowledge to determine the optimum print sequence

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

outline precautions to ensure the cylinders are not damaged during installation

list WHS precautions for webbing up the machine

explain how to determine position of the reel

explain what can happen if brake tension is not set correctly

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

describe consequences if the web is not spliced correctly

demonstrate knowledge of how the particular web viewing device works

explain the principle of ESA roller operation on the gravure printing machine

name the type of substrate used on the ESA roller

list WHS precautions for setting up the delivery

explain how the web is controlled in the rewind unit

describe the result of incorrect rewind tension

outline remedial steps if there is a possibility of the ink marking in the rewind

describe problems that could be attributed to a blunt knife when sheeting

explain the function air blast plays in the delivery of sheets

list WHS precautions for preparing inks and additives

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

outline special end-use requirements that may be necessary

explain why additives are used in gravure inks

outline the range, in seconds, for zahn cup measurements

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

demonstrate knowledge of why pigmented ink should be brought to operating temperature before correcting viscosity

identify essential checks to be made

list advantages of using automatic viscosity controllers

outline precautions to minimise waste when preparing ink

describe how to determine shelf life of most inks

outline conditions relevant to storage of inks and additives

list conventions to adhere to when labelling mixed inks

identify advantages of using automatic viscosity controllers

describe precautions to minimise waste when preparing ink

describe how to determine shelf life of most inks

outline conditions relevant to storage of inks and additives

list conventions to adhere to when labelling mixed inks

list WHS factors for setting up the machine

describe the function of chill rollers on a machine

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

identify the consequence of excess printing pressure

explain how pressure applied to the doctor blade is determined

describe print faults that can be caused by excessive overspill of air from the inter-colour drier

identify the recommended air ratio for efficient inter-colour drying

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

list WHS precautions for slitting on the machine

identify the pre-heat web temperature required for lamination

outline reasons for a printed product to be punched

describe what should be considered when setting hole punching in relation to repeat length

explain the purpose of the dwell when cutting and creasing in-line

demonstrate knowledge of how to control the ratio of print to in-line speed

describe the consequence of excessive pressure on the slitters

outline what causes doctor blade wear on a gravure printing unit

explain how to reduce doctor blade wear

demonstrate how to determine optimum make ready speed for the job

explain how the steps involved in the make ready are communicated to other team members

describe why it is necessary to grade drying speeds of each progressive colour, so first-down colours dry faster the subsequent colours

list causes of a decrease in web tension

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

identify the major cause of a telescopic roll

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

describe how metallised surface is measured for coating thickness

outline the effect of annealing on aluminium foil

explain purpose of using thermal imaging face stocks

describe how substrates are metallised

identify client requirements for bar codes

describe print characteristics related to excessive printing pressure

explain what causes picking when printing multicoloured work

outline print faults that can result from using an over-reduced ink

describe causes of moire patterns when printing by the gravure process

name the instrument 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 resulting from a worn doctor blade

demonstrate knowledge of correct checks for ink viscosity while using ink pumps

identify problems that result from excessive use of slow solvents

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

outline the result of excessive print area tension

list some of the problems the printer may associate with cold seals

identify who has responsibility for the final say regarding job approval

locate machine manuals, safety and other documentation relevant to this task, and outline the information included in these documents.

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 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

2. Set up reels

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

2.2 Webbing procedures are carried out according to non-routine job specifications

2.3 Web-control system is set up and adjusted according to job specifications

2.4 Reels are spliced/joined according to job specifications

2.5 Printed web viewing devices are set up and adjusted according to job specifications

2.6 Folder and sheeter are set up and adjusted according to job specifications

2.7 Set off / marking prevention devices are set up and adjusted according to job specifications

3. Select and prepare inks and additives

3.1 Inks, dyes or additives are selected according to job specifications and end-user requirements

3.2 Quality and suitability of inks, dyes or additives are checked and appropriate action is taken

3.3 Inks, dyes and additives are prepared according to 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 prepared to match requirements of the printing process and job specifications

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

3.6 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

4. Set up machine for complex gravure printing

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

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

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

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

5. Conduct proof run

5.1 Material to be used for proof is organised correctly

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

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

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

5.5 Results are interpreted and adjustments are carried out according to product and machine specifications to determine adjustment 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 
Unwind and rewind reels are set up and adjusted according to job specifications 
Webbing procedures are carried out according to non-routine job specifications 
Web-control system is set up and adjusted according to job specifications 
Reels are spliced/joined according to job specifications 
Printed web viewing devices are set up and adjusted according to job specifications 
Folder and sheeter are set up and adjusted according to job specifications 
Set off / marking prevention devices are set up and adjusted according to job specifications 
Inks, dyes or additives are selected according to job specifications and end-user requirements 
Quality and suitability of inks, dyes or additives are checked and appropriate action is taken 
Inks, dyes and additives are prepared according to 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 to match requirements of the printing process and job specifications 
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 and enterprise procedures to produce a specified proof 
Production does not commence without client approval or authority where appropriate 
Results are interpreted and adjustments are carried out according to product and machine specifications to determine adjustment requirements 

Forms

Assessment Cover Sheet

ICPPRN421 - Set up for complex 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

ICPPRN421 - Set up for complex 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: