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

ICPPRN471 Mapping and Delivery Guide
Set up for complex coating

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency ICPPRN471 - Set up for complex coating
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to set up non-routine coating that includes set up of rollers and the reel or sheet systems for coating a range of carbon, carbonless, latex, wax, resin and metallic coatings, aqueous and UV varnishes and machine varnishes.It applies to individuals who use specialised knowledge and planning, organising and problem-solving skills to ensure production speeds are attained and quality standards are met.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 dedicated coating 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 job specifications
  • Job requirements are read and interpreted from job documentation or production control system
  • Set up is planned and carried out correctly and in minimum time
  • Availability of all job related components is checked
       
Element: Set up delivery systems
  • Delivery systems are set up and adjusted according to job specifications
  • Substrate is added to and removed from process according to job instructions
       
Element: Select and prepare coating
  • Coating is selected according to job specifications and end-user requirements
  • Quality and suitability of coating is checked and appropriate action taken
  • Coatings 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 weight/volume of coating is prepared to match requirements of the job specification and coating process
  • Coating viscosity is confirmed as correct for the job
  • Formulation of coating is appropriately recorded
       
Element: Set up machine for coating
  • Appropriate rollers/cylinders are selected and secured to the machine and set
  • Application system is set up and adjusted according to job specifications
  • Appropriate anilox roller is chosen, and installed to manufacturer’s specifications
  • Set doctor blades to manufacturer’s specifications
  • Coating delivery system is set up with correct flow and return flow determined by air pressure or pump speeds and adjusted according to job specifications
  • Coating blanket is cut or a plate installed for non-image areas
  • Blanket or plate packing is checked as suitable to the job
  • Coating temperature is checked and deemed suitable for the job
  • 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 set up and operated, and roller and pressure settings are checked, to produce a specified proof according to WHS requirements, manufacturer’s specifications and enterprise procedures
  • Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures
  • 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 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 and in minimum time

1.3 Availability of all job related components is checked

2. Set up delivery systems

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

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

3. Select and prepare coating

3.1 Coating is selected according to job specifications and end-user requirements

3.2 Quality and suitability of coating is checked and appropriate action taken

3.3 Coatings and additives 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 weight/volume of coating is prepared to match requirements of the job specification and coating process

3.5 Coating viscosity is confirmed as correct for the job

3.6 Formulation of coating is appropriately recorded

4. Set up machine for coating

4.1 Appropriate rollers/cylinders are selected and secured to the machine and set

4.2 Application system is set up and adjusted according to job specifications

4.3 Appropriate anilox roller is chosen, and installed to manufacturer’s specifications

4.4 Set doctor blades to manufacturer’s specifications

4.5 Coating delivery system is set up with correct flow and return flow determined by air pressure or pump speeds and adjusted according to job specifications

4.6 Coating blanket is cut or a plate installed for non-image areas

4.7 Blanket or plate packing is checked as suitable to the job

4.8 Coating temperature is checked and deemed suitable for the job

4.9 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 set up and operated, and roller and pressure settings are checked, to produce a specified proof according to WHS requirements, manufacturer’s specifications and enterprise procedures

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

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 for THREE complex coating operations (one spot coating, one overall coating and one fine detail, using three different coatings of which one must be metallic, and include at least one in-line process), including:

setting up rollers and reel or sheet systems for coating a range of carbon, carbonless, latex, wax, resin and metallic coatings, aqueous and UV varnishes and machine varnishes

conduct a proof run and adjusting 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:

describe key information on the work ticket listing type of coating required

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

list checks to do prior to set up (availability of materials etc.)

describe how to choose the coating side of material

describe the effect of offside lay selection on the job

explain how to carry out a register check

For reel systems only

describe the effect of:

low web tension on the print

inefficient web splices

explain how to:

determine reel position for the job

check for a web break

identify safety risks associated with rewind of the machine

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

For sheet systems only

explain how to:

determine sheet position for the job

select appropriate front lays

check a missing or late sheet

explain use of a two-sheet cut out on most feeders (sheet)

describe the effect of:

not enough coating on a sheet

excessive temperature on the sheet

describe the effect too much vacuum on the slow-down wheels has on the job

describe how to determine position of register or bustle wheels

describe the effect excessive jogging has on the stack

identify major WHS concerns when setting up the sheet or reel transportation system

identify WHS concerns relevant to the use of coatings

list types of coatings and their applications

explain suitability of the coating for the job

explain how the coat adheres to the product

identify the amount of coating required

describe the range of viscosities to run with on an aqueous coating

describe the effect of incorrect viscosity on coating

explain how to adjust viscosity of a coating

describe methods to solidify coating

explain drying UV coating

describe the printing principle being utilised to apply aqueous coating

explain why gluing tabs are not coated

identify the temperature the drier is set at to dry aqueous coating

explain when to use different image carriers (plate or blanket)

outline the effect skeleton wheels can have on the coating surface

describe how to measure the amount of gloss on the surface

outline organisational responsibility for the final approval on the job

describe the effect in the following scenarios:

UV coating on a wet print

viscosity is too high or too low

ink coverage is excessive, i.e. over 250%

identify key types of information in, and the location of, machine manuals, safety and other documentation relevant to this task.


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 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 and in minimum time

1.3 Availability of all job related components is checked

2. Set up delivery systems

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

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

3. Select and prepare coating

3.1 Coating is selected according to job specifications and end-user requirements

3.2 Quality and suitability of coating is checked and appropriate action taken

3.3 Coatings and additives 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 weight/volume of coating is prepared to match requirements of the job specification and coating process

3.5 Coating viscosity is confirmed as correct for the job

3.6 Formulation of coating is appropriately recorded

4. Set up machine for coating

4.1 Appropriate rollers/cylinders are selected and secured to the machine and set

4.2 Application system is set up and adjusted according to job specifications

4.3 Appropriate anilox roller is chosen, and installed to manufacturer’s specifications

4.4 Set doctor blades to manufacturer’s specifications

4.5 Coating delivery system is set up with correct flow and return flow determined by air pressure or pump speeds and adjusted according to job specifications

4.6 Coating blanket is cut or a plate installed for non-image areas

4.7 Blanket or plate packing is checked as suitable to the job

4.8 Coating temperature is checked and deemed suitable for the job

4.9 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 set up and operated, and roller and pressure settings are checked, to produce a specified proof according to WHS requirements, manufacturer’s specifications and enterprise procedures

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

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

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:

unwind

webbing procedures

splicing/joining reels

print web viewing devices

set off / marking prevention devices

OR

feeder and delivery

sheet pick-up and transportation system

transfer and control systems

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 planned and carried out correctly and in minimum time 
Availability of all job related components is checked 
Delivery systems are set up and adjusted according to job specifications 
Substrate is added to and removed from process according to job instructions 
Coating is selected according to job specifications and end-user requirements 
Quality and suitability of coating is checked and appropriate action taken 
Coatings 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 weight/volume of coating is prepared to match requirements of the job specification and coating process 
Coating viscosity is confirmed as correct for the job 
Formulation of coating is appropriately recorded 
Appropriate rollers/cylinders are selected and secured to the machine and set 
Application system is set up and adjusted according to job specifications 
Appropriate anilox roller is chosen, and installed to manufacturer’s specifications 
Set doctor blades to manufacturer’s specifications 
Coating delivery system is set up with correct flow and return flow determined by air pressure or pump speeds and adjusted according to job specifications 
Coating blanket is cut or a plate installed for non-image areas 
Blanket or plate packing is checked as suitable to the job 
Coating temperature is checked and deemed suitable for the job 
Drying system is set up and adjusted according to job specifications 
Material to be used for proof is organised correctly 
Machine is set up and operated, and roller and pressure settings are checked, to produce a specified proof according to WHS requirements, manufacturer’s specifications and enterprise procedures 
Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures 
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

ICPPRN471 - Set up for complex coating
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

ICPPRN471 - Set up for complex coating

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: