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

ICPPRN551 Mapping and Delivery Guide
Set up for specialised relief printing

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency ICPPRN551 - Set up for specialised relief printing
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to set up for specialised relief printing.It applies to individuals who can problem-solve and experiment with substrate and press settings when operating reel- or sheet-fed plate, cylinder or rotary printing machines for specialised print jobs.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 a reel- or sheet-fed platen, cylinder or rotary 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 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 delivery systems
  • Delivery systems are set up, evaluated and adjusted according to job specifications
  • Substrate is added to and removed from process 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 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 prepared according to 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 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 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 adjustments 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.

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

1. Confirm specialised job specifications

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

1.2 Availability of all job related components is checked

2. Plan and carry out specialised set-up

2.1 Specialised job specifications are identified and analysed

2.2 Specialised set-up requirements are determined

2.3 Specialised set-up is completed in minimum time with minimum wastage

3. Set up delivery systems

3.1 Delivery systems are set up, evaluated and adjusted according to job specifications

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

4. Evaluate, select and prepare inks and additives

4.1 Inks, dyes or additives are evaluated according to end-user requirements and job specifications

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

4.3 Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions with suitable precautions to minimise waste

4.4 Correct colour and weight/volume of ink are mixed and prepared according to requirements of the printing process and job specifications

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

4.6 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

5. Set up machine for specialised relief printing

5.1 Appropriate relief plates are selected and secured to the machine

5.2 Relief polymer plates/forme are set up and adjusted according to job specifications (platen)

5.3 Relief polymer cylinders are set up and adjusted according to job specifications (platen)

5.4 Impression is set up and adjusted according to job specifications (platen and rotary)

5.5 Inking system is set up and adjusted according to requirements of the relief process and job specifications (platen and rotary)

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

6. Conduct specialised proof run

6.1 Material to be used for specialised proof is organised correctly

6.2 Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specialised proof

6.3 Specialised proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

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

6.5 Results are interpreted and adjustments are carried out according to product and machine specifications

7. Troubleshoot machinery and material problems

7.1 Corrective or preventive action is recommended and implemented where appropriate

7.2 Changes are communicated to relevant personnel in a logical and easily understood manner

7.3 Changes are monitored to confirm improvement to production efficiency

7.4 Ongoing problems are reported according to enterprise procedures

Evidence of the ability to:

safely set up a relief printing machine for specialised printing on TWO occasions, using different substrates and including at least two in-line processes, according to manufacturer’s and job specifications, enterprise procedures and the performance criteria

set up reel- or sheet-fed platen, cylinder or rotary printing machines for specialised print jobs including conducting 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:

explain why it is important that job specifications are read and properly understood

discuss production problems that might occur if job specifications are not read and properly understood

name the person to discuss any production problems with

outline the importance of printing plate hardness

list faults that may be detected on new plates

identify type of solvents used on photopolymer plates

define V-block mounting

explain how V-block mounting is achieved

discuss the purpose of binding plates after mounting

list checks to perform prior to cylinder installation

explain precautions to ensure plate/cylinders are not damaged during installation

list WHS precautions for preparing inks and additives

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

describe any special end-use requirements that may be necessary

discuss additives and their use in inks

explain the use of a spectrophotometer to assess colour of an ink

outline the formula for calculating correct quantity of lithographic ink

describe the print fault likely if excessive driers are mixed into the ink

identify precautions to minimise waste when preparing the ink

explain shelf life of most inks

discuss conditions relevant to storage of inks and additives

describe conventions for labelling mixed inks

list major WHS concerns of setting up the machine

list the order eccentric or concentric roller adjustments should be made in

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

discuss how to determine the ink duct setting

explain the ideal ink duct sweep setting

outline recommended degrees shore hardness for forme rollers

name various types of ink drying/curing systems

explain the operation of the true inch function fitted to some machines

identify problems that may cause the machine to keep stopping

list necessary checks prior to engaging the impression

outline checks performed when running the machine

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

explain importance of communicating steps involved in operating the machine to other team members

identify aids available for testing the machine proof

explain what tests are necessary for an individual job

identify where testing should take place

describe the function of a polarisation filter in a densitometer

explain ideal conditions for inspecting the proof

explain the cause of a halo effect on the image

identify methods available to check and adjust ink colour and consistency

discuss adjustments that may cause mis-register

outline adjustments made to position the image laterally

outline adjustments made to position the image circumferentially

describe the effect of changing the colour sequence on the final colour cast

explain the difference between mechanical and optical dot gain

explain the cause of excessive mechanical dot gain

name who has responsibility for the final say in the OK of the job

discuss in-line processes used in specialised pad printing

identify machine manuals, safety and other documentation relevant to this task and where they are kept, and describe the information in them.

For reel systems only

describe how to determine position of the reel

discuss what happens if brake tension is not set correctly

explain the function of the ‘dancer’ roller on a web machine

outline the function of nip rollers

discuss what happens if the web is not spliced correctly

explain how the web is controlled in the rewind unit

outline the function of a slitter on a web machine

list problems attributable to a blunt knife when sheeting

list the main reason for blistering on a heatset machine

explain how the drying unit cures the ink

For sheet systems only

list the major work health and safety (WHS) concerns of setting up the sheet transportation system

explain the cause of more than one sheet being picked up in the feeder

explain why accurate feeder set up is essential

describe what determines position of the sheet prior to being transferred to the printing unit

outline how to determine which front lays to use

identify the type of substrate that requires additional front lays to be engaged

explain the need for additional front lays when printing this type of substrate

identify the most important WHS precaution to observe when setting up the delivery

List WHS precautions for removing sheets from the delivery

explain the cause of sheets being delivered incorrectly

outline necessary adjustments if changing from lightweight to heavyweight stocks

explain what determines sheet release into the delivery

identify problems from excessive use of anti-set off spray powder

explain what causes printed sheets to set off in the delivery

describe how to reduce the possibility of set off in the delivery

explain how air blast can assist sheet delivery

explain how much packing is required in the tympan

explain how the level of printing pressure is determined

explain the ideal condition of the tympan

discuss how to achieve the correct top sheet tension when fitting a new tympan

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

discuss the need to use visual aids on the printed sheets

explain the procedure to lengthen print length on this type of press

explain the procedure to shorten print length on this type of press

explain the importance of keeping machine frames and unit slides clean

list WHS precautions for installing printing cylinders in the machine

explain how to determine the optimum print sequence

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

list WHS precautions for webbing up the machine

discuss remedial steps to take if there is a possibility of the ink marking in the rewind sheet delivery system on a sheet-fed machine


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 specialised job specifications

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

1.2 Availability of all job related components is checked

2. Plan and carry out specialised set-up

2.1 Specialised job specifications are identified and analysed

2.2 Specialised set-up requirements are determined

2.3 Specialised set-up is completed in minimum time with minimum wastage

3. Set up delivery systems

3.1 Delivery systems are set up, evaluated and adjusted according to job specifications

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

4. Evaluate, select and prepare inks and additives

4.1 Inks, dyes or additives are evaluated according to end-user requirements and job specifications

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

4.3 Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions with suitable precautions to minimise waste

4.4 Correct colour and weight/volume of ink are mixed and prepared according to requirements of the printing process and job specifications

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

4.6 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

5. Set up machine for specialised relief printing

5.1 Appropriate relief plates are selected and secured to the machine

5.2 Relief polymer plates/forme are set up and adjusted according to job specifications (platen)

5.3 Relief polymer cylinders are set up and adjusted according to job specifications (platen)

5.4 Impression is set up and adjusted according to job specifications (platen and rotary)

5.5 Inking system is set up and adjusted according to requirements of the relief process and job specifications (platen and rotary)

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

6. Conduct specialised proof run

6.1 Material to be used for specialised proof is organised correctly

6.2 Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specialised proof

6.3 Specialised proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

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

6.5 Results are interpreted and adjustments are carried out according to product and machine specifications

7. Troubleshoot machinery and material problems

7.1 Corrective or preventive action is recommended and implemented where appropriate

7.2 Changes are communicated to relevant personnel in a logical and easily understood manner

7.3 Changes are monitored to confirm improvement to production efficiency

7.4 Ongoing problems are reported according to enterprise procedures

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, evaluating and adjusting MUST include EITHER:

unwind and rewind reels

webbing procedure and web control systems

splicing/joining reels

print web viewing devices

folders and sheeters

set off / marking prevention devices

OR

feeder and delivery sections

sheet pick-up and transportation system

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 
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 
Delivery systems are set up, evaluated and adjusted according to job specifications 
Substrate is added to and removed from process 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 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 prepared according to 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 
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 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 adjustments 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

ICPPRN551 - 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

ICPPRN551 - 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: