ICPPR313C
Set up for basic flexographic printing

This unit describes the performance outcomes, skills and knowledge required to set up machines for routine flexographic printing.

Application

This unit requires the individual to set up flexographic printing machines. The individual will conduct a proof run and adjust settings to ensure production speeds are attained.

Mounting and proofing plates is covered in ICPPR211C Mount and proof flexographic plates for basic printing.


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

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 is checked

1.4. Proofed job is checked for conformance with job specifications

2. Set up routine reel system (OR Element 3)

2.1. Reels are checked for treatment levels, coatings, printing side and age of product

2.2. Unwind reels are secured on reel shaft according to job specifications

2.3. Reels are correctly positioned on unwind stand according to job specifications

2.4. Correctly cut cores are positioned and mounted securely on rewind shafts

2.5. Press is webbed for single-sided surface print according to job specifications

2.6. Edge guide is centred and set according to job specifications

2.7. Unwind tension is set to suit substrate according to job specifications

2.8. Rewind tension is set to suit substrate according to job specifications

2.9. Nip rollers are set according to job specifications

2.10. PIV (Positively Infinitely Variable) drive is set for appropriate tensioning of substrate

3. Set up routine sheet system (OR Element 2)

3.1. Feeder is set up and adjusted according to job specifications

3.2. Sheet pick-up and transportation system is set up and adjusted according to job specifications

3.3. Transfer systems are set up and adjusted according to job specifications

3.4. Delivery is set up and adjusted according to job specifications

3.5. Substrate is removed from stacker according to job specifications

3.6. Sheet transfer and control system is set up and adjusted according to job specifications

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

4. Select and prepare inks and solvents

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

4.2. Quality and suitability of inks and solvents are checked and appropriate action is taken

4.3. Inks and solvents are prepared according to OHS 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 viscosities checked and modified according to press requirements and routine job specifications

4.5. Ink formula and approved colour draw downs appropriately recorded

4.6. Inks and solvents are appropriately labelled, handled and stored according to manufacturer's/supplier's instructions and the relevant hazardous liquids storage regulations

5. Set up machine for basic flexographic printing

5.1. Flexographic plate cylinders are installed and register adjustments centred OR

5.2. Sleeves are installed in press and register adjustments made OR

5.3. Plate mounting sheets are mounted on cylinders in press and register adjustments made

5.4. Plate cylinders are gauged up or pre-set to impression

5.5. Inking system is set up and roller nips/blades are set correctly

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

5.7. Viscosities are adjusted according to job specifications

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

5.9. Air volume is adjusted between colours to maximise drying and minimise air overspill

6. Set up in-line units for basic process(es)

6.1. Minor in-line printing/converting/binding units are set up for basic process(es) and adjusted to suit machine requirements and job specifications

6.2. Assistance is given in the set up of major in-line printing/converting/binding units. (Note: if entire set up is done refer to appropriate Set up competency standards.)

7. Conduct proof run

7.1. Material to be used for proof is organised correctly

7.2. Press is set up and operated according to OHS guidelines

7.3. Print impressions are set to minimum kiss impression

7.4. Web tensions are correctly set at unwind, between stations and rewind

7.5. The print is checked for register

7.6. Drying is checked as sufficient to key ink to the substrate

7.7. The viscosities are adjusted to obtain the correct colour at proof speed and checked against colour matching system

7.8. The substrate is checked against job specifications

8. Organise proof inspection and/or testing

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

8.2. Production does not commence without client approval or authority where appropriate

9. Readjust settings to production speed

9.1. Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings

9.2. Adjustments are made according to product specifications and press performance

9.3. Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals

9.4. Press setting is documented and samples are retained

Required Skills

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 job tickets and requirements

collecting, analysing and organising information by collecting and assessing data about printing process and machine specifications and characteristics and how these interact

planning and organising activities by providing input into production scheduling about time requirements for set up to ensure efficient operation

teamwork when working with other workers to coordinate set up to ensure efficient operation

mathematical ideas and techniques by calculating substrate requirements

problem-solving skills by recognising proofing faults and determining adjustments to correct them

use of technology by using monitoring equipment and interpreting readouts

Required knowledge

action if vital information was missing from the job ticket

checks that are undertaken prior to set up (availability of materials etc.)

flexographic printing plates and cylinders or sleeves or plate mounting sheets

precautions that should be taken to avoid damaging plates and cylinders

OHS factors that need to be considered when operating the reel in-feed and delivery system

choosing the printing side of the material

effect of low web tension on the print

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

sheet in-feed

OHS factors that need to be considered when operating the sheet in-feed and delivery system

sheet is normally set up in the middle of the machine

effect that side lay selection has on the job

appropriate front lays to be selected

determining the position of the sheet before it is transported to the printing unit

registering check be carried out

two-sheet cut is used on most feeders

sheet is missing or late

reel delivery system

effect of excessive web tension at the rewind of the machine

minimising risks associated with the rewind of the machine

sheet delivery system

application of spray powder is sometimes advisable

effects of too much spray powder

slowdown devices may be used in the delivery

effect excessive jogging would have on the stack

selection and preparation of inks and additives

major environmental and OHS concerns with regard to inks and additives

suitability of ink matched to the particular job

implications if the ink were too viscose

modifying ink that was slightly light

methods that are available to check the ink for correct colour

who passes the colour prior to running the job

machine set up

OHS factors that need to be considered when setting up the machine

how machine specifications are determined, relating to the specific job

steps that should be taken to ensure that the inking system is adjusted correctly

why inking system ink level is maintained at a certain level

precautions that are necessary when handling doctor/chamber blades

optimum make ready speed for the job

basic in-line processes

steps that are taken to incorporate the in-line processes into the make ready

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

precautions that should be taken if UV drying is utilised to dry the ink film

proofing and adjustment

methods that can be used to minimise waste during make ready

procedures that are followed to have the print approved

quality control measurements that should be applied to the proof to test against known standards

checking the initial print prior to running

determining settings to be adjusted

processes to be used to plot the success of the machine adjustment

final results recorded for future reference

relevant test procedures

identifying and describing the tests for scuffing and coefficient of friction

circumstances in which these tests should be applied

leaching

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

Evidence Required

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 flexographic printing machines for routine 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

demonstrate all safety devices on the machine

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, 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.

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:

ICPSU201C Prepare, load and unload reels and cores on and off machine

ICPSU202C Prepare, load and unload product on and off machine

ICPSU207C Prepare machine for operation (basic)

ICPSU211C Prepare ink and additives

ICPPR211C Mount and proof flexographic plates for basic printing

ICPPR214C Produce basic flexographic printed product.


Range Statement

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.

Substrate handling may include:

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

Substrate types may include:

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

Inks/coatings may include:

range of standard inks commonly used in colour printing.

Routine may include:

routine within this context relates to the set up and production of print runs. The set up of equipment and production are straightforward and do not involve a significant amount of deviation from using standard equipment settings. In this sense, routine does not refer to a job that an individual might repeat on a regular basis.

Machines may include:

a range of stack, in-line and central impression flexographic printing machines with manual, semi-automated, fully automated or computerised process control.

In-line processes may include:

minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, date coding, slitting that do not in themselves constitute another defined unit of competency. Where a major in-line process is defined as a separate competency (eg flat-bed cutting, folding) it should be assessed as such.

Colour matching systems may include:

use of visual colour assessment and densitometry to match basic standard colours under controlled lighting conditions.

Design may include:

colours, simple graphics and text. Minor variation in registration and position.


Sectors

Unit sector


Competency Field

Printing


Employability Skills

This unit contains employability skills.


Licensing Information

Not applicable.