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.
Elements and Performance Criteria
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 Performance
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.
Evidence of Knowledge
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
Assessment Conditions
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.
Foundation Skills
This section describes language, literacy, numeracy and employment skills incorporated in the performance criteria that are required for competent performance.
Skill | Performance Criteria | Description |
Reading | 1.1, 2.1, 4.1-4.4, 4.6, 5.2-5.6, 6.2, 6.5 | Recognises and interprets text to establish job requirements from information contained within relevant instructions, procedures and specifications |
Writing | 4.5, 4.6, 6.4, 7.2, 7.4 | Completes workplace records and labels accurately and according to requirements Considers context and audience when composing texts |
Oral Communication | 6.4, 7.2, 7.4 | Participates effectively in spoken interactions using appropriate vocabulary, questioning and listening techniques to gain approvals, report problems or provide information |
Numeracy | 2.3, 4.4 | Interprets and analyses a range of mathematical information used in familiar and routine tasks |
Navigate the world of work | 4.3, 4.5, 4.6, 6.2-6.4, 7.4 | Complies with legislative requirements and follows organisational policies and procedures relevant to own role Recognises boundaries of own role and responsibilities |
Interact with others | 6.4, 7.2, 7.4 | Complies with legislative requirements and follows organisational policies and procedures relevant to own role Recognises boundaries of own role and responsibilities |
Get the work done | 1.2, 2.2, 2.3, 4.3, 4.4, 4.6, 5.1-5.6, 6.1-6.5, 7.1-7.4 | Plans, evaluates, identifies and assembles resources required to complete tasks Determines priorities and sequences steps involved in complex tasks Monitors results to determine whether requirements are met and to identify opportunities for improvement Takes responsibility for addressing predictable and unpredictable problems in familiar work contexts Uses familiar digital systems and tools to access, organise, analyse and display information relevant to role Reads data from electronic monitoring and control systems |
Range Statement
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 |
Sectors
Printing