NTISthis.com

Evidence Guide: ICPPR413C - Set up for complex flexographic printing

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

ICPPR413C - Set up for complex flexographic printing

What evidence can you provide to prove your understanding of each of the following citeria?

Confirm non-routine job specifications

  1. Job requirements are read and interpreted from job documentation or production control system
  2. Set up is planned and carried out correctly in minimum time with minimum wastage
  3. Availability of all job related components is checked
  4. Proofed job is checked for conformance with job specifications
Job requirements are read and interpreted from job documentation or production control system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up is planned and carried out correctly in minimum time with minimum wastage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Availability of all job related components is checked

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Proofed job is checked for conformance with job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up reel transportation and delivery system on web-fed machine

  1. Reels are checked for treatment levels, coatings and printing side and age of product
  2. Unwind reels are secured on reel shaft
  3. Reels are correctly positioned on unwind stand
  4. Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications
  5. Edge guide is centred and set to non-routine job specifications
  6. Unwind tension is set to suit substrate
  7. Rewind tension is set to suit substrate
  8. PIV (Positively Infinitely Variable) drive is set for appropriate tensioning of substrate
Reels are checked for treatment levels, coatings and printing side and age of product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Unwind reels are secured on reel shaft

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Reels are correctly positioned on unwind stand

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Edge guide is centred and set to non-routine job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Unwind tension is set to suit substrate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rewind tension is set to suit substrate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rewind tension is set to suit substrate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select and prepare inks and solvents

  1. Inks and solvents are selected according to job specifications and end-user requirements
  2. Quality and suitability of inks and solvents are checked and appropriate action is taken
  3. Inks and solvents are prepared according to OHS requirements, and manufacturer's/supplier's instructions with suitable precautions to minimise waste
  4. Correct colour and weight/volume of ink are mixed and viscosities checked and modified according to the press requirements and non-routine job specifications
  5. Ink formula and approved colour draw downs are appropriately recorded
  6. Inks and solvents are appropriately labelled, handled and stored according to manufacturer's/supplier's instructions and the relevant hazardous liquids storage regulations
Inks and solvents are selected according to job specifications and end-user requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks and solvents are prepared according to OHS requirements, and manufacturer's/supplier's instructions with suitable precautions to minimise waste

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct colour and weight/volume of ink are mixed and viscosities checked and modified according to the press requirements and non-routine job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ink formula and approved colour draw downs are appropriately recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up machine for complex flexographic printing

  1. Flexographic plate cylinders are installed and register adjustments centred OR
  2. Sleeves are installed in press and register adjustments made OR
  3. Plate mounting sheets are mounted on cylinders in press and register adjustments made
  4. Plate cylinders are gauged up or pre-set to impression
  5. Anilox rollers are selected to suit individual colour and plate reproduction requirements for each unit
  6. Appropriate ink metering system is selected for each unit
  7. Inking system is set up and roller nips/blades are set correctly
  8. Ink circulation is maintained at correct level and flow for machine
  9. Viscosities are adjusted according to job specifications
  10. Air volume and drier temperatures curing units are selected to suit inks, substrate, solvents and according to job specifications
  11. Air volume is adjusted between colours to maximise drying and minimise air overspill
Flexographic plate cylinders are installed and register adjustments centred OR

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sleeves are installed in press and register adjustments made OR

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plate cylinders are gauged up or pre-set to impression

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Anilox rollers are selected to suit individual colour and plate reproduction requirements for each unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate ink metering system is selected for each unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ink circulation is maintained at correct level and flow for machine

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Viscosities are adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Air volume and drier temperatures curing units are selected to suit inks, substrate, solvents and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

  1. Minor in-line printing/converting/binding units are set up for basic process(es) and adjusted according to machine requirements and job specifications
  2. Assistance is given in set up of major in-line printing/converting/binding units
Minor in-line printing/converting/binding units are set up for basic process(es) and adjusted according to machine requirements and job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assistance is given in set up of major in-line printing/converting/binding units

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct proof run

  1. Material to be used for proof is organised correctly
  2. Press is set up and operated according to OHS guidelines
  3. Print impressions are set to minimum kiss impression
  4. Web tensions are correctly set at unwind, between stations and rewind
  5. Drying is checked as sufficient to key ink to the substrate
  6. The viscosities are adjusted to obtain the correct colour at proof speed and checked against colour matching system
  7. The substrate is checked against job specifications
Material to be used for proof is organised correctly

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Press is set up and operated according to OHS guidelines

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Print impressions are set to minimum kiss impression

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Drying is checked as sufficient to key ink to the substrate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The substrate is checked against job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Organise proof inspection and/or testing

  1. Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures
  2. Production does not commence without client approval or authority where appropriate
Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production does not commence without client approval or authority where appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Readjust settings to production speed

  1. Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings
  2. Adjustments are made according to product specifications and press performance
  3. Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals
  4. Press settings are documented and samples are retained
Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjustments are made according to product specifications and press performance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Press settings are documented and samples are retained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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 non-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

set up a flexographic 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 and job 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

a wide or narrow flexographic press.

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:

ICPPR314C Produce complex flexographic printed product

ICPPR411C Mount and demount flexographic plates for complex printing.

Required Skills and Knowledge

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 the job brief and advising the client (internal or external) about options and limitations

collecting, analysing and organising information by collecting and analysing data about printing process, machine specifications and performance to calculate appropriate adjustments for the job

planning and organising activities by providing information about time and materials requirements for production scheduling

teamwork when cooperating with other workers and coordinating the production unit to ensure efficient operation

mathematical ideas and techniques by calculating substrate requirements and pressures

problem-solving skills by recognising proofing faults and calculating adjustments necessary to meet job specifications

use of technology by using monitoring equipment and computerised production records

Required knowledge

interpreting complex job specifications

production problems that could eventuate by not reading and understanding the job specifications

mounting and proofing flexographic plates

OHS factors needing to be considered when mounting and proofing flexographic plates

most common cause of photopolymer plates crazing on the image side

resiliency of the printing plate

main advantage of using thin photopolymer plates in process printing

faults that may be detected on new plates

types of solvents that should be used on photopolymer plates

benefits of optical mounting

purpose of binding plates after mounting

possible print faults that could be eliminated by using cushion mount

installation of printing cylinders or sleeves

OHS factors that need to be considered when installing printing cylinders or sleeves

precautions that should be undertaken to ensure that the plates and cylinders or sleeves are not damaged during installation

checking to ensure plates and cylinders or sleeves have been installed correctly

reel transportation system

OHS precautions to be observed when webbing up the machine

position of the reel

how the substrate pulled into the machine

result of insufficient unwind tension

result of excessive unwind tens

function of the "Dancer" roller on a web machine

function of the PIV unit

adjustments to the PIV

function of the lay-on roller

what will be the effect of excessive lay-on roller pressure

what can happen if the web is not spliced correctly

how does the particular web viewing device work

delivery system

OHS precautions that must be observed when setting up the delivery

how web controlled in the rewind unit

result of incorrect rewind tension

remedial steps that can be taken if there is a possibility of the ink marking in the rewind

function the use of air blast plays in the delivery of sheets

preparing inks and additives

OHS precautions that must be observed when preparing inks and additives

necessary checks to test an ink's suitability for the printing process

special end-use requirements that may be necessary

main functions of a pigmented extender used in flexographic printing

purpose of plasticisers added to flexographic inks

additives used in flexographic inks

range in seconds for zahn cup measurements

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

recommended pH range when printing with aqueous inks

precautions to observe to minimise waste when preparing the ink

shelf life of most inks

conditions are that relevant to the storage of inks and additives

conventions that should be adhered to when labelling mixed ink

complex machine set up

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

advantage of centring all machine controls

checks that should be made on cylinders and gears

checks that should be performed prior to cylinder or sleeve installation

angle that should the chamber blades be set at

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

cell count of the anilox roller is used when printing solids

water treatment additives used in a central impression drum and chill roller coolant system

advantages of laser engraved ceramic anilox rollers

things relating to the anilox roller that a roller scope will measure

reasons for anilox wear

type of job would be printed using a hexagonal cell configuration

recommended web temperature when printing polypropylene film

method of drying used when printing on polythene by the flexographic process

factors affecting the drying rate of liquid inks

factors affecting the drying of aqueous inks

operating range of UV lamps

in-line processes

OHS precaution to be observed when slitting on the machine

how is a cold seal formed

reasons for a printed product to be punched

setting hole punching in relation to repeat length

result of excessive pressure on the slitters

problem solving proofing and adjustment

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

why is it that in flexographic printing as the press speed increases so does the colour strength

decrease in web tension

increasing rewind tension after the roll has been partially rewound

major cause of a telescopic roll

print characteristics related to excessive printing pressure

causes of picking when printing multicoloured work

print faults from using an over-reduced ink

problems that can cause lateral streaks showing up in uneven printing

causes of moire patterns when printing by the flexographic process

result of air being trapped under mounted plates

instrument used to identify retained solvent trapped in the print

purpose of taking Dyne readings

purpose of the crinkle test when testing an ink

result if an excessive final drying temperature was used when printing polypropylene film

property of ink that can be adjusted to reduce dot gain

when checking the viscosity for ink whilst using ink pumps, why should the ink returning from the ink fountain not be used

problems resulting from the excessive use of slow solvents

why do laminating inks once printed appear dull and easy to scratch

result of excessive print area tension

problems that the printer may associate with cold seals

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

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.

Non-routine may include:

non-routine within this context relates to the set up and production of print runs. The set up of equipment and production involves a significant amount of deviation from using standard equipment settings. It also involves significant problem solving and the development of new criteria and procedures for performing current practices. It does not refer to a job that an individual does only occasionally.

Substrate handling may include:

wide and narrow reel delivery systems.

Inks/coatings may include:

range of inks commonly used in 4 or more colour printing, including standard and special colours.

Machines may include:

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

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.

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.

Design may include:

4 or more colours, complex graphics and text. Critical "tight" registration, fit and position, registration should be at least that required for four-colour process work.