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Evidence Guide: ICPPR521C - Set up for specialised gravure 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

 

ICPPR521C - Set up for specialised gravure printing

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

Confirm specialised 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
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:

 

 

 

 

 

 

 

Plan and carry out specialised set up

  1. Specialised job specifications are identified and analysed
  2. Special set up requirements are determined
  3. Specialised set up is completed in minimum time with minimum wastage
Specialised job specifications are identified and analysed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Special set up requirements are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Specialised set up is completed in minimum time with minimum wastage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up reels

  1. Unwind and rewind reels are set up and adjusted according to job specifications
  2. Webbing procedures are carried out according to job specifications
  3. Web-control system is set up, evaluated and adjusted according to job specifications
  4. Reels are spliced/joined according to job specifications
  5. Printed web viewing devices are set up, evaluated and adjusted according to job specifications
  6. The folder and sheeter are set up, evaluated and adjusted according to job specifications
  7. Set off/marking prevention devices are set up, evaluated and adjusted according to job specifications
Unwind and rewind reels are set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Webbing procedures are carried out according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Web-control system is set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Reels are spliced/joined according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Printed web viewing devices are set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The folder and sheeter are set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set off/marking prevention devices are set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select and prepare inks and additives

  1. Inks, dyes or additives are evaluated with reference to specialised requirements
  2. Inks, dyes or additives are selected according to job specifications
  3. Inks, dyes and additives 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 prepared according to job specifications and the printing process
  5. Formulation of the ink, colour match and the approved colour are appropriately recorded
  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 prolong shelf life
Inks, dyes or additives are evaluated with reference to specialised requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes or additives are selected according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes and additives 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 prepared according to job specifications and the printing process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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 prolong shelf life

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up machine for specialised gravure printing

  1. Gravure cylinders are selected, installed, set up and adjusted according to job specifications
  2. Impression roller is set up and adjusted according to job specifications
  3. Inking system/doctor blade is set up and adjusted according to the gravure process and job specifications
  4. Drying system is set up and adjusted according to job specifications
Gravure cylinders are selected, installed, set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Impression roller is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inking system/doctor blade is set up and adjusted according to the gravure process and job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Drying system is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct specialised proof run

  1. Material to be used for proof is organised correctly
  2. Machine is operated according to manufacturer's specifications and enterprise procedures to produce a specified proof
  3. Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures
  4. Production does not commence without client approval or authority where appropriate
  5. Results are interpreted and evaluated with adjustments carried out according to product and machine specifications
Material to be used for proof is organised correctly

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Machine is operated according to manufacturer's specifications and enterprise procedures to produce a specified proof

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Troubleshoot machinery and material problems

  1. Corrective or preventive action is recommended and implemented where appropriate
  2. Changes are communicated to relevant personnel in a logical and easily understood manner
  3. Changes are monitored to confirm improvement to production efficiency
  4. Ongoing problems are reported according to enterprise procedures
Corrective or preventive action is recommended and implemented where appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Changes are monitored to confirm improvement to production efficiency

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ongoing problems are reported according to enterprise procedures

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 gravure printing machines for specialised 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 gravure printing machine for a specialised job on TWO occasions (if possible using different substrates) 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

gravure printing machine.

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:

ICPPR322C Produce complex gravure printed product

ICPPR421C Set up for complex gravure 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 providing advice to internal or external clients 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 maintaining the production process in association with others

mathematical ideas and techniques by calculating cylinder position, pressures and substrate requirements

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

need to ensure that the job specifications are read and properly understood

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

responsible person you would discuss any production problems

OHS precaution that must be observed when installing printing cylinders on the machine

optimum print sequence

visual aid on the cylinder that identifies the colour of ink to be used

precautions that are taken to ensure that the cylinders are not damaged during installation

OHS precautions that must be observed when webbing up the machine

determining the position of the reel

effect if the brake tension is not set correctly

function of the "Dancer" roller on a web machine

effect if the web is not spliced correctly

operation of the particular web viewing device

principle of ESA roller operation on the gravure printing machine

type of substrate that should be used on the ESA roller

OHS precautions that must be observed when setting up the delivery

control of the web 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

problems that could be attributed to a blunt knife when sheeting

use of air blast play in the delivery of sheets

OHS precautions that must be observed when preparing inks and additives

details that are necessary to check an ink's suitability for the printing process

special end-use requirements that may be necessary

additives and their use in gravure inks

range in seconds for zahn cup measurements

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

reason pigmented ink is brought to operating temperature before correcting the viscosity

reason for these essential checks

advantage of using automatic viscosity controllers

precautions that you observe to minimise waste when preparing the ink

shelf life of most inks

conditions that are relevant to the storage of inks and additives

conventions that should be adhered to when labelling mixed inks

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

the function of chill rollers on a machine

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

result of excess printing pressure

determining the pressure to be applied to the doctor blade

print faults that could be caused by excessive overspill of air from the inter-colour drier

recommended air ratio for efficient inter-colour drying

advantages of using high velocity air in the drying system

the cause of the doctor blade wearing on a gravure printing unit

options for reducing the wear of the doctor blade

determining the optimum make ready speed for the job

communicating the steps involved in make ready to other team members

need to grade the drying speeds of each progressive colour, so that first-down colours dry faster the subsequent colours

cause of a decrease in web tension

result of increasing rewind tension after the roll has been partially rewound

major cause of a telescopic roll

test methods of metallised film to find out which is the correct side on which to print

measuring the metallised surface for coating thickness

effect of annealing on aluminium foil

purpose of using thermal imaging face stocks

metallising substrates

client requirements for bar codes

print characteristics that are related to excessive printing pressure

causes of picking when printing multicoloured work

print faults that result from using an over-reduced ink

causes of moire patterns when printing by the gravure process

instrument used to identify retained solvent trapped in the print

purpose of taking Dyne readings

purpose of the crinkle test when testing an ink

print faults that would result from a worn doctor blade

effect of using the ink returning from the ink fountain when checking the viscosity for ink whilst using ink pumps

problems that result from the excessive use of slow solvents

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

result of excessive print area tension

problems which the printer may associate with cold seals

responsibility for the final say in the "OK" of the job

machine manuals, safety and other documentation that are relevant to this task and where they are kept and information that 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.

Specialised may include:

specialised within this context relates to the set up and production of print runs that involve new products, or a new mix of substrates and inks that requires a certain amount of problem solving and experimentation with the substrate and press settings. The set up of equipment and production involves the development of new set up and production approaches based on solving technical problems arising from new product or equipment combinations.

Inks/coatings may include:

range of inks commonly used in 3 or more colour printing, including standard and special colours.

Colour matching systems may include:

use of viscosity controls, densitometers and spectrophotometry.

Machines may include:

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

Design may include:

3 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.

Substrate types may include:

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

Substrate handling may include:

wide and narrow reel handling systems.