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Evidence Guide: ICPPRN313 - Set up for basic 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

 

ICPPRN313 - Set up for basic flexographic printing

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

Confirm routine job specifications

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Availability of all job-related components are checked

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Proofed job is checked for conformance with job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up delivery systems

  1. Delivery systems are correctly set up and adjusted according to job specifications
  2. Substrate is added to and removed from process according to job specifications
Delivery systems are correctly set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select and prepare inks and solvents

  1. Inks and solvents are selected according to routine job specifications and end-user requirements
  2. Quality and suitability of inks and solvents are checked and appropriate action taken
  3. Inks and solvents are prepared according to work health and safety (WHS) 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 press requirements and routine job specifications
  5. Ink formula and approved colour drawdowns are appropriately recorded
  6. Inks and solvents are appropriately labelled, handled and stored according to manufacturer’s/supplier’s instructions and relevant hazardous liquids storage regulations
Inks and solvents are selected according to routine job specifications and end-user requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks and solvents are prepared according to work health and safety (WHS) 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 press requirements and routine job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ink formula and approved colour drawdowns are appropriately recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up machine for basic flexographic printing

  1. Flexographic plate cylinders are installed and register adjustments centred
Flexographic plate cylinders are installed and register adjustments centred

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

OR

  1. Sleeves are installed in press and register adjustments made
Sleeves are installed in press and register adjustments made

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 to suit 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 to suit 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 print run

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Press is set up and operated according to WHS 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:

 

 

 

 

 

 

 

Print is checked for register

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Drying is checked as sufficient to key ink to the substrate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Viscosities are adjusted to obtain correct colour at proof speed and checked against colour matching system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Substrate is checked against job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Organise print inspection and/or testing

  1. Print is visually inspected and/or tested, or laboratory testing is organised according to enterprise procedures
  2. Production does not commence without client OK where appropriate
Print 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 OK 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 where applicable
  4. Press setting is 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 where applicable

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Press setting is documented and samples are retained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

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 are checked

1.4 Proofed job is checked for conformance with job specifications

2. Set up delivery systems

2.1 Delivery systems are correctly set up and adjusted according to job specifications

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

3. Select and prepare inks and solvents

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

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

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

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

3.5 Ink formula and approved colour drawdowns are appropriately recorded

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

4. Set up machine for basic flexographic printing

4.1 Flexographic plate cylinders are installed and register adjustments centred

OR

4.2 Sleeves are installed in press and register adjustments made

OR

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

4.4 Plate cylinders are gauged up or pre-set to impression

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

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

4.7 Viscosities are adjusted according to job specifications

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

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

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

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

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

6. Conduct print run

6.1 Material to be used for print is organised correctly

6.2 Press is set up and operated according to WHS guidelines

6.3 Print impressions are set to minimum kiss impression

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

6.5 Print is checked for register

6.6 Drying is checked as sufficient to key ink to the substrate

6.7 Viscosities are adjusted to obtain correct colour at proof speed and checked against colour matching system

6.8 Substrate is checked against job specifications

7. Organise print inspection and/or testing

7.1 Print is visually inspected and/or tested, or laboratory testing is organised according to enterprise procedures

7.2 Production does not commence without client OK where appropriate

8. Readjust settings to production speed

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

8.2 Adjustments are made according to product specifications and press performance

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

8.4 Press setting is documented and samples are retained

Required Skills and Knowledge

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

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

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 are checked

1.4 Proofed job is checked for conformance with job specifications

2. Set up delivery systems

2.1 Delivery systems are correctly set up and adjusted according to job specifications

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

3. Select and prepare inks and solvents

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

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

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

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

3.5 Ink formula and approved colour drawdowns are appropriately recorded

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

4. Set up machine for basic flexographic printing

4.1 Flexographic plate cylinders are installed and register adjustments centred

OR

4.2 Sleeves are installed in press and register adjustments made

OR

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

4.4 Plate cylinders are gauged up or pre-set to impression

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

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

4.7 Viscosities are adjusted according to job specifications

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

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

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

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

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

6. Conduct print run

6.1 Material to be used for print is organised correctly

6.2 Press is set up and operated according to WHS guidelines

6.3 Print impressions are set to minimum kiss impression

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

6.5 Print is checked for register

6.6 Drying is checked as sufficient to key ink to the substrate

6.7 Viscosities are adjusted to obtain correct colour at proof speed and checked against colour matching system

6.8 Substrate is checked against job specifications

7. Organise print inspection and/or testing

7.1 Print is visually inspected and/or tested, or laboratory testing is organised according to enterprise procedures

7.2 Production does not commence without client OK where appropriate

8. Readjust settings to production speed

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

8.2 Adjustments are made according to product specifications and press performance

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

8.4 Press setting is documented and samples are retained

Evidence of the ability to:

demonstrate all safety devices on the machine

demonstrate use of control, monitoring and data entry systems

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 and enterprise procedures. The individual will also conduct a proof run and adjust settings to ensure production speeds are attained.

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:

Job requirements

describe what to do if vital information is missing from the job ticket

ensure all required materials are available prior to set up

Flexographic printing plates and cylinders or sleeves OR plate mounting sheets

identify precautions to avoid damaging plates and cylinders

For reel systems only

Reel in-feed

explain work health and safety (WHS) factors to consider when operating the reel in-feed and delivery system

explain how to correctly select printing side of the material

describe the effect of low web tension on the print

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

Reel delivery system

describe effect of excessive web tension at the rewind of the machine

discuss how to minimise three risks associated with the rewind

For sheet systems only

Sheet in-feed

explain WHS factors to consider when operating the sheet in-feed and delivery system

describe why the sheet is normally set up in the middle of the machine

describe effect side-lay selection has on the job

describe how appropriate front lays should be selected

describe what determines position of the sheet before it is transported to the printing unit

explain how a register check is carried out

discuss why a two-sheet cut is used on most feeders

discuss how the machine recognises if a sheet is missing or late

Sheet delivery system

describe why application of spray powder is sometimes advisable

discuss effects of too much spray powder

show how slowdown devices may be used in delivery

identify effect of excessive jogging on the stack

Selection and preparation of inks and additives

name major environmental and WHS concerns with regard to inks and additives

describe how ink suitability is matched to a particular job

describe implications if ink is too viscose

describe how an ink that is slightly light can be modified to meet the job needs

identify methods to check ink for correct colour

name the person who passes the colour prior to running the job

Machine set-up

discuss all WHS factors to consider when setting up the machine

show how machine specifications are determined, relating to a specific job

discuss steps to ensure the inking system is adjusted correctly

describe why inking system ink level is maintained at a certain level

list necessary precautions when handling doctor/chamber blades

identify optimum make-ready-speed for the job

explain basic in-line processes

list steps to incorporate the in-line processes into the make-ready

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

list precautions to take if uv drying is utilised to dry the ink film

Proofing and adjustment

identify methods to minimise waste during make-ready

list procedures required to have the print approved

describe quality control measurements to apply to the proof to test against known standards

outline how to check on initial print prior to running

describe how setting adjustments are determined

identify processes to plot success of the machine adjustment

describe how final results are recorded for future reference

Relevant test procedures

identify and describe tests for scuffing and coefficient of friction

show circumstances in which these tests should be applied

Leaching

discuss leaching

Information sources

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

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 and adjusting MUST include EITHER:

checking reels for treatment levels, coatings, printing side and age of product

securing reels on reel shaft

correctly positioning reels on unwind stand

positioning and mounting correctly cut cores on rewind shafts

centring and setting edge guide

setting unwind and rewind tension to suit substrate

setting nip rollers

OR

feeder

sheet pick-up and transportation system

transfer system

delivery

sheet transfer and control system

set off / marking prevention devices