Unit of competency details
ICPPRN421 - Set up for complex gravure printing (Release 1)
Summary
Usage recommendation:
Superseded
Releases:
| 1 1 (this release) |
26/Mar/2015 |
Companion volumes:
Unit of competency
Assessment requirements
Training packages that include this unit
Qualifications that include this unit
Classifications
Classification history
| ASCED Module/Unit of Competency Field of Education Identifier | 030103 | Printing | 30/Jul/2015 | |
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Unit of competency
Modification History
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Release
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Comments
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Release 1
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This version first released with ICP Printing and Graphic Arts Training Package Version 1.0.
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Application
This unit describes the skills and knowledge required to set up non-routine gravure printing machines for non-routine print jobs. It includes the ability to conduct a proof run and adjust settings to ensure production speeds are attained.
It applies to individuals working as print machinists in the printing and graphic arts industry. They prepare material, set up, monitor and operate equipment and machinery, apply solutions to a defined range of problems associated with the print medium and analyse and evaluate information from a variety of sources. They may also provide leadership and guidance to others with some limited responsibility for the output of others.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Unit Sector
Printing
Elements and Performance Criteria
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ELEMENT
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PERFORMANCE CRITERIA
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Elements describe the essential outcomes.
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Performance criteria describe the performance needed to demonstrate achievement of the element.
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1. Confirm non-routine job specifications
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1.1 Job requirements are read and interpreted from job documentation or production control system
1.2 Set up is planned and carried out correctly in minimum time with minimum wastage
1.3 Availability of all job related components is checked
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2. Set up reels
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2.1 Unwind and rewind reels are set up and adjusted according to job specifications
2.2 Webbing procedures are carried out according to non-routine job specifications
2.3 Web-control system is set up and adjusted according to job specifications
2.4 Reels are spliced/joined according to job specifications
2.5 Printed web viewing devices are set up and adjusted according to job specifications
2.6 Folder and sheeter are set up and adjusted according to job specifications
2.7 Set off / marking prevention devices are set up and adjusted according to job specifications
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3. Select and prepare inks and additives
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3.1 Inks, dyes or additives are selected according to job specifications and end-user requirements
3.2 Quality and suitability of inks, dyes or additives are checked and appropriate action is taken
3.3 Inks, dyes and additives are prepared according to 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 prepared to match requirements of the printing process and job specifications
3.5 Formulation of ink, colour match and approved colour are appropriately recorded
3.6 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
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4. Set up machine for complex gravure printing
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4.1 Gravure cylinders are selected, installed, set up and adjusted according to job specifications
4.2 Impression roller is set up and adjusted according to job specifications
4.3 Inking system / doctor blade is set up and adjusted according to the gravure process and job specifications
4.4 Drying system is set up and adjusted according to job specifications
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5. Conduct proof run
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5.1 Material to be used for proof is organised correctly
5.2 Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof
5.3 Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof
5.4 Production does not commence without client approval or authority where appropriate
5.5 Results are interpreted and adjustments are carried out according to product and machine specifications to determine adjustment requirements
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Foundation Skills
This section describes language, literacy, numeracy and employment skills incorporated in the performance criteria that are required for competent performance.
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Skill
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Performance Criteria
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Description
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Reading
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1.1, 2.1-2.7, 3.1, 3.3, 3.4, 3.6, 4.1-4.4, 5.5
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- Recognises and interprets text to establish job requirements from information contained within relevant instructions, procedures and specifications
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Writing
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3.5, 3.6, 5.4
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- Completes records and documents accurately and according to workplace requirements
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Oral Communication
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5.4
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- Participates effectively in spoken interactions using appropriate vocabulary, questioning and listening techniques to gain approvals
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Navigate the world of work
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3.3, 3.5, 3.6, 5.2-5.4
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- Complies with legislative requirements and follows organisational policies and procedures relevant to own role
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Interact with others
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5.4
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- Follows accepted communication practices and protocols when seeking approval to commence production
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Get the work done
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1.1-1.3, 2.1-2.7, 3.1-3.4, 3.6, 4.1-4.4, 5.1-5.3, 5.5
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- Takes responsibility for planning and organising own workload using analytical processes to decide on a course of action, and assembles required resources
- Implements actions as per instructions, making adjustments if necessary
- Responds to predictable problems and implements standard or logical solutions related to role in immediate work environment
- Reads data from electronic monitoring and control systems
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Unit Mapping Information
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Code and title
current version
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Code and title
previous version
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Comments
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Equivalence status
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ICPPRN421 Set up for complex gravure printing
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ICPPR421C Set up for complex gravure printing
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Updated to meet Standards for Training Packages
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Equivalent unit
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Links
Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=a74b7a0f-a253-47e3-8be0-5d426e24131d
Assessment requirements
Modification History
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Release
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Comments
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Release 1
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This version first released with ICP Printing and Graphic Arts Training Package Version 1.0.
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Performance Evidence
Evidence of the ability to:
- set up a gravure 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 specifications and enterprise procedures
- conduct proof run and adjust settings to ensure production speeds are attained
- demonstrate use of control, monitoring and data entry systems.
Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.
Knowledge Evidence
To complete the unit requirements safely and effectively, the individual must:
- explain why it is necessary to ensure job specifications are read and properly understood
- identify production problems that could eventuate if job specifications are not read and properly understood
- identify who production problems should be discussed with
- list work health and safety (WHS) precautions for installing printing cylinders on the machine
- demonstrate knowledge to determine the optimum print sequence
- identify the visual aid on the cylinder that identifies colour of ink to be used
- outline precautions to ensure the cylinders are not damaged during installation
- list WHS precautions for webbing up the machine
- explain how to determine position of the reel
- explain what can happen if brake tension is not set correctly
- outline the function of the ‘Dancer’ roller on a web machine
- describe consequences if the web is not spliced correctly
- demonstrate knowledge of how the particular web viewing device works
- explain the principle of ESA roller operation on the gravure printing machine
- name the type of substrate used on the ESA roller
- list WHS precautions for setting up the delivery
- explain how the web is controlled in the rewind unit
- describe the result of incorrect rewind tension
- outline remedial steps if there is a possibility of the ink marking in the rewind
- describe problems that could be attributed to a blunt knife when sheeting
- explain the function air blast plays in the delivery of sheets
- list WHS precautions for preparing inks and additives
- identify details to check an ink’s suitability for the printing process
- outline special end-use requirements that may be necessary
- explain why additives are used in gravure inks
- outline the range, in seconds, for zahn cup measurements
- describe the effect foaming has in a zahn cup when measuring ink viscosity
- demonstrate knowledge of why pigmented ink should be brought to operating temperature before correcting viscosity
- identify essential checks to be made
- list advantages of using automatic viscosity controllers
- outline precautions to minimise waste when preparing ink
- describe how to determine shelf life of most inks
- outline conditions relevant to storage of inks and additives
- list conventions to adhere to when labelling mixed inks
- identify advantages of using automatic viscosity controllers
- describe precautions to minimise waste when preparing ink
- describe how to determine shelf life of most inks
- outline conditions relevant to storage of inks and additives
- list conventions to adhere to when labelling mixed inks
- list WHS factors for setting up the machine
- describe the function of chill rollers on a machine
- outline main advantages of gauging up and dry register prior to printing a job
- identify the consequence of excess printing pressure
- explain how pressure applied to the doctor blade is determined
- describe print faults that can be caused by excessive overspill of air from the inter-colour drier
- identify the recommended air ratio for efficient inter-colour drying
- outline advantages of using high-velocity air in the drying system
- list WHS precautions for slitting on the machine
- identify the pre-heat web temperature required for lamination
- outline reasons for a printed product to be punched
- describe what should be considered when setting hole punching in relation to repeat length
- explain the purpose of the dwell when cutting and creasing in-line
- demonstrate knowledge of how to control the ratio of print to in-line speed
- describe the consequence of excessive pressure on the slitters
- outline what causes doctor blade wear on a gravure printing unit
- explain how to reduce doctor blade wear
- demonstrate how to determine optimum make ready speed for the job
- explain how the steps involved in the make ready are communicated to other team members
- describe why it is necessary to grade drying speeds of each progressive colour, so first-down colours dry faster the subsequent colours
- list causes of a decrease in web tension
- outline consequences of increasing rewind tension after the roll has been partially rewound
- identify the major cause of a telescopic roll
- explain how to test metallised film to find out which is the correct side to print on
- describe how metallised surface is measured for coating thickness
- outline the effect of annealing on aluminium foil
- explain purpose of using thermal imaging face stocks
- describe how substrates are metallised
- identify client requirements for bar codes
- describe print characteristics related to excessive printing pressure
- explain what causes picking when printing multicoloured work
- outline print faults that can result from using an over-reduced ink
- describe causes of moire patterns when printing by the gravure process
- name the instrument used to identify retained solvent trapped in the print
- explain the purpose of taking Dyne readings
- explain the purpose of the crinkle test when testing an ink
- describe print faults resulting from a worn doctor blade
- demonstrate knowledge of correct checks for ink viscosity while using ink pumps
- identify problems that result from excessive use of slow solvents
- explain why laminating inks, once printed, appear dull and easy to scratch
- outline the result of excessive print area tension
- list some of the problems the printer may associate with cold seals
- identify who has responsibility for the final say regarding job approval
- locate machine manuals, safety and other documentation relevant to this task, and outline the information included in these documents.
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 special purpose tools, equipment and materials, including a gravure printing machine.
Assessors must satisfy NVR/AQTF assessor requirements.
Links
Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=a74b7a0f-a253-47e3-8be0-5d426e24131d
