Unit of competency Outline
Date retreived
22/07/2026 10:02 AM AWST
22/07/2026 10:02 AM AWST
Whilst all efforts are made to provide accurate and timely information from the relevant source/documentation, please be aware that the information supplied may not be the most current version. The accuracy of the detail has not been confirmed by the Department and therefore should not be relied upon without first confirming the contents.
Set up for complex flexographic printing
Set up for complex flexographic printing
Unit of competency
National Code
ICPPR413C
ICPPR413C
State Code
D3190
D3190
TGA Status
Replaced
Replaced
DTWD Status
Replaced
Replaced
State Implementation and Classification
Approved Date
10/08/2012
Field of Education
030103 - Printing
Original Release Date
10/08/2012
Nominal Hours
50
Description
This unit describes the performance outcomes, skills and knowledge required to set up machines for non-routine flexographic printing.
Notes
Elements and Performance Criteria
1. Confirm non-routine job specifications
- 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
- 1.4. Proofed job is checked for conformance with job specifications
2. Set up reel transportation and delivery system on web-fed machine
- 2.1. Reels are checked for treatment levels, coatings and printing side and age of product
- 2.2. Unwind reels are secured on reel shaft
- 2.3. Reels are correctly positioned on unwind stand
- 2.4. Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications
- 2.5. Edge guide is centred and set to non-routine job specifications
- 2.6. Unwind tension is set to suit substrate
- 2.7. Rewind tension is set to suit substrate
- 2.8. Rewind tension is set to suit substrate
- 2.9. PIV (Positively Infinitely Variable) drive is set for appropriate tensioning of substrate
3. Select and prepare inks and solvents
- 3.1. Inks and solvents are selected according to job specifications and end-user requirements
- 3.2. Quality and suitability of inks and solvents are checked and appropriate action is taken
- 3.3. Inks and solvents are prepared according to OHS 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 the press requirements and non-routine job specifications
- 3.5. Ink formula and approved colour draw downs are appropriately recorded
- 3.6. Inks and solvents are appropriately labelled, handled and stored according to manufacturer's/supplier's instructions and the relevant hazardous liquids storage regulations
4. Set up machine for complex 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. Anilox rollers are selected to suit individual colour and plate reproduction requirements for each unit
- 4.6. Appropriate ink metering system is selected for each unit
- 4.7. Inking system is set up and roller nips/blades are set correctly
- 4.8. Ink circulation is maintained at correct level and flow for machine
- 4.9. Viscosities are adjusted according to job specifications
- 4.10. Air volume and drier temperatures curing units are selected to suit inks, substrate, solvents and according to job specifications
- 4.11. 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 according to machine requirements and job specifications
- 5.2. Assistance is given in set up of major in-line printing/converting/binding units
6. Conduct proof run
- 6.1. Material to be used for proof is organised correctly
- 6.2. Press is set up and operated according to OHS 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. Drying is checked as sufficient to key ink to the substrate
- 6.6. The viscosities are adjusted to obtain the correct colour at proof speed and checked against colour matching system
- 6.7. The substrate is checked against job specifications
7. Organise proof inspection and/or testing
- 7.1. Proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures
- 7.2. Production does not commence without client approval or authority 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
- 8.4. Press settings are documented and samples are retained
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.
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.
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.
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.
Replaces
| State Code | National Code | Title | Type |
|---|---|---|---|
| D0442 | ICPPR413B | Set up for complex flexographic printing | Unit of competency |
Replaced By
| State Code | National Code | Title | Type |
|---|---|---|---|
| AUO21 | ICPPRN413 | Set up for complex flexographic printing | Unit of competency |
| State Code | National Code | Title | Type |
|---|---|---|---|
| W785 | ICP40310 | Certificate IV in Printing and Graphic Arts (Printing) | Qualification |
| J184 | ICP30512 | Certificate III in Printing and Graphic Arts (Printing) | Qualification |