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Orientation
Introductions and Backgrounds
This time will be spent getting to know the background of the trainer and each trainee.
Training Program Preview
Brief explanation of what can be expected during the training course.
The Flexographic Process
Flexographic Applications
Discussion of the many industries that are involved in flexo printing. Emphasis will be placed on
the high level of quality that is possible using current flexo technology. Advantages and limitations
of the process will also briefly be introduced.
Flexographic Components
Introduction of the major components of anilox rolls, inks, papers, inking systems, and plates.
The Press Run - 1 Color Job
The purpose of this press run is to teach trainees how to quickly reach correct printing impressions
through efficient press set up procedures. Ink handling will not be explained at this point. The
following procedures will be discussed in depth as the class works through each them to achieve
a well printed single color job.
• Pre-setting impressions
• Selecting stickyback
• Plate mounting
• Setting anilox roll pressure
• Setting plate impression
Impression Setting Exercise
The trainees will work together to create sample press sheets that illustrate the effects of over or under impressed anilox rolls and plates. Trainees are encouraged to keep samples for future reference.
Press Cleanup
Trainees will be instructed on the correct way to clean a print unit through demonstration and hands-on experience. Emphasis will be placed on the anilox roll.
The Flexographic Components in Detail
Each of the following components will be discussed in detail with an emphasis on the inter-relationships of the components to one another. Discussions will include the importance of standardizing components and operating procedures in order to create a consistent product. Press samples, training aids, and hands-on exercises will be used during discussions.
Components in Detail
Graphic Elements
• types of graphics
• ink film thickness requirements
Paper characteristics
• smoothness
• holdout and absorption
• color
• ink film thickness requirements
Anilox roll engravings
• cell count
• cell volume
• controlling ink film thickness
Waterbased ink
• components
• pH
• viscosity
• using additives
• matching colors
• managing throughout a run
Plate package
• stickyback types
• plate hardness
• plate package thickness
Flexographic Components Press Run
This single color press run is designed with various exercises that give trainees hands-on instruction in the testing and selection of appropriate anilox roll engravings and in the adjustment of ink pH, viscosity, and color.
Using Print Information
Using press samples from the Flexographic Components Press Run, trainees will analyze the print to determine the types of graphics that are successful with certain component variations. They will also discuss compensations and procedures that may be made in the prepress department to facilitate consistently successful print. Dot gain, combination printing, distortion, etc. will be discussed.
Recognizing Printing Problems - Press Run
The training group will be split into 2 teams. Team 1 will be given a list of very specific tasks to complete, of which Team 2 must recognize and correct. For instance, Team 1 may be asked to slightly squeeze the plate to the impression cylinder. Team 2, without knowing what has been changed, must look at a printed sheet to determine the problem and how to fix it. After completing the list of tasks, the teams will switch and repeat the exercise.
Review and Q/A