· Gravure & Flexography Printing ... 4 Surjeet Gupta A guide to Printing Inks Print India...

w.e.f. Academic Year 2014-15 ‘G’ Scheme

MSBTE – Final Copy Dt. 11/12/2014 1

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION, MUMBAI TEACHING AND EXAMINATION SCHEME FOR POST S.S.C. DIPLOMA COURSES

COURSE NAME : DIPLOMA IN PRINTING TECHNOLOGY COURSE CODE : PN DURATION OF COURSE : 6 SEMESTERS WITH EFFECT FROM 2014-15 SEMESTER : THIRD DURATION : 16 WEEKS PATTERN : FULL TIME- SEMESTER SCHEME : G

SR. NO.

SUBJECT TITLE Abbreviation

SUB CODE

TEACHING SCHEME EXAMINATION SCHEME

TH TU PR PAPER HRS

TH(01) PR(04) OR(08) TW(09) SW (19300) MAX MIN MAX MIN MAX MIN MAX MIN

1 Paper & Ink Technology PIT 19325 04 -- 02 03 100 40 -- -- -- -- 25@ 10

50

2 Sheet Fed Presses SFP 19326 04 -- 02 03 100 40 50# 20 -- -- 25@ 10

3 Print Finishing PFI 19327 04 -- 02 03 100 40 -- -- -- -- 25@ 10

4 Image Carrier offset ICO 19328 03 -- 02 03 100 40 25@ 10 -- -- -- --

5 Manual Book Binding MBB 19044 01 -- 04 -- -- -- 25# 10 -- -- 25@ 10

6 Professional Practices - I PPR 19045 -- -- 03 -- -- -- -- -- -- -- 50@ 20

TOTAL 16 -- 15 -- 400 -- 100 -- -- -- 150 -- 50 Student Contact Hours Per Week: 31 Hrs. THEORY AND PRACTICAL PERIODS OF 60 MINUTES EACH. Total Marks : 700 @ Internal Assessment, # External Assessment, $ - Common to All Conventional Diploma, No Theory Examination. Abbreviations: TH-Theory, TU- Tutorial, PR-Practical, OR-Oral, TW- Termwork, SW- Sessional Work. Conduct two class tests each of 25 marks for each theory subject. Sum of the total test marks of all subjects is to be converted out of 50

marks as sessional work (SW). Progressive evaluation is to be done by subject teacher as per the prevailing curriculum implementation and assessment norms. Code number for TH, PR, OR and TW are to be given as suffix 1, 4, 8, 9 respectively to the subject code.

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MSBTE – Final Copy Dt. 11/12/2014 2

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION, MUMBAI TEACHING AND EXAMINATION SCHEME FOR POST S.S.C. DIPLOMA COURSES

COURSE NAME : DIPLOMA IN PRINTING TECHNOLOGY COURSE CODE : PN DURATION OF COURSE : 6 SEMESTERS WITH EFFECT FROM 2014-15 SEMESTER : FOURTH DURATION: 16 WEEKS PATTERN : FULL TIME - SEMESTER SCHEME : G

SR. NO SUBJECT TITLE Abbrev

iation SUB

CODE

TEACHING SCHEME

EXAMINATION SCHEME

TH TU PR PAPER HRS

TH(01) PR(04) OR(08) TW(09) SW (19400) MAX MIN MAX MIN MAX MIN MAX MIN

1 Environmental Studies $ EST 17401 01 -- 02 01 50#* 20 -- -- -- -- 25@ 10

50

2 Digital Imaging DIM 19416 04 -- -- 03 100 40 -- -- -- -- -- --

3 Gravure & Flexography Printing

GFP 19417 04 -- 04 03 100 40 50# 20 -- -- 25@ 10

4 Web Fed Presses WFP 19418 04 -- 02 03 100 40 50# 20 -- -- 25@ 10

5 Image Carrier Gravure & Flexo

ICG 19419 04 -- 02 03 100 40 -- -- -- -- 25@ 10

6 Professional Practices - II PPR 19061 -- -- 03 -- -- -- -- -- -- -- 50@ 20 TOTAL 17 -- 13 -- 450 -- 100 -- -- -- 150 -- 50

Student Contact Hours Per Week: 30 Hrs. THEORY AND PRACTICAL PERIODS OF 60 MINUTES EACH. Total Marks : 750 @ Internal Assessment, # External Assessment, $ - Common to All Conventional Diploma, No Theory Examination. Abbreviations: TH-Theory, TU- Tutorial, PR-Practical, OR-Oral, TW- Termwork, SW- Sessional Work. Conduct two class tests each of 25 marks for each theory subject. Sum of the total test marks of all subjects is to be converted out of 50 marks

as sessional work (SW). Progressive evaluation is to be done by subject teacher as per the prevailing curriculum implementation and assessment norms. Code number for TH, PR, OR and TW are to be given as suffix 1, 4, 8, 9 respectively to the subject code.



MSBTE – Final Copy Dt. 11/12/2014 19325 PN3 3

Course Name : Diploma in Printing Technology

Course Code : PC

Semester : Third

Subject Title : Paper & Ink Technology

Subject Code : 19325

Teaching and Examination Scheme:

Teaching Scheme Examination Scheme

TH TU PR PAPER

HRS TH PR OR TW TOTAL

04 -- 02 03 100 -- -- 25@ 125

NOTE:

Two tests each of 25 marks to be conducted as per the schedule given by MSBTE.

Total of tests marks for all theory subjects are to be converted out of 50 and to be

entered in mark sheet under the head Sessional Work (SW).

Rationale:

Paper and Ink are the basic raw material used in Printing Industry. Student should know the

Physical and Chemical properties of Paper and Ink. In today’s state of art print houses, the tests for

various properties are carried out in the Q.C department using different instruments. A Diploma

Holder is required to supervise this section in Press and therefore knowledge of this Subject is very

essential. Student should know how good quality paper and ink will provide high-speed production

with better quality and greater accuracy.

General Objectives:

The student will be able to:

1. Develop knowledge of Paper and ink properties.

2. Use effectively different instruments to carry out property tests.

3. Analyse various tests to offer the best or required quality material.




Learning Structure: Application Procedure Principle Concept Facts

To produce better quality printed product (paper and Ink) to fulfill the needs of society, industry, office

Testing of paper before and after printing

Testing of inks before and after printing

End use requirements of paper and ink, Print requirements of ink and

paper

Properties of different types of inks, paper Testing of inks and

paper

Jobs to be marketed, Eye appealing, cost/profit factor. Market survey Economics in operations, the functioning

Quires, make-up, calculations, office requirement, sizes capacity, strength, durability, variety of products

Methods in each operation, economics of each process, need of operation, terminology etc.

Offset, Gravure, Flexo, Screen processes of printing

Paper, Ink, driers, vehicles, Resins

Intended Equipments for paper and ink




Contents: Theory

Topic 1: Paper Manufacturing Process Hours Marks

1.1 1.2 1.3

Specific Objectives: Outline and explain paper manufacturing process

Preparing the Stock Manufacturing process- Paper, Board. After Treatments - Calendaring, Coating, conditioning, other finishing processes

08 12

Topic 2: Paper Properties : Printability

2.1 2.2

2.3

2.4

Specific Objectives: Define and explain various properties of paper.

Appearance Properties - Brightness, Color, Gloss opacity Chemical composition related properties - Coating Composition, Moisture contents and RH, pH: Acidity, Alkalinity, Sizing, Structural Properties - Compressibility, Resiliency, Hardness and softness, dimensional stability, Grain direction, Curl and sheet flatness, Internal Bond strength, Porosity, App. Density, Basis weight & grammage, Caliper and bulk Surface properties - Cleanliness, Dirt, Ink absorbency, Printability, Smoothness, Surface strength and Pick resistance,Wire & felt side

12 16

Topic 3: Paper properties: Runnability and End Use

3.1

3.2

3.3

Specific Objectives: Define and explain various properties of paper. Infer and describe end use properties.

Chemical composition and Related properties - Adhesion from surface, Flame resistance, Light fastness, Moisture content, permanence & durability, Resistance from chemicals,water & vapor resistance Mechanical Properties - Bursting strength, Folding Endurance, Tearing strength, Wet strength Surface properties -Abrasion resistance, cleanliness, Frictional resistance, Smoothness

08 12

Topic 4: Introduction To Ink Technology:

4.1 4.2 4.3

Specific Objectives: List and briefly explain different printing processes. State and explain pigment properties.

Different Printing Processes and types of inks used Pigment properties - Organic, Inorganic, White, Black Ink terminology - pH, Viscosity, Thixotropy, Length, Tack, Water in Ink emulsion and Ink in Water emulsion

04 12

Topic 5 – Ingredients of Inks

5.1

5.2 5.3

5.4

Specific Objectives: List and briefly explain printing ink ingredients. State the functions of the ingredients.

Vehicles - Function &Types - Drying vehicles, Non Drying vehicles Resins -Natural resins, Synthetic Resins Solvents - Hydrocarbons, Aliphatic, Alcohols, Wash up solvents Additives - Plasticizers, Waxes, wetting agents, Anti set off compounds, Shortening compounds, Reducers, Stiffening agents Driers - Liquid driers, Paste driers, Inhibitors, Accelerators

08 08

Topic 6 – Ink Manufacture and Properties Specific Objectives: 08 12




Practical: Skills to be developed: Intellectual Skill:

1. Select proper material ink or paper, for particular job. 2. Interpret results.

Motor Skills:

1. To find out correct properties of paper and ink with use of suitable instruments. 2. Quality checks by using instruments.

List of Practical: Ink Testing:

1. To test the ink samples for length, drying, opacity. 2. To test the resistance towards acids and alkali, detergents. 3. To check the resistance towards rubbing and scratching. 4. To check the resistance towards press stability. 5. To check the resistance towards light fastness.

Paper testing:

6. Testing of paper samples for grammage and thickness. 7. Testing of paper samples for tensile, bursting, tearing and folding strength. 8. Testing of paper samples for opacity. 9. Testing of paper samples for moisture content and absorbency. 10. Testing of paper samples for pH value.

A student shall submit a journal on above practicals as Term Work.

6.1 6.2 6.3

Outline and explain ink manufacturing process Infer and describe end use properties.

Liquid Ink Manufacture –Mixing & milling - ball mill, Paste Ink Manufacture –Mixing & milling - three roll mill End use properties - Rub and scuff resistance, Adhesion flexibility block resistance, Skid & product resistance, Light fastness, heat seal resistance, lamination tests; Optical properties- Opacity, Gloss

Topic 7: Inks used for different Printing Processes 7.1 7.2

Specific Objectives: List and briefly explain different printing inks. Describe ink drying methods.

Offset inks - General formulation, properties Gravure inks - General formulation, properties Flexographic inks - General formulation, properties Screen Inks - General formulation, properties Speciality inks - Toners, Ink jet inks, magnetic inks, OCR inks, Scratch off inks, water washable inks, Water sensitive inks, Invisible inks, Thermo - chromic ink. Ink drying methods: Absorption, oxidation & polymerization, evaporation, precipitation, heat set, cold set, radiation drying i.e. ultra violet curable and electron beam curable

12

04

20

08

Total 64 100




Learning Resources: Books:

Sr. No. Author Title of Book Publisher’s Name

1 L. C. Young Materials in Printing Processes Focal Press Ltd., London

2 D. E. Visset The Printing Ink Mannual Northwood Books London

3 P. J. Hartsuch Chemistry for the Graphic Arts GATF, USA

4 Surjeet Gupta A guide to Printing Inks Print India Journal, Delhi

5 Arthur W. Johnson Manual For Book Binding Thames and Hudson

List of Equipment:

1. pH meter.

2. EEL opacimeter.

3. Demmy Quadrant Scale.

4. Oil absorbancy tester.

5. Laray’s Viscometer.

6. Proofing Kits.





Course Code : PC

Semester : Third

Subject Title : Sheet Fed Presses




TH TU PR PAPER


04 -- 02 03 100 50# -- 25@ 175

Notes:




Rationale:

There are many different Offset presses in the market today with many minute operational

differences. The purpose of this course is not to provide a general operational manual, but to deal

with the fundamental understanding that will enable the student to run any offset duplicator or

single and multi-colour sheet-fed offset printing press after studying the manufacturer’s operating

manual.

This course covers the information necessary to run an offset press and to give important

information on press trouble-shooting concerns also.

General Objectives:


1. Understand working of sheet fed offset printing machine.

2. Identify the trouble.

3. Perform the registration on the machine.




Learning Structure:

Application

Procedure Principles Concepts Fact

Printing various jobs by using multi colour Offset Presses

Setting of different

units

Pre-make ready & make ready procedures

Quality control aids &

procedure

Maintenance Procedures

Offset Principles

Feeding Unit, Printing Unit, Inking Unit, Damening Unit & Delivery Unit

Paper, Ink, Offset M/cs

Electricity, Man Power

Chemicals

Infra structure, Water, Land




Contents: Theory

Topic and Contents Hours Marks Topic 1 : The Printing Unit Specific Objective: Describe parts of Printing unit

1.1

1.2

1.3

Plate cylinder - Construction - Undercut - Cylinder gap - Bearer contact and bearer clearance - Plate clamps – Types, pin register system. - Plate mounting - Cylinder packing – Types - Cylinder gears: comparison of spur and helical gears Blanket cylinder Construction, undercut, cylinder gap, blanket mounting, packing. Types of Blanket – requirements of an ideal blanket, compressible, non-compressible, Blanket cleaning devices, handling, storage Impression cylinder Construction, cylinder gap, packing, grippers, nip pressure, effect of change in packing (of P., B.and I.cyls.) on printed image.

Topic 2: Feeding Unit Specific Objective: Explain working of ever part of feeding unit

2.1

2.2 2.3 2.4 2.5

Introduction to lithographic offset printing process, Typical design of machine - perfecting press. Feed board- different parts and purpose Sheet transport and control Types of grippers – Tumbler, swing arm, rotary feed, roll feed Transfer cylinder

13 20

Topic 3: Dampening System Specific Objective: Describe different type of dampening system Explain purpose of each contents of dampening solution

3.1 3.2 3.3 3.4

Roller setting Roller covering materials Conventional & other dampening systems Dampening Contents & their functions

11

16

Topic 4: Inking System Specific Objective: Describe ink flow theory Explain type of Inking system

4.1 4.2

4.3 4.4

Ink flow theory Inking rollers, coverings, ink duct construction, ink agitator, roller setting and metering Inking systems- Central Drum, Multi roller Roller wash up and Ink pumping system,introduction to various drying systems, anti-set-off spray,

12 20

Topic 5: The Printing Unit




Specific Objective: Describe parts of Printing unit

5.1

5.2

5.3

Plate cylinder - Construction - Undercut - Cylinder gap - Bearer contact and bearer clearance - Plate clamps – Types, pin register system. - Plate mounting - Cylinder packing – Types - Cylinder gears: comparison of spur and helical gears Blanket cylinder Construction, undercut, cylinder gap, blanket mounting, packing. Types of Blanket – requirements of an ideal blanket, compressible, non-compressible, Blanket cleaning devices, handling, storage Impression cylinder Construction, cylinder gap, packing, grippers, nip pressure, effect of change in packing (of P., B.and I.cyls.) on printed image.

18 28

Topic 6: Troubleshooting Specific Objective: Causes & solution of different printing problems

6.1

6.2

Sheet jamming, front or side lay variation, creasing, jogging. Slurring, marking, doubling, uneven impression. Blanket - Loss of sharpness, puncture (low spot), glazing, mis-register, Mottling, dot gain, set–off, hickeys, ghosting, chalking, emulsification, piling, tinting, trapping, plate-blinding, scum Use of Quality control devices - Printing of test forme, contents of test forme, UGRA, Gracol test chart

10 16

Total 64 100 Practical: Skills to be developed: Intellectual Skills:

1. Select proper plate, paper, ink etc. 2. Interpret results.

Motor Skills:

1. Correct single color and multi color production 2. Controlling and production on machine 3. Quality checks by using instruments.

List of Practical:

1. Feeder setting for various stocks. 2. Mounting of plate with packing. 3. Mounting of blanket with packing. 4. Gripper setting of impression cylinder. 5. Setting of dampening roller. 6. Preparation of foundation solution. 7. Cleaning & washing of dampeners. 8. Setting of inking rollers. 9. Cleaning & wash up.




10. Setting – joggers, skeleton wheels, delivery anti set-off spray. 11. Make ready operations for multicolor printing line and halftone printing. 12. Setting of impression lever, inking, dampening lever, feed board devices. 13. Study of ink water balance.

A student shall submit a journal on above practicals as Term Work



1 Ian Faux Modern Lithography Macdonald & Evans

2 Latham, Litho Offset press operating GATF

3 L. C. Young Materials in Printing Processes Focal Press, London

4 Bisset, Goodacre The Printing Ink Manual Northwood Books, London Idle, Leach & Williams

5 GATF staff Solving Sheet fed offset problems --

6 W. R. Durrant Machine Printing Focal Press, London

7 Faux Litho printing Blue printing

8 Adams, Faux Printing Technology Delmar Publication





Course Code : PC

Semester : Third

Subject Title : Print Finishing




TH TU PR PAPER


04 -- 02 03 100 -- -- 25@ 125

NOTE:


Total of tests marks for all theory subjects are to be converted out of 50 and to be entered in

mark sheet under the head Sessional Work (SW).

Rationale:

Binding is required to protect as well as to enhance the appearance of the printed product.

This subject is required for students to understand various binding techniques depending upon the

need of the product. In today’s state of art print houses, most of the finishing operations are carried

out using machines, the working and principle of these machines is also a part of the course. Hot

foil stamping, numbering, perforating, embossing, die cutting, are the various finishing processes a

student should know in order to understand how these processes increase the utility and beauty of

the product.

General Objectives:


1. Understand relevance of print finishing techniques in various segments of industry.

2. Understand material, machinery and equipments used in various print finishing process.




Learning Structure

Application


Undertaking different print finishing Operations

Print Layout preparation

Finalising sequemce of

finishing

Setting quality parameters of

finishing operation

Production planning and maintenance

Chemical adhesion, Nipping, creasing, perforating.

Folding, layout, imposition, trim and untrimmed sizes.

Printed product, value addition print

End use requirement of printed product

Automation requirement in

finishing




Contents: Theory

Topic Contents Hours Marks 1. Introduction to Print Finishing

Specific Objective: Classify print finishing on different basis. List print finishing as per industry and printing technology.

1.1 1.2

Introduction to Print Finishing and its application areas. Printing technology wise and printing industry segment wise print finishing operations.

04 08

2. Basics of Binding Specific Objective:

Classify binding on different basis. List stages involved in book binding.

2.1

2.2

Introduction to binding and its type. Introduction to tools, machinery, equipments used, and application of each of its type. Major operations performed in binding- pre-forwarding and forwarding.

12 18

3. Operations in Binding Specific Objective:

Classify operations as preforwarding and forwarding. Describe important preforwarding and forwarding operations.

3.1

3.2

Detailed study of pre-forwarding operation- jogging & knocking, removing mis-registrered sheets, counting, folding, bundling, gathering, collating, sewing, etc. Detailed study of forwarding operations- removing the swell, fixing end papers, fraying out the slips, gluing the back, trimming, rounding and backing, fixing head & tail bands, lining the back, edge decoration, cutting the boards, capping up, squaring the board, lacing in, covering, setting the joints, pasting down, pressing, jacketing.

12 16

4. Machinery and Equipments in Binding Specific Objective:

Describe construction and design construction of machines. Describe working of different machines used in book binding.

4.1

4.2

Construction and working of different machines and equipments used in binding such as- single knife trimmer, nipping, perforating, perfect binding, gathering machine, sewing and stitching machine. Construction and working Knife folding; Buckle folding, Combination folding.

12 18

5. Binding Techniques Specific Objective:

List binding techniques along with application area.. Describe working of binding techniques.,

5.1

5.2 5.3

5.4

Working principle and stages involved in Burst, Notch, and Two shot wet on wet binding. Case binding, Case making machine - Parts, Function Covering- Quarter, Half, Full, Limp & Library style binding. Boarding methods- pasting down, split, drawn in work, cut flush, extra square, ASTI (all sides turned in). Thread securing methods. Wire-o-wire, spiral, comb binding techniques, machine construction & working, Loose leaf binding – Thong binder, Universal style

12 20




6. Print Finishing Techniques Specific Objective:

List product related finishing process. Describe important finishing operations regards industrial printing.

6.1

6.2

6.3

6.4

6.5

Study of finishing operations performed on screen, flexography and gravure printed products or substrates. Study of types and applications of lamination and varnishing operations. Laminating films used and their required properties. Troubles and remedies associated with lamination operation. Study of construction and working principle of creasing and die cutting machine. Study of design and materials used in cutting rules. Troubles and remedies with regard to creasing and die cutting operation. Applications of die cutting. Study of types and applications of foil stamping and embossing operation. Foil stamping films used and their required properties. Troubles and remedies associated with foil stamping, operation. Study of types and applications of edge decoration and index cutting operations.

12 20


1. Select raw material for printing and finishing operations 2. Estimate the time and labor required for finishing operations. 3. Understanding stages involved in various print finishing operations.

Motor Skills:

1. Preparing imposition scheme for book binding. 2. Setting up various binding machines. 3. Operating binding, laminating and paper cutting machine.

Sr. No. Practical

1 Studying and Observing Different types of Automatic Cutters, Fixing and changing Knives, Safety of Cutters, maintenance and care.

2 Studying and observing various types of Automatic folders and their principles, purpose, handling, care.

3 Understanding working of jogging, counting, Tipping in machines, Gathering Machines 4 Handling wire stitching machine for side stitching and Center stitching. 5 Observing functions of Automatic Stitching Machines 6 Studying different types of sewing machines- Side Sewing, Section sewing. 7 Understanding the working of Perfect Binding Machine. 8 Observing gluing, in-line gluing (Modular Binder) smashing, rounding, Backing Machine. 9 Observing and understanding case making, casing in machines.

10 Observing Operations for hot foil stamping, die cutting, punching, Numbering, ruling machines.

A student shall submit a journal on above practical as Term Work




Reference Books

Sr. No.

Title of Book Author Publisher's Name

1 Binding & Finishing Mendiratta Printek Publication, New Delhi

2 Binding & Finishing --- GATF 3 Binding & Finishing Geoff & Potter Blue Print 4 Modern Book Binding Alex J. Vaughan --- 5 Finishing Processes in Printing A.G. Martin Focal Press Ltd., London 6 Manual For Book Binding Arther W. Johnson Thames and Hudson

List of Equipments: Sr. No Equipment/Machinery Specification Quantity

1 Different binding tools -- 2 sets 2 Wire stitching machine -- 2 3 Embissing machine -- 1 4 Punching machine -- 1 5 Perforating machine -- 1 6 Paper cutting machine -- 1 7 Cold Web Fed Lamination machine -- 1





Course Code : PC

Semester : Third

Subject Title : Image Carrier Offset




TH TU PR PAPER


03 -- 02 03 100 25@ -- -- 125

Notes:




Rationale:

Offset is still the leading technology of all the printing processes. This course will impart an

extensive knowledge of all the elements of image carrier making for the offset process. Imposition

schemes, image assembly, various methods of plate making & their proper application, study of

useful characteristics of metals, various quality control aids, etc. are the main elements of this

course which will enable the student to handle all the necessary operations related to the image

carrier.

General Objectives:


1. Develop plate making knowledge for offset printing.

2. Understand effective use of components parts.

3. Analysis of print characteristics.




Learning Structure: Application Procedure Principles Concepts Fact

To prepare plates for offset printing process.

Coating, Exposing, Inking, Developing, Finishing the plates / screens

Chemical, Physical, Mechanical Principles

Coating Solutions, Exposure Phenomenon, Developing, Finishing.

Colloids, Daizos, Polymers, metals, non-metalic substrates, developing solution, water, developing ink, machines, man power, equipments, electricity, Acids, Bases, Bichrometes, Light.




Contents: Theory Topic 1: Image Carrier and Film Planning Hours MarksSpecific Objective: Compare in between sheet work & Half sheet work imposition scheme Explain Different binders marks

1.1

1.2

Imposition schemes Definition of Imposition, Full sheet work & Half sheet work – work & turn, work & tumble Terms related with imposition schemes- gripper margin, folding margin, gutter margin, cutting marks, centerline, plate clamping allowance and binder’s marks, page characteristics- portrait and landscape, verso and recto. Variation in imposition schemes according to binding styles i.e. center, side, loose leaf binding Step & Repeat System Introduction: Plate register, multiple negatives or positives contact. Working of semi-automatic, automatic machines.

12 24

Topic 2: Plate Department Environment and Storage conditionsSpecific Objective: Explain storage method & care taken for plate storage

2.1

2.2

Room layout, lighting, ventilation, flooring, air conditioning, temperature and humidity, coloring, waste disposal Storing methods, care and precaution, dark reaction, shelf life and pot life.

03

03 16

Topic 3: Equipments and plate-making materials. Specific Objective: Explain various equipment used in plate making department

3.1

Whirler, Printing down frame, Plate processor Light sources- Metal-halide, carbon arc, mercury vapor, pulsed xenon Detail study of aluminium, zinc, copper, chromium and stainless steel : contact angle, wettability, surface tension -

11 22

Topic 4: Different Types of Plates. Specific Objective: Describe steps of preparing various plates�

4.1

4.2 4.3

4.4

Chemistry of graining, counter Etching , coating, sensitizer, developer, finisher, spectral sensitivity of coating Plates- Wipe on, Pre-sensitised – positive & negative: Methods of preparation and chemistry involved. Introduction to waterless offset concept, Preparation of Toray waterless plates, advantages and limitations Thermal plate & Violet plate

16 28

Topic 5: Quality Control in Plate making. Specific Objective: Explain importance of quality control in plate making

5.1 Importance of pH scale, star target, Step wedge, densitometer, standardization of plate exposure.

03 10

Total 48 100




Practical: Skills to be developed: Intellectual Skills:

1. Select proper original, chemicals and other components. 2. Interpret results.

Motor Skills:

1. Correct production. 2. Quality checks by using instruments.

List of Practicals:

1. Imposition Schemes: Preparing following layouts:

A. Single page layout. B. 4-page half sheet work. C. 8-page sheet work, 8-page half sheet work and turn. D. Packaging application E. 8-page half sheet work and tumble. F. 16-page full sheet work. G. 4-page half sheet work and twist. H. 12-page full sheet work. I. 32-page full sheet work.

2. Checking of positive and negative, screen angle and squaring-up of positive. 3. Positive working paste-up. 4. Negative working paste-up. 5. Preparation of wipe-on plates 6. Preparation of plate by- P.S. positive 7. Preparation of plate by- P.S. negative, 8. Analysis of variation of exposure on dot formation and processing time- under and over

exposed and correctly exposed on the plate by half tone positive. A student shall submit a journal on above practicals as Term Work Learning Resources: Books:



2 A. L. Gatehouse K. N. Roper

A Manual for Film Planning & Plate Making Litho Training Services London

3 P. J. Hartsuch Chemistry for the Graphic Arts GATF, USA

4 R.Reed Offset lithographic platemaking GATF

5 -- Lithographer’s manual GATF Publication, USA





Course Code : PC

Semester : Third

Subject Title : Manual Book Binding




TH TU PR PAPER


01 -- 04 -- -- 25# -- 25@ 50

Notes:




Rationale:

This is a core Subject. After Printing is complete the printed sheets are required from be put

in a proper shape such as books, magazines, registers. For this Knowledge of various methods and

techniques of Binding are very essential.

General Objectives:


1. Develop the knowledge of manual binding operations.

2. Understand the use of Tools & Equipment and their care in Binding department.

3. Select different Binding Material and method to suit the product requirement.

4. Produce the final finished printed product with suitable method.




Learning Structure: Application Procedure Principles Concepts Facts

To Process Printed & Blank paper into finished product for the use of society, industry, offices and marketing

Manual Book binding and finishing

Stationery, files etc. binding

Book Repairing

Manual Operation-cutting, folding, gathering, insetting, securing, reinforcing, covering, decorating, repairing of old books

Pulling into pieces, Cutting folding, pasting, covering, lamination, varnishing, gold blocking

Understanding the printed products, kinds of jobs, cost of product, paper sizes, requirement and kinds of material, selection of procedures, planning deciding standards, department plant layout, purchasing material, store procedure, quality control standards and norms.

Methods used for each operation as single unit and their principles

Methods in each operation, economics of each process, need of operation, terminology etc.

Quires, make-up, calculations, office

requirement, sizes capacity, strength, durability, variety

of products

Life Value of the books, age, purpose, decoration.Eye appealing, cost/profitfactor. Market survey.Economics in operations, thefunctioning




Contents: Theory Topic 1: Introduction Hours

1.1 1.2 1.3

History and importance of binding. Classification and Divisions of binding. Parts of book

01

Topic 2: Material 2.1 2.2

Paper, board, covering material, reinforcement material, Securing, miscellaneous material. 03

Topic 3: Tools and Equipment 3.1 3.2 3.3

Forwarding Tools Finishing Tools Equipment used in binding

02

Topic 4: Paper sizes 4.1 4.2 4.3

Types of papers. British Standard Paper Sizes :- Merits and Demerits ISO Standard Paper Sizes :- Advantages and Disadvantages

02

Topic 5: Pre forwarding Operations 5.1 5.2 5.3

5.4 5.5

Receiving and Checking Printed Material Jogging, Counting, Cutting, Slitting, Trimming and Binder’s Aids Folding - Folding Styles, Folding Schemes, Hand Folding :- Merits and Demerits Making Up - Tipping in, Gathering, Insetting, Collating, Inter leaving Securing: Stapling, Thread Sewing, Adhesive Binding, Loose leaf binding

04

Topic 6: Forwarding Operations 6.1 6.2 6.3

End Papers- Properties, Selection, Types and Applications Spine Gluing, Smashing, Rounding, backing, lining Boarding Methods :- Attachments, Care

02

Topic 7: Finishing Operations 7.1 7.2 7.3 7.4

Different Covering Styles Suitability and Application Cover Decorations by Hand Tools Estimation for Binding Material

02

Total 16 Practical: Skills to be developed: Intellectual Skills:

1. Select proper material, methods and tools for particular job. 2. Material Estimation.

Motor Skills:

1. Correct production by using proper method and tools. List of Practical:

Introduction To Binding And Binder’s Tools, Machines And Equipments.

Making Quarter Bound Cut Flush Book.

Making Quarter Bound Cut Flush Turn-In Book.

Making Limp Binding Books.




Making Tear-Off and Perforated Pad.

Making Loose Leaf File.

Making Pocket Diary and Case Board.

Making Index Diary and Counter Foil.

Making Half and Full Bound Book.

Making Office and Box File by Multiple Punching Machines.

A student shall submit a journal and sample on above practicals as Term Work Learning Resources: Books:


1 L.C.Young Material in Printing Processes Focal Press, London

2 J. Odham Practical Printing and Binding --

3 Geoff & Potter Binding and Finishing Blue Print

4 A.G. Martin Finishing Processes in Printing Focal Press Ltd., London

5 Arther W. Johnson Manual For Book Binding Thames and Hudson





Course Code : PC

Semester : Third

Subject Title : Professional Practices-I




TH TU PR PAPER


-- -- 03 --- --- --- --- 50@ 50

Rationale:

Most of the Diploma holders in Printing Technology opt for jobs in the printing and allied

industry. Due to globalization coupled with high economic growth the selection of the eligible

candidates by the industry is mostly competitive tests based.

While selecting a candidate a normal practice followed is to judge general confidence, soft

skills such as communication skill, attitude and last but not the least the knowledge of the core

technical subject.

The subject professional practices provide an opportunity to student to undergo activities,

which will make them develop confidence related soft skills. Industrial visits, expert guest lecture,

seminars are the important variables required to harness and imbibe all traits discussed above,

among the students.

General Objectives:

Students will be able to:

1. Acquire information from different sources.

2. Prepare notes for prevailing subjects.

3. Prepare seminar in the most prevailing subject.

4. Prepare report on the industrial visits and expert guest lecture.




Learning Structure:

Application:

Procedure:

Principle:

Concepts:

Facts:

Use of systematic approaches for technical report writing on industrial visits and presentation of report on lectures.

Principle of effective listening, understanding and ability to present the same.

Industrial Visits, Group Discussion, Guest Lecture.

Learning method of presenting report on industrial visit

Learning techniques of effective learning and preparing a summary

Understanding of concept and keen observation

Studying principles of listening.




Content:

Sr. No

Activity Hours

1

Industrial Visits:

Structured industrial visits be arranged and the report of the same should be submitted by every student.

Visit to any of the following establishment-

1. Small sheet fed commercial lithographic offset printing, screen-printing, advertising and shops trading raw materials such as paper, ink and other pre press chemicals.

2. Local printing and allied organization press.

3. Local book publication house.

16

2

Lecture by professional or industrial expert be arranged on any three from following topics:

1. Pollution control.

2. Fire hazard and safety norms.

3. Topics related to social awareness such as AIDS awareness and poverty elimination and yoga.

4. Attending exhibition and cultural programs.

18

3

Group Discussion:

The students should discuss in a group of 6-8 and write a brief report on the same discussion in the form of term work. The respective faculty members will give topics for a discussion. Areas of discussion are-

1. Sport and cultural activities 2. Discipline and housekeeping. 3. Prevailing general topic from the printing technology and allied area.

14

Total 48

A student shall submit a journal on above activities as Term Work




Course Name : All Branches of Diploma in Engineering & Technology

Course Code : AE/CE/CM/CO/CR/CS/CW/DE/EE/EP/IF/EJ/EN/ET/EV/EX/IC/IE/IS/ME/

MU/PG/PT/PS/CD/CV/ED/EI/FE/IU/MH/MI/DC/TC/TX/AU/FG/AA/DD/GT/

ML/FC/PN/PC/SC/TR Sixth for PC

Semester : Fourth

Subject Title : Environmental Studies




TH TU PR PAPER


01 -- 02 01 50#* -- -- 25@ 75

#* Online Theory Examination NOTE:


Total of tests marks for all theory subjects are to be converted out of 50 and to be entered in

mark sheet under the head Sessional Work (SW).

Rationale: Environment essentially comprises of our living ambience, which gives us the zest and

verve in all our activities. The turn of the twentieth century saw the gradual onset of its degradation by our callous deeds without any concern for the well being of our surrounding. We are today facing a grave environmental crisis. The unceasing industrial growth and economic development of the last 300 years or so have resulted in huge ecological problems such as

overexploitation of natural resources, degraded land, disappearing forests, endangered species, dangerous toxins, global warming etc.

It is therefore necessary to study environmental issues to realize how human activities affect the environment and what could be possible remedies or precautions which need to be taken to protect the environment.

The curriculum covers the aspects about environment such as Environment and Ecology, Environmental impacts on human activities, Water resources and water quality, Mineral resources and mining, Forests, etc. General Objectives: The student will be able to,

1. Understand importance of environment 2. Know key issues about environment 3. Understands the reasons for environment degradation 4. Know aspects about improvement methods 5. Know initiatives taken by the world bodies to restrict and reduce degradation




Learning Structure: Applications Procedure Principles Concept Fact

Awareness amongst the society, about Environmental aspects, pollution control, conservation of resources and biodiversity. Concept of Carbon credit and its importance

Methods to find component of force and resultant of forces

Natural resources such as Forest, Water, Food, Energy

Sources, effects, prevention

Threats, Conservation

Principle of Ecosystem,

Conservation of Natural Resources, Classification

Classification of pollution

Conservation of biodiversity

Environment, Ecosystem

Natural Resources

Pollution, Pollution Control

Biodiversity

Natural Resources, Biodiversity, Environmental Pollution, Carbon Credit,

Ecosystem




Theory:

Topic and Contents Hours Marks Topic 1: Nature of Environmental Studies Specific Objectives: Define the terms related to Environmental Studies State importance of awareness about environment in general public

Contents: Definition, Scope and Importance of the environmental studies Importance of the studies irrespective of course Need for creating public awareness about environmental issues

01 04

Topic 2: Natural Resources and Associated Problems Specific Objectives: Define natural resources and identify problems associated with them Identify uses and their overexploitation Identify alternate resources and their importance for environment

Contents: 2.1 Renewable and Non renewable resources

Definition Associated problems

2.2 Forest Resources General description of forest resources Functions and benefits of forest resources Effects on environment due to deforestation, Timber extraction,

Building of dams, waterways etc. 2.3 Water Resources

Hydrosphere: Different sources of water Use and overexploitation of surface and ground water Effect of floods, draught, dams etc. on water resources and

community 2.4 Mineral Resources:

Categories of mineral resources Basics of mining activities Mine safety Effect of mining on environment

2.5 Food Resources: Food for all Effects of modern agriculture World food problem

04 10

Topic 3. Ecosystems Concept of Ecosystem Structure and functions of ecosystem Energy flow in ecosystem Major ecosystems in the world

01 04

Topic 4. Biodiversity and Its Conservation Definition of Biodiversity Levels of biodiversity Value of biodiversity Threats to biodiversity Conservation of biodiversity

02 06




Topic 5. Environmental Pollution Definition Air pollution: Definition, Classification, sources, effects, prevention Water Pollution: Definition, Classification, sources, effects,

prevention Soil Pollution: Definition, sources, effects, prevention Noise Pollution: Definition, sources, effects, prevention

03 08

Topic 6. Social Issues and Environment Concept of development, sustainable development Water conservation, Watershed management, Rain water

harvesting: Definition, Methods and Benefits Climate Change, Global warming, Acid rain, Ozone Layer

Depletion, Nuclear Accidents and Holocaust: Basic concepts and their effect on climate

Concept of Carbon Credits and its advantages

03 10

Topic 7. Environmental Protection Brief description of the following acts and their provisions:

Environmental Protection Act Air (Prevention and Control of Pollution) Act Water (Prevention and Control of Pollution) Act Wildlife Protection Act Forest Conservation Act

Population Growth: Aspects, importance and effect on environment

Human Health and Human Rights

02 08


1. Collection of information, data 2. Analysis of data 3. Report writing

Motor Skills:

1. Presentation Skills 2. Use of multi media

List of Projects: Note: Any one project of the following:

1. Visit to a local area to document environmental assets such as river / forest / grassland / hill / mountain

2. Visit to a local polluted site: Urban/Rural/Industrial/Agricultural 3. Study of common plants, insects, birds 4. Study of simple ecosystems of ponds, river, hill slopes etc

Prepare a project report on the findings of the visit illustrating environment related facts, analysis and conclusion. Also suggest remedies to improve environment.




Learning Resources: Books: Sr. No. Author Title Publisher

01 Anindita Basak Environmental Studies Pearson Education

02 R. Rajgopalan Environmental Studies from Crises to Cure

Oxford University Press

03 Dr. R. J. Ranjit Daniels, Dr. Jagdish Krishnaswamy

Environmental Studies Wiley India





Course Code : PC

Semester : Fourth

Subject Title : Digital Imaging




TH TU PR PAPER


04 -- -- 03 100 -- -- -- 100

NOTE:




Rationale:

Imaging systems or Image carrier generation techniques are one of the most controlling

factor for print quality and print production. The conventional techniques are get superior by

advancement in Electronic and Mechanical technology. This subject contains conventional imaging

systems and modern imaging systems in detail for image carrier generation for Impact and non-

impact printing workflow.

General Objectives:


1. Understand Imaging systems for image generation

2. Understand photo-mechanics behind image generation.




Learning Structure Application Procedure

Principles Concepts Facts

Use of light sensitive sliver halide materials for film forming, UV

sensitive photopolymer rubber plate, pre-sensitized metal plate for image

generation

Generate an Image carrier using different techniques as per requirement of

printing process, minimises the stages involved in converting process of

digital image to physical image carrier.

Laser sources, spectral

sensitivity, polymerization cross

linking, photo-mechanics

Polymerization, light sensitive chemistry, electrophotography, comparative

sensitivities, laser ablation for thermal process

CtP techniques,

Thermal and non

thermal laser

exposing

Laser ablation, rastering for

photography and mechanical image

generation

Electrophotography

photopolymer plate

exposing,

Image setter, film

exposing, Com. to Film

using sliver halide films,




Content: Theory Topic Topics and Contents Hours Marks

01 Overview of conventional imaging techniques and Digital Imaging

08 12

Specific Objective: Introduction to conventional and digital imaging techniques

1.1

1.2

1.3

Definition, applications and factors that accelerated the development of Digital Imaging in graphic prepress technologies. Comparison of conventional film, plate making and digital imaging approaches used in graphic reproduction. Advantages of Digital Imaging prepress techniques.

02 Requirements for an ideal Digital Imaging system

10

16

Specific Objective: Explain photo chemistry

2.1

2.2 2.3

Energy i.e. photo speed requirements of different light sensitive chemistries in use. Study of required properties of exposing medium (such as laser) used in digital imaging devices. Requirements for computer-to-plate and computer-to-film devices. Different types of Digital Imaging systems. Classification of computer-to-plate and computer-to-film systems as light and non-light sensitive

03 Silver Halide based light sensitive Digital Imaging systems

08 12

Specific Objective: Explain light sensitivity of sliver halide

3.1

3.2

Study of working principle, spectral sensitivity, stages involved in different silver halide based computer-to-plate &computer-to-film systems Study of advantages, applications and limitations of silver halide based computer-to-plate and computer-to-film systems

04 Electro photography based light sensitive Digital Imaging systems

10

14

Specific Objective: Learn electrophotography imaging

4.1

4.2

Study of working principle, spectral sensitivity, stages involved in electro photography. Study of advantages, applications and limitations of electro photography

05 Organic Photopolymer light sensitive Digital Imaging systems

08 12

Specific Objective: Explain organic photo polymerization process

5.1

5.2

Study of working principle, spectral sensitivity, stages involved in organic photopolymer based computer-to-plate systems. Study of advantages, applications and limitations of organic Photopolymers.

06 Non light sensitive or heat based Digital Imaging Systems 16

Specific Objective: Explain CtP techniques for film and plate




6.1

6.2

6.3

6.4

Study of working principle and characteristics of imaging with the help of thermal cross-linking mechanism & comparative sensitivities of optical i.e. light sensitive & cross-linked plates. General comparison of light and non-light sensitive Digital Imaging systems used in graphic prepress industry. Study of working principle; stages involved in different laser ablation i.e. heat based computer-to-plate making systems. Study of advantages, applications & limitations of heat based i.e. thermal computer-to-plate & computer-to-film systems.

06

06

08

04

07 Outputting or Digital Imaging in CTP and Image-setters

04 10

Specific Objective: Explain process of rasterisation and chemistry of exposing

7.1

7.2

Study of concept of raster and working principle of raster scanning as used in optical devices such as CTP or Image setter. Inline and off-line chemical processing of digitally exposed film or plate required for graphic reproduction

Total 64 100 Learning Recourses: Books:

Sr. No. Author Title Publisher

01 Helmut Kipphan Handbook of Print Media: Technologies and Production methods.

Heidelberg and Springer

02 Bob Thompson Printing Materials: Science and Technology

PIRA International

03 Joe Farace Digital Imaging Focal Press Ltd. London





Course Code : PC

Semester : Fourth

Subject Title : Gravure and Flexographic Printing




TH TU PR PAPER


04 -- 04 03 100 50# -- 25@ 175

Notes:




Rationale:

Gravure & Flexography Processes of Printing are Major Printing Techniques for Printing

for Packaging, Newspapers and many other such Products. The subject is being introduced for the

first time, exclusively. This will enable students to learn various machines, their configurations and

working, used for gravure & flexography Printing.

General Objectives:


1. Understand working of Gravure and flexo printing machine.



.




Learning Structure: Application Procedure Principles Concepts Facts

Printing various jobs by Gravure & Flexography Process of Printing

Setting of different units of machine

Pre make ready Pre Register Make ready & Run machine

Quality control devices and their use

Maintenance of Machines

Gravure and Flexography Printing Principles

Feeding, Printing, Inking, Delivery Units

Paper, Ink, water, Infrastructure, Manpower, Chemicals, Electricity, Buildings.




Contents: Theory

Topic 1: Gravure Process Hours Marks

Specific Objective: Describe characteristics & application area of Gravure printing

1.1 Brief idea of process, image carrier, application areas and characteristics of gravure printing process 04 06

Topic 2: Gravure machine: major parts Specific Objective:

Describe assembly of doctor blade Explain function & setting of doctor blade

2.1

2.2

2.3

Doctor blade : a) Materials b) Assembly- angle, force, deflection, causes of wear

c) Holder configurations, wiping & contact angles, pressure control d) Setting, Make-ready

Impression roller : a) Functions, materials & hardness b) Configurations – pressure, conductivity balance, deflection & compensation c) Roller storage d) Roller setting & effects on web tension e) Electrostatic assist

Gravure proofing machines – construction and working

16 26

Flexography Topic 3: Printing machines

Specific Objective: Describe construction & applications of flexography machine

types Describe construction of flexo plate & Impression cylinder.

3.1

3.2

3.3

3.4

Principal types of printing machines- construction, application, Advantages and limitations,

a) Inline b) Stack c) Common Impression cylinder d) Hybrid presses, sheetfed presses and their application, drying

systems. Plate cylinder- construction, types- integral, demountable, sleeves and magnetic, plate mounting devices and tapes. Impression cylinder- construction, loading method- pneumatic or hydraulic. Impression (Tympan bar)- construction, tension control, impression adjustment Inline converting operation- slitting, laminating, punching, coating

16 24

Topic 4: Ink Metering System Specific Objective:

Describe inking system used in flexography Explain specification of anilox roller




4.1 4.2

Need of ink metering i) Standard two roll inking system ii) Two roll inking system with doctor blade iii) Reverse angle doctor blade system iv) Chambered doctor blade

Fountain roll- formulation, types of roll coverings, requirements, storage Anilox Roll

a) Specifications- cell wall, land, depth, opening, cell count, cell volume, cell angle, depth to opening ratio

b) Different types of engravings on Anilox roll and methods of engraving, Considerations for choosing proper anilox roll.

16 26

Topic 5: Inks for flexography process Specific Objective:

Describe composition & requirement of gravure & flexography ink

5.1 5.2 5.3

Gravure – Composition, Classification, Properties, Solvents, Toxicity, Viscosity, Temperature Flexography - Ingredients of flexographic ink- dyes, pigments, vehicles and solvents with their types, properties and applications. Different end use requirements of flexographic products- ink adhesion, scratch, rub and block resistance, weather resistance, gloss, coefficient of friction test. Water based, solvent based and U.V. inks- composition, properties, and areas of applications, advantages and disadvantages.

08 12

Topic 6: Troubleshooting Specific Objective:

Explain problems related with gravure & flexography presses

6.1 Problems encountered in Gravure and Flexo process, their causes & remedies

04 06

Total 64 100 List of Practical: The following practicals shall be conducted by video demonstration / industrial visit.

1. Different parts of gravure machine & their working.

2. Setting of feeding unit.

3. Setting of printing unit- doctor blade assembly, impression roller, registration control.

4. Setting of delivery unit.

5. Preparation of gravure cylinder.

6. Printing of multi color job.

7. Study of gravure cylinder proofing machine.

8. Demonstration to different configurations of machines of flexo process.

9. Checking quality of printed jobs using quality control aids.

A student shall submit a journal on above practicals as Term Work.




Reference Books: Sr. No. Author Title Publication

1 Helmut Kipphan Handbook of Print Media: Technologies and Production methods.

Heidelberg and Springer

2 Bob Thompson Printing Materials: Science and Technology

PIRA International

3 -- Flexography Primer GATF

4 -- Gravure Primer GATF

5 -- Gravure Process GAA

6 -- Flexography: Process and Technology FTA

7 Bisset, Leach The Printing Ink Manual Northwood Publication





Course Code : PC

Semester : Fourth

Subject Title : Web Fed Presses




TH TU PR PAPER


04 -- 02 03 100 50# -- 25@ 175

Notes:




Rationale:

Web machine operation is required to be learnt in order to understand efficient working

procedures. There is plenty of scope for skillful personnel in this branch of printing. This course

imparts extensive knowledge about all the elements of web machines used in all the printing

processes such as offset, flexography, gravure, as well as quality control procedures & auxiliary

operations.

General Objectives:


1. Understand working of web offset printing machine.






Learning Structure:

Application

Procedure Principles Concepts Facts

Setting of different

units

Pre-make ready & make ready procedures

Quality control aids & procedure

Maintenance Procedures

Paper, Ink, Offset M/cs Electricity, Man Power

Chemicals Infra structure, Water, Land

Printing various jobs by using multi colour Offset Presses ( Web fed)

Offset Principles

Feeding Unit, Printing Unit, Inking Unit, Dampening Unit & Delivery Unit




Contents: Theory

Sr. No. Contents Hours Marks

Topic 1: Introduction Specific Objective:

Describe web machine designs Distinguish between sheet fed & web machines

1.1

1.2

Construction & Design – Common impression cylinder (Satellite), Blanket to blanket, Inline, I, Y, H, N configurations, paper path and color combinations Comparison with sheetfed machines based on feeding, dampening, Inking, Printing, Delivery, wastage percentage

05 12

Topic 2: Infeed Specific Objective:

Describe infeed unit of web machine in detail

2.1

2.2

2.3

Reel stands- Single, Multiple, revolving; locations such as inline, perpendicular, basement, Automatic Splicers- Need , types , comparison

a. Zero speed- festoons b. Flying splicer (match speed)

Web tension - Dancer roller & its types, Infeed metering rollers; tension spans, draw, slip, tension control principles Surface speed - unwind and rewind Angle bar, Turner bar, Web guide rollers.

06

05

08

08

12

12

Topic 3: Dryers& Chill Rollers Specific Objective:

Explain the need of dryer & chill rollers

3.1

Need, operations and types - Open flame, High velocity hot air, radiation-UV, EB, IR curing, combination

06 08

3.2 Need, operations and types- Baffle plates, Jacketed (Embedded); Silicone application

04 08

Topic 4 : Folders & Related Ancillary Equipments Specific Objective:

Working of different types of folder

4.1

Need, operations, maintenance, types, - Former & its types, Jaw, Chopper, Combination; cut-off and different products, collect cylinders, conveyor mechanisms, and types of folds.

06 08

Topic 5: Registration and Web Control Specific Objective:

Describe registration on web machine�

5.1

5.2

Fan out and Controlling fan out(RPL & RPW) mechanical and electrical color register, Web to web register, Register control devices: Stroboscopes, Oscillating mirrors, Video viewers.

10 16





1. Select proper plate, paper, ink etc. 2. Interpret results.

Motor Skills:

1. Correct production. 2. Controlling and production on machine. 3. Quality checks by using instruments.

The following practicals shall be conducted by actual performance/video demonstration/ industrial visit. List of Practical:

1. Mounting & dismounting Blankets.

2. Learn make ready processes.

3. To pass web with different threading diagrams.

4. To set Web tension control mechanism.

5. To print single color jobs.

6. To print single / multi color jobs.

7. Run on problems and remedies 8. Use and study of Quality control aids in Printing.

Practice:

1. Press Visits & Demonstration.

2. Print various jobs on web fed presses.

A student shall submit a journal and printed sample of above practicals as Term Work

Topic 6: Ancillary operations

Specific Objective: Purposing & working of ancillary equipments

6.1

6.2

Slitting and trimming – Blades, slot type, rotary scissors, hard on hard slitters, perforators, sprocket punching. Web reconditioners, water-cooled ink oscillators, Blanket washers, Web break detectors, imprinters, side lay sensors, Cut-off control, anti static devices, remoisturisers.

14 16

Total 64 100






1 Ian Faux Modern Lithography Macdonald & Evans

2 J. Odhams Practical Printing & Binding --


4 Bisset, Goodacre, Idle, Leach & Williams The Printing Ink Manual Northwood Books, London

5 E. J. Kelly Web Offset- Press Operating GATF, USA

6 W. R. Durrant Web Control Focal Press, London

7 -- Handbook of Print Media Heidelberg

8 -- Solving Web-fed press troubles GATF





Course Code : PC

Semester : Fourth

Subject Title : Image Carrier Gravure & Flexography




TH TU PR PAPER


04 -- 02 03 100 -- -- 25@ 125

Notes:




Rationale:

This subject is intended to provide an understanding of the basics related to flexographic

and gravure image carriers and covers concepts regards to variables, processes and technical

advancements with limitations. The Gravure process is particularly important for packaging

applications. The sufficiently addressed of gravure and flexographic image carrier making

environment shall help students to cope up with constantly increasing demands of developing

imaging needs of competitive packaging field.

General Objectives:

The student will be able to-

1. Understand developments in photomechanical processes involved.

2. Understand material, machinery and equipments used in filmmaking process.




Learning Structure

Application


Imaging various originals by using different printing techniques

Scaling, Chemical

Preparation

Digital Image Editing, Out

device setting

Imaging media section and processing

Quality control,

maintenance

Exposure, Chemical Development, Chemical etching, Raster Imaging, solubility difference

Surface and subsurface metals, hardness, plating variables, photosensitivity

Rotary Image Carrier

Features and properties of image

carrier

Printability and runnability of image carrier




Contents: Theory

Topic Topic & Contents Hours Marks1 Overview of Image carriers Specific Objective:

Classify flexographic image carrier on different basis. Compare features of flexographic and gravure image carrier.

1.1 1.2

Introduction to flexographic printing image carriers. Classification and features of flexographic and gravure image carrier. Development of flexographic image carrier.

04 06

2 Rubber and Nylo Flexographic Plate Specific Objective:

Describe stages involved in plate making. Analyze troubles and remedies involved.

2.1

2.2

2.3

Study of construction, features and limitations of rubber plate. Required physical and chemical properties of rubber plate. Chemistry of raw material used in rubber plate material. Stages involved in making rubber type duplicate plate. Study of construction, advantages, and limitations of nylo plate. Required physical, chemical properties and sensitometric properties of nylo plate. Photographic requirement of nylo plate making and stages involved in nylo plate making. Study of processing chemicals and other process variables affecting imaging quality. Troubles and remedies involved.

12 18

3 Photopolymer Flexographic Plate Specific Objective:

Describe stages involved in photopolymer plate making. Analyze troubles and remedies involved.

3.1

3.2

3.3

3.4

3.5

Study of construction, advantages, and limitations of photopolymer plate. Required physical and chemical properties of photoploymer plate. Chemistry of raw material used in of photopolymer plate. Study of classification, applications of photopolymer plate. Photographic positive and negatives and their ideal optical and physical requirements for different plate making techniques. Detailed study of the stages, troubles and remedies involved in different types of photopolymer, liquid photopolymer. Introduction to computer-to-plate technology (CtP), its advantages, types. Sensitometry, light sensitive chemistry used, laser engine, printing resolution selected for flexographic CtP systems. Introduction to heat sensitive flexographic CtP systems. Study of processing chemicals and other process variables affecting imaging quality. Troubles and remedies involved.

14 22




4 Gravure Printing Cylinder by Chemical Etching Specific Objective:

Describe stages involved in electroplating. Study factors affecting plating quality.

4.1

4.2 4.3

4.4

Study of characteristics and construction of gravure printing cylinder. Study of required properties of surface metals such as copper, nickel used in gravure printing cylinder making. Study of purpose, working and construction of electroplating bath. Study of different variables that affect electroplating quality such as immersion factor, current density, temperature, cathode anode distance, etc. Study of calculation of total electroplating time. Stages involved in reclaiming gravure printing cylinder. Study of troubles and remedies involved in electroplating of copper and chromium.

14 20

5 Gravure Printing Cylinder by Electronic Engraving Specific Objective:

State working principle, Components of techniques. Identify stages involved electronic engraving.

5.1

5.2

5.3

5.4

Study of working principle and construction of electronic engraving unit. Study of cell type, cell wall, depth-to-opening ratio, cell angle, engraving resolution, calculation of total engraving time. Study of different types and calculation of volume formula of engraved cell geometries such as inverted pyramidal, quadrangular, channeled, hexagonal, etc. Study of printing quality of electronically engraved gravure printing cylinder in terms of resolution, color density, etc. Study of troubles and remedies involved in an electronic engraving of gravure printing cylinder.

10 18

6 Gravure Printing Cylinder by Digital Techniques Specific Objective:

State working principle, Components of digital techniques. Identify stages involved engraving by digital techniques.

6.1

6.2

Study of gravure cylinder making by laser engraving method. Study of type of laser, its classification, energy requirement. Study of advantages and limitations of gravure cylinder making by laser engraving method. Study of printing quality of laser engraved gravure printing cylinder in terms of resolution, color density, etc. Study of gravure cylinder making by electronic beam engraving method. Study of type of laser, its classification, energy requirement. Study of advantages and limitations of gravure cylinder making by electron beam engraving method

10 16

Total 64 100





1. Select raw material, characteristics and limitations of image carrier. 2. Observe and analyze the photochemical changes in image carrier making. 3. Understanding stages involved in positive and negative image carrier making.

Motor Skills:

1. Preparing sheet and liquid photopolymer plate. 2. Carrying out finishing operations on processed flexo plate. 3. Preparing processing chemicals.

The following practical shall be conducted by video demonstration / industrial visit. Sr. No Practical

01 Introduction to different machinery and equipments used in flexographic and gravure image carrier making department information.

02 Making of line and tone nylo plate. 03 Making of half tone nylo plate for full color graphic original’s reproduction.

04 Study of effect of effect of under, over exposure and development on an output quality of nylo plate.

05 Making of line and tone sheet photopolymer plate.

06 Making of half tone sheet photopolymer plate for full color graphic original’s reproduction.

07 Study of effect of effect of under, over exposure and development on an output quality of sheet photopolymer plate.

08 Study of different quality control graphic aids and instruments used flexographic image carrier making to ensure color and tone reproduction and gray balance.

09 Demonstration of flexographic plate making on CtP unit and electronic engraving of gravure cylinder, electroplating of gravure printing cylinder base and listing of trouble and remedial action taken..

10 Demonstration of chemical etching i.e. imaging of gravure printing cylinder and listing of trouble and remedial action taken.

11 Demonstration of electronic and laser engraving of gravure printing cylinder. A student shall submit a journal and sample on above practical as Term Work Reference Books: Sr. No. Title of Book Author Publisher's Name

1 Gravure Process Technology

Gravure Association of America

--

2 Flexography Primer GATF, USA James Crouch

3 Flexography: Principles & Practices

Flexographic Technical Association

N. Y. Flexographic Technical Association

4 Gravure Primer GATF, USA --





Course Code : PC

Semester : Fourth

Subject Title : Professional Practices-II




TH TU PR PAPER


-- -- 03 -- -- -- -- 50@ 50

Rationale:

The student of printing technology having introduced, learnt and understood the basics of

graphic reproduction process is well placed to grasp different processes carried out in graphic arts

industry. Inclusion of the subject professional practices III requiring student to undertake little

enhanced activities so that he or will have developed attitude toward learning and knowing subject

related aspect wherein class room environment would be just complementary. The variable for the

students to enrich their knowledge kitty are info search, group discussion, industrial visits, seminar

presentations and expert or guest lectures.

General Objectives:

The student in question will be able to:

1. Identify different areas eligible for info collection of his or her interest.

2. Identify prevailing or important topic from different areas eligible for seminar preparation

or presentation of his or her choice.

3. Relate excerpts of the expert guest lecturers to the theory or practical subjects from the

ongoing curriculum.

4. Make a note and report on a industrial training or visit as a part of curriculum and ask

opinion on the same from his or her teaches.

5. Prepare a seminar report on any topic from a prevailing subject of his or her choice.




Learning Structure:

Application:

Procedure:

Principle:

Concepts:

Facts:

Use of systematic approaches for seminar writing, presentation and group discussion.

Prepare primary draft, get approval and presentation aided by audiovisual aids.

Ordering the points of anticipatory discussion to give effective thought sharing.

Principle of effective listening, understanding and ability to present the same.

Understanding of importance and influences of the topic.

Understanding technical magazines and adjoining industry.

Industrial Visits, Expert lecture, Group Discussion, Information Search, Technical report writing and presentation.




Content: Theory

Sr. No

Activity Hours

1

Industrial Visits: Structured industrial visits be arranged and the report of the same should be submitted by every student. Visit to any of the following establishment-

1. Small sheet fed commercial lithographic offset printing, screen-printing, advertising and shops trading raw materials such as paper, ink and other prepress chemicals.

2. Gravure & Flexography printing press. 3. Label Industry 4. Paper manufacturing unit

10

2

Lecture by professional or industrial expert be arranged on any three topics from the following area-

1. Paper manufacturing process. 2. Fire hazard and safety norms. 3. Role of printing technology in an advertising industry. 4. Illumination of shop floor.

08

3

Group Discussion: The students should discuss in a group of 6-8 and write a brief report on the same discussion in the form of term work. The respective faculty members will give topics for a discussion. Areas of discussion are-

1. Sport and cultural activities 2. Discipline and housekeeping. 3. Prevailing general topic from the printing technology and allied area.

10

4

Information Search: The student, in tandem with subject teacher, should identify the additional info needed for better understanding of the given part of the ongoing curriculum. The collected or searched information may be from institute or private library, expert lectures, technical exhibitions, sponsored or free lanced market survey, and industrial visits.

08

5

Technical Report Writing and PresentationEvery student after having exposure to either industrial visit or expert guest lecture should and be able to write meticulous and qualitative technical report which could be used as a resources material for printing technology students as well as professional and amateurs in printing technology.

12

Total 48

A student shall submit a reports on above activities as Term Work


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