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Transcript of Printing Technology II
TEACHERS' SOURCEBOOK
VOCATIONAL HIGHER SECONDARY
State Council of Educational Research & Training (SCERT)Vidyabhavan, Poojappura, Thriuvananthapuram-12, Kerala
GOVERNMENT OF KERALADepartment of Education
2006
PRINTING TECHNOLOGY
SECOND YEAR
Prepared by:State Council of Educational Research & Training (SCERT)
Vidyabhavan, Poojappura, Thiruvananthapuram -12Kerala
E-mail:[email protected]
Type setting by:SCERT Computer Lab.
©Government of KeralaEducation Department
2006
This Teacher’s Sourcebook on Printing Technology introduces theteacher to the main principles and practices of the revised pedagogywhich is activity-based, process-oriented and learner-centred.
The realisation that learning is not mere storing information inmemory and that real learning is construction of knowledgethrough observation, comparison, classification and analysis hasled us to give a new thrust to the teaching-learning process atVocational Higher Secondary level to make it more meaningful andlearner-friendly.
This sourcebook has been developed primarily for the benefit ofteachers who teach Printing Technology at Vocational HigherSecondary level. The subject matter has been dealt with utmostcare, in tune with the revised curriculum and pedagogic principles.It is hoped that this book will enable the teacher to provide suitablelearning activities for effective learning.
The success of the approach depends upon the vision andcommitment of the teacher. They are expected to make use of thissourcebook at all stages of their teaching process. It is also expectedthat the teacher would seek help and guidance from other sourceslike libraries and websites.
Hope that this sourcebook will help the teacher to develop the skillsand experience required for effective classroom transaction.
Creative criticism and suggestions for improvement are mostwelcome.
With regards,
Thiruvananthapuram Dr E. Valsala Kumar July, 2006 Director
SCERT, Kerala
Foreword
Dear Teachers,
C O N T E N T SPART I
GENERAL APPROACH ................................................................. 6LEARNING STRATEGIES ......................................................... 23CURRICULUM OBJECTIVES ....................................................33SYLLABUS ....................................................................................... 39PLANNING .....................................................................................4 5E V A L U A T I O N ................................................................................ 50MONITORING AND SUPPORTING SYSTEM ...................... 6 1
PART II1. P A P E R ................................................................................... 6 4
2. I N K .......................................................................................... 7 53. PRESS DEVELOPMENTS ................................................. 814. OFFSET PRESS OPERATION..........................................9 25. ROLLER AND BLANKET PROBLEMS AND
ITS ADJUSTMENTS ........................................................... 9 86. MULTI COLOUR SHEET FED OFFSET PRESSES .. 1067. PRINTING PROCESS-COLOUR ON SHEET FED ... 1 1 28. WEB OFFSET PRESSES ....................................................1 1 79. TROUBLE SHOOTING .................................................... 12310. SCREEN PRINTING .........................................................13011. OTHER PRINTING PROCESS ......................................1 4 212. FINISHING OPERATIONS ............................................. 1 4813. PRINTING AND PACKAGING ...................................... 1 6 114. BASIC ENGINEERING .................................................... 170
PART III
A P P E N D I X............................................................................................. 1 7 7
A b o u t t h i s B o o k
This book is intended to help the Vocational Higher Secondary School teachersin Printing technology ( Second year)
SyllabusThe Syllabus helps to go through the modern printing techniques.
ActivitesIf necessary, innovative and better activities may be used instead ofsuggested activities.
Lab workCertain units have wide scope to link Lab work with theory. Experimentin lab is not a mere mechanical work, it must be done as a part ofinvestigatory learning. The cycle of experiments for practicals should bearranged in a such a way that theory and practical go parallel to eachother. Activities suggested in the lab are meant for 25-30 students at atime. The number of groups formed should be according to the labfacilities of the school.
PeriodsIn the activity based approach, the periods suggested for each unit isslightly different from that given in the syllabus. The total periodsrequired to transact cos may be varied with the level of students andschool facilities. After preparing the year plan, it is found that all thecos can be transacted within the stipulated time.
QuestionsCertain sample questions are given for TE at the end of each unit.
CE ItemsCE items suggested for each unit are given at the end.
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Printing Technology
GENERAL APPROACH
SIGNIFICANCE OF VOCATIONAL EDUCATION
The ultimate aim of education is human refinement. Education should enable the learner to formulatea positive outlook towards life and to accept a stand which suits the well being of the society and theindividual as well.
The attitude and potential to work has determined the destiny, progress and cultural developmentof the human race. As we all are aware, the objective of education is to form a society and individualshaving a positive work culture. The educational process expected in and outside our formal schoolsshould concentrate upon inculcating concepts, abilities, attitudes and values in tune with these workculture. Hence vocationalised education cannot be isolated from the main stream of education. Inanother sense, every educational process should be vocationalised. However due to our inability toutilize the resources wisely, scarcity of job opportunities is a severe issue of the present society. Forovercoming this deep crisis, emergent techniques have to be sorted out and appropriate researcheshave to be seriously carried out. It is in the sense that the content and methodology of VocationalHigher Secondary Education have to be approached. The need for meaningful linkages between theworld of work and world of education is well recognized. The essence of the recommendationsmade by various commissions and committees is that the vocationalisation should be the main featureof the future system of education at the higher secondary stage, it can be extended to school levelalso.
Vocational education is system of education which intends to prepare students for identifiedoccupations , opening several areas of activities.
The Vocational Higher Secondary course was envisaged as a part of the National Policy onEducation with the noble idea of securing a job along with education. The relevance of vocationaleducation is very great in this age of unemployment. This education system, which ensures a jobalong with higher education stands aloof from other systems of education.
This education imparts the life skills required by the youth to enter the world of work and assumingthe responsibilities of adulthood. As per the expert meeting report 2001 of UNESCO, the life skillsare grouped under 4 categories. They are1. Skills for personal fulfillment
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2. Skills for living in society3. Skills for dealing with changing economies4. Skills for dealing with changing work patterns.
Vocational Education ensures fulfillment of manpower requirement or national development andfor social security for the citizens through self-employment. It also helps to reduce the migration ofrural youth to urban areas and thus helps in rural development.
The learners of Vocational Education get an opportunity to avail one year apprenticeshiptraining in industries to improve their practical skill. During the course of study, on the job training(OJT) for 10 days in a year is arranged to improve the skill and efficiency of the learner. Thiseducation system motivates the attitude towards self –employment through Production Cum ServiceTraining Centres. (PSTC)
OBJECTIVE OF VOCATIONAL EDUCATION
The National policy on education has accorded very high priority to the program ofvocationalisation of education, considering the following objectives.
1. To fulfill national goals of development and the removal of unemployment and poverty.2. To impart education relevant to increased production and productivity, economic development
and individual prosperity.3. To make available skilled work force at all levels to alleviate the rural unemployment and for
the development of nation.4. To develop environmental awareness to ensure sustainable development.5. To develop vocational aptitude, work culture, values and attitudes of the learners so as to
enrich the productivity of the nation.6. To develop entrepreneurial competencies and skills of learners for self reliance and to undertake
gainful self employment.7. To facilitate the expansion of higher education and explore future opportunities through
innovative guidance and programmes.8. To develop vocational competencies, creative thinking in the related areas and facilitate training.9. To create awareness on mental, physical and social health.10. To acquire awareness about different job areas and to provide backgrounds for accruing
higher level training in subjects concerned.
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LearningLearning is construction of knowledge through a continuous mental process. It is an
advancement through adding and correcting in the light of comparing the new issue with the previouslylearned concepts. Learning is an intellectual process rather than the mere memorization of facts.Learning is a conglomeration of a variety of activities like problem solving, finding out co-relations,prediction, arriving at conclusions, rational as well as critical thinking, finding applications, groupingfor other possibilities and extracting the crux when opportunities are provided for intellectual processeslearning will become effective and intellectual ability will get strengthened.Theoretical foundations of learning
Education is the best device that can be adopted for creation of a new society. It should bedemocratic in content and process and should acknowledge the rights of the learner. It should alsoprovide opportunity for better citizenship training. The concept of equality at all areas should getrecognition in theory and practice. There should be conscious programme of action to developnationality, humanness and love against the encroachment of sectarianism of caste and religion. Thelearner should become cognisent of the implications of privatisation, liberalisation, globalisation etc.
They should develop a discrimination to use the acquired learning as a liberative weapon.
They should be able to view education and life with the perspective of social well being.
A basic awareness of all the subjects needed for life is essential for all students.
The remnants of perspectives formed in us during the colonial period still influence our educationalphilosophy. The solution to the present day perplexities of the society which approaches educationon the basis of competitions and marketisation is only a comprehensive view of life.
It is high time that education was recognized on the basis of the philosophy of human education.The human approach to education has to reflect in its content, learning process and outlook. Theperspective of ‘learning to be’ and learning to live together as expressed by the UNESCO and theconcepts of existential, intrapersonal and interpersonal intelligence.
The basis of new approaches on curriculum and teaching- learning process are derived from thedevelopments tookplace in the east and west of the world.
When we begin to see the learner at the centre of the learning process, the teaching process hasto be changed timely. It is the result of the rapid growth and development of Science and Technologyand Pedagogy. If we want to undergo the changing process, we have to imbibe the modern hypothesisregarding learner that they have
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w great curiosityw good imaginationw numerous other qualities and interestsw independent individualityw interest in free thinking and working In a fearless atmosphere.w interest in enquiring and questioning.w ability to reach conclusions after logical thinking.w ability for manifest arid establish freely the conclusions arrived at.w interest for recognition in the society.w determination to face the interference of society and make components which is a part of
social life..When we consider the learning system, the domains to be stressed in education according to themodern development becomes relevant.
The knowledge domain consists ofw Facts
w Ideas
w Laws
w The temporary conclusions and principles used presently by scientists.
The learning is a process. The continuous procedures we undergo to reach a particular goal isprocess. The skills which are parts of the process to analyze the collected ideas and proofs andcome to a conclusion is called process skills. Some important process skills are,The skills;
w To observe
w To collect data and record
w To classify
w To measure and prepare charts
w To experiment
w To predict
w To recognize and control the variables
w To raise questions
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Printing Technology
w To generalize
w To form a hypothesis and check.
w To conclude
w To communicate
w To predict arid infer
w To use tools.
Observation is the process of acquiring knowledge through the senses. It is purelyobjective oriented. Learning experiences which provide the use all the sense may beused.
The process of grouping is known as classifying. Starting from simple groupings ofdata, it can extend to the level of classification into minute sub-groups.
In addition to this, consider the skills related to creative domain also, they areskills:
w To visualize
w To connect facts and ideas in new ways.
w To find out new and uncommon uses of objects
w To fantasize
w To dream
w To develop creative isolated thoughts
Creativity is an essential component of process and activities. The element of creativityis involved in finding out problems, formation of hypothesis, finding ‘solutions’ to problemsetc. Through activity oriented learning experiences, opportunities to express creativitycan be created.
Again, the following factors consisting in the Attitudinal domain are also important as;w Self confidence
w Love for scientific knowledge
w Attitude to know and value history
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w Respect human emotions
w Decide with reasonable present problems
w Take logical decisions regarding personal values
‘Hypothesis’ is a temporary conclusion drawn using insight. Based on knowledgeand experiences relating to the problems the causes and solutions can be guessed.
As regards the application domain the important factors are the ability to:w observe in daily life examples of ideas acquired.
w take the help of scientific process to solve the problems of daily life.
w choose a scientific life style
w connect the ideas acquired with other subjects.
w integrate the subjects with other subjects.
Some basic stands have to be taken on the new scientific knowledge about intelligence learningand teaching. When such basic concepts are accepted changes are required in the following factors.
w The vision, approach, structure and content of the curriculum.
w The vision, approach, structure and content of the textbooks.
w Role of the teacher and the learner.
w Learner atmosphere, learning materials and learning techniques.
Some scientific perspectives accepted by modem world in educational psychology are givenbelow.Constructivism
This approach puts forward the concept that the learner constructs knowledge. New knowledgeis constructed when ideas are examined and practiced in new situations relating them with thepreviously acquired knowledge and experience. That is assimilated into the cognitive structure ofone’s knowledge. This method which gives priority to critical thinking and problem solving providesopportunity for self motivated learning.Social Constructivism
Social constructivism is a sub section of constructivism. Knowledge is formed, spread and imbibedand it becomes relevant in a social environment. Interactive learning, group learning, co-operativeparticipatory learning, all these are concepts put forward by social constructivism.
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Printing Technology
The main propounders of constructivism are piaget, vygotsky and Bruner.
Discovery learning and interactive learning have prime importance. Learning takes place as apart of the attempt for problem solving. The activities of a learner who confronts cognitivedisequilibrium in a learning situation when he tries to overcome it leads to the renewal of cognitivestructure. It is through this process construction of new knowledge and the assimilation of them takeplace. Observation and enquiry are unavoidable factors. The learner advances towards new areasof acquisition of knowledge where he tries to compare his new findings with the existing concepts.
Learning is a live mental process. Rather than the ability for memorization of facts cognitiveprocess has to be given emphasis. The process of problem analysis, elucidation, critical thinking,rational thinking, finding out co-relation, prediction, hypothesis formation, application, probing forother possibilities, extracting the crux and other processes are of critical importance in learning.
Constructivism gives greater predominance to co-operative learning. Social and cultural factorsinfluence learning. Sharing of knowledge and experience ántong learners, collective enquiry,assessment and improvement, group activity and collaborative learning by sharing responsibilitieswith the objective of public activity, provide opportunity for effective learning.
In learning internal motivation is more important than external motivation. The learner shouldhave interest and initiative in learning. Learning situation should be capable of forming a sense ofownership in the learner regarding the learning process.
Learning is not a linear process. It progresses in a spiralled way advancing deeper and wider.New concepts of Learning
1.. Discovery LearningThe teacher has to create a motivating atmosphere for the learner to discover concepts and facts,
instead of listening always. Creating occasion to progress towards discovery is preferred. Instead oftelling everything before and compelling to initiate the models, situations are to be created to help thechildren act models as themselves.2. Learning by discussion
Discussion leads to learn is Burner’s theory. Here discussion is not opposing each other. It is asharing on the plane of ideas. New ideas are arrived at by seeking explanations, by mutual givingand taking of ideas and by problem solving.3. Problem solving and learning
Only when the learner feels that some thing is a problem to be solved that he takes the responsibilityof learning it. It is an inborn tendency to act to solve a problem that causes cognitive disequilibriumin a particular area. It is also needed to have confidence that one is capable of doing it. The problems
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are to be presented in consideration of the ability and level of attainment of the learner.4. Collaborative learning
This is the learning in which the responsibilities are distributed among the members of the groupkeeping common learning objectives. The common responsibility of the group will be successfulonly if each member discharges his duties. All the members will reach a stage of sharing the result oflearning, equally through the activity with mutual understanding. The teachers who arrange collaborativelearning will have to make clear the responsibilities to be discharged. This is possible through thediscussion with the learners. Collaborative learning will help to avoid the situations of one personworking for the whole group.5. Co-operative learning
This is the learning in which the learners help one another. Those who have more knowledge,experience and competency, will help others. By this exchange of resources the learners develop aplane of social system in learning also. As there are no high ups and low ones according to statusamong the learners they can ask the fellow students doubts and for helps without any hesitation or inhesitation Care should be taken not to lead this seeking of help to mechanical copying. It should beon the basis of actual needs. So even while encouraging this exchange of ideas, among the membersof the group cautious acceptance is to be observed as a convention. There should be an understandingthat satisfactory responses should come from each member and that the achievement of the groupwill be assessed on the basis of the achievement of all the members6. Zone of Proximal Development
Vygotsky observes that there is a stage of achievement where a learner can reach by himself andanother higher zone where he can reach with the help of his teachers and peers and elders. Eventhough some can fulfil the learning activity by themselves there is the possibility Of a higher excellence.If appropriate help is forth covering every learner can better himself.7. Scaffolding
It is natural that the learner may not be able to complete his work if he does not get support at theproper-time-The learner may require the help of the teacher in several learning activities. Herehelping means to make the learner complete the activity taking responsibility by himself. The teacherhas to keep in mind the objective of enabling the learner to take the responsibility and to make itsuccessful.
8. Learning an active mental processLearning being a cognitive process, the teacher needs to know cognitive processes to facilitate
the creation of learning opportunities. Learning can be made effective by providing learning experiencesinvolving mental processes like
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Printing Technology
w Retrieves/recollects/retells informationw Readily makes connections to new information based on past experiences and formulates
initial ideas /concepts.w Detects similarities and differencesw Classifies/categories/organizes information approximately.w Translates/transfer knowledge or understanding and applies them in a new situation.w Establishes cause-effect relationshipsw Makes connections/relates prior knowledge to new information/applies reasoning and draw
inferencesw Communicates knowledge/understanding through different media.w Imagines/fantasises/designs/predicts based on received informationw Judges /appraises/evaluates the merits or demerits of an idea/develops own solutions to a
problem.9. Intrinsic Motivation
Intrinsic motivation is given more importance than extrinsic motivation. The teacher has to arousethe internal motivation of the learner. A person internally motivated alone can immerse in learning andown its responsibility.
developing this area of intelligence10 . Multiple intelligence
The Theory of Multiple Intelligence put forward by Howard Gardener has created a turning pointin the field of education. The National curriculum documents has recommended that the curriculumis to be designed taking into consideration of this theory.
Main factors of the intellect:1. Verbal/linguistic Intelligence
Ability to read and write, making linguistic creations, ability to lecture competence to effectivecommunication, all these come under this. This can be developed by engaging in language gamesand by teaching others.2. Logical/mathematical Intelligence
Thinking rationally with causes and effect relation and finding out patterns and relations comeunder this area. Finding out relations, explaining things, sequential and arithmetical calculations etc.are capable of developing this area of intelligence.3. Visual/spatial Intelligence
In those who are able to visualize models and bringing what is in the imagination into visual formand in philosophers, designers and sculptors this area of intelligence is developed. The activities like
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modeling using clay and pulp, making of art equipments, sculpture, and giving illustrations to storiescan help the development of this ability.4. Bodily Kinesthetic Intelligence
The activities using body language come under this. This area of intelligence is more developedin dancers and actors who are able to express ideas through body movements and in experts insports, gymnastics etc.5. Musical Intelligence
This is an area of intelligence which is highly developed in those who are able to recognize thedifferent elements of music in musicians and in those who can here and enjoy songs. Playing musicalinstruments, imitating the songs of musicians, listening silently to the rhythms and activities like thisare capable of developing this area of intelligence.6. Interpersonal Intelligence
Those in whom this area of intelligence is developed show qualities of leadership and behavewith others in a noble manner. They are capable of understanding the thought or others and carryingon activities like discussion successfully7. Intrapersonal Intelligence
This is the ability to understand oneself. These people can recognize their own abilities anddisabilities. Writing diaries truthfully and in an analyzing way and assessing the ideas and activities ofothers will help developing this areas of intelligence8. Naturalistic Intelligence
A great interest in the flora and fauna of the nature, love towards fellow beings interest in spiritualand natural factors will be capable of developing this area.9. Existential Intelligence
The ability to see and distinguish ours own existence as a part of the universe, ability to distinguishthe meaning and meaninglessness of life, the ability to realize the ultimate nature of mental andphysical existences, all these re the peculiarities of this faculty of intelligence.10. Emotional Quotient
The concept of emotional intelligence put forward by Daniel Golman was used in framing the newcurriculum. The fact that one’s Emotional Quotient (E.Q) is the greatest factor affecting success inlife is now widely accepted. The teacher who aims to focus on improving the emotional intelligenceof students need to concentrate on the following.
i) Ability to take decisions
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Rather than imposing decision on students while planning and executing activities, the studentsmay be allowed to take part in the decision making process. Taking decisions through open discussionin the class, inviting students suggestions on common problems etc. are habits to be cultivated.ii) Ability to reach consensusw When different opinions, ideas and positions arise, the students may be given the responsibility
to reach a consensus.w Imagining what would be the course of action in some situations, allowing to intervene in a
healthy way in problems between individuals.iii) Problem solving
w Developing the idea that there is reason and solution to any problem.
w Training in finding reasons for problems.
w Suggesting solutions through individual or group efforts.
w Discussing social problems.
w Analyzing the shortcomings in methods to solve problems.
Whether plastic can be banned within school premises can be given as a problem. Group discussionwill provide reasons and solutions. Problems which can influence classroom learning and for whichthe learner can actively contributeSolution need to be posed
w Self criticism, evaluation
w Ability to face problem-situation in life
w Thinking what one would do if placed in the situation of others, how one would respond tocertain experiences of others - All these foster the growth of emotional intelligence.
iv) Life skillsLife skills need to be given a prominent place in education. W.H.O. has listed : skills required for-
success in life.w Self awareness
w Empathy
w Inter personal relations
w Communication
w Critical thinking
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w Creative thinking
w Decision making
w Problem solving
w Coping with emotion
w Coping with stress
The new curriculum addresses these areas.
Knowing the characteristics of the learner, role of the teacher and how to use the teachershandbook help the teacher to plan and effectively implement learning activities.
Role of a TeacherIn the earlier approach the teacher was mainly depending on the lecture method for teaching. But
in the new method of education the student centered approach in given more importance than theteacher centered approach. Under this changed scenario the teacher has to perform the followingroles in the classroom.
The teacher should be
w A facilitator of learning
w A guide to the overall development of the student
w A good observer and motivator
w Able to consider the activities, needs, special features and age group of students at highersecondary level.
w Able to understand the limitations of learner and their learning problems.
w An instructional material developers
w A good communicator
w An innovator
w Able to raise leadership qualities and self confidence of the learner
w An authoritarian in the concerned subject
w Able to arrest and sustain the attention of the learner
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Printing Technology
w Able to bring out and encourage the inborn talents.
w A resource manger to ensure the optimum utilization of resources.
w A systematic record keeper
w A controller to issue guidance to the students
w A person with high level of practical competency
w Able to correlate area of study with familiar environmental situations
w A self evaluator and good listener
w Able to create awareness in social problems
w A person with democratic and humanitarian approach
w A professionalist as well as philosopher
w A good evaluator
w A good organizer and a friend.
w A co-learner as well as co-researcher
w Able to give assistance and advice in placement needs and self employment by giving moraland technical support
w Able to keep moral values
w A person equipped with skill for using new techniques of learning
w Optimistic and impartial
Child friendly Class Room AtmosphereLearning can be effective and enjoyable only when the class atmosphere is according to the new
conception of learning and the characteristics of higher secondary teacher.
w Class and seating are arranged in an attractive wayw Democratic nature is upheldw Always activew Students interact with teachers without fearw Opportunity for a variety of activitiesw Students allowed to involve interesting group activities
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w Learning speed, learning style and differencing levels of attitudes are considered.Help is extended whenever needed.
w Sufficient instructional materials are availablew These is freedom of expression, students share their ideas and experiencesw Students are given acceptance and encouragementw Healthy atmospherew Needs of each students is given consideration. Happy and energetic atmospherew Teachers work considering the rights of studentsw Problems handled in a patient wayw Teachers work at all events from the students view point
These will be students of various ability levels in any class because learning style, learning speed,varying exposure to language experiences, physical ad psychological problems and varying socio-cultural background.
The learning experiences provided must help to bring the low activities to an expected level andextended the breadth and depth of the skills of the high activities.
By repeating experiences, introducing variations in a learning experience to suit different levelsand if needed, formulating additional experiences the problem of varying ability levels can be tackled
Role of LearnerThe learner in second year has undergone a learner centered and process oriented learning
experience up to first year. The learner at this age is in awakening stage and he is enthusiastic aboutenvironment. He needs recognition and encouragement from environment and also recognize as agrown up man. He is adequately competent to select vocational subjects according to his aptitudeand interact and to acquire higher education and profession as he wishes. The aspirations aboutfuture life is framed in this particular age for seeming national and international job opportunities.Some of the peculiarities of learner at this stage are;
w Physical, intellectual and emotional planer are intensive changes during the age and theirreflections can be observed
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Printing Technology
w Ability to enquire discover and establish cause effect relationship between phenomena
w Headiness to undertake challenges
w Capacity to shoulder leadership roles
w Attempt to interpret oneself
w Susceptibility to different pressures
w Doubts, anxieties and eagerness about sex
w Imaging for social recognition
Needs of Learnerw To make acquaintance with a job or self employment through vocational education
w To acquire more knowledge in the concerned area through higher education
w To recognize and encourage the peculiar personality of the later adolescent period
w To enable him to defined against the unfavorable circumstances without any help
Role of learnerw Active participant in the learning process
w Act as a researcher
w Sharer of information
w Sharer of responsibilities
w Collect information
w Jakes leadership
w Involves in group work
w Act as a co-participant
w Observes his environment
w Experiments and realize
w Make interpretations and draw inferences
w Mould himself in to an active contributor for the welfare of the society
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EVALUATIONIn vocational higher secondary education, a new approach to education and evaluation should
be made. Evaluation must be a systematic and continuous process. As the curriculum is based onvocational stream, capacity building is a most important part and it should be evaluated accordingly.The technical skills, interest in the particular field, communication skill, analysis organizing andpresentation skills etc have to be evaluated. The personal and social qualities also have to be evaluated.Therefore, evaluation should be transparent, continuous and comprehensive.
SUBJECT APPROACH -APPROACH TO LEARNING PRINTING TECHNOLOGY
I. IntroductionThe art of preserving all arts, printing has since the eighties undergone a complete transformation
with the application of electronics, computers and microprocessors and advanced science andtechnology. This technology has developed by incorporating the advancements from other disciplinesand adopting the latest technical information from commercial art, photography, applied science,computer, mechanical and electronic engineering etc.
The diversity of language and the multitude of literate population, which is roughly 1000 million,create an ever increasing demand for printed materials in social, cultural, educational, artistic andscientific fields. Achievement of full literacy and higher levels of education mainly depend upon theavailability of printed materials in the form of books, journals, magazines, newspapers, researchpapers, reports and so on. Printed material is the main medium of communication and disseminationof knowledge, but more than this, the medium of print is improving its position in today’s multimediasociety. The trend is towards approaching target groups directly, faster production, more and morecolour and even higher quality The methods of print production are also changing, in the direction ofenvironmentally compatible, highly automated and easily operated printing systems integrated in adigital data environment. There is a dearth of technical man-power operators, technicians andsupervisors with broad based science, engineering background combined with a knowledge ofBusiness Administration to manage modern printing and allied establishments.
Packaging is an integral part of Printing Industry. The printing and packaging industries in Indiahave assumed growing significance during the last decade. This has become a dynamic and key areafor manufactures and trading companies all over the country with the element of aesthetics, hygienicand cost effectiveness receiving increasing importance in commercial operations. The exterior looksand presentability of marketable goods leave a lasting impression on the minds of consumers and inthis context packaging occupies the centre stage. New packaging machines and technologies havebeen introduced to meet the challenges. Today, the Indian Packaging Industry is growing at a rate of15—20 percent per annum.
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Printing Technology
The printing industry is one of the biggest and fastest growing industries in India More than onelakh printing presses are in operation all over the country with a capital investment of over Rs.80,000 million. This industry provides direct and indirect employment to another two million people.It is natural that along-side the growth of literacy, there is a commensurate rise in demand for variousinputs for the printing industry.Training and Manpower Requirements
The Indian Printing Industry today requires trained and technically qualified personnel at thefollowing levels.1. Operators2. Technicians3. Supervisors4. Managers and Production Executives5. Sales Executives6. Machine manufacturing and Machine maintenance personal7. Personnel for research and development.
In order to meet the above demands for supplying required manpower to the printing industry,the entire system of printing education in India has lately been restructured and summed up into threetiers. At the lowest level ie. first - tier, there are I.T.Is offering certificate courses in the concernedspecialised trades of Printing Technology mostly covering the categories (1) and (2) given above.Vocational Higher Secondary courses in printing technology has also been categorised under thisgroup.
The categories (3), (4) and (5) are being covered by the middle level (second tier) Diplomainstitutions.
The categories (6) and (7) and also category (4) to a certain extent, are being covered by thehigher level institutions (third-tier) offering degree in printing technology
The present syllabus (VHSE) has been designed to produce operators and technicians in the firstgroup as mentioned above.
The computer has entered every aspects of print production and has become the overridingelement that guided all changes. Hence, the most current procedures and state-of-the-art materialsin each phase of the printing process. We have discussed about the pre press produces in first year.The second year mainly deals with press work, post work operation and materials.
The press work generally starts with print job on machine. The completion of printing job is saidto be with it is designed, printed and despatched.
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LEARNING STRATEGIES
In the modern era of globalization the introduction of new technologies ensure only the survival ofthe fittest. So it becomes a necessity to equip the leanness to face the growing challenges in thecompetitive world. Hence the traditional approach to learning is no more relevant in the presentcontext. The teacher should use instructional techniques that motivate the student to construct hisown knowledge. Now the learners are not passive listeners , but they are the active participants inthe construction of knowledge. Here the teacher – student interaction should be given muchimportance.
In the new instructional strategy while selecting the methods of teaching, the social and psychologicalaspects of the learner is to be taken into consideration. The given activities for learning are onlysuggested one. It can be altered according to the discretion of the teacher.
To obtain the objectives, the new system of education is introduced in the Vocational HigherSecondary Education for attaining the objectives of the courses in this system, we can adopt thefollowing strategies.1. Assignment
Assignment is some specific work assigned to the students as a part of their academic enrichment.There are learning activities undertaken as a continuation of class room activities to realize thecurriculum objectives to a broader extent . They should be completed in time bound manner. Theyhelp to lead learner to higher level of learning from the present status. Challenging assignment canmotivate the students to involve in group dynamics and achieve fruitful results . The teachers may atas a guide.
Assignment may be given on individuals or group basics. Assignment includes preparation ofnotes, preparation of charts, models, collection, of materials from institutions etc. Assignment developskills of reference, observation, enquire reporting etc. It ensure the effective utilization of leisure timeof the students.2. Seminar
Seminar is a learning strategy involving an in-depth analysis of specific topic, preparation ofa paper and presentation . The paper is presented by either one students or a group of students.After the presentation, there will be a discussion/ interaction in which all the students can participate. The students get an opportunity to clear their doubts and make clarification. Seminar helps todevelop communication skill and overcome stage fright.
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Stages1. Selection of Topic
The topic of seminar should be relevant to the subject of study2. Assignment of topic to individuals students or team
The topic may be assigned to one students may be given to a group of students
3. Collection of relevant information
Information required for seminar can be collected from various sources namely books, magazines,internet, institutions, place and persons.4. Preparation of draft paper
Based on the information collected the student may prepare a draft paper and submit it tothe teachers for comments. Revise the draft paper based on the comments of the teachers. Therequired drafts is submitted for approval.5. Program Scheduling
The date, time and venue of the seminar is fixed. A seminar leader may be selected from thestudents6. Seminar paper presentation
The student/ students shall present the paper in the seminar. The teacher may function as themoderator during the initial stages.7. Discussion / Interaction
A number of respondents from the students make comments on the topic. This will be followedby a general discussion. All the group members should actively participate in discussion.8. Summing up deliberation
The moderator sums up the deliberation9. Evaluation / Feed back
Both teachers and students evaluate the programme.10. Preparation of final report
A final seminar report is prepared covering all the additional points discussed and consolidated
3. Panel DiscussionIt is a learning strategy in which a panel of experts are allowed to discuss a specific subjects
under the control and direction of a moderator. Subjects can be divided according to the number ofpanel members. Number of panel members are fixed according to subdivision of points in the
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subject. Relevant materials and hand out may be given in advance to the learners. The monitor ormoderator introduces the subject of discussion and invite a panel member to start the discussion.Each panel member is invited for discussion afterwards. After briefing by the panel members thequestion are raised from the audience and the panel members give suitable answer to them. A reportshould be submitted by each learner to the moderator .
4. ProjectProject is a self-learning strategy which can exert great influence on the overall development
of the learner. Project as learning strategy is to be selected where a problem arises in any part of thecurriculum. The students may be divided into groups and assigned different aspects of the problem.Each group works independently .Specific aspects of the problem such as data collection, classification,analysis, report preparation and presentation is to be undertaken by each of the members. Eventhough the work is divided among the members, it must be ensured that the execution of each andevery activity is done with the active participation of all. After analyzing data collected from differentsources, the learner arrives at a conclusion that can help to solve the problem. There by learnerlearns the topic though his own activity. The other advantage of this learning activities is that it helpsthe learner to scientifically handle any problematic situation. It helps in the development of scientificthinking and thereby builds up the students aptitude for the subject.Stages of the project1. Selection of a topic
The project selected should be related to the curriculum and it should not be a project forprojects sake. The topic or problem should arise from the curriculum.2. Planning of the Project
(A) Hypothesizing: Hypothesizing means making assumptions based on the available primaryinformation.
(B) Methods and Technique : The methods and Technique should be based on the aim andHypothesizing of the Project. The nature of the project, suitability of the tools, and the methods oflearning should be related to each other.3. Collection and Tabulation of Data
The data may be primary, Secondary or territory. Either census or sampling method can be usedbased on the objective of the project. Suitable questionnaires are to be prepared for the collectionof primary data.
The collected data is to be classified and tabulated so as to make it easily understandable.
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4. Analysis of data and formulation of conclusion By analyzing the data, the reliability of the hypotheses can be examined. Preparation of
graphs and diagrams and maps will positively help the analysis. The similarities relations anddifferences gathered from the analyzed information would tell whether the hypotheses should beaccepted or rejected.5. Preparation of Report
The cover page should have the title of the project, the period of study, name (s) of investigator/ group, and the address of the school. The report should be structured in the following order.1. Title2. Preface3. Hypotheses and aim4. Methodology5. Sources of data6. Analysis and conclusion7. Suggestions (if any)8. References9. Appendices (Questionnaire, Observation schedule, check list Etc.)
6. Presentation of the Project
When the project is presented , the learner is being evaluated and accepted. It is through thispresentation that ideas are shared with others in the class and society.
The project methods promotes scientific self learning and makes him capable of solving theproblem arising in real life situations.5. Debate
Debate is a hot and interesting learning activities. A debate can be organized only on a topic onwhich there is difference of opinion. Therefore a topic suitable for debate has to be found.
Debate can be on relevant topic that is different and interesting to the students and relevant tosociety. Students with different opinion have to be identified for discussion. Those who have similaropinion should join together to form a side . Those who hold the opposite view with form the otherside. It would be good to write down the topic of the debate and displayed in advance. Thereshould also a person to control debate.
Students should be given opportunity to absorb the ideas obtained from discussion and debate,develop the idea through reading and study, and to express them through writing or other means
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Stages of Debate
1. Topic Selection2. Selection of panels keeping in balance with intelligence, gender etc.3. Selection of moderator4. Collection of information guided by the teacher5. Conducting the debate under the control of moderator by avoiding any sort of personal conflicts6. Conclusion by the moderator expressing his final version or verdict.6. Case Study
A case may be a person, institution or a community case study is an in depth analysis of an actualevent or situation. It presents real pictures of situation with facts, objective information or data :learners analyse the case to interpret, predict and resolve issues associated with it. The case studyprovides the learner an opportunity to analyse and apply concepts, data and theory taught from theclass. Learners can work individually or in groups.
By studying realistic cases in the classroom, students develop new insights into the solution ofspecific on – the – job problem and also acquire knowledge of the latest concepts and principlesused in problem solving.
Case may be presented by the teachers or may be provided in print form.
A simple case study may have the following steps1. Collection of data2. Conversion of data into information3. Analysis of the case in groups4. Presentation of the finding by each group leader.5. Evaluation
In addition to the above mentioned learning strategy there are many other learning strategieswhich can be used in appropriate situations to enrich leaning process such as problem solving, Roleplay, brain storming, debate etc.
7. Brain StormingThis is the best method for solving creative problems. It facilitates generation of ideas quickly.
Rules for conducting Brain storming.1. No response is wrong. So welcome every response.2. Welcome as many responses as possible3. No criticism is allowed
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4. Allow to work on others ideaSteps in Brain storming1. Presentation of the problem2. Provide relevant information3. Record the ideas put forth by the participants4. Combine similar ideas5. Evaluate each idea and solution6. Selection of the best solution
If brainstorming is used as an instruction strategy, the last step is not essential
8. DiscussionDiscussion is essential for the student to share new finding, idea and conclusion at each stage of
learning with follow students and teachers. In general discussion the teachers should guide thediscussion though questioning and summarizing. The major steps involved are
1. Introduction initiated by the teacher2. Development of discussion by giving lead points and follow up interactions3. Transaction stage in which the key points are reviewed by the teacher and4. Summarizing stage in which teacher provides additional support materials to ensure the
achievement of the objectives
9.Group DiscussionGroup discussion is an ideal method to develop Co-operation, democratic attitude, friendliness
and compromising attitude which are the ultimate aims of education. During group discussion theteacher may observe each group and it needed help them to Channel the discussion towards thecommon objectives. All students may be given opportunity to take part and express their ideaswithin a time limit. The conclusion reached may be entered by each students. A group representativemust present this during consolidation in which the teacher may correct or add information’s toensure that all the relevant ideas have been covered
10. CollectionCollection is a continuous learning activity, which ensure complete participation of students. The
Collected item may be materials, pictures, charts, ideas, data etc. Collection provides directexperience to learn. An exhibition of collected materials will help to strengthen the concept.
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11. Practical works
Experimentation contains the process skill in an integrated way. In the new approach of curriculumthe student forms idea and comes to conclusion though process. The term ‘Practical ‘ when associatedwith a science subject usually means an experiment. The objective of doing a experiment is toexplore new ideas though investigation only. Its main purpose is to verify some principles associatedwith theory. The Subjects ends here. But this is not the case with ‘Vocational Practical’
The ultimate goal of a Vocational Education is to generate skill through continuous practice alongwith investigation and invention. Continuous practice transforms the unskilled to the skilled. This isthe significance and importance of practicals in the Vocational stream. Hence it is very crucial thatVocational teachers as well as instructor should understand the importance of vocational practicaland act accordingly.
12. QuizQuiz programmes can be used as an interesting class room tool for transaction of curriculum
objectives as well as to evaluate the effectiveness of transaction and achievement of students.
For conducting a quiz programme a topic should be selected based on the above objective
The students are asked to prepare question based on the topic individually. The next day / nexthour the students are grouped into 3-4 groups randomly. A question is raised by a particular teamand the other teams to answer them if they can answer the question they get points for that if allother teams fail to answer the question raised by the 1St team the 1st team answer the questionand explain the background if necessary. All the teams get equal number of chance to ask thequestion . Time limit is also prescribed for the conduction of the programme. The team who scoresmaximum points wins
All the participants can make notes on the questions asked answer and their explanation whichhelp them in learning
13. ModelsModels are used in learning process. It enhanced the leaning experience. This is based on the
‘seeing is believing”. It helps the learner a chance to see feel the model presented . Still models andworking models help the students to understand the structure , working principles, actual operationetc.
Several steps are involved1. Feeling the problem2. The teacher should plan the type of model according to co’s
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3. Grouping the students4. Briefing the tasks
- Aim- Need- Material required- Source & Materials- Cost of materials- Division of Labour- Guidance- Fixing of a time limit
5. Presentation y each group about(A) How the models were prepared(B) Details of - Expenses- working and principles
Finally Documentation of the process6. Evaluation
- By the other groupslater a consolidation by teachers are to be done.
14. GamesClass rooms can be made attractive by introducing different types of games. Games should be
interesting as well as informative some of suitable games are1. Odd man out2. Cross word puzzles3. Match the following4. Aswamedham5. Link game – Answer using clues.15. Survey
This strategy involves collection of data from the group under study (book, person, materialsetc.) It develop the social interaction and communication ability of the learner. It also provide ascope for discovery learning.
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Step involved in survey- Objective of survey- Selection of area for survey/sampling frame- Selection of survey method
wDirect methodwWith help of questionnaire/schedule
- Tabulation and analysis- Consolidation and Presentation16. Exhibition
It is a learning strategy by which the learner can get a chance to show the skill developed. Itprovides the intrinsic motivation and exposure.
Exhibition item can be conducted either individually or as a group task. It can be conducted atschool / Regional/State/National Level. Necessary publicity and other arrangement can be provided.Presentation, documentation participation and innovative skills of the learner can be evaluated.17. Interview
Interview is one of the important learning strategy taking the help of a resource person. Interviewis an interview. It provide opinion and information about a topic.
An interview is conducted by the following steps1. How to introduce a problem?2. Invite a resource person3. Decide the questions by learners4. Decide the time, place etc.5. How to discuss6. How many students to participate7. Implementation of the interview8. Conclusion (Facilitator)Items required1. Interview Schedule
List of question prepared by learners Selection of students, selected names sequence of question
18. Field VisitField visit is an inevitable vocational tool to be implemented in vocational Higher Secondary
Education. This helps the students to familarise with the modern technologies and new situation in adifferent atmosphere. It provides learning though viewing. It is based on the principle that seeing isbetter than having. It enables the learning to retain the learned informations longer and to make thesubject more interesting. It motivates and give more confidence in his/her particular vocation.
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The facilitation should identify suitable center/ institution/site. Get prior permission from theauthorities before conducting the field visit. Give instructions to the learners for collection data’s/information’s/materials/Specimens. Teacher may assign different duties to learners by working themdifferent groups.
Each learner should take utmost care and interest during the visit. He/She should observe andinteract at the center/ institution where the field visit is conducted
After the visit, learner should acquire the ability to apply the ideas/concepts in his future carrier.Each learner should submit a detailed report about the field visit.
19. DemonstrationThough demonstration we can present an item/product and emphasis its features very effectively
Eg:- To understand the functioning of a computer1. Material/Item/Process2. Demonstration3. Venue4. Additional requirements depending upon the nature of the item
Demonstration Process1. Introduction about the item/Material2. Principles – Working3. Operation4. Components5. Merits of the item
20. Chart displayIt is also one of the important teaching aid. It can be used in every activities of a learning process.
Chart display is a written or pictorial representation of idea or concept. It is abbreviate brief andclear. It is prepared by studyBenefits1. A learner gets clear idea about the concept2. The leaner can retain the ideas in his mind for longer periods3. A complicated idea can be simplified though a chart4. Cheap method of teaching aid.
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CURRICULUM OBJECTIVES
UNIT 1 PAPER
1. To understand the items paper, board etc and their classification through discussion, samplecollection and prepare note.
2. To acquire knowledge about International and Indian standard paper sizes and its nomenclaturethrough discussion, chart presentation, demonstration, collection of data, lab work and preparenote, Lab diary / or Record book/.
3. To understand paper calculations and wastage through discussion calculation, chart,presentation, and prepare note,
4. To acquire knowledge about paper making process through discussion, field visit; preparefield visit report and note.
5. To understand properties affecting paper through discussion, sample collection and preparenote.
6. To understand handling of paper in the press room through discussion, field visit; preparefield visit report and note.
UNIT 2 INK1. To understand printing ink and its ingredients and colour mixing through discussion, sample
presentation, labwork and prepare note, record book.2. To understand properties of ink through discussion , sample presentation and prepare note. 3.To acquire knowledge about new generation of inks and their chemical properties through discussion, ink sample presentation and prepare note.4. To understand various ink drying methods through discussion, sample presentation of ink, printed products and prepare note.UNIT 3 PRESS DEVELOPMENTS
1. To understand the development of printing presses through discussion, chart , field visit, preparefield visit report and note.
2. To understand principles and classification of offset presses through discussion, chartpresentation, field visit; prepare field visit report and note.
3. To understand operation of feeder unit through discussion, lab demonstration, chart , labwork; prepare field visit report , note and record book.
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4. To understand and apply the function and importance of registration unit through discussiondemonstration, chart presentation, lab work ; prepare note and record book.
5. To understand printing unit and cylinder configuration through discussion lab demonstration,chart presentation field visit, lab work, prepare field visit report and note, record book.
6. To understand the inking unit through discussion, lab demonstration, chart, lab work, and ;prepare note and record book
7. To understand and apply the function of damping unit through discussion, lab demonstration,chart; lab work and; prepare note and record.
8. To understand delivery unit through discussion, lab demonstration, chart, lab work and preparenote and record book
UNIT 4 OFFSET PRESS OPERATION
1. To understand feeding of paper through discussion, demonstration, lab work and preparenote, and Record book.
2. To acquire knowledge about preparing the printing unit through discussion, demonstration,lab work and prepare note, record book
3. To apply starting up and proofing through discussion, demonstration lab work and preparenote and record book.
4. To understand the cleanup procedures through discussion, demonstration, lab work andprepare note, record book.
UNIT 5 ROLLER AND BLANKET -PROBLEMS AND ITS ADJUSTMENTS
1. To familiarise the function of roller and blanket problems through discussion, prepare note..2. To understand plate and blanket adjustments and packing through discussion, demonstration,
lab work and prepare note record book.3. To understand inking and damping roller unit adjustment through discussion, demonstration,
lab work and prepare note, record book.4. To acquire knowledge about common press concerns with damping solution and its pH value
through discussion, demonstration lab work, prepare note,record book.5. To understand ink and paper considerations for offset printing through seminar and prepare
report.
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UNIT 6 MULTICOLOUR SHEET – FED PRESSES
1. To understand multicolour sheet-fed presses through discussion, chart, demonstration, fieldvisit, slide presentation, Lab work; prepare field visit report and note, record book.
2. To make awareness about perfecting presses through discussion, chart, field visit, preparefield visit report and note.
3. To understand multicolour presses monitoring and control system through discussion, fieldvisit, demonstration, lab work; prepare field visit report and note and record book
4. To familiarise the press console through discussion, field visit, demonstration, lab work; preparefield visit report and note and record book.
UNIT –7 PRINTING PROCESS – COLOUR ON SHEET – FED OFFSET PRESSES
1. To apply press concerns and colour on sheet-fed through discussion demonstration charts,lab work and prepare note, record book.
2. To understand sequence of colours and registration control for multi-colour printing throughdiscussion, sample collection, progressive proof, field visit, demonstration , lab work; preparefield visit report and note and record book
3. To acquire knowledge about quality control devices through discussion sample collection,field visit, prepare demonstration, labwork, field visit report, note and record book.
UNIT - 8 WEB – OFFSET PRESSES1. To understand web-offset presses and different types through discussion, chart, field visit,
prepare field visit report and note.2. To acquire knowledge about components of web presses through discussion, chart, field visit,
prepare field visit report and note.3. To familiarise press console through discussion, chart, field visit, prepare field visit report and
note.UNIT - 9 TROUBLE SHOOTING
1. To understand defects in paper and its remedy through discussion, sample presentation, labwork; prepare note, b diary .
2. To understand defects in ink and its remedy through discussion, sample, presentation , labwork and prepare note and record book.
3. To understand defects and remedies of printing through discussion, sample presentation, labwork, and prepare note and record book.
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4. To understand and apply press maintenance and lubrication through discussion, demonstration,field visit, lab work, and prepare note and record book.
UNIT - 10 SCREEN PRINTING
1. To understand the basic concepts, classification type of stencils, fabric and frame preparationthrough discussion demonstration labwork and prepare note record book.
2. To acquire knowledge about photographic stencil through discussion, demonstration, labwork and prepare note and record book.
3. To get awareness about squeegee, substrates, ink consideration and basic registrationtechniques in screen printing through discussion, demonstration, lab work and prepare noteand record book.
4. To acquire knowledge about masking the stencil through discussion demonstration, lab workand prepare note and record book.
5. To understand idea about multicolour printing in screen printing through discussiondemonstration, lab work, and prepare note and record book
6. To understand half tone reproduction through discussion, demonstration, lab work and preparenote and record book
7. To familiarize high speed production presses through discussion and chart presentation andprepare note.
8. To acquire knowledge about machine configuration through discussion, field visit and chartpresentation and prepare note.
UNIT- 11 OTHER PRINTING PROCESS
1. To understand, flexography printing through discussion, chart, sample collection, field visit,prepare field visit report and note.
2. To understand and apply xerography printing through discussion, chart, sample presentation,field visit, lab work; prepare field visit report, note and record book.
UNIT -12 FINISHING OPERATIONS
1. To understand binding and its classification through discussion, sample, chart and preparenote
2. To acquire knowledge about warehouse and its functions through discussion, field visit andprepare field visit report and note
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3. To familiarise tools and equipments used in binding through discussion, presentations andprepare note.
4. To understand materials, its selection, care and use through discussion, presentation and preparenote.
5. To understand different types of sewing through discussion, sample, chart, demonstration andlab work prepare note and record book.
6. To understand and apply automation in binding through discussion, chart, demonstration, labwork, field visit, prepare field visit report, note and record book.
7. To acquire knowledge about account book binding through discussion, sample, lab workprepare note and record book.
8. To understand and apply publishers binding through discussion, sample, lab work and preparenote, record book.
9. To understand different styles of binding through discussion, sample, lab work and preparenote.
10. To understand and apply repairing works of book through discussion, demonstration, labwork ; prepare note and record book.
11. To acquire knowledge about estimating the materials required for particular work through anassignment and present in the form of a report
UNIT - 13 PRINTING AND PACKAGING
1. To understand the materials, properties application and advantageous of packaging throughsample collection, discussion, field visit, prepare field visit report and note.
2. To understand about flexible packaging and flexible laminates through sample collection, fieldvisit, discussion, prepare field visit report and note.
3. To understand ink and solvent used in packaging industry through sample collection discussion,and prepare note.
4. To acquire idea about special packages through sample collection discussion, and preparenote.
5. To understand various processes of paper and aboard package through a seminar.6. To acquire idea about forme making, cutting, creasing and make ready operations through
field visit, discussion, demonstration, practical work; prepare field visit report note and recordbook.
7. To understand corrugated, fibre, board and rigid boxes through sample collection, chart andprepare note.
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8. To understand selection of materials used for packing through sample collection, and discussionand prepare note.
UNIT 14 BASIC ENGINEERING1. To understand the characteristics of direct current and alternative through discussion, chart
and prepare note.2. To familiarise motors and transformers through discussion, chart and prepare note3. To understand basic electronic circuits through discussion, chart and prepare note.4. To get an idea about the characteristics of principles of mechanical components through
discussion chart and prepare note.5. To familiarise the characteristics of hydraulics and pneumatics through discussion, chart and
prepare note.6. To understand the electrical, electronics, mechanical and pneumatic parts of a printing machine
through an assignment.
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SYLLABUS - THEORY
UNIT 1 PAPER
Paper and board-different classification appearance-thickness-size-Ream Basis weight-Mweight-durability-types of papers-International and Indian paper sizes-cutting machine, papercalculation and wastage-quantity of paper-wastage of paper-paper making process-propertiesaffecting paper-printability-Runnability-Handling of paper
(9 hours)UNIT 2 INK
Ingredients of ink-its nature-pigment vehicle-Additives-Ink mixing-Properties of ink-Tack-viscosity-colour-hue-drying characteristics-methods of measuring-new generation of ink andchemical properties-New trends and developments-water based ink for flexography -Ink dryingmethods-
(9 hours)UNIT 3 PRESS DEVELOPMENTS
Development of Printing Presses, Platen press to Rotary Press-Lithography to offset-Basicand working principle of offset-classification-hydrophilic and oleophilic nature, Feeder unit-parts-loading system, Type of feeder-feeder control-sheet dictators-Registration unit-Feed boardequipments-lay adjustments- grippers printing unit- Impression cylinder adjustment-cylinderconfiguration-impression control-cylinder gears-inking unit-classification-configuration-Rollercleaning-Damping unit-conventional and non conventional-Damping roller covering-Damper rollercleaning Delivery unit-pile control-Types-Skeleton wheel-Ancillary operation
(10 hours)
UNIT 4 OFFSET PRESS OPERATION
Feeding of paper-fanning-wedges Adjusting pile height-Adjusting the air blats-Adjusting-registration system-delivery side guides-make ready procedures preparing the printing unit-Adjusting
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ink feed-Adjusting ink fountain-Adjusting water feed –Attaching the plate-starting up inking theplate-press proofing-lays and cylinder adjustment clean up procedure of plate, blanket, Damping,inking and impression cylinder
(10 hours)
UNIT 5 ROLLER AND BLANKET -PROBLEMS AND ITS ADJUSTMENTS
Roller and Blanket problems-Roller and Blanket caring-various blankets-hardness of Blanket-plate packing Blanket packing-under cut-Depression gap-cylinder bearers-Adjustment of plate cylinder to Blanket cylinder-inking rollers arrangements-its settings-Damping roller arrangement-its setting-setting of forme roller to the plate cylinder-fountain solution for damping-pH of dampingsolution-alcoholic Damping-Ink and paper consideration
(12 hours)UNIT 6 MULTICOLOUR SHEET – FED PRESSES
Two colour machine-Four colour machine working-blanket-to-blanket-press monitoring-controlsystem-Density values Dot gain- Ink trapping-print contrast console computer
(8 hours)UNIT –7 PRINTING PROCESS – COLOUR ON SHEET – FED OFFSET PRESSES
Process colour-Multi colour printing press concerns-process inks-Transparent and opaque ink-sequence of colour Registration and its importance-checking and controlling-Registration-qualitycontrol-devices-star target-control strip-Dot gain scale- slur gangue –Densitometer
(10 hours) UNIT 8 WEB – OFFSET PRESSES
Working principle-general features parts-paper feeding, infeed registration-printing unit-deliveryunits-Blanket-to-Blanket-CIC-Inline Reel stand-splicer-web tension-Drier-Chiller-Folder-cutter-Auxiliary equipments-press console
(10 hours)UNIT 9 TROUBLE SHOOTING
Paper defects-curl paper tail end hook-picking-linting-dusting show through-Geasing-strike
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through –static electricity-ink defects-poor drying mottle-grain ness-emulsification-set off printingdefects-image wear-image blinding-dot gain-catch up-scum-tinting slur-ghosting-doubling-hickies-maintenance preventive-periodical-lubrication-types characteristics and application-press roomchemicals (9 hours)
UNIT - 10 SCREEN PRINTING
Porous printing process-Basic concept classification-stencil-fabrics-frame preparation-framestitching technique, stencil preparation-direct and indirect-exposure-developer-drying-squeegee ink-substrate-basic registration techniques on and off contract printing-printing the stencil-masking-liquid block out mask steps and procedures for multi colour printing troubles and trouble shooting ofdogged screens –half tone reproduction-moiré pattern-high speed presses-semi automatic andautomatic presses-configuration
(10 hours)UNIT - 11 OTHER PRINTING PROCESS
Flexography-in feed-printing unit out feed unit-plates-rubber and photo polymer plates-stepsand procedure xerography-charring -exposure-development transfer-fixing cleaning
(6 hours)UNIT - 12 FINISHING OPERATIONS
Binding-stages-letter press binding stationary binding-ware house and its functions-tool andequipments-material and its selection care and use –type of sewing-automation in binding-guillotinefolding machine-perforator-creasers-slitter Binding machine-gathering machine-perfect bindingmachine ,case making machine, lamination machine, account book binding-publishers binding –styles of binding-book repairing-overcast sewing procedures-estimating the materials
(13 hours)UNIT - 13 PRINTING AND PACKAGING
Materials, properties, application-advantages of packaging – flexible packaging-flexible laminates-advantages-different materials-characteristics-ink and solvent used ink storage and handling-specialproperties of ink-special packages, paper and board packages-carton styles –design-form making-cutting-creasing-make ready-corrugated-fibre board-rigid box-selection of materials
(12 hours)
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UNIT - 14 BASIC ENGINEERING
Emf-current-potential difference-resistance-ohms law-electric power and energy electromagnetism and magnetic flux-Faradays laws of electro magnetism-fundamentals of alternate currentand its circuit-three phase induction motor-transformer-intrinsic and extrinsic semi conductors-semiconductor diode-bi-polar Junction transistor. Nuts bolts, screws, studs, keys, cotters lever shaft,gears, cam and follower, plane bush, ball and roller bearings, chain and sprockets, soldering, rivettedjoints cultches and brake, lubrication, maintenance, viscosity demulsibility and stability, mechanical, electrical, electronics and pneumatic parts of a printing machine.
(12 hours)
SYLLABUS - PRACTICALSUNIT-1 PAPER
Operation of cutting machine
-Parts of cutting machine
-Precaution to handle the machine
-Cutting procedures
(15 hours)UNIT-2 INK
Ink mixing-primary colour-secondary colour- tertiary colour- opaque ink transparent ink(15 hours)
UNIT-3 PRESS DEVELOPMENTSOperation of feeder unit-pile height governor, blowers, suckers, forwarding roller loading system-
sheet separation-sheet dictatorOperation of registration unit-conveyor tapes-conveyor assemblies-rotary brush wheels-trailing
brushes-ball control assemblies-front lay-side lay-gripper-operation of printing unit-plate cylinderblanket cylinder-impression cylinder -impression control-cylinder gears
Inking unit-ink duct-fountain roller set of screw- distribution roller-forme rollersDamping unit-fountain roller feed roller-forme roller-rider roller fountain solutionDelivery unit-delivery pile control, skeleton wheels-joggers-anti-set-off spray-perforation-setting-
numbering
(40 hours)
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UNIT-4 OFFSET PRESS OPERATION
Feeding the paper-blind feeding fanning-using wedges-adjust pile height, adjust air blast; adjustregistration grippers-adjust delivery side guides
Preparing the printing unit-adjusting ink feed-adjusting ink fountain-water feed-attaching plate
Starting up and proofing-inking, press proofing-paper ink balance-lays cylinder arrangements
Cleaning up procedures of plate, blanket impression, inking and damping-automatic wash upmechanical clean up
(45 hours)
UNIT-5 ROLLER AND BLANKET- PROBLEMS AND ITS ADJUSTMENTS
Roller and blanket caring-roller and blanket problems-plate packing-blanket packing-setting ofplate cylinder adjustment of plate cylinder to blanket cylinder-roller settings inking unit Roller settingin damping unit-preparing damping solution
(40 hours)UNIT-6 MULTI COLOUR SHEET FED PRESSES
Press monitoring-control system-register-dot gain-doubling-console computer
(45 hours)UNIT-7 PRINTING PROCESS-COLOUR ON SHEET FED PRESSES
Multi colour printing-press, concerns for a multi colour-sequence of colours-registration qualitycontrol
(45 hours)UNIT-8 WEB-OFFSET PRESSES
Adopt Industrial Training (20 hours)
UNIT-9 TROUBLE SHOOTINGPaper defects and remedies, ink defects and remedies, printing defects and remedies, press
maintenance and lubrication, press room chemicals.
(20 hours)
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UNIT-10 SCREEN PRINTINGFrame preparation-direct and indirect stenciling method-stencil exposure stencil developer-printing
stencil-registration techniques-masking-multi colour printing-half tone printing
(30 hours)UNIT-11 OTHER PRINTING PROCESS
Components of flexography-flexographic plate-steps and procedures-xerography steps andprocedures
(15 hours)UNIT-12 FINISHING OPERATIONS
Binding operation-wire stitching-thread sewing (flexible and double flexible)-tape sewing-sawnin sewing-folding machine-perforator creaser-slitter-gathering machine-perfect binding machine-lamination machine-bundling machine- account book binding publishers binding-styles-cut flesh turnedin-quarter cloth leather, half cloth , leather full cloth and leather overcast sewing procedures-calculationof paper, board, calico, fancy paper, leather, tape etc.
(70 hours)UNIT-13 PRINTING AND PACKAGING
Forme making-cutting-creasing-make ready-rigid box-corrugated-board
(20 hours)
45
PLANNING
To make Printing Technology Education activity based, we have to provide learningexperiences that would help to develop process skills and components of multiple intelligence.Whether the activities are conducted in the class or outside, they are to be completed in a timebound manner.
The facilitator has to plan the activities necessary to make learning effective time required,evaluation methods and all other aspects. Facilitator must prepare at least three planning documents.
• Year plan• Unit plan• Daily plan
1. Year planThe year plan will include the total number of units to be transacted through the academic year
i.e. the three terms, units to be covered during each month and the number of period required foreach unit.
A model of year plan is given below
46
Printing Technology
YE
AR
PL
AN
June
1Pa
per
915
24
2In
k9
1524
July
3Pr
ess
1040
50de
velo
pmen
ts
4O
ffse
t pre
ss10
4555
oper
atio
n
Aug
ust
5R
olle
r and
bla
nket
pro
blem
s12
4052
and
its a
djus
tmen
tSe
ptem
ber
6M
ulti
colo
ur s
heet
fed
pres
ses
845
53
Oct
ober
7Pr
intin
g pr
oces
s -
colo
ur o
nsh
eet f
ed o
ffse
t pre
sses
1045
558
Web
-off
set p
roce
ss10
2030
Nov
embe
r9
Trou
bles
hoot
ing
920
2910
Scre
en p
rintin
g10
3040
Dec
embe
r11
Oth
er p
rintin
g pr
oces
s6
1521
Janu
ary
12Fi
nish
ing
oper
atio
ns13
7083
13Pr
intin
g an
d pa
ckag
ing
1220
32Fe
brua
ry14
Bas
ic e
ngin
eerin
g12
12
Tot
al14
042
056
0
Ter
ms
Mon
thU
nit
Nam
e of
Peri
ods
Tot
alun
itT
heor
yP
ract
ical
II nd TERMIst TERM IIIrd TERM
47
2. UNIT PLAN
Facilitator may prepare unit plan before actual transaction of the unit in the classroom. This planmust make clear the curriculum objective, intended, periods required for transaction of theseobjectives, instructional strategies to be used and materials required. How the output is to be evaluatedmay also be spelt out. Unit analysis for each unit given in the source book may be utilized forpreparing unit plan.A model of unit plan is given below:-
48
Printing Technology
1.To
und
erst
and
pape
r,bo
ards
and
diff
eren
tcl
assif
icat
ion
Gro
up d
iscu
ssio
nba
sed
on s
ampl
esof
var
ious
pap
ers
colle
cted
Var
ious
type
s of
pap
ers
Lear
ners
par
ticip
atio
non
col
lect
ion
Subj
ect
diar
y
Cur
ricu
lum
Act
iviti
esL
earn
ing
Eva
luat
ion
Tim
eob
ject
ive
mat
eria
ls
2 hr
s
3.To
und
erst
and
pap
erca
lcul
atio
n an
d w
asta
geD
iscus
sion
Cal
cula
tion
Cha
rt pr
esen
tatio
n
Var
ious
size
s of p
aper
Cah
rt, R
efer
ence
book
s
Subj
ect d
iary
3 hr
s
4.To
Acq
uire
kno
wle
dge
abou
t pap
er m
akin
gpr
oces
s
Disc
ussio
nFi
eld
visit
Han
d m
ade
and
,ach
ine
mad
e pa
pers
, Ref
eren
cebo
oks,
Inte
rnet
Field
visi
t1
hr
2.To
acq
uire
know
ledg
eab
out I
ntrn
atio
nal a
ndIn
dian
sta
ndar
d pa
per
sizes
and
its
nom
encl
atur
e
Disc
ussio
nSa
mpl
e co
llect
ion
Cha
rt pr
esen
tatio
nLa
b w
orks
Diff
eren
t pap
er si
zes
Ref
eren
ce b
ooks
Skill
to c
ut p
aper
Sam
ple
colle
ctio
nSu
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
s
1 hr
5.To
und
ersta
ndpr
oper
ties a
ffect
ing
pape
r
Disc
ussio
nSp
ecim
en p
aper
s,R
efer
ence
boo
ks
Subj
ect d
iary
1 hr
6.To
und
ersta
nd H
andl
ing
of p
aper
in p
ress
room
Disc
ussio
nFi
eld
visit
RH
met
erPH
met
erR
efer
ence
boo
ksIn
tern
et
Fiel
d vi
sit re
port,
Subj
ect d
iary
1 hr
UN
IT P
LA
N1-
PA
PER
49
3. DAILY PLAN
Signature of Principal Signature of Teacher
The daily plan help to transact the curriculum objectives during class period, learning activities,learning aids and feedback.
Daily plan for unit 1. Paper:
Date……… Class:.......• CO: to understand paper, board and different classifications• Learning Materials: Various types of papers, reference books
Activity Response
DiscussionSample collections
50
Printing Technology
EVALUATION
Evaluation is a systematic process of collecting, analyzing, synthesizing and interpreting evidencesof students’ progress and achievements both in cognitive and non-cognitive areas of learning. Evaluationhas to play significant role in making the learning process more effective. It provides diverse experiencesto the learners, keeping in view the skill to be attained continuously by them.
As the curriculum is based on a particular vocation in the selected stream is the most importantpart and it should be evaluated accordingly. Technical skills, interest and devotion in the field,communication skills, organizational and presentation skills are to be evaluated. Evaluation of thepersonal and social qualities also should be done. So the evaluation should be continuous andcomprehensive.
Terminal or Term End Evaluation (TE)
It is the written form of evaluation aimed at evaluating the facts, concepts and ideas gained by thelearner. The test should not be aimed to evaluate the memory alone. Questions are framed in such away that the learners are able to apply different mental process while answering. The TerminalEvaluation questions give more emphasis on application, analysis and synthesis level.
The maximum scores for TE is 80 and the minimum is 24 (30%). The questions should beformulated taking into consideration the time required to read, think, understands and write answers.These aspects should be considered while fixing the scores also. To avoid blind guessing, multiplechoice and application level questions may be mixed. The total number of questions may vary fromtime to time. All the questions should be based on the curricular objectives. Open ended questionsbut the choice questions also should be based on the same curricular objectives.
Continuous and comprehensive evaluation (CCE)
Our traditional evaluation method measures only the memory and recollection capacity of thelearner. To eliminate/ overcome the limitation the evaluation should be done on multi dimensionalways by measuring multiple intellectual capacities of the learner. So it is better to evaluate the learnerin a continuous and comprehensive manner. CCE helps the learner to understand and developadequate his own progress and to develop adequate strategies for further improvement.
51
Merits• Assess the all round development of the learner on a continuous basis through a variety of
activities.• Effective feed back is possible• Remedial diagnostic teaching is possible• Process as well as products are assessed.
A series of learning activities are grouped into five major thrust areas as follows
1) Investigative activities
Activities which create a spirit of enquiry, investigation and a mind for research in the learnerbelongs to this group for example.
• Study project• Case study• Field study
2) Interactive activities
Activities which improve the communication skill, activities of sharing ideas, etc.
For eg:-
• Seminar• Panel discussion’• Debate• Group discussion
3) Assigned taskActivities assigned to the learners to enrich/ strengthen the concept and ideas.
For eg:-• Assignment• Collections
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Printing Technology
4) Performance task (Tests)
Activities related to the achievements of the learner.For eg:-• Class test (oral/ written/ performance test)• Quiz• Open book examination• Interview• Group testing
5) Practical based activities
• Preparation of working model• Album• Improvisation
From the above five group of activities, the teacher has the freedom to choose any four areasfor evaluation purpose.
1. Investigative Activities
53
1. STUDY PROJECT
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Printing Technology
Sl.No Criteria Score Total Scores
1 Identifying the problem 4/3/2/12 Approach to the problem 4/3/2/13 Time bound Action 4/3/2/1 204 Analysis of the problem 4/3/2/15 Problem solving / Reporting 4/3/2/1
3. Field study
1 Attitude and readiness towards the task 4/3/2/12 Capacity for Observation 4/3/2/13 Data collection 4/3/2/1 204 Application of ideas 4/3/2/15 Documentation / Recording 4/3/2/1
4. Assignment
1 Awareness of the content 4/3/2/12 Comprehensiveness of the content 4/3/2/13 Systematic and sequential arrangement 4/3/2/1 204 Observation/suggestion/views/judgment/evaluation 4/3/2/15 Timely Submission 4/3/2/1
5. Seminar
1 Planning and Organization 4/3/2/12 Collection and data / content 4/3/2/13 Observation / appraisal and clarity 4/3/2/1 204 Content knowledge 4/3/2/15 Presentation 4/3/2/1
6. Debate
1 Readiness to participate 4/3/2/12 Depth of subject knowledge 4/3/2/13 Communication skill 4/3/2/1 204 Ability to justify the stand 4/3/2/15 Presentation 4/3/2/1
2. CASE STUDY
55
7. Group discussion
1 Readiness to participate 4/3/2/12 Depth of subject knowledge 4/3/2/13 Communication skill 4/3/2/1 204 Ability to justify in a democratic way 4/3/2/15 Leadership quality 4/3/2/1
8. Interview
1 Planning 4/3/2/12 Preparation of Questions 4/3/2/13 Communication skill 4/3/2/1 204 Participation 4/3/2/15 Report preparation 4/3/2/1
9. Quiz
1 Preparation of Questions 4/3/2/12 Relavance of Questions 4/3/2/13 Presentation 4/3/2/1 204 Active participation 4/3/2/15 Time management 4/3/2/1
10. Collection
1 collecion of materials/ Documents 4/3/2/12 Relavance and comprehensive uses 4/3/2/13 Presentation 4/3/2/1 204 Awareness of the content 4/3/2/15 Time bound progress of work at each stage 4/3/2/1
56
Printing Technology
Practical Evaluation (PE)
The goal of vocational Education is to generate skills through continuous practices along withinvestigation and innovations. Continues and comprehensive practice transforms the unskilled learnerto a skilled one. This is the importance and significance of vocational practicals.
PE is done to evaluate the practical skills achieved by the learner in the concerned vocationalsubject Total Scores for PE is 150 and minimum is 60 score ie 40%. Practical Examination isconducted for a batch of 8 learners having 6 hours duration.
Practical evaluation should be done taking into account the whole practicals included in thecurriculum since Learning of practical skills is a continuous process through out the period of study.
The scholastic area includes those area in which the learner attains the knowledge and skill basedon curriculum.This leads to create more interest on areas of subject. Emphasis should be given toeach topic for learning activity and to develop skills.In practical examination, the external examinersshould be able to evaluate the skills that are attained by learning experiences.The practical examinationquestion paper also activity based.
In practical examination , the student capability on basic skills in printing technology to beexamined.Questions are to be framed in such a way that it should evaluate the practical skills andknowledge in Print production techniques.The teacher / examiner prepares a bunch of questionpapers covering the syllabus and each student should be given a question randomly to write thesteps/procedures for making models / experiments in the questions.The procedures and tools requiredare to be verified and students are allowed to do it in the laboratory. Once the student has completedthe work, the teacher checks for its correctness and clarity of output and scores are awarded.Aproper record of the work done in the laboratory should be maintained in the lab diary or labrecord.Separate Lab diary should be used for recording the first year and second year works.Valuationof the Lab diary will be done at the time of PE
57
Vocational Competency Evaluation (VCE)Vocational Competency Evaluation is to evaluates the vocational skill and aptitude developed
by the students during the learning process. This is a system to judiciously evaluate the requiredvalue addition and consequent capacity building in the concerned vocational curriculum. The vocationaleducation is aimed at developing interest, skills and devotion in specific vocational fields. As otherevaluation components like CE. PE and TE cannot assess the vocational competence and professionalskills, acquired by the students an internship evaluation (IE) components has been introduced tomeet this requirement.
Internship evaluation should be done based on the following components like regularity andpunctuality, value addition and capacity building.1. Regularity and punctuality
Regularity and punctuality has vital role in vocational education learning continuous process,the regular presence of the Learner is must for attaining maximum efficency.2. Value Addition
Value addition is the qualitative measure of the learner’s interest, devotion perseverance andefficiency. Value addition can be evaluated through conducting field visits/ vocational survey. Theexperiences gained through field visit / vocational survey increases the level of intrinsic motivationand positive attitude towards the vocational field and thereby increase his value as a semiprofessional.3. Capacity Building
It gives a quantitative measure of the student’s skill in graded area exposure. Capacitybuilding can be evaluated through conducting the following activities.
1. OJT / Simulated experiment
No Evaluation Indicators Percentage Score
1 Identifying Tools/ Materials, Instruments 10% 15
2 Preparation of layout and handling of tools and equipments 15% 22.5
3 Estimating Material, Study of parts Equipments and Procedure 15% 22.5
4 Accuracy / Working skills 20% 30
5 Calculation/ Result 15% 22.5
6 Viva-voce 15% 22.5
7 Record / Lab dairy 10% 15
Total 100% 150
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Printing Technology
1. Regularity and punctuality can be assessed by using attendance of the learner and time bound
completion of tasks. It is evaluated by using 5 point grading system. Rating Scale
2. Performance – camp/exhibition/clinic3. Performance – PCT/Service cum Training center.
These components help the learner to practice the acquired skills in the real situation andthereby increasing self-confidence and promoting self reliance.Vocational Competency Evaluation Indicators
No Items Scores1. Regularity and punctuality 102. Field visit / survey (anyone) vocational project 203. OJT/Simulated experiment performance –
Camp/exhibition/clinicPerformance – PSCTC(anyone)/Practical skills 20
TOTAL 50
Sl.No Items 1 2 3 4 51. Regularity Never After Equally Most Always
regular regular regular of the time regularregular
2. Puntuality Never Often Usually Most of the Alwayspunctual punctual punctual time punctual punctual
59
Iitem Evaluation indicators Scores Score
Regularity and punctuality 10
Value addition Field visit1.Attitude and readiness towards the task 4/3/2/12. Capacity for observation 4/3/2/13.Data collection 4/3/2/14.Application of ideas 4/3/2/15. Documentation/recording 4/3/2/1 Or 20Survey1.Planning 4/3/2/12.Data collection 4/3/2/13.Consolidation of data and analysis 4/3/2/14.Drawing inference 4/3/2/15.Reporting 4/3/2/1
Capacity Building OJT/Simulated experiment
1.Involvement/participation 4/3/2/12.Skills in doing work/ communication skills 4/3/2/13.Time bound action 4/3/2/14.Capacity for observation, analysis and innovation 4/3/2/15.Documentation, recording and display 4/3/2/1
OrPerformance in camp/exhibition/clinic1.Ability for planning and organizing 4/3/2/12.Mastery of subject 4/3/2/1 203.Ability for communication 4/3/2/14.Innovation 4/3/2/15.Involvement/social commitment 4/3/2/1
OrPerformance in production/servicecum training center (PSCTC)1.Mastery of vocational skills 4/3/2/12.Managerial capacity 4/3/2/13.Promoting self confidence 4/3/2/14.Innovation approach 4/3/2/1Promoting self reliance 4/3/2/1
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Printing Technology
CRITERIA FOR PROMOTION
• A minimum of 80% attendance is required to register for the public examination. Those who arehaving at least 65% can apply for condo nation from higher authorities. Those who have shortageof attendance below 65% should repeat the second year.
• The students should obtain minimum 30% score in all subjects separately in TE. In first year if thestudent failed to obtain 30% minimum score in any subject he will be promoted and will be givenchance for improvement.
• The students should obtain a minimum of 40% score in the vocational practical Evaluation (PE)that is 60 out 150 score. If a student fails to attain the minimum required score for TE and secureminimum score for pass in TE, he need not reappear for practical examination and vice versa.
• A minimum of 30% is required forVCE. The component other than regularity and punctuality canbe improved before the end of academic year for those who fail to attain this minimum.
• Chances will be given for improvement of the TE, PE,VCE for those who fail to attain theminimum even after formal completion of course.
• Course certificate will be issued to students who have successfully completed part-I andII . A learner is eligible for higher studies provided they secure minimum scores in allsubjects including part III
61
MONITORING AND SUPPORTING SYSTEM
Supporting SystemIn learner centered vocational education, a learning methodology has to be organized and a
proper learning atmosphere is to be provided. Many organizations can support the learning activity.They are:-1) School Resource Group (SRG)
Comprising all teachers (vocational and non vocational) instructors, and lab assistants withacademic head as the group leader.2) School support Group (SSG)
Comprising PTA president, members of local bodies, members of social clubs, subjectexperts etc who can contribute guidance /technology /infrastructure /financial assistance etc.3) Parent Teacher Association (PTA)
Can provide adequate funds for field trips, production cum training centers (PCTC),exhibition, On Job training (OJT) etc.4) Local bodies
Grama Panchayat, District Panchayat and Block Panchayat can provide infrastructure ie, classrooms, laboratory, library, seminar hall, audiovisual equipment etc.5) Subject club
All vocational teachers handling same vocational subjects should form a subject at regional levelor district level. This will helps to share the knowledge and practical facilities, production and marketingof materials, service etc.6) Based on the excellency, district wise nodal schools may be selected to provide facilities like
central library, museums, video conferencing etc.7) Institution Industry Interaction Project (III P)
This should be implemented in every institution to update knowledge. This also helps for OJT ,PSTC and field visit.Monitoring system
Education is a kind of journey from darkness to light satisfying the needs and the wants of theindividual and the society. The modernization of education through activity oriented system enhances
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Printing Technology
free thinking and working in a fearless atmosphere. It is a qualitative process not a quantitative onethis necessitates a proper monitoring system. The system of monitoring should have the followingfeatures.1) It must be transparent2) It must enrich the ideas of the facilitator through innovative process3) It must be time bound and rational4) It must motive the facilitator to adopt new strategies5) It must be recordable and ensure effective feedback for the effective monitoring of the system,
three levels of the mechanism should be setup.1. School level monitoring group2. Regional level monitoring group3. State level monitoring groupMoreover a social auditing system is advisable to attain the objective effectively.Features of learning process in the new system of education
In the new system of education the learning process should be modified in such a way as toenable the learner to construct the knowledge of his own through observation, co-operation, problemsolving, social interaction etc. The learning process should consider the nature ability, social setup,inborn talents and subject selected by the learner. Therefore the learning process should be,• A continuous mental process• Simple learner must feel that he is able to undertake the task• Enable the learner to attain the curriculum objective• Interesting• Suitable to the age and attitude of the learner• Future possibilities• Enable group activity• Challenging• Time bound• Constructive and curiosity developing• Possibilities for evaluation• Capacity to generate independent thinking• Ability to enquire discover and establish cause effect relationship between phenomena.
63
Learning AidsTo make the teaching and learning process simple and effective , certain learning aids and necessary
use of such aids are transacting a complex idea makes the class room live and students get more andmore involved. The advances in science and technology may be effectively utilized for this purpose.Some of the learning aids listed below.• Multimedia• Over Head Projector• Computer• Internet• Liquid Crystal display Projector• TV, VCD, DVD and tape recorders• Working models• Charts• Slides• Video Conferencing facility• Library• Text book• Source bookSOCIETY
The new educational policy uplifts the social commitment of the learner. Therefore the societycan also give some valuable contributions in this changing situation. The new system also ensuresthat the learner can perform certain useful services for the betterment of society. The social obligationscan be illustrated as follows.• To enrich social values, aptitude and ability in learner• To develop entrepreneurial aptitude and ability which helps social welfare and self employment• New system of education adopts OJT, PSTC etc is a part of vocational curriculum which
helps to make close contact with the society.• The resources available from our society can be positively utilized to convene seminars, interview
etc.• Social organisations can help learners to make their education socially committed.• The social clubs like NSS, Tourism club, CDO club, energy club etc functioning in schools
can make direct link with the society.
64
Printing Technology
UNIT-1PAPER
Introduction
Paper is a substrate used to print, write, wrap etc. It is made from cellulose fibres of plants andis hygroscopic in nature i.e. affinity for water. Paper is a main raw material for printing, hence it hasvital role in the field.
Now-a-days different types of papers are available in colour and textures. Hand made andmachine made papers are in the market to satisfy the customers needs. The Printing and PaperIndustry accepted International paper sizes to standardize the measurements. This unit gives anawareness about paper and its properties like runnability and printability.
The facilitator adopts strategies like discussion, demonstration, sample collection, field visit,chart presentation and lab work.Curriculum Objectives• To understand the items paper board etc and their classification through discussion, sample
collection and prepare note (Subject diary )
• To acquire knowledge about International and Indian standard paper sizes and its nomenclaturethrough discussion chart, demonstration and collection of data lab work and prepare noteand record.
• To understand paper calculation and wastage through discussion, calculation, chartpresentation and prepare note.
• To acquire knowledge about paper making process through discussion and field visit preparefield visit report and note.
• To understand properties affecting paper through discussion and prepare note
• To understand handling of paper in the press room through discussion field visit; preparefield visit report and note
65
1.1 Paper, board and classificationActivities :
Sample collection of different papers, boards, group discussionLearning materials
Various types of papers, boards, reference books• Divide the learners into small groups and introduce the collected sample• Let them observe and identify• Invite the learners awareness about the collected samples.• Group discussion
Discussion points- Appearance - colour and beauty- Thickness- Size- Ream- Basis- weight- M-weight- Life (durability)- Boards- Types of papers (news print, map litho, art paper etc.)
Hand Out Basis Weight :Weight in pounds of one ream (500 Sheets) of the basic sheet size of aparticular paper type.M weight:Weight of 1000 sheets of the basic sheet size of a particular paper
type. A paper's M weight is twice its basis weight.Consolidation
Paper, boards and its classification, weight etc.Product:
Subject diary (class note)1.2.Paper sizesActivities :
Discussion, demonstration, sample collection, paper cuttingLearning materials
Different paper sizes, Reference books,
66
Printing Technology
• Divide the learners into groups and discussion based on the collected samples• Let them analyse dimensions of paper and identify
• Introduce paper cutting
• Observe and demonstrate
Discussion Points- International and Indian paper sizes
- Use cutting machine to sub divide the paper sizes
Consolidation pointsNational and international classification of papers
Product:Subject diaryLab diary /
Record book1.3 Paper calculation and wastage
Activities :Discussion, calculation
Learning materialsVarious sizes of papers, chart, Reference books
Discuss paper sizes in the learners groups
• Introduce quantity of papers for a particular job
• Wastage of paper for colour and black and white job
• Give example to calculate quantity of paper for a job
Discussion Points - Quantity of paper
- Wastage of paper
67
Paper CalculationThe quantity of paper required for any job can be calculated by using the following formula:
Quantity of paper requiredIn order to calculate the quantity of paper required for the production of a complete job in a
particular size. , the following formula may be used.
Where section = No.of pages obtained from one sheet of the required size of paper.For example : To find out the total quantity of paper required in 61 cm x 88cm size for the
printing of 20,000 booklets in 210 mm x 297 mm size assuming that each booklet contains 24pages?
Since 16 pages of size 210 x 297 mm are obtained from one sheet of 61 x 88 cm size, the valueof a section shall be 16.
.6016
000,2024wastagewithoutReams
xrequiredPaperThereforre ==
Paper required in reams =No of pages in a copy X No of copies to be printed
Section X 500
HandOut Paper Spoilage Allowances (Percentage Represents Press Size Sheets, Not Impressions)
Lithographic 1000 2500 5000 10,000
Single colour equipmentOne Colour one side 8% 6% 5% 4% 3%One Colour, work-and- turn or work-and - tumble 13% 10% 8% 6% 5%Each additional colour (per side) 5% 4% 3% 2% 2%
Two colour equipmentTwo colours, one side -- 5% 4% 3%Two colours, two sides or work- and -turn -- -- 8% 6% 5%Each additional Two colours ( Perside) -- -- 3% 2% 2%
Four colours equipmentFour- Colours, One side only -- -- -- 6% 5%Four colours , two sides or work- and - turn -- -- -- 8% 7%
Bindery SpoilageFolding,Stitching,Trimming 4% 3% 3% 2% 2%Cutting, punching, or drilling 2% 2% 2% 2% 2%Varnishing and gumming 7% 5% 4% 3% 3%
Use the next higher percentage for the following papers.1. Coated papers when plant does not usually run coates2. Papers that caliper: 0025 and less3. difficult papers such as foil, cloth,plastic etc..
25,000and over
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Printing Technology
97.5
-99.
5% W
AT
ER
83
%W
AT
ER
67
%W
AT
ER
67
%W
AT
ER
20
%W
AT
ER
5-5
.5%
WA
TE
R
WA
TE
R L
INE
Hea
d
SC
RE
EN
S
FIG
: PA
PER
MA
NU
FAC
TU
RIN
G P
LA
NT
69
FIG: STEPS OF PAPER MAKING
ConsolidationPaper calculation for a particular job
Product:Subject diary
1.4 Paper making processActivities :
Discussion, field visitLearning materials
Hand made and machine made papers, reference books, Internet• Discuss paper making process and its procedures• Presentation of charts
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Printing Technology
• Field visitDiscussion Points
- Raw materials- Pulping- Stock preparation- Paper making operations- After treatments
ConsolidationPaper making process
Products:Subject diary , field visit report
1.5.Properties affecting paperActivity
DiscussionLearningMaterials
Specimen of papers, Reference books
• Divide the learner into groups and discuss the runnability and printability of paperDiscussion points
- Runnability- Grain direction- Two sideness- Density- Moisture content- Flatness- Dimensional stability- Curling- Piling tendency- Paper dust- Smoothness- Brightness- Opacity- Gloss- Tensile strength- Bursting strength- Folding endurance
71
- Tearing resistance- Pick resistance- Stiffness- Internal bond strength- Ink absorbency
ConsolidationProperties affecting runnability and printability
ProductSubject diary
1.6. Handling of paperActivities
Discussion, field visitLearning materials
RH Meter , pH meter, reference books, Internet• Divide the learners into groups and discuss handling of paper in the pressroom• Conduct field visit and observe the warehouse roomDiscussion points
- Temperature- Moisture conditioning of pressroom- Static electricity- RH of Pressroom- pH of paper- Handling of paper in the pressroom
ConsolidationHandling of paper
Product Subject diaryCE ITEMS
Collection: collection of papers and boards.
Field visit:
1 Field visit toapaper manufacturing unit
2 Conduct field visit to see warehouse and its arrangements
72
Printing Technology
TE ITEMSSample questions1 Identify the basic material of paper from the following
a) Plastic
b) Cellulose fibre
c) Fibre glass (1 score)
2 You visited Hindustan News Print factory Velloore, Kottayam to observe the papermanufacturing process. Introduce your ideas about the visit
(6 scores)
3. Your school anniversary is to be conducted in the next month. For this purpose an invitationnotice of A4 size is needed with single colour printing of 1000 copies. Size of machine isdummy. Calculate the quantity of paper required in reams with wastage
(6 scores)
4. Paper is hygroscopic material in nature. Express your views about this opinion
(3 scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1. Operation of cutting machine
73
To u
nder
stand
pape
r and
thei
rcl
assif
icat
ions
Lear
n pa
per
and
itscl
assif
icat
ions
weig
ht
Obs
ervi
ngcl
assif
ying
com
parin
gan
alyz
ing
mea
surin
gra
ising
que
stion
s
Disc
ussio
n,sa
mpl
eco
llect
ion
Var
ious
type
sof
pap
ers,
boar
ds,
refe
renc
ebo
oks
Col
lect
ion,
Subj
ect d
iary
Parti
cipa
tion
in c
olle
ctio
n,Su
bjec
t dia
ry(c
lass
not
e)
To
acqu
irekn
owle
dge
abou
t Int
erna
-tio
nal a
ndIn
dian
sta
ndar
dpa
per s
izes
and
its n
omen
cla-
ture
Inte
rnat
iona
lan
d na
tiona
lpa
per s
izes
Obs
ervi
ngcl
assif
ying
com
parin
gan
alyz
ing
raisi
ngqu
estio
ns
Disc
ussio
n,sa
mpl
eco
llect
ion
dem
on-
strat
ion,
char
t, pa
per
cutti
ng b
ym
achi
ne
Diff
eren
tpa
per s
izes
,re
fere
nce
book
s
Subj
ect d
iary
Lab
diar
yR
ecor
dbo
ok/
Sam
ple
colle
ctio
n,Sk
ill to
cut
pape
rSu
bjec
t dia
ryLa
b di
ary
Rec
ord-
book
.
To
unde
rsta
ndpa
per
calc
ula-
tions
and
was
tage
To u
nder
stand
pape
rca
lcul
atio
nsan
d w
asta
ge
Iden
tifyi
ngm
easu
ring
clas
sifyi
ngan
alyz
ing
raisi
ngqu
estio
ns
Disc
ussio
nca
lcul
atio
nch
arts
pres
enta
tion
Var
ious
size
sof
pap
ers
,cha
rt,re
fere
nce
book
s
Inte
rnat
iona
lan
d na
tiona
lsiz
es o
fpa
per,
Subj
ect d
iary
Parti
cipa
tion
in c
olle
ctio
n,Su
bjec
t dia
ry
UN
IT
AN
AL
YSI
S1
- PA
PER
Sl No 1 2 3
Theory 2 hrs 1 hr
15 hrs
3 hrs
Practical
74
Printing Technology
Theory
To a
cqui
rekn
owle
dge
abou
t pap
erm
akin
g pr
oces
s
Raw
mat
eria
ls,pu
lpin
g sto
ckpr
epar
atio
n,pa
per m
akin
gop
erat
ions
,af
ter
treat
men
ts
Iden
tifyi
ngob
serv
ing
raisi
ng q
uesti
ons
Disc
ussio
nFi
eld
visit
Han
d m
ade
and
mac
hine
mad
e pa
pers
Ref
eren
cebo
oks
Inte
rnet
Fiel
d vi
sitre
port
,Su
bjec
t dia
ry
Fiel
d vi
sitre
port,
Subj
ect d
iary
1 hr
To u
nder
stand
prop
ertie
saf
fect
ing
pap
er
Run
nabi
lity
grai
ndi
rect
ion,
two
side
ness
dens
ity,
pilin
gte
nden
cym
oistu
reco
nten
t,fla
tnes
s,di
men
siona
lsta
bilit
ycu
rling
,pi
ckin
g,
Obs
ervi
ngid
entif
ying
clas
sifyi
ngco
mpa
ring
mea
surin
gra
ising
ques
tions
Infe
rring
Disc
ussio
nSp
ecim
en o
fpa
pers
refe
renc
ebo
oks,
Subj
ectD
iary
Subj
ectD
iary
1 hr
To u
nder
stand
hand
ling
ofpa
per i
n pr
ess
room
Han
dlin
g of
pape
r in
pres
s ro
om,
moi
sture
cond
ition
ing
static
elec
trici
ty R
Hof
pre
ssro
om, P
H o
fpa
per
Obs
ervi
ngid
entif
ying
mea
surin
gra
ising
ques
tions
Disc
ussio
n,Fi
eld
visit
RH
met
erpH
met
erR
efer
ence
-bo
oks
inte
rnet
Fiel
d vi
sitre
port,
Subj
ect d
iary
Fiel
d vi
sitre
port,
Subj
ect D
iary
1 hr
Practical
UN
IT A
NA
LY
SIS
1- P
APE
RSl N
o 4 5 6
75
UNIT-2INK
Introduction
Ink forms images on the substrate while printing. Whatever may be the printing process, ink istransferred to the substrate from image carrier.
All printing inks are made from three basic ingredients: pigment, vehicle and additives (driers)etc. This unit gives an over all idea on printing ink and it properties.
The facilitator upholds various strategies like discussion, sample presentation, collection and labwork to the learners.Curriculum objectives
• To understand printing ink ingredients and colour mixing through discussion, samplepresentation demonstration , lab work and prepare note and record.
• To understand properties of ink through discussion, sample presentation and prepare note.• To acquire knowledge about new generation of inks and their chemical properties through
discussion, ink sample presentation, and prepare note.• To understand various ink drying methods through discussion, sample presentation, printed
products and prepare note.2.1 Printing ink and ingredients
Activities: Discussion, sample presentation, demonstration lab worksLearning materials Ink Samples, Reference books, Internet• Divide the learns into groups and present ink samples.• Observe the sample and let them discuss the ingredients .• Introduce ink mixing procedure.• Observe and do in the lab.Discussion points
- Ink and its nature- Ingredients- Pigments
76
Printing Technology
- Vehicle- Additives- Characteristics- Ink mixing procedures.
Hand OutThe Pantone Matching System (PMS)
Pantone Matching System (PMS) is a method universally accepted for specifyingand mixingcolours. Using this technique, artists and customers can select any of the more than 500 huesfrom a “swatch book.” The printer can then mix the desired colour by us ing the swatchnumber and referring to to a formula guide.” The guide gives the formula for making thecolour. It identifies the basic colours involved and indicates how much of each to mix together.The ten basic colours in the PAN-TONE MATCHING SYSTEM are rhodamine red, purple,reflex blue, yellow, warm red rubine red, process blue, green, black, and transparent white.
Consolidation pointsPrinting ink, ingredients, ink mixing procedures.
ProductSubject diary, Lab diary / Record book.
2.2 Properties of inkActivities
Sample presentation, discussionLearning materials
Ink sample, measuring instruments, reference books, internet.
• Present ink sample in the learners group• Ask to observe and discuss the properties of printing ink
Discussion points- Properties of ink- Viscosity- Tack- Drying quality- Colour brilliance- Hue of pigments- Rub resistance- Drying characteristics
77
- Methods of measuringConsolidation
Properties of inkProduct
Subject diary2.3 New generation of ink and chemical propertiesActivities
Ink sample presentation, DiscussionLearning materials
Ink sample, reference books,internet
• Divide learners into groups and present the ink sample• Observe and discuss the features of new generation of ink and its
chemical propertiesDiscussion points
- Gloss inks- Quick set- Heat set- Moisture set(cold set)- Magnetic- Fugitive- Ultra violet- Infra red- Electron beam drying.- Chemically reactive ink- Water based ink for flexography- New trends and developments
ConsolidationNew generation ink, chemical properties
Product:
Subject diary2.4 Ink drying methodsActivitis :
Discussion, sample presentation of ink and printed productsLearning matrials
Ink Sample, Printed products, reference books, Internet
78
Printing Technology
• Divide the learners into groups and present ink sample and printed products• Discuss the ink drying methods• Let them identify the different ink drying methods
Discussion points - Absorption- Penetration- Evaporation - Polymerisation- Precipitation etc.
ConsolidationInk drying methods
Product:Subject diary
CE ITEMS
Sample collectionTE ITEMSSample questions1. Ink has colour in nature. This colour is obtained by adding ingredients. Select the ingredient
that gives colour from the followinga) Vehicleb) Drierc) Pigment (1score)2. As a printer you are familiar with printing ink. Assess the properties of printing ink in experience.
(6scores)3. You have conducted a field visit to a printing press, where printing works are being done on
substrates like paper, metal foil, plastic and boards. Discuss the ink drying methods in thepress.
(6scores)LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1 Primary colour2 Secondary colour3 Tertiary colour4 Opaque ink5 Transparent ink
79
To
unde
rsta
ndpr
intin
g in
k, a
ndits
in
gred
ient
s,co
lour
mix
ing
Pigm
ents
vehi
cles
addi
tives
,co
lour
mix
ing
Obs
ervi
ngId
entif
ying
Cla
ssify
ing
Com
parin
gA
naly
sing
Rra
ising
Que
stion
s
Disc
ussio
nsa
mpl
epr
esen
tatio
nD
emon
str-
atio
nLa
b w
orks
Prin
ting
ink
sam
ples
,R
efer
ence
book
sIn
tern
et
Subj
ect d
iary
,La
b di
ary
/R
ecor
d bo
ok.
To u
nder
stand
prop
ertie
s of
ink
Visc
osity
Tack
Dry
ing
Qua
lity
Col
our
Bril
lianc
eHue
of pigm
ents,
Rub
Res
ista
nce,
Dry
ing
Char
acter
istics
,M
etho
d of
mea
surin
g
Obs
ervi
ngcl
assif
ying
com
parin
gan
alyz
ing
raisi
ngqu
estio
ns
Disc
ussio
n,sa
mpl
eco
llect
ion
dem
on-
strat
ion,
char
t, pa
per
cutti
ng b
ym
achi
ne
Diff
eren
tpa
per s
izes
,re
fere
nce
book
s
Subj
ect d
iary
Lab
diar
yR
ecor
dbo
ok/
To
acqu
irekn
owle
dge
abou
t new
gene
ratio
n of
Inks
and
chem
ical
prop
ertie
s
Iden
tifyi
ngO
bser
ving
Cla
ssify
ing
Ana
lysin
gR
aisin
gQ
uesti
ons
Pred
ictin
g
Disc
ussio
n,In
k Sa
mpl
epr
esen
tatio
n
Ink
Sam
ples
Ref
eren
ceB
ooks
,In
tern
et
Subj
ect D
iary
Glo
ss In
kQ
uick
est
Hea
t Set
,M
oist
ure
Set,
Mag
netic
Fugi
tive
Etc
..
Sl No 1 2 3
Practical
Theory
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
2 hrs
Sam
ple
colle
ctio
n,Sk
ill to
cut
pape
rSu
bjec
t dia
ryLa
b di
ary
Rec
ord-
book
.
1 hr15 h
rs
Subj
ect D
iary
2 hrs
15 hrs
UN
IT A
NA
LY
SIS
2- I
NK
80
Printing Technology
Practical
Theory
To u
nder
stand
vario
us in
kdr
ying
met
hods
Abs
orpt
ion
pene
tratio
nev
apor
atio
npo
lym
erisa
tion
prec
ipita
tion
Iden
tifyi
ngob
serv
ing
Cla
ssify
ing
raisi
ngQ
uesti
ons
Disc
ussio
nsa
mpl
epr
esen
tatio
nof
ink
and
prin
ted
prod
ucts
Ink
sam
ple
prin
ted
prod
ucts
,re
fere
nce
book
s, in
tern
et
Sub
ject
dia
ryId
entif
y th
ein
k dr
ying
met
hods
Subj
ect d
iary
2 hrs
Sl No 4
UN
IT A
NA
LY
SIS
2- I
NK
81
UNIT-3PRESS DEVELOPMENTS
Introduction
The development of press in the later half of this century has been the result of extensive researchin this field.
This unit mainly deals with the press developments and comes to a detailed study of the sheet-fed offset printing machine such as feeding unit, registration unit, printing unit, inking unit, dampingunit and the delivery unit.
The facilitator can adopt various strategies like discussion, field visit demonstration, chartpresentation and lab work.Curriculum objectives
• To understand the development of printing presses through discussion chart, field visit , preparefield visit report and note.
• To understand principles and classification of offset presses through discussion chartdemonstration, field visit, prepare field visit, report and note.
• To understand operation of feeder unit through lab discussion, demonstration, chart, labwork, prepare field visit report and note and record book..
• To understand and apply the function and importance of registration unit through discussion,demonstration, chart presentation, lab work and prepare note, record book.
• To understand printing unit and cylinder configuration through discussion lab demonstration,chart presentation, field visit, lab work; prepare field visit report and note, recordbook.
• To understand the inking unit through discussion, lab demonstration, chart, lab work andprepare note and record.
82
Printing Technology
• To understand and apply damping unit through discussion, lab demonstration, chart presentation,lab work and prepare note and record.
• To understand delivery unit through discussion, lab demonstration, chart, lab work and preparenote and record book.
3.1. Develepoments of printing pressesActivities
Discussion, field visit to different presses, chart presentationLearningmaterials
Chart, Plates machine, Cylinder machine, Rotary machine, Offset machine, Reference books,Internet
• Divide the learners in to groups and discuss the topic• Present chart• Conduct field visit to learn the latest developments of printing presses
Discussion points- Press developments from its initial stage- Platen press to rotary press
- Litho press to offset pressConsolidation
Press developmentsProduct
- Subject diary- Field visit report
3.2 Principles and classification of offset pressess
ActivitiesDiscussion, chart, field visit
Learning materialsChart, sheet fed, Offset machine, web offset machine reference books, Internet.
• Divide the learners into groups and discuss about the field visit• Present chart• Observe and identify the classification of presses
Discussion points- Basic principle- Hydrophilic and oleophilic nature- Working principle
83
- Classification of offset pressesConsolidation
Principle and classification of offset pressProduct
- Subject diary- Field visit report
3.3.Feeder unitActivities
Discussion, lab demonstration chart, lab work.Learning materials
Sheet fed machine, reference books, Internet• Divide the learners into groups• Discuss feeder unit• Lab demonstration• Chart presentation• Give lab work to learn the feeder unit and its working• Observe and do in the lab
Discussion points- Parts of feeder unit (pile height governor, blower, sucker, forwarding
roller etc.)- Loading system- Types of feeder- single sheet and stream feeder.- Automatic feeder control- Sheet separation- Sheet dictators
ConsolidationParts, types and setting of feeder unit
Product- Subject diary- Lab diary /- Record book
84
Printing Technology
3.4. Registration UnitActivities
Discussion, lab demonstration, chart, lab work.Learning materials
Chart, Sheet fed offset machine, Reference books, Internet
• Divide the learners into groups• Discuss about registration unit• Chart presentation• Lab demonstration to learn the parts of registration unit• Give labwork to operate the registration unit
Discussion points- Importance of registration- Feed board equipments
Conveyor tapesConveyor assembliesRotary brush wheelsTraining brushesBall control assembliesFront laySide lay
- lay adjustments- Grippers
ConsolidationThe function and importance of registration unit
Product- Subject diary- Lab diary /
Record book
3.5. Printing Unit and Cylinder configurationActivities
Discussion, chart presentation, Lab demonstration, , field visit, lab work.Learning materials
Chart , sheet fed offset machine, reference books, Internet
85
• Discuss printing unit
• Chart presentation• Lab demonstration• Lab work to learn the printing unit, Cylinder configuration and gears.• Field visit
Discussion point- Plate cylinder and its adjustments- Blanket cylinder and its adjustments- Impression cylinder and its adjustments- Cylinder configuration- Impression control- Cylinder gears- Cylinder bearers
ConsolidationPrinting unit and cylinder configuration
Product- Subject diary- Lab diary /
Record book3.6. Inking UnitActivities
Discussion, lab demonstration, chart presentation, lab workLearning materials
Chart, sheet fed offset machine, reference books, Internet
• Divide the learners into groups and discuss the topic.• Present chart• Lab demonstration• Lab work to operate inking unit
Discussion points- Inking unit configuration- Classification of inking system- Ink duct
86
Printing Technology
- Fountain roller- Set of screws- Dwell time- Ink distribution rollers- Ink forme roller- Inking unit operation- Roller coverings- Roller cleaning
ConsolidationInking Unit
Products- Subject diary- Lab diaryRecord book
3.7. Damping UnitActivities
Discussion, lab demonstration, chart presentation, lab workLearning materials
Chart, Sheet fed offset machine , reference books, Internet• Divide the learners and discuss delivery unit• Present chart• Demonstration• Lab work to learn damping unit working, observe and do
Discussion points- Damping unit configuration- Fountain solution- Conventional and non conventional damping unit- Fountain roller- Feed roller (vibrator)- Rider roller- Forme roller- Damping roller coverings
87
- Damper roller cleaningConsolidation points
Damping UnitProducts
- Subject diary- Lab diary /Record book
3.8.The Delivery Unit
ActivitiesDiscussion, lab demonstration chart presentation, lab work
Learning materialsChart, sheet fed offset machine, Reference books, Internet
• Divide the learners into groups and discuss delivery unit• Lab demonstration• Lab work to learn delivery unit setting
Discussion points- Delivery unit- Delivery pile control- Types of delivery system- Skeleton wheels- Joggers- Ancillary operation (anti-set-off spray, perforation, slitting, numbering)
Consolidation pointsDelivery unit
ProductsSubject diaryLab diary /
Record bookCE ITEMS
Field Visit : Conduct field visit to printing press to understand different offset machines and it developments
88
Printing Technology
TE ITEMSSample questions
1. “Ink and water do not mix together” Express your opinion related to offset printing processabout this statement.
(3 scores)2. Name the roller which touches the plate cylinder for applying ink during printing
(1 score)
3. Comment about the feeding system of an offset machine which you have seen during field visitto a press. (4 scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1 Feeder unit2 Registration unit3 Printing unit4 Inking unit5 Damping unit6 Delivery unit
89
UN
IT A
NA
LY
SIS
3- P
RE
SS D
EV
EL
OPM
EN
TS
Practical
Theory
To u
nder
stand
the
deve
lopm
ent
of p
rintin
gpr
esse
s
Pres
sde
velo
pmen
tfro
m p
late
n to
offs
et
Obs
ervi
ngC
lass
ifyin
gA
naly
sing
Rai
sing
Que
stion
sId
entif
ying
Fiel
d V
isit
Disc
ussio
nPr
esen
ting
Cha
rts
Cha
rt,Pl
aten
Mac
hine
,C
ylin
der
Mac
hine
,R
otar
yM
achi
ne,
Offs
etM
achi
ne,
Ref
eren
ceB
ooks
,Inte
rnet
.Fiel
d vi
sitre
port
Subj
ect D
iary
Fiel
d V
isit
Rep
ort
Subj
ect D
iary
2 hrs
Cha
rt,Sh
eet F
edO
ffset
Mac
hine
,W
eb O
ffset
Mac
hine
,R
efer
ence
Boo
ks,In
tern
et
To
unde
rsta
ndpr
inci
ples
and
clas
sific
atio
n O
fof
fset
pre
sses
Obs
ervi
ngC
lass
ifyin
gA
naly
sing
Iden
tifyi
ngR
aisin
gQ
uesti
ons
Fiel
d V
isit
Disc
ussio
nPr
esen
ting
Cha
rts
Fiel
d vi
sitSu
bjec
t dia
ryFi
eld
visit
repo
rtSu
bjec
t dia
ry
1 hrD
iffer
ent
clas
sific
atio
nof
offs
etpr
esse
s
To u
nder
stand
oper
atio
ns o
ffe
eder
uni
t
Obs
ervi
ngId
entif
ying
Mea
surin
gC
lass
ifyin
gA
naly
sing
Rai
sing
Que
stion
s
Dem
onstr
ation
Disc
ussio
nPr
esen
ting
Cha
rtsLa
b W
ork
Subj
ect D
iary
Lab
Dia
ry /
Rec
ord
Boo
k
Skill
sSu
bjec
t dia
ry,
Lab
diar
y/R
ecor
d bo
ok
1 hrW
orki
ng o
fth
e fe
eder
unit
Shee
t Fed
Offs
etM
achi
neR
efer
ence
Boo
ks,In
tern
et
9 hrs
Sl No 1 2 3
90
Printing TechnologyU
NIT
AN
AL
YSI
S3-
PR
ESS
DE
VE
LO
PME
NT
S
Theory
To u
nder
stand
and
appl
y th
efu
nctio
n an
dim
porta
nce
ofre
gistr
atio
n un
it
Wor
king
and
setti
ng o
fre
gistr
atio
nun
it
Obs
ervi
ngId
entif
ying
Ana
lyzin
gR
aisin
gQ
uesti
ons
Disc
ussio
n,La
bD
emon
-st
ratio
nPr
esen
ting
Cha
rts L
ab W
ork
Cha
rtSh
eet F
edO
ffset
Mac
hine
,R
efer
ence
Boo
ks,
Inte
rent
Subj
ect d
iary
Lab
diar
y,R
ecor
d B
ook
Skill
s,Su
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
2 hrs
Cha
rtSh
eet F
edO
ffset
Mac
hine
Ref
eren
ceB
ooks
,In
tern
et
To u
nder
stand
prin
ting
unit
and
cylin
der
conf
igur
atio
n
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Disc
ussio
nLa
bD
emon
-st
ratio
nPr
esen
ting
Cha
rtsLa
b w
ork
Subj
ect d
iary
Lab
diar
yR
ecor
d bo
ok
Skill
s,Su
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
1 hrW
orki
ng o
fpr
intin
g un
it,cy
linde
rco
nfig
urat
ion
To u
nder
stand
inki
ng u
nit
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Disc
ussio
nD
emon
-st
ratio
nPr
esen
ting
Cha
rt,La
bW
ork
Subj
ect d
iary
Lab
diar
yR
ecor
d bo
ok
Skill
s,Su
bjec
t dia
ryla
b di
ary/
Rec
ord
book
1 hrW
orki
ng o
fan
inki
ng u
nit
and
its p
arts
Cha
rtSh
eet F
edO
ffset
Mac
hine
Ref
eren
ce-
book
sIn
tern
et
Sl No 654
Practical 7 hrs9 hrs 4 hrs
91
UN
IT A
NA
LY
SIS
3- P
RE
SS D
EV
EL
OPM
EN
TS
Practical
Theory
To u
nder
stand
and
appl
yda
mpi
ng u
nit
Wor
king
of
dam
ping
uni
tan
d its
par
ts
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Disc
ussio
nD
emon
-st
ratio
nPr
esen
ting
Cha
rt,La
bW
ork
Cha
rtSh
eet F
edO
ffset
Mac
hine
Ref
eren
ce-
Boo
ksIn
tern
et
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Skill
s,Su
bjec
t dia
ryLa
bdia
ry/
Rec
ord
book
1 h
r
Cha
rtSh
eet
Fed
Off
set
Mac
hine
,R
efer
ence
-B
ooks
Inte
rnet
To u
nder
stand
prin
ting
unit
and
cylin
der
conf
igur
atio
n
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Disc
ussio
nD
emon
-st
ratio
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esen
ting
Cha
rt La
bW
ork
Subj
ect d
iary
,La
b di
ary/
Rec
ord
book
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s,Su
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
1 hrW
orki
ng o
fde
liver
y un
itan
d its
par
ts.
6 hrs 5 hrs
Sl No 7 8
92
Printing Technology
UNIT-4OFFSET PRESS OPERATION
Introduction
At present there are different kinds of offset presses on the market with so many minute operationaldifferences. It is easy to learn the press operation by the switch-does-what method. The problemswith this approach is that the operator is lost if moved to another type of machine
This unit reveals the information necessary to run any sheet fed offset press and its generaloperational steps.
The facilitator introduces different tactics like discussion, demonstration and lab work
Curriculum objectives
• To understand feeding of paper through discussion, demonstration, lab work and preparenote and record.
• To acquire knowledge about preparing the printing unit through discussion, demonstration,lab work and prepare note and record.
• To apply starting up and proofing through discussion, demonstration, lab work and preparenote and record.
• To understand the clean up procedures through discussion, demonstration, lab work andprepare note and record.
4.1 Feeding of paperActivities
Discussion, demonstration, lab workLearning materials
Machine, Paper, wedges , reference books, Internet
• Group the learners and discuss about paper feeding• Introduce paper feeding in lab
93
• Let them observe and do the working procedures in the lab• Blind feeding
Discussion points- Fanning the press sheet- Adding paper to the feeder- Using wedges to level the paper- Adjusting the pile height- Adjusting the air blast- Adjusting the registration system- Adjusting the delivery side guides- Make ready procedures
ConsolidationFeeding of paper
Product- Subject diary,- Lab diary /
Record book
4.2.Preparing the printing unitActivities
Discussion, demonstration, lab workLearning materials
Machine, Tools, Ink, Reference books, Internet• Divide the learners into small groups and discuss the topic• Introduce printing unit preparation in lab• Observe and demonstrate.
Discussion points- Adjusting the ink feed- Adjusting the ink fountain- Adjusting the water feed
- Attaching the plate
ConsolidationPreparing the printing unit
94
Printing Technology
Product- Subject diary- Lab diary
Record book
4.3.Starting up and proofing
ActivitiesDiscussion, demonstration, lab work
Learning materialsMachine, paper, Progressive proof book, reference books, Internet
• Group the learners and discuss about ‘starting up’ and ‘proofing’• Demonstrate starting up and proofing in the lab• Observe and do
Discussion points- Inking the plate- Press proofing- Achieving proper ink water balance- Lays and cylinder adjustments
ConsolidationStarting up and proofing
Product- Subject diary- Lab diary /
Record book4.4.Clean up proceduresActivities
Discussion, demonstration, lab workLearning materials
Machine, automatic wash up device, mechanical clean up system, Ink cleaning solution,reference books.
• Divide the learners into groups and discuss about clean up procedures• Introduce clean up procedures in the lab• Observe and do
95
Discussion points- Clean up procedures of plate, blanket, damping, inking and impression cylinder.- Automatic wash up devices- Mechanical clean up system
ConsolidationClean up procedures
Product- Subject diary- Lab diary /
Record bookCE ITEMS
Nil
TE ITEMS
Sample Questions
1. Introduce the steps to feed paper in a printing lab in your words(6 scores)
2. In a printing press the cleaning of machine is very important. Write your ideas about cleaningup procedures
(6 scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1 Feeding of paper2 Preparing the printing unit3 Starting up and proofing4 Cleaning up procedures
96
Printing Technology
UN
IT
AN
AL
YSI
S4-
OFF
SET
PR
ESS
OPE
RA
TIO
N
To u
nder
stand
feed
ing
of p
aper
Fann
ing
Add
ing
pape
rto
the
feed
erw
edge
sA
djus
ting
the
pile
hei
ght a
irbl
ast,
regi
strat
ion
syste
m,
deliv
ery
side
guid
esus
ing
mak
ere
ady
shee
ts
Obs
ervi
ngid
entif
ying
Rai
sing
ques
tions
Infe
rring
Mea
surin
g
Disc
ussio
nD
emon
-st
ratio
nLa
b w
ork
Mac
hine
Pape
r, w
edge
sR
efer
ence
book
s,In
tern
et
Subj
ect d
iary
lab
diar
y/R
ecor
d bo
ok
Feed
ing
skill
sSu
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
To a
cqui
rekn
owle
dge
abou
t pre
parin
gth
e pr
intin
g un
it
Obs
ervi
ngcl
assif
ying
anal
ysin
gid
entif
ying
raisi
ng q
uesti
ons
Mea
surin
g
Disc
ussio
nD
emon
st-ra
tion
Lab
wor
k
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Skill
topr
epar
ePr
intin
g un
itSu
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
Adj
ustin
g th
ein
k fe
ed, i
nkfo
unta
inw
ater
fee
dat
tach
ing
the
plat
e
Mac
hine
,To
ols,
ink,
foun
tain
solu
tion
refe
renc
e-bo
oks
inte
rnet
To a
pply
starti
ng u
p an
dpr
oofin
g
Obs
ervi
ngid
entif
ying
Rai
sing
ques
tions
Infe
rring
Mea
surin
g
Disc
ussio
nD
emon
s-tra
tion
Lab
wor
k
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Skill
tosta
rting
up
and
proo
fing
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Inki
ng th
epl
ate,
pre
sspr
oofin
g in
kw
ater
bala
nce
Mac
hine
,Pa
per,
prog
ress
ive
proo
f boo
kR
efer
ence
-bo
oks
Inte
rnet
Sl No 1 2 3
Practical
Theory 3 hrs
14 hrs
3 hrs
13 hrs
2 hrs
9 hrs
97
UN
IT A
NA
LY
SIS
4-
OFF
SET
PR
ESS
OPE
RA
TIO
N
Practical
Theory
Mac
hine
,au
tom
atic
was
h up
devi
cem
echa
nica
lcl
ean
upsy
stem
, ink
clea
ning
solu
tion
To u
nder
stand
clea
n up
pro
ce-
dure
s
Aut
omat
icw
ash
upde
vice
,m
echa
nica
lcl
eani
ngsy
stem
Obs
ervi
ngId
entif
ying
Infe
rring
Disc
ussio
nD
emo-
nstra
tion
Lab
wor
k
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
/Cle
anin
gsk
ills
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
2 hrs
9 hr
s
Sl No 4
98
Printing Technology
UNIT-5ROLLER AND BLANKET- PROBLEMS AND ITS
ADJUSTMENTS
Introduction
An offset press, consists of plate cylinder, blanket cylinder, impression cylinder inking unit anddamping unit. When the three cylinders are in contact sufficient pressure must be produced to effectgood transfer of the inked image from the plate cylinder to the blanket and from there to the stockwhich is carried on the surface of the impression cylinder
In this chapter we deal with the roller and blanket problems, plate-to-blanket packing and itsadjustments,.ink unit rollers and its setting, damping unit rollers and its setting, damping solution, inkand paper consideration for an offset printing and its trouble shooting;
The facilitator can adopt various learning strategies like field visit, sample collection, groupdiscussion, demonstration, chart preparation and lab work.
Curriculum objectives
• To familiarise of roller and blanket problems through discussion and prepare note.• To understand plate and blanket adjustment and packing through discussion, demonstration,
lab work; prepare note and record book.• To understand inking and damping roller unit adjustment through discussion, demonstration
lab work and prepare note, record book• To acquire knowledge about common paper concerns with damping solution and its pH
values through discussion, demonstration, lab work; prepare note and record book.• To understand ink and paper consideration for offset printing through seminar and prepare
report
5.1.Roller and Blanket ProblemsActivity
Discussion
99
Lerning materialsSingle colour offset machine, reference books, Internet
• Group the learners and discuss about roller and blanket problems.• Let them identify the problems.
Discussion points- Blanket and roller caring- Various blankets- Hardness of blanket- Problems affecting rollers- Problems affecting blankets
Consolidation pointsRoller and blanket problems
Product- Subject diary
5.2. Plate Blanket, impression cylinder adjustment and packingActivities
Demonstration, Discussion, Lab work.Learning materials
Single colour offset machine, reference books, Internet• Divide the learners into groups and discuss.• Introduce plate, blanket, impression cylinder adjustment and packing.• Ask them to observe and demonstrate.• Lab works
Discussion points- Plate packing- Blanket packing- Impression packing- Under cut- Depression gap- Cylinder bearers- Setting of plate cylinder- Setting of blanket cylinder- Setting of impression cylinder
100
Printing Technology
Consolidation pointsPlate, blanket, impression cylinders adjustments and packing
Product- Subject diary- Lab diary /
Record book5.3. Inking and damping roller adjustmentsActivities
Discussion, Demonstration, Lab workLearning materials
Single colour offset machine, Reference books, Internet• Divide the learners into groups and discuss the topic.• Introduce the inking and damping rollers adjustments• Demonstration• Ask them to observe and do.
Discussion points- Inking unit rollers structure and adjustments- Damping unit rollers structure ans adjustments
Consolidation pointsInking and Damping rollers adjustments
Product- Subject diary- Lab diary /
Record book5.4. Damping solution and pHActivities
Discussion, Lab work, demonstration.Learning materials
Single colour offset machine, pH meter, reference books, Internet
• Divide the learners into groups and discuss about damping solution and pH
• Measure pH value of damping solution in the lab
• Ask the learners to observe and demonstrate.
101
Discussion points- Fountain solution for damping- pH of damping solution- Alcoholic Damping
Hand out
Damping solution and pHThe moisture applied to the surface of a lithographic plate actually serves two functions.
First , the presence of water in the nonimage areas reples ink. The second purpose of themoisture, is to ensure that the nonimage areas of the plate remain water- receptive.AloisSenefelder recoganised the dual role of the moisture layer on the stone and used asolution made from a combination of water, acid and gum arabic. Damping solutions areavialable ready-mixed from a commerical supplier or can be purchased as separatecomponents and mixed by the printer . Most solutions are now made from an acid concentrate,gum , arabic, and a gum preservative.
The pH value for various substances
102
Printing Technology
For the lithographers, the most meaningful measure of damping solution usabilityis the levelof acidity of the liquid. The numeric scale that measures acidity in a range from 0 (veryacid)to 14 ( very alkaline, or a base)is called a pH scale. The midpoint 7 is consideredneutral. Platemanufactuers specify a recommanded pH level to be used with their plates.A readingbetween5.5 and 4.5 is acceptable for most plates.
The printer can measure pH in several ways .Litmus paper pH indicators are avialablefrom printing suppliers and givean acceptable reading of the level of acidity for mostproductionsituations. To make a test, remove a small piece of litmus paper from the roll anddip it into the fountain solution. The wet paperwill change colour and can be matched tocolour patches supplied with the roll. A pH number will be identified next to each colourpatch. If the pH is not in the recommended range, remix the fountain solution.
Some presses have built-in sensors that continually monitor the pH level of the dampeningsolution. With such sensors the required pH is dialed into the unit and the device automaticallycompensates for any variation by adding water or acid concentrate. A veriety of problems canoccur as a result of too acid a fountain solution (pH reading from 1 to 3) A strongly acidicsolution can greatly shorten plate life. The acid tends to deteriorate the image area of allsurface plates and can eventually make the image “ walk off the plate”. When the press roomhumidity is high the action of acid with ink will cause drying problems on the press sheets( especially when runninghigh acid content papers).A high acid bath will also break down theink. The ink is attacked by the high acid content of the fountain solution, and ink becomespaste – like or emulsified. The rollers will appear glazed , and no quantity of ink that is addedto the system will correct the problem. The rollers must be cleaned and the unit rinked.
If the acid level of the dampening solution is too low(pH readings from 7 to 14), theactionof the moisture layer on the nonimage areas will decrease water receptivity and the plate willscum with ink.
Consolidation pointsDamping solution and pH
Product- Subject diary- Lab diary /
Record book5.5. Ink and paper consideration for offset printingActivities:
- Seminar
103
Learning materialsReference books
• Conduct a seminar and present reportDiscussion points
- Give pointsConsolidation points
Ink and paper considerationProduct
- Seminar report
CE ITEMSSeminar: Conduct seminar on Ink paper consideration for offset printing
TE ITEMS1. write the factors you are considering while selecting paper, ink and damping solution.
(3Scroes)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION1. Plate, blanket, impression cylinder adjustments and packing2. Inking and damping roller adjustment3. Damping solution and pH.
104
Printing Technology
UN
IT A
NA
LY
SIS
5- R
OL
LE
R A
ND
BL
AN
KE
T-P
RO
BL
EM
S A
ND
IT
S A
DJU
STM
EN
TS
To
fam
iliar
ise th
efu
nctio
n of
rolle
r and
blan
ket
prob
lem
s
Kin
d of
blan
kets
,ha
rdne
ss,
prob
lem
saf
fect
ing
rolle
rs a
ndbl
anke
t
Obs
ervi
ngid
entif
ying
Rai
sing
ques
tions
Disc
ussio
nSi
ngle
col
orof
fset
mac
hine
Ref
eren
cebo
oks
inte
rnet
Subj
ect d
iary
Subj
ect d
iary
To u
nder
stand
plat
e an
dbl
anke
t adj
ust-
men
ts an
d its
pack
ing
Obs
ervi
ngid
entif
ying
raisi
ng q
uesti
ons
Mea
surin
g
Disc
ussio
nD
emon
-st
ratio
nLa
b w
ork
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Skill
s to
adju
st p
late
,bl
anke
t and
pack
ing
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Plat
e, b
lank
etad
justm
ents
and
pack
ing
Sing
le c
olou
rO
ffset
mac
hine
Ref
eren
cebo
oks
Inte
rnet
To u
nder
stand
inki
ng a
ndda
mpi
ng ro
ller
adju
stmen
t
Obs
ervi
ngid
entif
ying
Rai
sing
ques
tions
Com
parin
gM
easu
ring
Disc
ussio
nD
emon
-st
ratio
nLa
b w
ork
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Skill
s for
adju
sting
inki
ng a
ndD
ampi
ngro
llers
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Inki
ng u
nit
rolle
rad
justm
ents
Dam
ping
uni
tro
ller
adju
stmen
t
Sing
le c
olou
rO
ffset
mac
hine
Ref
eren
ce-
book
sIn
tern
et
Sl No 1 2 3
Practical
Theory 2 hrs 2 hrs
19 hrs
3 hrs
19 hrs
105
UN
IT A
NA
LY
SIS
5-R
OL
LE
R A
ND
BL
AN
KE
T-P
RO
BL
EM
S A
ND
IT
S A
DJU
STM
EN
TS
Theory
To u
nder
stand
ink
and
pape
rco
nsid
erat
ions
for o
ffset
prin
ting
Com
mun
icat
ing
Infe
rring
Inte
rpre
ting
data
Sem
inar
Parti
cipa
tion
in th
e se
min
aran
d its
repo
rt
Sem
inar
repo
rt3 hrs
Ink
and
pape
r for
offs
et p
rintin
g
Han
d ou
tsIn
k, p
aper
Ref
eren
cebo
oks
To a
cqui
rekn
owle
dge
abou
t com
mon
pres
s co
ncer
nw
ith D
ampi
ngso
lutio
n an
d its
pH v
alue
Foun
tain
solu
tion
and
its p
Hal
coho
licD
ampi
ng
Obs
ervi
ngId
entif
ying
Rai
sing
Que
stion
s
Disc
ussio
nLa
b w
ork
Sing
le c
olor
Offs
et m
achi
nePh
met
erR
efer
ence
book
sIn
tern
et.
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
2 hrs
Practical
2 h
rs
Sl No 54
106
Printing Technology
UNIT –6MULTI COLOUR SHEET FED PRESS
Introduction
The demand for multi colour printing is constantly increasing. To meet this demand, manufacturershave developed many types of multi colour printing machines. Multi colour sheet fed pressesoperate in the same manner as single colour sheet fed presses, but they are equipped with two ormore printing units.
This unit explains multi colour sheet fed presses, perfecting transfer, multi colour press monitoringcontrol system and the press console.
The facilitator adopts various learning strategies like discussion, chart presentation, field visit,demonstration and lab work in the classCurriculum objectives
• To understand multi colour sheet fed presses through discussion, chart, demonstration, fieldvisit, slide presentation, lab work; prepare field visit report and note, lab diary / record book.
• To make an awareness about perfecting presses through discussion chart, field visit, slidepresentation; prepare field visit report and note
• To understand multi colour presses monitoring and control system through discussion, fieldvisit, demonstration, lab work; prepare field visit report and note
• To familiarise the press console through discussion, field visit; prepare field visit report andnote
6.1 Multi color sheet fed pressesActivities:
Discussion, chart presentation, slides show, field visit , lab workLearning materials
Chart, visual aids, Machine, reference books, Internet• Divide the learners into groups and discuss the topic.
107
• Field Visit,• Slideshow.• Use chart and machine to learn the working procedures• Let them observe the working procedures and demonstrate.
Discussion points- Two colour presses- Four colour presses- Five colour presses etc
ConsolidationMulti colour presses
Product- Subject diary- Field visit report- Lab diary /
- Record diary6.2.Perfecting pressesActivities
Discussion, chart presentation, slideshow, field visitLearning materials
Chart, visual aids, machine, reference books, Internet• Divide the learners into groups and discuss the topic.• Use chart and perfecting machine• Slide show• Let them observe and identify the working procedures• Field visit
Discussion points- Blanket-to-blanket
ConsolidationPerfecting presses
Product- Subject diary- Field visit report
108
Printing Technology
6.3 Multi color presses, monitoring and control systemActivities :
Discussion, field visit , demonstration, lab workLearning materialsChart, Visual aids, Machine , reference books, Internet
• Divide the learners into small groups .• Introduce monitoring and control system and discuss• Let them observe control and monitoring system and do in the lab• Field visit
Discussion points- Press monitoring- Control system
ConsolidationPress monitoring and control system
Product- Subject diary- Field visit report- Lab diary /- Record book
6.4. Press console
ActivitiesDiscussion, field visit .
Learning materialsVisual aids, Machine, console computer scanner, densic to meter, reference books, Internet
• Group the learners and discuss the topic.• Start a job and collect a sample press sheet and check with scanning
densitometer• Use console computer to correct press problems
Discussion points- Density values- Register- Dot gain
109
- Doubling- Ink trapping- Print contrast- Console computer- Scanning densitometer
ConsolidationPress console
Product- Subject diary- Field visit report
CE ITEMSField visit : conduct field visit
TE ITEMSSample questions1. Blanket -to -blanket means printing both sides of a sheet at a time in one pass through the
machine. Write another name for this printing machine (1 score)
2. Demand for multi colour printing is increasing. Explain (6scores)
3. You are working on a multi colour sheet fed offset machine as a printer. Write the ways to getan OK sheet
(6 cores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1) Multi colour sheet fed presses2) Multi colour press monitoring and control systems
110
Printing TechnologyU
NIT
AN
AL
YSI
S6-
MU
LT
I C
OL
OU
R S
HE
ET
PR
ESS
ES
Theory
To u
nder
stand
mul
ti co
lour
shee
t fed
pres
ses
Mul
ti co
lour
shee
t fed
pres
ses-
Two
colo
rFo
ur c
olor
Five
col
orpr
esse
s et
c
Obs
ervi
ngA
naly
sing
Com
parin
gC
lass
ifyin
gId
entif
ying
Com
mun
icat
ing
Rai
sing
Que
stion
s
Disc
ussio
nch
art
pres
enta
tion
field
visi
t,sli
de sh
ow,
lab
wor
k
Cha
rt, v
isual
aid
s,m
achi
neR
efer
ence
book
s,in
tern
et
Sub
ject
dia
ryFi
eld
visit
repo
rt,La
b di
ary
Rec
ord
book
Subj
ect d
iary
Fiel
d vi
sitre
port
Lab
diar
y /
Rec
ord
book
2 hrs
To m
ake
anaw
aren
ess
abou
tpe
rfect
ing
pres
ses
Obs
ervi
ngA
naly
sing
Com
parin
gC
lass
ifyin
gId
entif
ying
Rai
sing
Que
stion
sC
omm
unic
atin
gPr
edic
ting
Disc
ussio
n,C
hart
pres
enta
tion
slid
e sh
ow
Fie
ld v
isit
repo
rtSu
bjec
t dia
ry
Subj
ect d
iary
Fiel
d vi
sitre
port
2 hrs
Bla
nket
- to-
blan
ket
Cha
rt,vi
sual
aid
s,m
achi
neR
efer
ence
book
s,in
tern
et
To u
nder
stand
mul
ti co
lour
pres
ses
mon
itorin
g a
ndco
ntro
l sys
tem
Obs
ervi
ngA
naly
zing
Com
parin
gC
lass
ifyin
gId
entif
ying
Rai
sing
Que
stion
sIn
ferri
ng
Disc
ussio
nD
emon
-st
ratio
nfie
ld v
isit
Lab
wor
k
Subj
ect d
iary
Fiel
d vi
sitre
port
Lab
diar
yR
ecor
d bo
ok
Subj
ect d
iary
Fiel
d vi
sitre
port
Lab
diar
yR
ecor
d bo
ok
2 hrs
Pres
sm
onito
ring
cont
rol
syst
em
Cha
rt, v
isual
aids
, mac
hine
Ref
eren
cebo
oks,
inte
rnet
18 hrsPractical 27 hrs
Sl No 1 2 3
111
UN
IT A
NA
LY
SIS
6-M
UL
TI
CO
LO
UR
SH
EE
T P
RE
SSE
S
To fa
mili
arise
the
pres
sco
nsol
e
Den
sity
valu
es,
regi
ster
dot
gain
,do
ublin
g,In
k tra
ppin
gco
ntra
stco
nsol
eco
mpu
ter
Obs
ervi
ngA
naly
sing
Com
parin
gC
lass
ifyin
gId
entif
ying
Rai
sing
Que
stion
sC
omm
unic
atin
gM
easu
ring
Disc
ussio
non
, fie
ld v
isit
Visu
al a
ids,
mac
hine
,co
nsol
eco
mpu
ter,
scan
ning
,D
ensit
omet
erR
efer
ence
book
s, in
tern
et
Subj
ect d
iary
field
visi
tre
port
Fiel
d vi
sitre
port,
Subj
ect d
iary
Sl No 4
Theory
Practical
2 hrs
112
Printing Technology
UNIT-7PRINTING PROCESS
COLOUR ON SHEET FED OFFSET PRESSES
Introduction
Process colour is a system of producing a full variety of colours by printing a set of three standardcolour inks in various combinations and proportions, usually along with a fourth colour ink. Theinitial discussion will deal largely with idealized conditions, making it possible to explain more clearlythe basic concepts involved. In other cases the practical differences from the ideal are sufficient torequire special techniques to compensate for them as explained that on colour.
In this chapter we mainly deal with colour printing, method of registration, press concerns andquality control devices
The facilitator can adopt different strategies such as group discussion, sample collection,demonstration, field visit ,chart presentation and lab work.Curriculum objectives• To apply press concerns and colour on sheet fed presses through discussion, demonstration,
chart presentation, lab work and prepare note, lab dairy/ record book.• To understand sequences of colours and registration control for multi colour printing through
discussion, sample collection, progressive proof book, field visit, lab work; prepare field visitreport and note, lab diary/ record book.
• To acquire knowledge about quality control devices through discussion, sample collection,progressive proof book, field visit, demonstration, lab work; prepare field visit report andnote , lab dairy/ record book.
7.1 Press concerns colour on sheet fed offset presses
Activities:Group discussion, demonstration, chart presentation, Field visit, Lab work
Learning materialsSingle colour offset press, Progressive proof book, Reference books, Internet
• Divide the learners into groups and discuss about colour on sheet fed presses.• Field visit.
113
• Demonstration• Give lab work• Observe and do.
Discussion point- Process colour- Multi colour printing press
- Press concerns for multicolour printing
Consolidation point
Press concerns -colour on a sheet fed offset press
Product- Subject diary- Field visit report- Lab diary /
Record book7.2. Sequences of colours and registration control for multicolour printing
Activities: Group discussion, Field visit, Demonstration, Sample collection, chart presentation, Lab work
Learning materialsSingle colour offset press, Star target, dot gain scale, slur gauge, densic meter, Referencebooks, Internet.
• Divide the learners into groups and discuss about the topic• Present collected samples and identify the colour sequence and registration• Field visit.• Demonstrate sequence of colours and registration controls• Observe and demonstrate in the lab
Discussion points- Process inks- Transparent and opaque inks- Sequence of colour (ink) for a multi colour printing- Registration and its importance- Method of checking registration
- Controlling registration
114
Printing Technology
Consolidation pointSequence ofcolours and registration control
Product- Subject diary- Field visit report- Lab diary /
Record book7.3. Quality control devices in multi colour printingActivities:
Sample collection, Field visit, Discussion, Demonstration, Lab workLearning materials
Single colour offset press, star target, dot gain scale, slur gauge, densoto meter, referencebooks, internet
• Divide the learners into groups and discuss the topic.• Present the collected samples and assess the quality of products• Demonstrate quality control devices.• Give lab work to access quality control in multi colour printing.
Discussion points- Quality control and its importance- Quality control devices- Star target- Quality control strip- Dot gain scale- Slur gauge- Densitometer
Consolidation point
Quality control devices
Product- Subject diary- Field visit report- Lab diary /
Record book
115
CE ITEMSSample collection: Collect Sample materialsField Visit: Conduct field visit to printing press
TE ITEMS
Sample Questions
1. In a printing house a four colour work prints out of registration. Comment your points torectify this problem. (6scores)
2. In printing a four colour quality work, give your opinion to control quality(4scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1. Press concerns and colours on sheet fed presses2. Sequence of colours and registration control3. Quality control devices.
116
Printing TechnologyU
NIT
A
NA
LY
SIS
7- M
UL
TI
CO
LO
UR
SH
EE
T P
RE
SSE
S
To a
pply
pre
ssco
ncer
ns a
ndco
lour
on
shee
tfe
d pr
esse
s
Proc
ess
colo
ur, M
ulti
colo
urPr
intin
gObs
ervi
ngA
naly
sing
Cla
ssify
ing
Iden
tifyi
ngR
aisin
gQ
uesti
ons
Fiel
d vi
sitgr
oup
disc
ussi
onde
mon
-st
ratio
npr
esen
ting
char
t,sa
mpl
eco
llect
ion,
lab
wor
k.
Mul
ti co
lour
offs
et p
ress
,sin
gle
colo
urof
fset
pre
ss,
prog
ress
ive
proo
f boo
kR
efer
ence
book
sIn
tern
et
Fie
ld v
isit
repo
rtSu
bjec
t dia
ryLa
b di
ary/
Rec
ord
book
,Fi
eld
visit
repo
rt
Fiel
d vi
sitre
port
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
To u
nder
stand
sequ
ence
of
colo
ur a
ndre
gistr
atio
nco
ntro
l for
am
ulti
colo
urpr
intin
g
Obs
ervi
ngA
naly
zing
Cla
ssify
ing
Iden
tifyi
ngR
aisin
gQ
uesti
ons
Fiel
d vi
sit,
grou
pdi
scus
sion
dem
on-
stra
tion
sam
ple
colle
ctio
nla
b w
ork
Sub
ject
diar
yLa
b di
ary
Fiel
d vi
sitre
port
Rec
ord
book
Fiel
d vi
sitre
port,
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
4 hrs
Proc
ess
inks
sequ
ence
of
colo
urs,
and
its re
gistr
atio
n
Mul
ti co
lour
offs
et p
ress
or si
ngle
colo
ur o
ffset
pres
sR
efer
ence
book
s.In
tern
et
To a
cqui
re id
eaab
out q
ualit
yco
ntro
l dev
ices
Obs
ervi
ngA
naly
sing
Cla
ssify
ing
Iden
tifyi
ngR
aisin
gQ
uesti
ons
Fiel
d vi
sitgr
oup
disc
ussi
onde
mon
str-
atio
nsa
mpl
eco
llect
ion,
lab
wor
k
Subj
ect d
iary
Fiel
d vi
sitre
port
Lab
diar
y /
Rec
ord
book
Fiel
d vi
sitre
port,
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
.
Qua
lity
cont
rol a
ndits im
porta
nce
inco
lour
prin
ting
Mul
ti co
lour
offs
et p
ress
or si
ngle
colo
ur o
ffset
mac
hine
,St
ar ta
rget
,D
ot g
ain
scal
e,Sl
ur g
auge
Den
istom
eter
Ref
eren
cebo
oks
Inte
rnet
Theory 2 hrs 4 hrs
13 hrsPractical 9 hrs
23 hrs
Sl No 1 2 3
117
UNIT-8WEB OFFSET PRESSES
Introduction
A web offset is a press that prints on roll of paper. The growth of web offset printing particularlyfor printing books, newspapers, business forms, magazines, directories and packaging has madethe process a major part to the commercial Printing Industry
This unit explains the basic structure of web offset machine and its general features includingtypes of web presses, auxiliary equipments in feed, registration and delivery etc.
The facilitator adopts various learning strategies like discussion, chart, field visit, demonstration(As we know it is difficult to have web offset machine in each vocational higher secondary schoolfor training it is advisable to have field visit/ Industrial training till the machine is available)Curriculum objectives
• To understand web offset presses, and different types through discussion, chart, field visit,prepare field visit and report and note
• To acquire knowledge about components of web press through discussion, chart, field visitand prepare field visit report and note
• To familiarize press console through discussion, chart, field visit and prepare field visit reportand note
8.1. Web offset presses and different typesActivities:
Discussion, chart, field visitLearning materials
Chart, Web machine, Visual aids, Reference books, Internet• Divide the learners into groups and discuss the topic.• Present chart• Conduct field visit and observe and identify the general features.
Discussion points- Working principle- General features- Parts of machine- Paper feeding, in feed, registration
118
Printing Technology
- Printing and delivery units- Different types- Blanket- to- blanket- Common impression cylinder (CIC)- In- line- and other types
Hand out
ConsolidationWeb offset presses, types and general features
Product- Subject diary- Field visit report
8.2. Components of web pressActivities:
Discussion, visual aids presentation, chart, field visit.Learning materials
Chart, web machine, Visual aids reference books, Internet
• Divide the learners into small groups and discuss the topic.• Present chart• Visual aids presentation
119
• Conduct field visit and observe and identify web press componentsDiscussion points
- Plate cylinder- Blanket cylinder- Impression cylinder ink and water systems- Reel stand- Splicer- Web tensioner- Drier- Chill rolls- Folding and cutting- Dancer roller- Auxiliary equipments
ConsolidationComponents of web press
Product- Subject diary- Field visit report
8.3.Press consoleActivities:
Discussion, chart, visual aids presentation, field visitLearning materialsChart, offset machine, reference books, Internet
• Divide the learners into small groups and discuss the topic• Present chart• Use visuals• Conduct field visit and observe
Discussion points- Press console
ConsolidationPress console
Product- Subject diary- Field visit report
120
Printing Technology
CE ITEMSField Visit: Conduct field visit to a printing press observe and identify the general features of
web- offset machineTE ITEMS
1 If you are conducting field visit to a news paper printing unit, you will observe a web offsetmachine in the unit. Write components of the machine (6 score)
2 Discuss different types of web offset machine in your class room. (6 score)
3 In web offset machine the feeding of substrate entirely is different from that of a sheet fedoffset machine. Name the form of feeding(1 score)
LIST OF EXEPERIMENTS FOR PRACTICAL EVALUATION
1. Adopt industrial training (20hours)
121
UN
IT
AN
AL
YSI
S8-
WE
B-O
FFSE
T P
RE
SSE
S
To u
nder
stand
web
off
set
pres
ses
and
diffe
rene
t typ
es
Wor
king
prin
cipl
e,ge
nera
lfe
atur
es,
parts
of
mac
hine
pape
rfe
edin
g,B
lank
et –
to–
blan
ket,
Com
mon
impr
essio
ncy
linde
r(C
IC) i
n lin
e
Obs
ervi
ngA
naly
sing
Cla
ssify
ing
Iden
tifyi
ngR
aisin
gQ
uesti
ons
Disc
ussio
n,ch
art
pres
enta
tion,
Fiel
d vi
sit,
Cha
rt,w
eb m
achi
ne,
visu
al a
ids,
refe
renc
ebo
oks,
inte
rnet
Fie
ld v
isit
repo
rt,Su
bjec
t dia
ry
Fiel
d vi
sitre
port
Subj
ect d
iary
Theory 3 hrs
To a
cqui
re id
eaab
out c
ompo
-ne
nts
of w
ebpr
ess
Obs
ervi
ngA
naly
sing
Cla
ssify
ing
Iden
tifyi
ngco
mm
unic
atin
gR
aisin
gQ
uesti
ons
Disc
ussio
n,ch
art
pres
enta
tion,
Fiel
d vi
sit,
Fiel
d vi
sitre
port,
Subj
ect d
iary
Fie
ld v
isit
repo
rt,Su
bjec
t dia
ry
Plat
ecy
linde
r,bl
anke
tcy
linde
r,Ink
and
wat
ersy
stem
s re
elsta
nd, s
plic
er,
web
tens
ione
rdr
ier,
chill
rolls
, fol
ding
and
cutti
ngda
ncer
rolle
rAux
ilary
equi
pmen
ts
Cha
rt, w
ebm
achi
ne,
visu
al a
ids,
refe
renc
ebo
oks,
inte
rnet
3 hrs
Practical
Sl No 1 2
122
Printing TechnologyU
NIT
A
NA
LY
SIS
8- W
EB
-OFF
SET
PR
ESS
ES
To fa
mili
arise
pres
s co
nsol
ePr
ess
cons
olO
bser
ving
Ana
lysin
gC
lass
ifyin
gId
entif
ying
com
mun
icat
ing
Rai
sing
Que
stion
s
Disc
ussio
nch
art
pres
enta
tion
Fiel
d vi
sit
Cha
rt,w
eb m
achi
ne,
visu
al a
ids,
refe
renc
e -
book
s,in
tern
et
Fie
ld v
isit
repo
rtSu
bjec
t dia
ry
Fiel
d vi
sitre
port
Subj
ect d
iary
.
Sl No 3
Theory
Practical
2 hrs
123
UNIT -9TROUBLE SHOOTING
Introduction
In theory , press set and operations are simple. Unfortunately, difficulties may develop in everysituations and prevent a quality emage from printing on the final press sheets. The true draft of theprinter is to identify and the correct the problems. This process is called trouble shooting.
In this chapter we deal with the defects related to paper, ink and printing and its remedies, pressmaintenance and lubrication.
The facilitator can adopt various learning stratgies such as discussion, sample collection,demonstration, lab work.Curriculum objectives
• To understand paper defects and remedies through discussion, sample, demonstration, labwork and prepare note, lab diary/ record book.
• To understand ink defects and remedies through discussion, sample, demonstration, lab workand prepare note, lab diary/ record book.
• To understand printing defects and remedies through discussion, sample, demonstration, labwork and prepare note, lab diary/ record book.
• To understand and apply press maintenance, lubrication and press room chemicals throughdiscussion, sample, lab work and prepare note, lab diary/ record book.
9.1 Paper defects and remedies
Activities:Discussion, Sample collection , Demonstration, Lab work
Learning materialsSamples, offset machine, Reference books
• Group the learners and discuss the topic.• Present the samples and identify the defects.
124
Printing Technology
• Find remedies• Ask them to observe and do.
Discussion points- Paper curling- Picking- Linting, fluffing and dusting- Show through- Creasing- Strike through- Static electricity- Remedies
Consolidation pointPaper defects and remedies
Product- Subject diary- Lab diary /
Record book9.2.Ink defects and remediesActivities:
Discussion, Sample, Demonstration, Lab workLearning materials
Samples, offset machine, reference books
• Group the learners and discuss the topic• Present the samples and identify the defects.• Remedies• Observe and do.
Discussion points- Poor drying- Mottle- Grain ness- Chalking- Emulsification and bleeding- Set off
125
- RemediesConsolidation point
Ink defects and remediesProduct
- Subject diary- Lab diary /
Record book
9.3.Printing defects and remediesActivities:
Discussion, Sample, Demonstration, Lab workLearning materials
Samples, offset machine, reference books
• Group the learners and discuss the topic• Present samples to identify the defect.• Remedies• Observe and do.
Discussion points- Image wears- Image blinding- Dot gain- Catch up- Scum- Tinting- Poor image sharpness- Poor image contrast- Moiré patterns- Poor trapping- Ghosting- Slur- Doubling- Embossing- Hickies- Tail end hooks
- Remedies
126
Printing Technology
Consolidation pointPrinting defects and remedies
Product- Subject diary- Lab diary /
Record book9.4 .Maintenance, lubrication and press room chemicals
Activities:Discussion, Samples, Demonstration, Lab work
Learning materialsMachineries, press chemicals, reference books
• Group the learners and discuss the topic• Present samples of lubricants and chemicals• Observe and do
Discussion points- Preventive maintenance- Type and application of preventive maintenance- Periodical maintenance- Maintenance shop equipments and machines required for maintenance- Methods of lubrication- Types of lubricants- Characteristics and application
- Pressroom chemicals
Consolidation pointMaintenance, lubrication and press room chemicals
Product- Subject diary- Lab diary /
Record bookCE ITEMS
Sample collection: Collect samples of paper, ink, printing defect materials toshow
127
TE ITEMSSample question
1. The print on one side of the sheet is visible from the reverse side. Comment and identify theproblem and its remedies (3 scores)
2. Ink on printed sheet spreads to the back of the following sheet. Comment ideas.(1 score)
3. Match the following information from A with B
A B1 Paper Dot gain2 ik Ink Dusting3 Printing Mottle
(3 score)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1 Paper defects and remedies2 Ink defects and remedies3 Printing defects and remedies4 Maintenance, lubrication and press room chemicals
128
Printing Technology
UN
IT
AN
AL
YSI
S9-
TR
OU
LE
SH
OO
TIN
G
To u
nder
stand
pape
r def
ects
and
rem
edie
s.
Cur
l,Pic
king
,Li
ntin
g,Fl
uffin
g,D
ustin
g,Sh
ow th
roug
h,C
reas
ing,
Strik
e th
orug
h
Obs
ervi
ngA
naly
sing
Iden
tifyi
ngC
lass
ifyin
gC
ompa
ring
Infe
rring
Disc
ussio
n,Sa
mpl
e,co
llect
ion
pres
enta
tion
Dem
on-
strat
ion,
Lab
wor
k
Sam
ples
,of
fset
mac
hine
,R
efer
ence
book
s
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
To u
nder
stand
ink
defe
cts a
ndre
med
ies
Obs
ervi
ngA
naly
sing
Iden
tifyi
ngC
lass
ifyin
gC
ompa
ring
Infe
rring
Disc
ussio
n,Sa
mpl
e,co
llect
ion
Dem
on-
strat
ion,
Lab
wor
k
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Poor
dry
ing,
Mot
tle,
Gra
ines
s,C
halk
ing
Emul
sifica
tion,
Set o
ff,B
leed
ing
Sam
ples
,O
ffset
mac
hine
,R
efer
ence
-bo
oks
To
unde
rsta
ndpr
intin
g de
fect
san
d re
med
ies
Obs
ervi
ngA
naly
sing
Cla
ssify
ing
Iden
tifyi
ngR
aisin
gQ
uesti
ons
Fiel
d vi
sitgr
oup
disc
ussi
onde
mon
str-
atio
nsa
mpl
eco
llect
ion,
lab
wor
k
Subj
ect d
iary
Lab
diar
y /
Fiel
d vi
sitre
port
Rec
ord
book
s
Fiel
d vi
sitre
port,
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
s.
Imag
e w
ear,
Imag
ebl
indi
ng, D
otga
in, C
atch
up,
Scum
,Ti
ntin
g,Po
or im
age
Shar
pnes
s,C
ontra
st,
Moi
répa
ttern
s,Po
ortra
ppin
g,G
hosti
ng,
Slur
,D
oubl
ing,
Embo
ssin
g,H
icki
es T
ail
end
hook
s
Mul
ti co
lour
offs
et p
ress
or si
ngle
colo
ur o
ffset
mac
hine
,St
ar ta
rget
,D
ot g
ain
scal
e,Sl
ur g
auge
Den
istom
eter
Ref
eren
cebo
oks
Inte
rnet
Sl No 1 2 3
2 hrsTheory 2 hrs 3 hrs
5 hrsPractical 5 hrs 5 hrs
129
UN
ITA
NA
LY
SIS
9-T
RO
UL
E S
HO
OT
ING
Theory
To u
nder
stand
and
appl
y pr
ess
mai
nten
ance
,lu
bric
atio
n an
dpr
ess
room
chem
ical
s
Priv
entiv
em
aint
enan
ceTy
pe a
ndap
plic
atio
n,pe
riodi
cal
mai
nten
ance
,lu
bric
atio
nm
etho
d, ty
pe,
char
acte
ristic
san
dap
plic
atio
n
Obs
ervi
ngA
naly
sing
Iden
tifyi
ngC
ompa
ring
Cla
ssify
ing
Mea
surin
g
Sam
ple
colle
ctio
nD
iscus
sion,
Dem
on-
strat
ion,
Lab
wor
k
Mac
hine
ries,
Pres
sch
emic
als,
Ref
eren
ce-
book
s
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
2 hrs
5 hrs
Practical
Sl No 4
130
Printing Technology
Unit 10SCREEN PRINTING
Introduction
The dominant method of porous printing is screen – process printing which is also known as “silk screen” in the trade. Screen- process printing is at least in its contemporary form, is the oldestof all printing arts. The screen in screen – process printing is a cloth stretched and attached to aframe, the prepared frame serves as the printing – image carrier of this printing method.
In this chapter we deal with the basic concept, classification of materials, multi – colour printing,half tone printing, high speed production etc .
The facilitator can adopt different learning strategies like group discussion, demonstration, fieldvisit and lab work.
Curriculum objectives
• To understand the basic concept, classification, types of stencils, fabric and frame preparationthrough, demonstration, discussion, lab work and prepare note lab diary/ record book.
• To acquire knowledge about photographic stencil, through discussion, demonstration, labwork and prepare note, lab dairy/ record book.
• To get awareness about squeegee, substrate, ink, consideration and basic registrationtechniques in screen printing through discussion, demonstration, lab work and preparenote, lab dairy/ record book.
• To acquire knowledge about masking the stencil through demonstration, discussion, lab work;and prepare note, lab dairy/ record book.
• To understand idea about multi colour printing in screen-printing through discussion,demonstration, lab work; prepare note lab dairy/ record book.
• To understand half tone reproduction through discussion, demonstration lab work, preparenote lab dairy/ record book.
131
• To familiarise high-speed production presses through discussion, field visit and prepare fieldvisit report and note .
• To acquire knowledge about machine configuration through discussion, field visit, chartpresentation and prepare field visit report and note.
10.1.Basic concept, classification, type of stencil, fabric and frame preparationActivities:
Discussion, Demonstration, lab workLearning materials
screen frames, Fabric of different grades, nails , Tape hammer, scissors etc, referencebooks
• Group the learners and discuss the topic• Present materials used for screen• Introduce frame preparation• Let them to observe and demonstrate.
Discussion points- Porous printing process- Basic concept- Classification of screen printing- Stencil and its classification- Types of stencils- Materials used to attach image- Screen fabrics- Fabric treatment- Frame preparation- Frame stitching techniques
Consolidation pointsBasic concept, classification, types of stencils, fabric and frame preparation
Product- Subject diary- Lab diary /
Record book
132
Printing Technology
10.2 Photographic stencilActivities:
Discussion, Demonstration, Lab workLearning materials
Screened frames, film, red star, sensitizer, exporting unit, reference books
• Divide learners in to groups and discuss the topic.• Present stencil preparation.• Let them observe and do.
Discussion points- Photographic stencil- Preparation of stencil- Direct and indirect method- Stencil exposure- Stencil developer- Main requirement and steps of photographic stencil.- Drying techniques
Handout
133
Consolidation pointsPhotographic stencil
Product- Subject diary- Lab diary/
Record book10.3. Squeegee, substrate, ink and basic registration Activities:
Discussion, Demonstration , Lab workLearning materials
Inks, substrates, squeegees glass plate, fevicol
• Divide the learners into groups and discuss the topic• Present squeegee, ink, substrate• Introduce basic registration technique
134
Printing Technology
• Ask them to observe and do.Discussion points
- Factors considering squeegee and ink- Selecting proper squeegee- Substrate selection
- Ink selection
- Ink preparation
- Basic process
- Basic registration techniques
- On and off contact printing
- Printing the stencil
Consolidation pointsSqueegee, substrate, ink and basic registration technique
ProductSubject diary
- Lab diary /Record book
10.4 Making of stencilActivities:
Discussion, Demonstration, Lab workLearning materialsRed star, blue star, Mark, Tapes, paper pieces, reference books
• Divide the learners into groups.• Introduce masking the stencil• Ask them to observe and demonstrate.
Discussion points- Masking the stencil- Preparing paper mask- Liquid block - out masks
135
Consolidation pointsMasking of stencil
Product- Subject diary- Lab diary /
Record book
10.5.Multi colour printing
Activities:Discussion, Demonstration, Lab work
Learning materialsScreen printing unit, reference books
• Divide the learners into groups• Introduce multicolour printing, trouble shooting, cleaning the screen, removing
stencil.• Observe and do.
Discussion points- Printing using different colours- Steps and procedures for multi colour printing- Drying the image.- Cleaning the screen- Removing the stencil
- Troubleshooting clogged screenConsolidation points
Multicolour printingProduct
- Subject diary- Lab diary /
Record book10.6.Half tone reproductionActivities:
Discussion, Demonstration, Lab workLearning materials
Screen printing unit, reference books
136
Printing Technology
• Divide the learners into groups and discuss the topic• Introduce half tone reproduction.• Let them observe and demonstrate
Discussion points- Half tone reproductions- Method of half tone preparation- Fabric selection- Moire patterns
- Printing consideration
Consolidation pointsHalf tone reproduction.
Product- Subject diary- Lab diary /- Record book
10.7 High-speed production pressesActivities:
Discussion, Field visitLearning materialsScreen printing machines, reference books
• Group the learners and discuss the topic• Conduct field visit to understand high speed presses
Discussion points- General idea about screen printing presses- High speed presses- Features of lever action & hand operated.- Semi automatic presses - Automatic presses.
Consolidation pointsHigh speed production press
Product- Subject diary- Field visit report
137
10.8 Machine configurationActivities
Discussion, Field visit, Chart presentationLearning materials
Screen printing machine, reference books
• Conduct a field visit .• Group the learners and discuss the topic• Present chart
Discussion points- Configuration of screen-printing machines.- Screening cylindrical surfaces- Cylindrical screen- Operation of semi automatic screen press- Advantages of a cylindrical screen.- Wet-on-wet printing
Consolidation pointsMachine configuration
Product- Subject diary- Field visit report
CE items
Field visit: Conduct field visit to different firms Project: Give project work based on screen printing.
TE ITEMS
1. For printing a double colour visiting card, describe the procedures for doing the job. (6 scores)
2 You went to print on cylindrical surface. identify method of printing you can adopt(1 score)
138
Printing Technology
3. If you are going to start a screen printing unit as a small scale industry, explain your approachto start the unit (6 scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1. Fabric and frame preparation2. Photographic stencil3. Registration4. Masking the stencil5. Multicolour printing6. Half-tone reproduction
139
UN
IT A
NA
LY
SIS
10-
TR
OU
LE
SH
OO
TIN
G
To u
nder
stan
dth
e ba
sicco
ncep
t,cl
assif
icat
ion,
type
s of s
ten-
cils,
fabr
ic a
ndfr
ame
prep
ara-
tion
Bas
icco
ncep
t,cl
assif
icat
ion,
type
s of
stenc
ils,
mat
eria
ls us
edfo
r scr
een,
fram
epr
epar
atio
n
Obs
ervi
ngC
lass
ifyin
gId
entif
yin
grai
sing
Que
stio
nan
alyz
ing
com
parin
gM
easu
ring
Disc
ussio
nde
mon
-str
atio
n,La
b w
ork
Scre
en fr
ames
,fa
bric
of
diffe
rent
grad
es,N
ails
.tape
,ha
rmm
er,
scis
sors
etc
.R
efer
ence
-bo
oks
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
Subj
ect d
iary
Lab
diar
y /,
Rec
ord
book
To a
cqui
rekn
owle
dge
abou
t pho
to-
grap
hic
stenc
il
Var
ious
step
sfo
r ste
ncil
prep
arat
ion
Tim
e an
dsp
ace
rela
tion
Obs
ervi
ngId
entif
ying
Rai
sing
ques
tions
Cla
ssify
ing
Ana
lyzin
gM
easu
ring
Disc
ussio
nD
emon
-str
atio
n,La
b w
ork,
wat
ersp
raye
r,Po
sitiv
e or
butte
r im
age
Scre
ened
fram
e, fil
m,
red
star
sens
itize
r,ex
posin
g u
nit
Ref
eren
cebo
oks
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
SSub
ject
diar
y ,
Lab
dia
ry /
Rec
ord
book
Sl No 1 2
Theory
Practical
1 hr
6 hrs
1 hr
5 hrs
140
Printing TechnologyU
NIT
A
NA
LY
SIS
10-T
RO
BU
LE
SH
OO
TIN
G
Theory
To g
et a
war
e-ne
ss s
quee
gee,
subs
trate
, ink
and
basic
regi
strat
ion
Fact
ors
and
sele
ctio
ns o
fsq
ueeg
ee, i
nkan
dpr
epar
atio
n.B
asic
regi
strat
ion
tech
niqu
es
Obs
ervi
ngId
entif
ying
Rai
sing
ques
tions
,C
lass
ifyin
g,A
naly
sing
Mea
surin
g
Disc
ussio
nD
emon
-str
atio
n,La
b w
ork
Inks
,su
bsra
tes,
sque
egee
s,gl
ass
plat
e,Fe
vico
l etc
,R
efer
ence
book
s
Subj
ect d
iary
Lab
diar
y,R
ecor
d bo
ok
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
1 hr
To a
cqui
rekn
owle
dge
abou
t mas
king
the
stenc
il
Mas
king
,pr
epar
atio
n of
diffe
rent
type
sof
mas
ks
Obs
ervi
ngId
entif
ying
Mea
surin
g
Disc
ussio
nD
emon
-str
atio
n, la
b w
ork
Red
sta
r,B
lue
star,
Mas
ks,
Tape
s,Pa
per p
iece
s,R
efer
ence
-bo
oks
Subj
ect d
iary
Lab
diar
y/R
ecor
d bo
ok
1 hr
Subj
ect d
iary
Lab
dia
ry/
Rec
ord
book
To u
nder
stand
idea
abo
ut m
ulti
colo
ur p
rintin
g
Step
s an
dpr
oced
ures
for m
ulti
colo
urpr
intin
g,tro
uble
shoo
ting
Obs
ervi
ngI
dent
ifyin
gR
aisin
gqu
estio
nsM
easu
ring,
Cla
ssify
ing,
Ana
lysin
g,In
ferri
ng
Disc
ussio
nD
emon
-str
atio
n, la
b w
ork
Scr
een
prin
ting
unit
Ref
eren
cebo
oks
Subj
ect d
iary
Lab
dia
ryR
ecor
d bo
ok
Subj
ect d
iary
Lab
diar
yR
ecor
d bo
ok
2 hrs
Practical 3 hrs 4 hrs 7 hrs
Sl No 3 4 5
141
UN
IT
AN
AL
YSI
S10
-TR
OU
BL
E S
HO
OT
ING
To u
nder
stand
half
tone
repr
oduc
tion
Met
hod
ofha
lf to
nere
prod
uctio
n,fa
bric
sele
ctio
n,m
oiré
pat
tern
Obs
ervi
ngId
entif
ying
Rai
sing
ques
tions
Tim
ean
d sp
ace
rela
tion,
mea
surin
g ,
Cla
ssify
ing,
Ana
lysin
g
Disc
ussio
n,Fi
eld
visi
tD
emon
-st
ratio
nLa
b w
ork
Scre
en -
prin
ting
unit
Ref
eren
ce-
book
s
Subj
ect d
iary
Lab
diar
yR
ecor
d bo
okfie
ld v
isit
repo
rt
Fiel
d vi
sitre
port,
Subj
ect d
iary
Lab
diar
yR
ecor
d bo
ok
To fa
mili
arise
high
spee
dpr
oduc
tion
pres
ses
Scre
enpr
intin
gpr
esse
s, se
mi-
auto
mat
icpr
esse
s,au
tom
atic
pres
ses
Obs
ervi
ngen
tifyi
ngC
lass
ifyin
gA
naly
sing
Rai
sing
ques
tions
Mea
surin
g
Fiel
d vi
sit,
disc
ussio
n,sc
reen
prin
ting
mac
hine
Ref
eren
cebo
oks
Subj
ect d
iary
Subj
ect d
iary
To a
cqui
re id
eaab
out m
achi
neco
nfig
urat
ion
Con
figur
atio
nof
scr
een
prin
ting
mac
hine
,op
erat
ion
ofse
mi
auto
mat
icsc
reen
pre
ss
Obs
ervi
ngId
entif
ying
Cla
ssify
ing
Ana
lysin
gC
ompa
ring
Mea
surin
g
Fiel
d vi
sit,
disc
ussi
on S
cree
npr
intin
gm
achi
neR
efer
ence
book
s
Subj
ect d
iary
Subj
ect d
iary
Sl No 6 7 8
Theory 1 hr 1 hr 1 hr
Practical 5 hrs 5 hrs
142
Printing Technology
UNIT-11OTHER PRINTING PROCESS
IntroductionAll modern printing processes have been developed to meet a human quest for information .The
effect of Guttenbergs invention was to expand knowledge. This expansion of knowledge quickly toan increasing demand for more printed materials ie to produce printed information faster and faster.
This unit introduces printing process which are becoming increasingly important in the PrintingIndustry Flexography and Xerography.
The facilitator adopts various learning strategies like discussion, chart, sample presentation, fieldvisit, lab work etc.
Curriculum Objectives• To understand flexography printing through discussion, chart, sample collection, field visit,
prepare field visit and report and note.
• To understand and apply Xerographic printing through discussion, chart, sample presentation,field visit, labwork; prepare field visit report and note, lab dairy/ record books.
11.1 Fexography Printing
Activities:Discussion , Sample collection, Chart presentation, Field visit
Learning materialsSample, Chart, flexography, printing machine, reference books, Internet
• Divide the learners into groups and discuss the topics.• Field visit.to understand flexographic machine
• Observe the samples and flexography machine.Discussion Points
- Components of flexography Press.- Infeed Unit.- Printing Unit.- Outfeed Unit.
143
- Flexographic Plates.- Rubber Plates- Photo Polymer Plates and the developments.- Steps in producing rubber, Polymer, Liquid Polymer and Liquid Polymer
plate.- Future.
Hand out
Flexographic printingFlexographic printing, commonly referred to as flexo printing, is a rotaryrelief printing
process in which the image carrier is a flexible rubber or photopolymer plate with raisedimage areas .The process was first introduced in the early 1900s, at which time it was calledaniline printing because the inks used were made from synthetic, organic aniline dyes. A varietyof packaging products including foil, tissue, paper, paperboard, corrugated board and plasticfilm can be printed with flexo. A flexographic press consists of three major units the infeed,printing,and outfeed .
ConsolidationFlexography Printing
Product- Subject diary- Field visit report
144
Printing Technology
11.2. Xerography Printing
Activities :Discussion, Chart, Sample collection, Lab work.
Learning materialsChart, Xerography machine, Sample, reference books , Internet
• Group the learners and discuss the topic.
• Observe the samples, chart and xerography machine
• Do lab workDiscussion Points
- Charging- Exposure- Development- Transfer- Fixing- Cleaning- Importance of Xerography
Hand Out
Xerographic PrintingThe word “xerography’” comes from a combination of two Greek words: xeros. which
means “dry,” and graphos, which means “writing.” The invention of the xerographicprocesswas a response to the need for printing on demand. The process, commonly known asphotocopying, was developed in 1937 by Chester Carlson, a patent attorney and physicistwho was seeking a method for copying patent drawings without using photography. Allxerographic processes in use today rely on the fundamental principle that Carlson applied inhis original device: Unlike electrical charges attract; like electrical charges repel. Manydevelopments have occurred in xerography since Carlson’s original invention, but all commonxerographic processes involve six steps: charging, exposure, development, transfer, fixing,and cleaning.
145
1 2
ConsolidationXerography Printing
Product- Subject diary- Lab diary /- Record book
3 4
5 6
SIX STEPS IN THE XEROGRAPHIC PROCESS
146
Printing Technology
C.E. ITEMSSample Collection: Collect samplesof flexography products and xerography productsField visit. Conduct field visit
T.E ITEMSSample Questions1. Printing on plastic covers is familiar in our daily life. Name the type of printing process more
relevant from the following for the plastic printing1) Ink-jet printing 2) Laser printing 3) Flexography (1score)
1. Xerox copy of a certificate is to be produced. Write your views about Xerox printing.
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1. Xerography Printing.
147
UN
IT
AN
AL
YSI
S11
- OT
HE
R P
RIN
TIN
G P
RO
CE
SS
Theory
To u
nder
stand
Flex
ogra
phy
Prin
ting
Com
pone
nts
of Flex
ogra
phy
pres
s, in
feed
unit,
Prin
ting
unit,
Out
feed
uni
t,Fl
exog
raph
icpl
ate,
Rub
ber
plat
e,Ph
oto
poly
mer
pla
tean
d th
ede
velo
pmen
ts,
Rub
ber,
Poly
mer
,Li
quid
poly
mer
,Li
quid
poly
mer
pla
te,
Futu
re.
Obs
ervi
ngId
entif
ying
Com
mu-
nica
ting
Mea
surin
gR
aisin
gqu
estio
ns,
Com
parin
g
Disc
ussio
nSa
mpl
eco
llect
ion,
char
tpr
esen
tatio
n,Fi
eld
visit
,
Sam
ples
,ch
art,
Flex
ogra
phy
Prin
ting
mac
hine
,R
efer
ence
book
s,In
tern
et
Fie
ld v
isit
Rep
ort,
Subj
ect d
iary
Parti
cipa
tion
in
colle
ctio
nSu
bjec
t,D
iary,
Fiel
d vi
sit,
Rep
ort.
3 hrs
To u
nder
stand
and
appl
yX
erog
raph
ypr
intin
g
Practical
Cha
rgin
g,ex
posu
re,
deve
lopm
ents,
trans
fer,
fixin
g,C
lean
ing,
impo
rtanc
e of
Xer
ogra
phy
Obs
ervi
ngId
entif
ying
Com
mun
icatin
gM
easu
ring
Con
trol o
fva
riabl
esSp
ace
time
rela
tion
Infe
rring
Ana
lysin
g
Sam
ple
colle
ctio
n,ch
art,
disc
ussi
onLa
b w
ork
Cha
rt,X
erog
raph
ym
achi
ne,
sam
ple,
Ref
eren
cebo
oks,
Inte
rnet
Subj
ect
Dia
ryLa
b di
ary
/R
ecor
d bo
ok
Col
lect
ion,
Subj
ect,
Dia
ryLa
b di
ary
/R
ecor
d bo
ok
3 hrs
15 hrs
Sl No 1 2
148
Printing Technology
UNIT 12FINISHING OPERATIONS
IntroductionVast majority printed products require some sort of additional processing in order to meet the
job requirements. Those operations performed after printing are called finishing .In the presentsenario finishing operations are more important in Printing Industry.
This unit deals the main finishing operations like folding, gathering, cutting and binding.
The facilitator introduces various learning strategies like discussion, sample, chart, demonstrationand lab work.
Curriculum Objectives• To understand binding and its classification through discussion, sample, chart, and prepare
note.
• To acquire knowledge about ware house and its functions through discussion, field visit andprepare field visit report and note.
• To familiarise tools and equipments used in binding through discussion presentation and preparenote.
• To understand materials, its selection, care and use through discussion, presentation and preparenote.
• To understand different types of sewing through discussion, demonstration sample chart andlab work and prepare note, record book.
• To understand and apply automation in binding through discussion, chart, demonstration labwork, field visit; prepare field visit report and note lab diary/ record book.
• To acquire knowledge about account bookbinding through discussion sample, lab work;prepare note lab diary/ record book.
149
• To understand and apply publishers binding through discussion, sample, lab work and preparenote lab diary/ record book.
.• To understand different styles of binding through discussion, sample, lab work and prepare
note lab diary/ record book
• To understand and apply repairing works of book through discussion, demonstrate lab workand prepare note lab diary/ record book.
• To acquire knowledge about estimating the materials required for particular work through anassignment and present in the form of a report.
12.1. Binding and its classification
Activities:Discussion, Sample presentation, Chart.
Learning materialsSamples, Chart, reference books,
• Group the learners and discuss the topic.• Present chart and Samples.
Discussions Points- Definition of binding- Stages of binding- Letterpress binding- Stationary binding
ConsolidationBinding and its classification
ProductSubject diary
12.2 Ware house and its functions
Activities:Discussion, Field visit
150
Printing Technology
Learning materialsReference books
• Group discussion to learn about ware house andits functions• Field visit
Discussions Points- What is warehouse?- Functions of warehouse
ConsolidationWarehouse functions
Product- Subject diary- Field visit report
12.3 Tools and equipments in bindingActivities:
Discussion, PresentationLearning materials
Tools, equipments, reference books
• Group discussion about tools and equipements in binding• Present tools and equipments
Discussions Points- Tools- Equipments
ConsolidationTools and equipments
Product- Subject diary
12.4.Materials & its selection, care and use
Activities:Discussion, Presentation
• Group the learners and discuss the topic.• Present materials
151
Discussions Points- Different materials- Selection- Care
- UseConsolidation
Materials, Selection, Care, UseProduct
- Subject diary12.5. Different Types of SewingActivities:
Discussion, demonstration, Sample, Chart, lab work.Learning materials
Samples, reference books
• Group the learners and discuss the topic• Present chart and samples• Let them observe and demonstrate the sewing procedure in the lab.
Discussions Points- Purpose of sewing- Kinds of sewing- Wire stitching- Thread sewing- Types of sewing- Flexible sewing- Double flexible- Tape sewing- Saw-in sewing etc
ConsolidationDifferent types of sewing
Product- Subject diary- Lab diary /- Record book
152
Printing Technology
12.6. Automation in BindingActivities
Discussion, Demonstration, Field visit, lab workLearning materials
Chart, machines, reference books, Internet• Group discussion• Demonstration• Conduct field visit• Introduce binding machines and its operations; observe and do
Discussions Points- Suitability of machine- Maintenance- Adjustments- Operation- Guillotine- Folding machine- Perforator- Creasers- Slitter- Bundling machine- Gathering machine- Adhesive binding machine- Automatic case making machine- Laminating machine etc
ConsolidationAutomation in Binding
Product- Subject diary- Field visit report- Lab diary /- Record book
153
12.7.Account bookbinding
Activities:Discussion, Sample presentation, lab work.
Learning materialsSample book, Reference books
• Group learners and discuss the topic• Present sample Account book• Let them observe and do in the lab.
Discussion Points- End paper- Sewing- Pasting- Spine gluing- Split boards- Tacketting- Spring back- Cutting, attaching boards- Covering full leather- Banding- Laces
-Consolidation
Account Book BindingProduct
- Subject diary- Lab diary /
Record book
12.8 .Publishers Binding
Activities:Discussion, Sample presentation, lab work.
154
Printing Technology
Learning materialsSample book, Reference books
• Group discussion about publishers binding• Present sample book• Observe and do the publishers binding procedures in the lab.
Discussion Points- Folding
- Bundling- Gathering- Sewing- Nipping- Spine gluing- Trimming- Edge decoration- Rounding, backing- Alternative forwarding techniques- Cutting- Cover decoration- Casing- in- pressing- Loose-leaf binding
ConsolidationPublishers Binding
Product:- Subject diary- Lab diary /
Record book
12.9.Styles of bindingActivities:
Discussion, Sample presentation, lab work.Learning materials
Sample book, Reference books
155
• Group the learners and discuss the topic.• Present sample books of different styles.• Observe and do the work in the lab.
Discussion Points- Cut flesh- Turned in- Quarter cloth- leather- Half cloth- leather- Full cloth- leather
ConsolidationStyles of Binding
Product- Subject diary- Lab diary/
Record book12.10. Book Repairing
Activties:Discussion, Presentation, lab work.
• Group discussion about book repairing• Present book repairing.• Observe and do the book repairing work in the lab.
Discussion Points- Cutting- Glueing- Separating sections- Over cast sewing procedures.
ConsolidationBook Repairing
Product- Subject diary- Lab diary /
Record book
156
Printing Technology
12.11.Estimating the Materials
Activities:Discussion, Calculation, assignment.
• Group discussion.• Introduce calculation• Give assignment
Discussion Points- Calculation of paper, Board, calico, fancy paper, leather,tape- Cord, wire
- Adhesive etcConsolidation
Estimating the materialsProducts
- Subject diary- Assignment
CE ITEMS
Assignment: Give assignment on estimating the materials
T E ITEMSSample Questions1. List out the tools and equipments used in binding (6 scores)2. Paper storing is very important. Write your ideas. (4 scores)3. Introduce different styles of binding you know. (6 scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1. Different types of sewing2. Automation in binding3. Account book binding4. Publisher binding5. Styles of binding6. Repairing works of book
157
UN
IT
AN
AL
YSI
S12
-FIN
ISH
ING
OPE
RA
TIO
NS
Theory
Def
initi
on,
Stag
es o
fbi
ndin
g,Le
tter p
ress
,St
atio
nery
bind
ing
Practical
To u
nder
stand
bind
ing
and
itscl
assif
icat
ion
Cla
ssify
ing
Iden
tifyi
ngD
iscus
sion
sam
ple
and
Cha
rtpr
esen
tatio
n
Sam
ples
Cha
rtR
efer
ence
book
s
Sub
ject
dia
rySu
bjec
tDia
ry1 hr
To a
cqui
rekn
owle
dge
abou
t war
eho
use
func
tions
Obs
ervi
ngC
lass
ifyin
gId
entif
ying
Disc
ussio
nFi
eld
visit
Ref
eren
cebo
oks
Sub
ject
diar
yFi
eld
visit
repo
rt
Subj
ectd
iary
Fiel
d vi
sitre
port
1 hr
Wha
t is
war
ehou
se?
Func
tions
of
war
e ho
use
To fa
mili
arise
tool
s and
equi
pmen
tsus
ed in
bin
ding
Obs
ervi
ngId
entif
ying
Cla
ssify
ing
Disc
ussio
nTo
ols
equi
pmen
tsR
efer
ence
book
s
Sub
ject
Dia
rySu
bjec
tdia
ry1 hr
Tool
s,eq
uipm
ents
To u
nder
stand
mat
eria
ls,se
lect
ion,
car
ean
d us
e
Obs
ervi
ngId
entif
ying
,C
ompa
ring
Cla
ssify
ing
Disc
ussio
n,Pr
esen
tatio
nM
ater
ials
sam
ples
Ref
eren
cebo
oks
Sub
ject
Dia
rySu
bjec
tdia
ry1 hr
Mat
eria
ls,
Sele
ctio
n,ca
re, u
se
Sl No 1 2 3 4
158
Printing Technology
UN
IT
AN
AL
YSI
S12
- FI
NIS
HIN
G O
PER
AT
ION
S
Purp
ose
ofse
win
g, k
inds
of se
win
g,w
ire st
itchi
ng,
thre
ad se
win
g,ty
pes
ofse
win
g
To u
nder
stand
diffe
rent
type
sof
sew
ing
Obs
ervi
ngId
entif
ying
Mea
surin
gC
ompa
ring
Disc
ussio
nde
mon
-st
ratio
nsa
mpl
e ch
art
pres
enta
tion
,lab
wor
k
Sam
ples
,R
efer
ence
book
s
Subj
ectd
iary
Lab
diar
yR
ecor
d bo
ok
Skill
to se
wSu
bjec
tD
iary
Rec
ord
book
/La
b di
ary
To u
nder
stand
and
appl
yau
tom
atio
n in
bind
ery
Obs
ervi
ngC
lass
ifyin
gId
entif
ying
Mea
surin
gC
omm
unic
atin
gR
aisin
gqu
estio
ns
Disc
ussio
n,C
hart
pres
enta
tion,
Dem
ons-
tratio
n, F
ield
visit
, Lab
wor
k
Cha
rt,M
achi
nes,
Ref
eren
cebo
oks,
Inte
rnet
Fiel
d vi
sitre
port,
Res
ult,
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Subj
ect d
iary
Fiel
d vi
sitre
portL
abdi
ary
/Rec
ord
book
Suita
bilit
y of
mac
hine
,M
aint
enan
ce,
Adj
ustm
ents,
Ope
ratio
n,G
uillo
tine
fold
ing
mac
hine
,Pe
rfor
ator
,C
reas
ers,
Slitt
er,
Bun
ding
mac
hine
,G
athe
ring
mac
hine
,A
dhes
ive
bind
ing
mac
hine
,A
utom
atic
case
mak
ing
mac
hine
,La
min
atin
gm
achi
ne
Sl No 5 6
Theory 1 hr 2 hrs
Practical 10 hrs 10 hrs
159
UN
IT
AN
AL
YSI
S12
- FI
NIS
HIN
G O
PER
AT
ION
S
Ope
ratio
nal
step
sTo
acq
uire
know
ledg
e ab
out
acco
unt b
ook
bind
ing
Obs
ervi
ngId
entif
ying
Mea
surin
gR
aisin
gqu
estio
nsC
omm
unic
atin
g
Disc
ussio
nSa
mpl
epr
esen
tatio
nLa
b w
ork
Sam
ple
book
Ref
eren
cebo
oks
Parti
cipa
tion,
Res
ult,
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Skill
s Sub
ject
diar
y , L
abdi
ary
/,R
ecor
d bo
ok
Sl No 7
To u
nder
stand
and
appl
ypu
blish
ers
bind
ing
Obs
ervi
ngId
entif
ying
Cla
ssify
ing
Rai
sing
ques
tions
Mea
surin
g
Disc
ussio
n,Sa
mpl
epr
esen
ta-
tion,
Prac
tical
wor
k
Sam
ple
book
Ref
eren
cebo
ok
Subj
ect d
iary
Lab
diar
y/R
ecor
dbo
oks/
Subj
ect d
iary
Lab
diar
y/R
ecor
dbo
oks
Ope
ratio
nal
step
s8
To u
nder
stand
diffe
rent
styl
es o
fbi
ndin
g
Obs
ervi
ngId
entif
ying
Cla
ssify
ing
Com
parin
gC
omm
unic
atin
gM
easu
ring
Disc
ussio
n,Sa
mpl
ebo
ok,
Pres
enta
-tio
n, L
abw
ork
Sam
ple
book
Ref
eren
cebo
oks
Lab
Res
ult,
Subj
ect d
iary
Lab
diar
y /,
Rec
ord
book
Skill
s, Su
b-je
ct d
iary
,La
b di
ary
/,R
ecor
d bo
ok
Cut
fles
htu
rned
inqu
arte
r clo
than
d Le
athe
rha
lf cl
oth,
Leat
her f
ull
clot
h, L
eath
er
9
1 hrs
10 hrs
1 hrs
20 hrs
Theory 1 hr
Practical 10 hrs
160
Printing TechnologyU
NIT
A
NA
LY
SIS
12-
FIN
ISH
ING
OPE
RA
TIO
NS
Rep
airin
gpr
oced
ures
To u
nder
stand
and
appl
yre
pairi
ng w
orks
of b
ook
Obs
ervi
ngId
entif
ying
Mea
surin
gR
aisin
gqu
estio
ns
Dem
onst
ra-
tion
Disc
ussio
n,Pr
esen
ta-
tion,
lab
wor
k
Ref
eren
cebo
oks
Lab
Res
ult,
Subj
ect d
iary
Lab
diar
y /
Rec
ord
book
Skill
s,Su
bjec
t dia
ryLa
b di
ary
/R
ecor
d bo
ok
To a
cqui
rekn
owle
dge
abou
t esti
mat
ing
mat
eria
ls
Obs
ervi
ngId
entif
ying
Cal
cula
ting
Com
mun
icat
ing
Rai
sing
ques
tions
Mea
surin
g
Disc
ussio
nC
alcu
latio
nA
ssig
nmen
t
Ref
eren
cebo
ok S
ubje
ct d
iary
Ass
ignm
ent
Ass
ignm
ent
,Sub
ject
dia
ry
Estim
atio
n1 hrsTheory 1 hr
Practical 10 hrs
Sl No 10 11
161
UNIT-13PRINTING AND PACKAGING
Introduction
Package is defined as the outer cover or packing the material, which helps to protect, topreserve, to identify, to give a brand image etc to the product .A product in order to be sold has tobe conserved and preserved, effectively to the satisfaction of the customer. In this chapter we dealwith materials used for packaging, classification of packages, special type of packages etc..
Facilitator can adopt various learning strategies such as field visit, sample collection, demonstration,group discussion, seminar and lab work.
Curriculum objectives
• To understand the materials, their properties, application and advantages of packing throughdiscussion, sample collection, field visit prepare field visit report and note.
• To get awareness idea about flexible packaging and laminates through discussion, samplecollection, field visit and prepare field visit report and note.
• To understand ink and solvent used in package industry through discussion, sample collectiondemonstration and prepare note.
• To acquire idea about special packages through discussion sample collection and preparenote.
• To understand various processes of paper and board packages through a seminar andprepare seminar report.
• To acquire idea about forme making, cutting, creasing and make ready through discussion,field visit demonstration, lab work and prepare field visit report and note and record book.
• To understand corrugated, fiberboard and rigid boxes through discussion, sample collection,chart and prepare note.
162
Printing Technology
• To understand selection of materials used for packing through discussion, sample collection,and prepare note.
13.1.The materials, properties, application and advantages of packaging.Activities:
Sample collection , Discussion, Field visitLearning materials
Samples, reference books, Internet
• Field visit to a packaging centre to study about the materials used inpackages.
• Group the learners and introduce collected samples• Group discussion based on the collected samples to learn about materials,
application and its advantagees.Discussion Point
- Paperboard, metal, glass, plastic,- Timber and textiles, properties of plastic based packaging- Characteristics and principles- Cellulose film- Properties of film- Application and limitation. Application and advantages of polyfins, poly
vinyls, polymer, nylon
Consolidation pointMaterials, properties, application and advantages
ProductSubject diaryField visit report
13.2. Flexible packaging and flexible laminates-materials and advantages
Activities:Field visit, Sample collection, Discussion
Learning materialsReference books, Internet
• Field visit to study about flexible packaging and laminations
163
• Group discussion based on the collected samples.Discussion points
- Flexible packaging, flexible laminates- Advantages- Different material used for it- Character of flexible packages and laminates
Consolidation pointsFlexible packaging and Flexible laminates – materials and advantages
Product- Subject diary- Field visit report
13.3.Inks and solvents used in packages industryActivities:
Sample collection, DiscussionLearning materials
Reference books, Internet
• Group the learners and introduce the collected samples and discuss
Discussion Points- Solvent- Based vehicles- Water soluble inks- Coating lacquers- Ink storage and handling- Special properties of inks for flexography, gravure andscreen printing
Consolidation pointsInks and solvents used in packages
13.4 Special packages and its machinery
Activities:Discussion, Sample collection
Learning materialsReference books, Internet
• Collect different types of packages.
164
Printing Technology
• Group the learners and have discussion based on the collected samples.• Familiarise machinery
Discussion points- Different types of packages- Strip packages- Shrink packages- Blister packages- Skin package- Stretch wrapping- Machinery used in packaging
Consolidation pointsSpecial packages and its machinery
ProductSubject diary
13.5. Various processes of paper and board packagesActivity:
SeminarLearning materials
Reference books, Internet
Discussion point- Paperboard packages- Cartons styles – purposes- Principles of carton design- Methods of containing- Protecting and displaying the product-using carton.
Consolidation pointsVarious processes of paper and board packages
ProductSeminar report
13.6. Forme making, cutting and creasingActivities:
Field visit, Discussion, Demonstration Lab work
165
Learning materialsReference books, Internet
• Filed visit• Group the learners and discuss
• Introduce forme making, cutting and creasing• Observe and demonstrate in the lab.
Discussion point- Type of forme, wood block, rotary and caser formes- Advantages and sequence of operations involved in forme – making- Make ready procedures, cutting and creasing
Consolidation pointsForme making, cutting and creasing
Product- Subject diary- Field visit report- Record book
13.7.Corrugated, fibre board and rigid box in packaging
Activities:Discussion, Sample collection
Learning materialsReference books, Internet
• Group the learners and discuss the topic.• Introduce collected samples, corrugated, fiber board and rigid box• Observe and identify
Discussion points- Conversion of corrugated boards in to boxes- Equipments used for conversion- Manufacture of corrugated and fibre- board cases, rigid boxes- Styles, classification and purpose, conversion of board into boxes
Consolidation PointCorrugated, fibre board and rigid box
166
Printing Technology
ProductSubject diary
13.8.Selection of materialsActivities:
Sample collection, DiscussionLearning materials
Reference books, Internet
• Introduce the collected samples in the learners group and discuss.• Observe and identify.
Discussion points- Selection of board,- Lining covering papers and adhesives
Consolidation PointsSelection of materials
ProductSubject diary
CE ITEMSSample collection: Collect the samples of packages and laminatesSeminar: Conduct seminar on various process of paper and board packagesTE ITEMSSample question
1. Comment your ideas about packaging(6Scores)
LIST OF EXPERIMENTS FOR PRACTICAL EVALUATION
1. Forme making, cutting, creasing and make ready
167
UN
IT
AN
AL
YSI
S13
-PR
INT
ING
AN
D P
AC
KA
GIN
G
Theory
Cha
ract
erist
ics
of v
ario
usm
ater
ial u
sed
– pr
oper
ties
appl
icat
ion
Practical
To u
nder
stan
dth
e m
ater
ials,
prop
ertie
sap
plic
atio
n, a
ndad
vant
ages
of
pack
agin
g.
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Sam
ple
colle
ctio
n,di
scus
sion
Sam
ples
Ref
eren
cebo
ok In
tern
et
Sub
ject
dia
ryfie
ld v
isit
repo
rt
Fiel
d vi
sitre
port,
Subj
ect d
iary
2 hrs
To a
cqui
re id
eaab
out d
iffer
ent
mat
eria
ls an
dad
vant
ages
of
flexi
ble
pack
ag-
ing
and
lami-
nate
s
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Sam
ple
colle
ctio
ndi
scus
sion
Ref
eren
cebo
oks
Inte
rnet
Sub
ject
dia
ryfie
ld v
isit
repo
rt
field
visi
tre
port,
Subj
ect d
iary
.
1 hr
Mat
eria
lsch
arac
teris
tics
Adv
anta
ges,
Flex
ible
pack
agin
g,Fl
exib
lela
min
ates
To u
nder
stand
ink
and
solv
ent
used
in p
acka
gein
dustr
y
Obs
ervi
ngId
entif
ying
Ana
lysin
gR
aisin
gQ
uesti
ons
Sam
ple
colle
ctio
n,di
scus
sion,
Ref
eren
cebo
oks
Inte
rnet
Sub
ject
dia
ryfie
ld v
isit
repo
rt
Fiel
d vi
sitre
port
Subj
ect d
iary
1 hr
Solv
ent-
ink
spec
ial
prop
ertie
sdi
ffere
nt ty
pes
Sl No 1 2 3
168
Printing Technology
UN
IT
AN
AL
YSI
S13
-PR
INT
ING
AN
D P
AC
KA
GIN
G
Diff
eren
tty
pes
ofsp
ecia
lpa
ckag
espl
astic
corr
ugat
edbo
xes,
lined
carto
n, p
oly-
ethe
lene
,w
oven
sac
k
To a
cqui
re id
eaab
out s
peci
alpa
ckag
es.
Obs
ervi
ngA
naly
zing
com
parin
gId
entif
ying
Sam
ple
colle
ctio
ndi
scus
sion
Ref
eren
cebo
oks,
Inte
rnet
Subj
ect d
iary
Sem
inar
repo
rt
Sam
ple
colle
ctio
nD
iscus
sion,
Subj
ect d
iary
To u
nder
stand
vario
us p
roce
ssof
pap
er a
ndbo
ard
pack
ages
Obs
ervi
ngC
ompa
ring
Sem
inar
Ref
eren
cebo
oks
Inte
rnet
Sub
ject
dia
ryfie
ld v
isit
repo
rt
Subj
ect d
iary
Sem
inar
Rep
ort
Proc
ess
ofpa
ckag
es
To
acqu
irekn
owle
dge
abou
t for
me
mak
ing,
cut
ting
crea
sing
and
mak
e re
ady
Obs
ervi
ngId
entif
ying
Com
pairi
ngR
aisin
gQ
uesti
ons
Disc
ussio
nD
emon
stra
-tio
n,Fi
eld
visit
,la
b w
ork
Ref
eren
cebo
oksI
nter
net
Sub
ject
dia
ryLa
b di
ary
Rec
ord
book
Skill
s,Su
bjec
t dia
ryLa
b di
ary
Rec
ord
book
Ope
ratio
ns o
ffo
rme
mak
ing
cutti
ng,
crea
sing
mak
ere
ady
4Sl No 5 6
1 hr
2 hrsTheory
Practical
2 hrs
20 hrs
169
UN
IT
AN
AL
YSI
S13
-PR
INT
ING
AN
D P
AC
KA
GIN
G
Equi
pmen
tus
ed fo
rco
rrug
ated
conv
ersio
n,rig
id b
oxes
To u
nder
stand
conv
ersio
n an
dm
anuf
actu
re o
fco
rrug
ated
,fib
rebo
ard
and
rigid
box
es.
Obs
ervi
ngan
alys
ing
iden
tifyi
ng
Disc
ussio
nSa
mpl
eco
llect
ion
Ref
eren
cebo
okIn
tern
et
Subj
ect d
iary
Sam
ple
colle
ctio
nsan
d in
gro
updi
scus
sion,
Subj
ect d
iary
To u
nder
stand
sele
ctio
n of
mat
eria
l use
dfo
r pac
kagi
ng
Obs
ervi
ngA
naly
sing
iden
tifyi
ng
Disc
ussio
nSa
mpl
eco
llect
ion
Ref
eren
cebo
oks
Inte
rnet
Sub
ject
dia
rySa
mpl
eco
llect
ion,
Subj
ect d
iary
1 hr
Sele
ctio
n of
boar
d lin
ing,
low
erin
gpa
pers
and
adhe
sive
s
Theory
Practical
2 hrs
Sl No 7 8
170
Printing Technology
UNIT -14BASIC ENGINEERING
IntroductionElectrical, electronics and mechanical which are the basic engineering subjects have a vital role
in the Printing Industry. The parts of printing machine work according to these principles.
This unit deals with direct and alternate current, motors and transformers, basic electronics,mechanical components, hydraulics and pneumatics not in details but only basics of it.
The facilitator can adopt various strategies such as discussion, assignment, chart preparation etc.
Curriculum Objectives• To understand the characteristics of direct current and alternate current through
discussion, chart presentation and prepare note.
• To familiarize motors and transformers through discussion, chart presentation and preparenote.
• To understand basic electronics circuit through discussion, chart presentation and preparenote.
• To get an idea about the characteristics of mechanical principles of mechanical componentsthrough discussion, chart presentation and prepare note.
• To familiarize the characteristics of hydraulics and pneumatics through discussion, chartpresentation and prepare note.
• To understand electrical, electronics, mechanical and pneumatic parts of a printing machinethrough an assignment.
14.1.Direct current and Alternate current
Activities:Discussion, Chart presentation
171
Learning materialsReference books, Internet
• Group the learners and discuss direct and alternative current• Present chart
Discussion points- Emf, current, potential difference and resistance- Ohms law- Electric power and energy- Electromagnetism and magnetic flux- Faraday’s laws of electromagnetism.- Fundamentals of alternate current and its circuit
Consolidation pointsDirect current and alternative current current
ProductSubject diary
14.2.Motors and transformersActivities:
Discussion, Chart presentationLearning materials
Reference books, Internet
• Group the learners and discuss motors and transformers.• Present chart
Discussion Points- Construction and working principle of three-phase induction motor.- Construction and working principle of transformer.
Consolidation PointBasic concepts and working principles of motors and transformers
ProductSubject diary
14.3. Basic electronic circuit
Activities: Discussion, Chart presentation
172
Printing Technology
Learning materialsReference books, Internet
• Group the learners and discuss basic electronic circuit.• Present chart
Discussion point- Intrinsic and extrinsic semiconductors- Semiconductor diode(P-N junction)- Construction and operation of bi-polar junction transistor
Consolidation pointsElectronic circuit
ProductSubject diary
14.4. Mechanical componentsActivities:
Discussion, Chart presentationLearning materials
Reference books, Internet• Group the learners and discuss about mechanical components• Present chart
Discussion point- Nuts, bolts, screws, studs, keys, cotters, pin, lever and shafts-
identify.- Function of spur, helical and Bevel gear- Cams and followers –application- Plain bush, ball and roller bearings- Chain and sprockets, soldering, riveted joints- Clutches and brakes, feeler- Types of lubrication and lubricant- Maintenance
Consolidation pointMechanical components
Product
Subject diary
173
14.5.Hydraulics and pneumatics
Activities:Discussion, Chart presentation
• Group the learners and discuss about hydraulics and pneumatics
• Present chartDiscussion points
- Viscosity, Demulsibility and stability- Working, use of single stage air compressor
Consolidation pointHydraulics and Pneumatics
ProductSubject diary
14.6.Mechanical, Electrical, Electronics and Pneumatic parts of a printing machine
Activities:Discussion, Assignment
• Group the learners and discuss the topic• Give assignment
Discussion Points- Mechanical parts- Electrical parts- Electronic parts- Pneumatic parts
Consolidation PointsMechanical, Electrical, Electronics and pneumatic parts
Product- Subject diary :- Assignment
CE ITEMSAssignment: Give assignment on mechanical, electrical electronics and pneumatic parts ofprinting machine
174
Printing Technology
TE ITEMS
Sample Questions
1. Identify the electrical, electronics, mechanical and pneumatics parts of a single colour off setmachine (6scores)
175
UN
IT A
NA
LY
SIS
14- B
ASI
C E
NG
INE
ER
ING
Fund
amen
tal
of d
irect
curre
nt a
ndal
tern
ate
curre
nt a
ndits
circ
uit
To u
nder
stand
the
char
acte
ris-
tics o
f dire
ctcu
rrent
and
alte
rnat
e cu
rrent
Obs
ervi
ngan
alys
ing
com
parin
gm
easu
ring
Disc
ussio
nch
art
pres
enta
tion
Ref
eren
cebo
oks
Subj
ect d
iary
abili
ty to
anal
yse
diffe
rent
circ
uits
Subj
ect d
iary
Theory 2 hrs
Obs
ervi
ngan
alys
ing
com
parin
gm
easu
ring
To fa
mili
arise
mot
ors a
ndtra
nsfo
rmer
s
Disc
ussio
nch
art
pres
enta
tion
Ref
eren
cebo
oks
Sub
ject
dia
rySu
bjec
t dia
ry2 hrs
Fund
amen
tal
of m
otor
san
dtra
nsfo
rmer
s
Obs
ervi
ngan
alys
ing
com
parin
gm
easu
ring
To u
nder
stand
basic
ele
ctro
n-ic
s circ
uit
Disc
ussio
nch
art
pres
enta
tion
Ref
eren
cebo
oks
Sub
ject
dia
rySu
bjec
t dia
ry2 hrs
Fund
amen
tals
of B
asic
Elec
troni
cs
Obs
ervi
ngan
alys
ing
com
parin
gm
easu
ring
To
get a
n id
eaab
out t
hech
arac
teris
tics
of m
echa
nica
l,pr
inci
ple
ofm
echa
nica
lco
mpo
nent
s
Disc
ussio
nch
art
pres
enta
tion
Ref
eren
cebo
oks
Sub
ject
dia
rySu
bjec
t dia
ry3 hrs
Fund
amen
tal
of mec
hani
cal
prin
cipl
e of
mec
hani
cal
com
pone
nts
Practical
Sl No 1 2 3 4
176
Printing TechnologyU
NIT
A
NA
LY
SIS
14- B
ASI
C E
NG
INE
ER
ING
Fund
amen
tal
of h
ydra
ulic
san
dpn
eum
atic
s
To fa
mili
arise
abou
t the
char
acte
ristic
sof
hyd
raul
ics
and
pneu
mat
ics
Obs
ervi
ngan
alys
ing
com
parin
gm
easu
ring
Disc
ussio
nch
art
pres
enta
tion
Ref
eren
cebo
oks
Subj
ect d
iary
abili
ty to
anal
yse
diffe
rent
circ
uits
Subj
ect d
iary
Iden
tifyi
ngO
bser
ving
Ana
lysin
gC
lass
ifyin
gC
ompa
ring
Mea
surin
g
To u
nder
stand
mec
hani
cal,
elec
trica
l,el
ectro
nics
and
pneu
mat
ic p
arts
of a
prin
ting
mac
hine
Ass
ignm
ent
Sing
le c
olou
rof
fset
mac
hine
Rep
ort o
fas
signm
ent
Rep
ort o
fas
signm
ent
Parts
of a
nof
fset
prin
ting
mac
hine
Sl No 5 6
Theory 2 hrs 1 hr
Practical
177
APPENDIX
178
Printing TechnologyS
TUD
EN
TS E
VA
LUA
TIO
NP
RO
FILE
PE
CETE
Total
Grade
Che
mis
try
Total
Grade
Mat
hem
atic
s
CETE
PE
Engl
ish
CE
TETotalGrade
Gen
eral
Foun
datio
nC
ours
e
CETE
TotalGrade
Voc
atio
nal S
ubje
cts
CETE
TotalGradeTotalGrade
TotalGrade
CETE
VCE
PE
CE
TE
TotalGrade
Phys
ics
Nam
eSl
no:
179
CC
E Total (80)
Total
out o
f20
TE
(80)
Tot
al(1
00)
Gra
dePE
12
34
56
7To
talGr
ade
Voc
atio
nal C
ompe
tenc
y Ev
alua
tion
Regu
larit
yan
dPu
nctu
ality
(10)
Valu
eAd
ditio
n (2
0)
Capa
city
build
ing
(20)
FOR
MAT
FO
R V
OC
ATIO
NA
L C
OM
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TEN
CY
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ALU
ATI
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Total (50)
Grad
e4 (20)
1 (20)
2 (20)
3 (20)
Sl no:
Nam
e
180
Printing Technology
BOOKS FOR REFERENCE
1 T.M.Adams,; D.D.Faux, L.T.Ricber, Printing Technology, Delmar Publishers Inc. 1990.
2 V.S.Krishnamurthy, Basics of Modern Printing Process, Maxseltype, 1989.
3 A.G.Martin, Finishing process in printing, Facal Press Ltd. Britain, 1972.
4 Arthur W.Johnson, The Thames and Hudson Manual of Book Binding, Thames and Hudson,London 1989.
5 Arthur W.Johnson, Craft Book Binding, Thames and Hudson,
6 Herbert P.Home, The Binding of Books, Haskell House Publishers Ltd., New York, 1970.
7 Handbook of Modern Halftone photography, Perfect graphic arts, Demarset, U.S.A.
8 Jack Eggleston, Sensitometry for Photographer, Focal Press, London, 1984.
9 Woodlief Thomas, J.R.SPSE Handbook of Photographic Science and Engineering, John Wileyand sons.
10 J.Michael Adams David, D.Foux, Llyod, J.Ricber, Printing Technology, 3rd Edition, DelmarPublishers, 1988.
11 R.H.Leach, The Printing Ink Manual, Fifth Edition, Chopman and Holl, London, 1993.
12 Robert F.Reed-What the Printer should know about Inks; GATF, 1984.
13 C.G.Roffey. Photo polymerization of Surface Coatings, John Wiley & Sons, London 1985.
14 Eagle Charles. V. Hand Book of Adhesive bonding, M.C.Graw Hill Book Company, NewYork, 1978.
15 Alan Holmes, Electronic Composition, Emblem Books Ltd. 1984.
16 Les Heath and Ian Faux, Photo type setting, SITA Ltd. 1983.
17 J.Michael Adman, David D Foux, and Lyods J.Reiber; Printing Technology, Delmer (Pub),III Edition.
18 PIRA guide, Standardised Lithographic Colour Printing 1984/85
19 Mills, South Worth, Colour Seperation Techniques, Graphic Arts Publishing Co. Newyork,1981.
20 R.W.G Aunt, Reproduction, Colour, Fountain Press, 1981.
21 Principles of Colour Reproduction applied to photomechanical Reproduction, Colour
181
Photography and the Ink, Paper and other Related Industries, John Wiley & Sons U.K.
22 P.C.Pocket Guide
101. Page Maker Tips, Graham Jones
Galgotia Publications Pvt.Ltd
5, Ansari Road, New Delhi – 110002
23 Offset Printing Blankets
Technical Manual by John M.Smith (Tecl.Director) BTR Graphic Products Ltd. Prepared forthe 26th India Printer Conference
24 Offset Printing by Misra Lecturer
Institute of Printing Technology
Allahabad, New Delhi
Web sites
1 www. manu graph.com
2 www. heidelberg.com
3 www. hmt.org
4 www. print_ packaging .com
5 www. bindingmeachinery.com