PRODPP105 – Make photopolymer plates for flexographic printing

Overview

This standard is for printers preparing and processing photopolymer plates for flexographic printing.

This standard covers:

• preparing photopolymer plates for printing and
• processing photopolymer plates

This standard includes:

• identifying the work you have to do
• exposing plates
• processing plates
• checking the image created
• cleaning and recharging the processor
• correctly identifying, resolving or reporting faults.

When working with photopolymer plates it is important to make sure that negatives match with artwork elements and imposition, non-image density matches expected quality requirements and the correct exposure values to produce required plate characteristics are selected.

Performance criteria

You must be able to:

Prepare photopolymer plates

1. check that the job details you have are complete
2. check that you have all the materials of the right type needed for the job
3. match negatives with artwork elements and imposition
4. match non-image density with the manufacturer's recommendations and your company's quality standard
5. prepare exposure units so that they will produce desired outputs for each job
6. handle and load plates in a safe manner in accordance with organisational procedures
7. position plates so that all image elements fall on the finished plate
8. select exposure values which produce the required plate characteristics after processing
9. expose the assembly in line with manufacturer's requirements
10. pass the plate for processing when it is ready

Process photopolymer plates

11. load the processor in line with manufacturer's instructions
12. handle and load materials in a safe and efficient manner in accordance with organisational procedures
13. set and operate processor in a safe and efficient manner in accordance with organisational procedures
14. keep up the supply of solvents throughout each run so that runs are not interrupted
15. trim finished plates to the exact size required
16. check that finished plates meet your company's standard for thickness, relief height and spots and blemishes
17. rectify faults within your area of responsibility so that the run is not unnecessarily delayed
18. report faults and problems which it is not your job to rectify in accordance with organisational procedures
19. keep waste to a minimum and dispose of it in accordance with organisational procedures
20. report when the plate is ready for production in accordance with organisational procedures

Knowledge and understanding

You need to know and understand

1. the types of plates in use in your company, and the types of job for which they are used
2. why it is important to check negatives, elements and non-image density
3. the range, use and limitations of processing materials and equipment
4. the risks which arise when you handle plates and materials and operate exposure units and how to avoid them
5. the plate making methods and equipment in use in your company
6. what safe light conditions are
7. the risks associated with operating the equipment
8. how to set up and operate the equipment
9. your company’s waste disposal procedures
10. to whom you must report faults
11. how to recognise when you should correct faults yourself and when you should ask for help
12. what details you need for the job
13. your company’s quality standards

Scope/range

1. Prepare photopolymer plates

Operators prepare plates incorporating:

• coarse line and solid
• fine line
• line and halftone
• close register text and spot colour

Operators identify what is required from:

• job instructions
• the layout

2. Process photopolymer plates

Operators can process photopolymer plates consistently over a period of time:

• coarse line and solid
• fine line
• line and halftone
• close register text and spot colour

Keywords: digital, print, pre-press, photopolymer, plates, flexographic