Litho – Offset Machine Minder

ITI Litho – Offset Machine Minder Syllabus (English)

Course Overview

• Trade Name: Litho – Offset Machine Minder
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in operating, maintaining, and troubleshooting lithographic offset printing machines, preparing them for roles as offset machine operators, print technicians, or quality controllers in printing and publishing industries, or for self-employment in printing press services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Printing: History of printing, types (offset, digital, gravure), role of offset printing.
• Safety Practices: Handling chemicals (inks, solvents), PPE (gloves, masks), fire safety, machine guarding.
• Printing Materials: Paper types (coated, uncoated), inks, plates, chemicals; properties and uses.
• Offset Machine Basics: Components (feeder, printing unit, delivery), single-color machine operation.
• Pre-Press Basics: Image reproduction, plate making, film processing, color separation principles.
• Tools and Instruments: Micrometers, densitometers, loupes; usage and calibration.
• Engineering Drawing: Reading machine layouts, plate diagrams, print job sketches.

Trade Practical

• Safety Drills: Using PPE, handling ink spills, operating fire extinguishers, safe machine startup.
• Material Handling: Identifying paper grades, checking ink viscosity, storing plates.
• Machine Setup: Loading paper in feeder, mounting plates, adjusting rollers on single-color machines.
• Pre-Press Tasks: Preparing films, exposing plates, developing images manually.
• Basic Printing: Running single-color prints (posters, flyers), adjusting ink flow.
• Measurement Practice: Measuring paper thickness with micrometers, checking print density.
• Project Work: Printing a single-color job (e.g., poster) with proper alignment and ink balance.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Offset Machine Operations: Multi-color printing, dampening systems, ink-water balance.
• Plate Making: Computer-to-Plate (CTP), PS plates, aluminum plate properties, exposure techniques.
• Color Management: CMYK process, color matching, Pantone system, color correction.
• Paper Handling: Paper sizes (A-series, B-series), grain direction, moisture effects on printing.
• Maintenance Basics: Cleaning rollers, lubricating bearings, checking belts and gears.
• Quality Control: Print defects (ghosting, scumming), inspection methods, BIS standards.
• Workshop Calculation: Ink consumption, paper wastage, print run estimation.

Trade Practical

• Multi-Color Printing: Setting up two-color machines, printing brochures with registration accuracy.
• Plate Preparation: Exposing and developing CTP plates, ensuring image clarity.
• Color Adjustment: Matching CMYK colors, correcting hues using densitometers.
• Paper Setup: Cutting paper to size, adjusting feeder for different paper weights.
• Machine Cleaning: Washing ink rollers, cleaning dampening units, lubricating parts.
• Defect Correction: Identifying and fixing print issues (e.g., ink smudging, misalignment).
• Project Work: Printing a two-color job (e.g., booklet) with consistent color and registration.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Advanced Offset Machines: Sheet-fed vs. web-fed, four-color machines, automation features.
• Digital Pre-Press: RIP software, PDF workflows, imposition, proofing techniques.
• Ink Technology: UV inks, water-based inks, drying methods, environmental impact.
• Troubleshooting: Diagnosing machine faults (feeder jams, roller wear), error codes.
• Print Finishing: Cutting, folding, binding, lamination; integration with offset printing.
• Electrical Systems: Motors, sensors, relays in offset machines; basic electrical maintenance.
• Production Planning: Job scheduling, material estimation, cost optimization.

Trade Practical

• Four-Color Printing: Operating four-color machines, printing magazines with precise registration.
• Digital Pre-Press: Processing files through RIP, preparing digital proofs, setting imposition.
• Ink Handling: Mixing UV inks, adjusting drying units, testing ink adhesion.
• Troubleshooting Tasks: Fixing feeder jams, recalibrating rollers, checking sensor alignment.
• Finishing Tasks: Operating cutting machines, folding printed sheets, applying lamination.
• Electrical Checks: Testing motor circuits, replacing faulty relays, ensuring earthing.
• Project Work: Printing a four-color job (e.g., catalog) with pre-press and finishing integration.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Modern Printing Technologies: Hybrid printing, inline finishing, Industry 4.0 in printing.
• Automation in Offset: PLC controls, touch-screen interfaces, remote diagnostics.
• Environmental Practices: Recycling paper waste, using eco-friendly inks, energy-efficient machines.
• Quality Assurance: ISO 12647 standards, color profiling, defect-free printing.
• Entrepreneurship: Starting a printing press, costing, market trends in publishing.
• Safety Regulations: Handling hazardous chemicals, compliance with OSHA, press safety audits.
• Emerging Trends: 3D printing basics, smart packaging, digital offset integration.

Trade Practical

• Automated Machine Operation: Using PLC-based offset machines, configuring print settings.
• Quality Testing: Measuring color accuracy with spectrophotometers, ensuring ISO compliance.
• Eco-Friendly Printing: Using recycled paper, testing low-VOC inks, optimizing energy use.
• Finishing Automation: Operating automated binding machines, producing booklets.
• Field Exposure: Hands-on training in printing presses or publishing units (4-6 weeks).
• Maintenance Planning: Developing a machine maintenance schedule, logging repairs.
• Project Work: Producing a multi-color print job (e.g., magazine) with automation, finishing, and quality checks.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Paper consumption, ink coverage, production costs, print run efficiency.
  • Science: Chemistry of inks, paper properties, optics in color printing.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Offset machine schematics, roller alignments, pre-press layouts.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Client interaction, job reporting, teamwork.
  • IT Literacy: Using RIP software, Adobe Acrobat, online print management tools.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like machine setup, multi-color printing, defect correction, finishing.
• Evaluation Criteria: Print quality, machine handling, safety adherence, troubleshooting skills.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Offset machine operator, print technician, quality controller in printing presses, publishing houses, or packaging industries.
• Self-Employment: Printing press business, pre-press consultancy, print finishing services.
• Further Studies: Diploma in Printing Technology, certifications in digital printing or color management.