Gravure Printer

A vacancy has arisen within the Gravure print department for a highly skilled fully apprenticed Gravure-trained operator to run the Cerutti 960R press.

The successful candidate will form part of the highly skilled print team and will be expected to perform at the highest levels whilst bolstering the expertise within the department.

The successful candidate will be required to work a rotating shift pattern (including day shifts and night shifts) as part of a three-person press crew. The candidate will be given four weeks intensive training to familiarise themselves with the machine type and ancillary equipment. After this period they will be expected to run unassisted at the benchmarked standard and will be fully responsible for their quality level and output. Please note this is not a trainee position and previous print experience is required.

Duties and Responsibilities:

• Coordinate the activities of the printing process and make ready.
  
• Ensure the pre-make ready make ready and set-up process takes place in the allocated time.
  
• Ensure that all specifications are adhered to and understood adequately.
  
• Do all necessary quality checks and correct deviations timely.
  
• Ensure that all events that happen during the run are adequately logged during the shift.
  
• Ensure that the required press maintenance is reported by completing the T-Card and issuing it to Maintenance.
  
• Ensure that preventative maintenance is done accordingly and that cleaning of the press is executed to the highest standards.
  
• Operated the press to the highest standards and efficiencies while keeping waste to a minimum as per the job estimate.
  

Pre-Make Ready:

• Complete pre-make ready forms by checking the job bag for the current and next job.
  
• Ensure that the correct tooling (cylinders blades etc.) is allocated that the correct ink is allocated and that the correct material is issued and scanned properly as per the job specifications.
  
• Inspect cylinders for damage before and after a job run and record on the cylinder issue form.
  
• Ensure impression rollers are cleaned and ready for a new job.
  
• Ensure that all printing units have the correct ink filters.
  

Make Ready:

• Set the AVT to recommended standards.
  
• Set the Gamma System for all jobs.
  
• Set the doctor blades according to the Daetwyler best practices. Only adjust to get the best print quality & laydown.
  
• Set the lamination and coatings to the required specification and coat weights within the minimum time.
  
• Colour match inks with the ink technicians
  
• Viscosities to be checked and recorded
  
• Ensure that the splash guard is in good condition and fix it if it is broken.
  
• Ensure that all machine safety guards are operational.
  
• Confirm and position material onto the press set the web guides and register the job at a minimum 800lm or minimum.
  
• Report any out-of-spec items or operations immediately or ask for assistance.
  

Production:

• Produce a 1^st off sheet that complies with all requirements and ensure that Quality checks are done.
  
• Monitor AVT web and Gamma system.
  
• Produce good-quality reels with acceptable profiles and minimal waste.
  
• Tag all print waste properly and record on the DCU.
  
• All paper reels are to be labelled on the side with the job number.
  
• Report (T-Card) and isolate (Use RED Tape) defective ink pumps ink trolleys and air shafts or any defective tooling.
  
• Print the required quantity of labels or meters while ensuring the waste material is compensated for in the ticket.
  
• Sign off on each printed reels quality checks.
  
• Record all events that affect the job on Radius (downtime web-breaks ink starvation print defects splices etc.)
  

Press Set Down:

• Wash and remove all cylinders on completion of the job. 2k and adhesive cylinders to be covered with cylinder paste which reduces cell blocking.
  
• Wash the printing units for preparation of the next job and adequately flush the inking units.
  
• Check cylinders for defects and record data on the cylinder issue form. Sign the form once completed.
  
• Place the washed cylinders according to their storage boxes and return.
  
• Return all inks tooling and materials according to the procedure. Perform a versus report while ensuring that allocated material is scanned into the job and returned to Raw Material stores.
  

Housekeeping:

• Doctor Blades cutting table is to be kept clean at all times.
  
• Keep printing areas and units clean and free of all ink buckets and solvents that are not clamped. Keep all buckets in the print units clamped.
  
• All ink units to be covered in plastic and plastic to be removed post-printing and replaced with clean plastic.
  
• All unused print unit shout be kept clean.
  
• Clean spills immediately to avoid ink skin buildup.
  
• Keep all areas neat at all times.
  

Best Practices:

• Operators to complete all paperwork accurately and timeously with sign-off and date
  
• Complete shift handover daily highlighting all issues experienced
  
• Complete a Job report on the finalisation of each job with best practice suggestions for future production.
  
• Complete all safety tests/checks before starting your shift check all the guards and report malfunctioning items to the Maintenance and or Shift Supervisor.
  
• Work towards meeting the Safety Quality and Operations standards that meet the company and customer requirements.
  
• STOP the machine if unsure or in doubt. Do not continue running with a problem.
  

• Must be willing to work rotating day and night shifts
  
• Position operates within a three-person press crew environment
  

The successful candidate must have the following qualifications and experience:

Trade Test in Rotary Printing and Re-Reeling - Gravure

Minimum three years experience operating wide format Gravure print presses as a number one or two operator.

In-depth knowledge of Gravure print techniques.

Proven track record for leading and developing press production teams.

Two years experience in line lamination and filmic print techniques.

Proven track record of quality Gravure production preferably from within the label or food packaging sectors.

Understanding of the main printing substrates and their required ink formulations.

Ability to print on all substrates from paper to OPP.

• In-depth knowledge of solvent-based ink varnishes/coatings and adhesive systems.
  

Full knowledge of solvent selection and safe use methods.

Understanding of automated registration equipment.

Understanding of automated viscosity equipment.

Understanding modern print machine press controls.

Ability to understand and eradicate all basic printing faults to maintain quality Gravure production.

In-depth knowledge of quality control test protocols for Gravure printed media.

• Grade 12 / Matric
  
• Trade Test in Rotary Printing and Re-Reeling Gravure
  
• Computer Literate (MS Office)
  
• Minimum 2 years experience as a Number 1 Gravure Printer
  
• Minimum 3 years experience operating wide-format Gravure printing presses as a Number 1 or Number 2 Operator
  
• Experience within the label flexible packaging or food packaging sectors advantageous
  
• Experience in line lamination and filmic print techniques
  
• Strong knowledge of manufacturing processes print equipment and safety standards
  

• In-depth knowledge of Gravure print techniques
  
• Ability to print on various substrates including paper and OPP
  
• Understanding of solvent-based inks varnishes coatings and adhesive systems
  
• Knowledge of solvent selection and safe handling procedures
  
• Understanding of automated registration equipment
  
• Understanding of automated viscosity systems
  
• Understanding of modern press controls and print machinery
  
• Ability to identify and eliminate print defects while maintaining production quality
  
• Strong understanding of quality control procedures and testing protocols for Gravure printed media
  
• Proven ability to lead and develop press production teams