ITI Trade: Litho-Offset Machine Minder

Course Duration: 2 Years (Four Semesters)

Introduction

The Litho-Offset Machine Minder trade under CTS (Craftsmen Training Scheme) is designed to train candidates in the operation and maintenance of lithographic offset printing machines. This course develops technical skills and knowledge required for producing high-quality printed materials on paper and other substrates using offset printing techniques. During the training, candidates are equipped with expertise in pre-press, press, and post-press operations, with an emphasis on safety, quality control, and productivity.

The trade focuses on practical training, professional knowledge, engineering drawing, workshop calculation and science, and employability skills. It also includes project work and extracurricular activities to enhance hands-on experience and confidence.

Course Structure & Semester-wise Syllabus

The Litho-Offset Machine Minder trade course is divided into four semesters (each of six months). Below is the semester-wise structure:

First Semester

  • Introduction to Safety and Health: Personal protective equipment, fire safety, first aid, and environment-friendly practices.
  • Introduction to Printing Industry: History and development of printing, types of printing processes, importance of litho-offset printing.
  • Materials Used in Printing: Paper types and sizes, ink types, chemicals, and consumables used in offset printing.
  • Pre-Press Operations: Basic design concepts, layout preparation, typography, image editing, and introduction to graphic design software (CorelDRAW, Photoshop).
  • Plate Making: Process camera operations, plate preparation, and handling of printing plates.
  • Basic Machine Operations: Introduction to offset machines, components, feeding mechanisms, and simple maintenance.

Second Semester

  • Advanced Pre-Press Techniques: Color management, digital file preparation, proofing techniques, and imposition.
  • Offset Printing Machines: Single and multi-color printing machine operations, job setup, and troubleshooting.
  • Ink and Dampening System: Properties of printing inks, dampening solution preparation, and balance between ink and water.
  • Machine Maintenance: Lubrication, cleaning, and minor repair of machine components.
  • Quality Control: Identifying printing defects (ghosting, scumming, set-off, etc.), color consistency, and corrective measures.
  • Safety Practices: Electrical safety, handling hazardous materials, and ergonomics.

Third Semester

  • Multi-Color Printing Operations: Registration, color sequence, dot gain, trapping, and overprint control.
  • Paper Handling and Finishing: Loading, stacking, trimming, folding, and binding operations.
  • Machine Automation and Control Systems: Introduction to automated controls in modern offset machines.
  • Preventive Maintenance: Systematic checking, inspection schedules, and predictive maintenance techniques.
  • Production Planning and Scheduling: Job estimation, time management, resource allocation, and cost calculation.
  • Waste Management: Reducing paper and ink wastage, recycling practices.

Fourth Semester

  • Advanced Machine Operations: Operation of web offset machines, perfecting presses, and UV curing systems.
  • Packaging Printing: Introduction to packaging printing on non-paper substrates like plastics and metals.
  • Printing Business Management: Entrepreneurship, marketing, customer relations, and pricing strategies.
  • Employment Skills: Resume preparation, interview techniques, and communication skills.
  • Project Work: Execution of real-time printing jobs, quality audits, and submission of a comprehensive project report.
  • Final Assessment: Trade tests, theory exams, and viva-voce.

Job Roles & Career Opportunities

After successfully completing the course, candidates can work in various roles, including:

Litho-Offset Machine Minder

  • Operate and manage offset printing machines.
  • Set up printing jobs and control multi-color printing processes.
  • Maintain ink-water balance and control registration.
  • Conduct routine maintenance and troubleshooting.

Assistant Machine Operator

  • Assist in machine setup and feed operations.
  • Handle paper and ink supplies.
  • Assist in cleaning, lubrication, and maintenance.

Printing Technician

  • Inspect finished products for print quality.
  • Identify defects and make corrections.
  • Assist in pre-press and post-press operations.

Supervisor / Team Leader (with experience)

  • Manage production schedules.
  • Supervise machine minders and helpers.
  • Monitor quality control and customer satisfaction.

Entrepreneur

  • Start small printing press units or DTP centers.
  • Offer services like business card printing, wedding cards, leaflets, packaging labels, etc.

NSQF Level Compliance

  • NSQF Level: 4
  • This trade aligns with NSQF Level 4 as per the guidelines of the National Skill Qualification Framework, which includes comprehensive practical skills and professional knowledge leading to employment or self-employment.

NSQF Descriptors for Level 4

  1. Process: Work in familiar, predictable, routine and situations of clear choice.
  2. Professional Knowledge: Factual knowledge of the field of knowledge or study.
  3. Professional Skill: Recall and demonstrate practical skill, routine and repetitive in narrow range of application.
  4. Core Skill: Language to communicate written or oral, with required clarity; basic arithmetic and algebraic principles, basic understanding of natural and social environment.
  5. Responsibility: Responsibility for own work and learning.

Broad Learning Outcomes

  1. Apply safe working practices in the printing environment.
  2. Comply with environmental regulations and maintain workplace housekeeping.
  3. Interpret job orders and technical documents to carry out print jobs.
  4. Demonstrate basic mathematical concepts and perform calculations related to printing.
  5. Understand the basic principles of lithographic printing processes.
  6. Operate single-color and multi-color litho-offset printing machines.
  7. Perform basic maintenance of printing machines and equipment.
  8. Manage ink, dampening systems, and paper handling for optimum quality.
  9. Inspect print quality and implement corrective actions.
  10. Apply productivity and quality improvement techniques in day-to-day operations.
  11. Manage waste and recycle consumables in a sustainable manner.
  12. Communicate effectively with clients, supervisors, and co-workers.

Specific Learning Outcomes

First Semester

  • Practice safety and environmental protection.
  • Identify and handle printing materials (paper, ink, plates).
  • Operate basic printing machines and assist in pre-press activities.
  • Carry out plate making and handling.

Second Semester

  • Perform machine setup for single-color jobs.
  • Control ink and dampening balance.
  • Conduct quality checks and basic maintenance.

Third Semester

  • Execute multi-color printing jobs with proper registration.
  • Manage post-press operations like trimming and binding.
  • Maintain preventive maintenance schedules.

Fourth Semester

  • Operate advanced offset printing machines (web offset, perfecting presses).
  • Manage printing operations and supervise machine helpers.
  • Plan and execute commercial printing jobs.
  • Prepare for employment/self-employment through skill development and project work.
Subscribe to Litho- Offset Machine Minder