Gravure Printer

KORAKHOA SOLUTIONS; Boksburg; On-site; ZAR 335,000 - 502,000; Full time

Job summary

KORAKHOA SOLUTIONS in Boksburg, South Africa is seeking a Gravure press operator to run the Cerutti 960R press in a rotating day/night shift with a three-person crew. The role requires a fully apprenticed Gravure-trained operator with deep expertise, and the successful candidate will participate in a four-week training period before operating unassisted.

You will be responsible for maintaining quality, meeting timing, and ensuring safety and upkeep of the press, inks, dampening and ancillary

Qualifications

• Trade-tested Gravure experience required with leadership in press production.
• Minimum 3 years operating wide-format Gravure presses as top or second operator.
• Knowledge of inks, coatings, laminations and safety standards.

Responsibilities

• Coordinate printing process and make ready within allocated time.
• Perform pre-make ready, make ready and setup.
• Ensure specifications are met and quality checks completed.
• Report deviations and assist maintenance; uphold safety standards.
• Produce high-quality reels with minimal waste and document results.

Skills

Gravure printing

Press operation

Quality control

Team coordination

Safety compliance

Education

Trade Test in Rotary Printing and Re-Reeling - Gravure

Matric

MS Office (computer literate)

Tools

Automated registration equipment

Viscosity systems

Radius production system

Job description

Boksburg, South Africa

Job Description

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

Thesuccessful candidate will form part of the highly skilled print team and willbe expected to perform at the highest levels whilst bolstering the expertisewithin the department.

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

Key Performance Indicators & Duties

Duties and Responsibilities:

• Coordinate the activities of the printingprocess and make ready.
  
• Ensure the pre-make ready, make ready, andset-up process takes place in the allocated time.
  
• Ensure that all specifications are adhered toand understood adequately.
  
• Do all necessary quality checks and correctdeviations timely.
  
• Ensure that the required press maintenance isreported by completing the T-Card and issuing it to Maintenance.
  
• Ensure that preventative maintenance is doneaccordingly and that cleaning of the press is executed to the higheststandards.
  
• Operated the press to the highest standards andefficiencies, while keeping waste to a minimum as per the job estimate.
  

Pre-MakeReady:

• Complete pre-make ready forms by checking thejob 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 correctmaterial is issued and scanned properly as per the job specifications.
  
• Inspect cylinders for damage before and after ajob run, and record on the cylinder issue form.
  
• Ensure impression rollers are cleaned and readyfor a new job.
  
• Ensure that all printing units have the correctink filters.
  

Make Ready:

• Set the AVT to recommended standards.
  
• Set the Gamma System for all jobs.
  
• Set the doctor blades according to the Daetwylerbest practices. Only adjust to get the best print quality & laydown.
  
• Set the lamination and coatings to the requiredspecification 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 goodcondition and fix it if it is broken.
  
• Ensure that all machine safety guards areoperational.
  
• 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 operationsimmediately or ask for assistance.
  

Production:

• Produce a 1 st off sheet that complieswith all requirements and ensure that Quality checks are done.
  
• Monitor AVT, web and Gamma system.
  
• Produce good-quality reels with acceptableprofiles and minimal waste.
  
• Tag all print waste properly and record on theDCU.
  
• All paper reels are to be labelled on the sidewith 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 meterswhile ensuring the waste material is compensated for in the ticket.
  
• Sign off on each printed reel's quality checks.
  
• Record all events that affect the job on Radius(downtime, web-breaks, ink starvation, print defects, splices, etc.)
  

Press SetDown:

• Wash and remove all cylinders on completion ofthe job. 2k and adhesive cylinders to be covered with cylinder paste, whichreduces cell blocking.
  
• Wash the printing units for preparation of thenext job, and adequately flush the inking units.
  
• Check cylinders for defects and record data onthe cylinder issue form. Sign the form once completed.
  
• Place the washed cylinders according to theirstorage boxes and return.
  
• Return all inks, tooling and materials accordingto the procedure. Perform a versus report, while ensuring that allocatedmaterial is scanned into the job and returned to Raw Material stores.
  
• Doctor Blade's cutting table is to be kept cleanat all times.
  
• Keep printing areas and units clean and free ofall ink buckets and solvents that are not clamped. Keep all buckets in theprint units clamped.
  
• All ink units to be covered in plastic, andplastic to be removed post-printing and replaced with clean plastic.
  
• All unused print unit shout be kept clean.
  
• Clean spills immediately to avoid ink skinbuildup.
  
• Keep all areas neat at all times.
  

Best Practices:

• Operators to complete all paperwork accuratelyand timeously, with sign-off and date
  
• Complete a Job report on the finalisation ofeach job, with best practice suggestions for future production.
  
• Complete all safety tests/checks before startingyour shift, check all the guards and report malfunctioning items to theMaintenance and or Shift Supervisor.
  
• Work towards meeting the Safety, Quality andOperations standards that meet the company and customer requirements.
  
• STOP the machine if unsure or in doubt. Do notcontinue running with a problem.
  

Shift Requirements

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

Requirements

The successful candidate must havethe following qualifications and experience:

• Trade Test in Rotary Printing and Re-Reeling -Gravure
• Minimum three years’ experience operating wideformat Gravure print presses as a number one or two operator.
• In-depth knowledge of Gravure print techniques.
• Proven track record for leading and developingpress 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 usemethods.
• Understanding of automated registrationequipment.
• Understanding of automated viscosity equipment.
• Understanding modern print machine presscontrols.
• Ability to understand and eradicate all basicprinting faults to maintain quality Gravure production.
• In-depth knowledge of quality control testprotocols 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

Key Technical Requirements

• 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

R30 000 - R45 000 CTC per month (dependent on experience)