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Offset Printing Technology – Professional Machine Operator (6 Months)
Categories: CERTIFICATE COURSE
About Course
This intensive 6-month professional training program is designed to develop industry-ready offset printing machine operators capable of independently handling commercial, publishing, and packaging print jobs.
The course combines strong theoretical foundations with hands-on live press training on real offset machines including Heidelberg SORD (36×25 mono), Heidelberg PM74 (20×30 multicolour), and Sahil 20×30 single-colour presses.
Learners progress from printing fundamentals to advanced multicolour production, quality control, maintenance, safety protocols, high-speed production, and real-world job execution. By the end of the program, students can confidently manage make-ready, register accuracy, ink–water balance, troubleshooting, and live commercial production under real pressroom conditions.
This course is aligned with actual pressroom workflows practiced at Omega Offset Printers and prepares students for immediate employment in commercial printing and packaging industries.
What Will You Learn?
- Understand complete offset printing workflow from prepress to finishing
- Identify and operate all parts of offset printing machines
- Handle paper formats (DD, DC, DF) and grain direction correctly
- Perform professional plate mounting and register alignment
- Master inking and dampening systems and ink–water balance
- Execute fast and accurate make-ready procedures
- Print single-colour, two-colour, and four-colour jobs confidently
- Control print quality using density, dot gain, and register checks
- Run machines at high speed with minimum wastage
- Identify and fix common printing defects quickly
- Maintain rollers, blankets, feeders, and delivery systems
- Perform daily and weekly machine maintenance
- Follow strict safety and emergency handling protocols
- Execute real commercial, publishing, and packaging print jobs
- Prepare for final practical exams and professional certification
Course Content
CHAPTER 1 – INTRODUCTION TO PRINTING
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1.0
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1.1 What Is Commercial Printing?
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1.2 Types of Printing Technologies
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1.3 The Offset Principle: Planographic Printing
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1.4 Components of an Offset Machine
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1.5 Print Formats Used in Offset Presses
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1.6 Types of Offset Machines
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1.7 The Complete Offset Workflow
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1.8 The Offset Printing Process (Step-by-Step)
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1.9 Understanding Basic Terminology
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1.10 Safety in the Pressroom
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1.11 Role of an Offset Machine Operator
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1.12 Real-World Application: Omega Offset Printers Case Study
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1.13 Why Offset Printing Is Still Relevant Today
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1.14 Summary of Chapter
CHAPTER 2 – PAPER & INK BASICS
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2.0
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2.1 Understanding Paper as a Printing Substrate
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2.2 GSM, Thickness & Caliper
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2.3 Grain Direction in Paper
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2.4 Common Paper Sizes for Offset Printing
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2.5 Types of Paper Used in Offset Printing
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2.6 Paper Defects and How They Affect Printing
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2.7 Moisture and Paper Conditioning
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2.8 Introduction to Printing Inks
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2.9 Types of Offset Inks
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2.10 Ink Properties Critical for Operators
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2.11 How Ink Behaves on Different Papers
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2.13 Ink–Water Balance (Foundational Skill)
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2.14 Paper & Ink Compatibility Chart
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2.15 Tools for Paper & Ink Testing
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2.16 Real-World Case Studies (Omega Press Environment)
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2.17 Summary of Chapter 2
CHAPTER 3 – DAMPENING & INKING SYSTEMS
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3.0
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3.1 The Foundation of Offset Printing: Ink–Water Repulsion
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3.2 The Dampening System: Heart of Water Control
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3.3 Components of the Dampening System
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3.4 Fountain Solution: Chemistry of Water in Offset
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3.5 Alcohol Dampening (IPA) on PM74
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3.6 Water Form Rollers & Their Importance
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3.7 Common Dampening Problems & Causes
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3.8 The Inking System: Engine of Colour
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3.9 Ink Fountain & Duct Keys
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3.10 Oscillators & Distributors
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3.11 Form Rollers: The Most Critical Ink Rollers
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3.12 Roller Settings & Pressure Adjustment
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3.13 Ink–Water Balance: The Core Skill
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3.14 Troubleshooting Dampening & Inking Issues
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3.15 Dampening System Maintenance
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3.16 Inking System Maintenance
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3.17 Dampening & Inking in Heidelberg SORD vs PM74
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3.18 Real Press Case Studies (Omega Offset Printers)
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3.19 Practical Exercises for Students
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3.20 Summary of Chapter
CHAPTER 4 – PLATE TECHNOLOGY
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4.0
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4.1 What Is an Offset Printing Plate?
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4.2 Plate Materials: Why Aluminum?
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4.3 Types of Offset Plates
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4.4 Plate Surface: Graining, Anodizing & Coating
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4.5 Plate Resolution & Dot Formation
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4.6 Plate Exposure (For PS Plates)
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4.7 CTP Workflow (For Thermal Plates)
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4.8 Plate Bending & Punching
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4.9 Mounting the Plate on Machine
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4.10 Register Systems: Getting Perfect Alignment
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4.11 Plate Wear: Causes & Prevention
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4.12 Common Plate Problems & Troubleshooting
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4.13 Plate Care & Storage
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4.14 Comparison: PS Plates vs Thermal CTP Plates
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4.15 Plate Technology in SORD vs PM74
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4.16 Real Press Case Studies (Omega Offset Printers)
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4.17 Practical Exercises for Students
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4.18 Summary of Chapter
CHAPTER 5 – FEEDER SYSTEM
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5.0
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5.1 Purpose of the Feeder Section
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5.2 Main Components of the Feeder System
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5.3 The Feeder Pile: Setting the Foundation
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5.4 Pickup Suckers: The Start of Sheetfeeding
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5.5 Separation Suckers: Preventing Double Sheets
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5.6 Forwarding Suckers: Moving Sheet to Feed Board
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5.7 The Feed Board: Highway to the Printing Unit
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5.8 Side Lay: Left/Right Alignment
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5.9 Front Lay: Forward/Backward Register
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5.10 Registration System in Detail
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5.11 Air System: The Invisible Helper
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5.12 GSM & Paper Type Affect Feeder Settings
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5.13 Feeder Problems & Troubleshooting Guide
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5.14 Feeder Settings on Different Machines
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5.15 Operator Techniques for Perfect Feeding
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5.16 Sensors & Automation in Modern Presses
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5.17 Maintenance of Feeder System
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5.18 Real Press Case Studies (Omega Offset Printers)
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5.19 Practical Exercises for Students
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5.20 Summary of Chapter
CHAPTER 6 – DELIVERY SYSTEM
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6.0
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6.1 Purpose of the Delivery Unit
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6.2 Components of the Delivery System
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6.3 Chain Delivery & Gripper Bars
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6.4 Slowdown System (Sheet Brake Mechanism)
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6.5 Delivery Pile: The Final Collection Area
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6.6 Air System at Delivery
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6.7 Anti-Setoff Powder Spray System
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6.8 Joggers: Ensuring Pile Alignment
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6.9 Sensors in the Delivery System
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6.10 Delivery System Challenges on Different Papers
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6.11 Curl Control in Delivery
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6.12 Sheet Scratches & Scuff Marks
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6.13 Setoff: The Most Common Delivery Issue
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6.14 Delivery System Adjustments for High-Speed Printing
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6.15 Delivery System Maintenance
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6.16 Delivery System Behaviour: SORD vs PM74 vs Sahil
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6.17 Real Press Case Studies (Omega Offset Printers)
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6.18 Practical Exercises for Students
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6.19 Summary of Chapter
CHAPTER 7 – INKING UNIT OPERATION
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7.0
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7.1 Purpose of the Inking Unit
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7.2 Construction of the Inking Unit
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7.3 Ink Fountain and Ink Duct Keys
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7.4 Ink Knife & Ink Charging Technique
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7.5 Roller Train: The Heart of Ink Distribution
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7.6 Ink Film Thickness: Controlling Density
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7.7 Ink Splitting: The Core Mechanism
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7.8 Oscillation: Eliminating Ink Streaks
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7.9 Ink Form Rollers: Critical for Print Quality
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7.10 Roller Stripe Test (Pressure Adjustment)
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7.11 Ink-Water Balance: Role of Inking Unit
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7.12 Roller Glazing: A Serious Issue
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7.13 Ink Starvation: A Common Problem
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7.14 Ghosting: Ink Distribution Fault
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7.15 Colour Variation During Long Runs
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7.16 Handling Inks for Different Paper Types
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7.17 Inking Behaviour on Different Machines
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7.18 Ink Duct Setting Technique (Operator Skill)
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7.19 Temperature & Ink Viscosity
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7.20 Troubleshooting Guide for Inking Unit
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7.21 Maintenance of Inking Unit
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7.22 Real Press Case Studies (Omega Offset Printers)
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7.23 Practical Exercises for Students
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7.24 Summary of Chapter
CHAPTER 8 – DAMPENING UNIT OPERATION
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8.0
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8.1 Purpose of the Dampening Unit
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8.2 Types of Dampening Systems
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8.3 Components of the Dampening Unit
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8.4 Fountain Solution: The Chemistry Behind Water
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8.5 Water Form Roller: The Most Important Component
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8.6 Flow Path of Dampening Solution
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8.7 IPA (Isopropyl Alcohol) in Dampening
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8.8 Dampening Setting Techniques
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8.9 Common Dampening Problems and Solutions
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8.10 Dampening Unit Behaviour at Different Speeds
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8.11 Dampening in Heidelberg SORD vs PM74 vs Sahil
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8.12 Influence of Water on Dot Reproduction
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8.13 Fountain Solution Temperature Control (PM74)
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8.14 Plate Desensitization & Water Film
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8.15 Roller Material & Hardness
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8.16 Avoiding Emulsification
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8.17 Dampening & Ink-Water Balance Relationship
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8.18 Fountain Solution Contamination
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8.19 Troubleshooting Chart (Quick Reference)
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8.20 Dampening Unit Maintenance
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8.21 Real Press Case Studies (Omega Offset Printers)
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8.22 Practical Exercises for Students
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8.23 Summary of Chapter
CHAPTER 9 – MAKE-READY PROCEDURES
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9.0
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9.1 What Is Make-Ready?
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9.2 Importance of Make-Ready
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9.3 Make-Ready Workflow Overview
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9.4 Step 1: Reading the Job Card
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9.5 Step 2: Paper Preparation
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9.6 Step 3: Blanket & Packing Inspection
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9.7 Step 4: Plate Mounting
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9.8 Step 5: Feeder Setup
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9.9 Step 6: Ink Duct Pre-Setting
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9.10 Step 7: Dampening System Setup
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9.11 Step 8: Setting Register
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9.12 Step 9: Pulling Trial Proofs
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9.13 Step 10: Colour Calibration & Adjustment
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9.14 Step 11: Achieving Ink–Water Balance
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9.15 Step 12: Speed Calibration
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9.16 Make-Ready for Different Job Types
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9.17 Special Make-Ready for Difficult Papers
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9.18 Make-Ready Time & Wastage Targets
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9.19 Troubleshooting During Make-Ready
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9.20 Make-Ready in Different Machines
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9.21 Real Press Case Studies (Omega Offset Printers)
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9.22 Practical Make-Ready Exercises
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9.23 Summary of Chapter
CHAPTER 10 – PRINTING QUALITY CONTROL
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10.0
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10.1 What is Printing Quality Control?
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10.2 Why Quality Control is Important
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10.3 Stages of Quality Control
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10.4 Tools Used for Quality Control
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10.5 QC Step 1: Monitoring Ink Density
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10.6 QC Step 2: Dot Gain (Tone Value Increase)
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10.7 QC Step 3: Gray Balance
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10.8 QC Step 4: Trapping Analysis
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10.9 QC Step 5: Register Accuracy
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10.10 QC Step 6: Print Evenness (Uniformity)
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10.11 QC Step 7: Monitoring Emulsification
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10.12 QC Step 8: Scumming & Toning Detection
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10.13 QC Step 9: Detecting Ghosting
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10.14 QC Step 10: Slur & Doubling
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10.15 QC Step 11: Paper Defect Detection
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10.16 Continuous QC During Production
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10.17 Environmental QC Factors
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10.18 QC for Different Paper Types
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10.19 QC for Different Job Types
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10.20 Troubleshooting Guide for QC Defects
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10.21 Real Press Case Studies (Omega Offset Printers)
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10.22 Practical QC Exercises for Students
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10.23 Summary of Chapter
CHAPTER 11 – PRINTING ON DIFFERENT PAPERS
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11.0
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11.1 Why Paper Type Matters in Offset Printing
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11.2 Classification of Printing Papers
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11.3 Paper Properties That Affect Printing
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11.4 Printing on Art Paper (Coated Paper)
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11.5 Printing on Art Card (200–450 GSM)
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11.6 Printing on Maplitho (Uncoated Offset Paper)
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11.7 Printing on Bond Paper
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11.8 Printing on Ledger Paper
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11.9 Printing on Sticker Sheets (Chromo Sticker, Mirror Coat, PET)
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11.10 Printing on Kraft Paper
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11.11 Printing on Duplex Board
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11.12 Printing on SBS Board (FBB / Ivory)
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11.13 Printing on NCR / Carbonless Paper
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11.14 Printing on Specialty Papers (Metallic, Textured, Handmade)
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11.15 How Paper Affects Ink Behaviour
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11.16 How Paper Affects Water Usage
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11.17 How Paper Affects Machine Speed
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11.18 How Paper Affects Powder Usage
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11.19 Troubleshooting Based on Paper Type
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11.20 Real Press Case Studies (Omega Offset Printers)
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11.21 Practical Exercises for Students
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11.22 Summary of Chapter
CHAPTER 12 – LARGE FORMAT SIGNATURE PRINTING (16p / 32p)
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12.0
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12.1 What Is a Signature?
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12.2 Paper Formats Used for Signatures
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12.3 Page Imposition Basics
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12.4 Signature Printing on DD Format (SORD)
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12.5 Signature Printing on DC Format (PM74)
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12.6 Signature Printing on Sahil 20×30
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12.7 Grain Direction and Folding
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12.8 16-Page A5 Signature Printing
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12.9 32-Page A5 Signature Printing (Full DD)
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12.10 Folding Considerations for Signatures
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12.11 Signature Register Requirements
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12.12 Printing Conditions for Different GSM in Signatures
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12.13 Pressure & Packing in Signature Jobs
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12.14 Ink Requirements for Signature Jobs
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12.15 Water Requirements for Signature Jobs
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12.16 Powder Requirements
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12.17 Signature Print Problems & Solutions
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12.18 Signature Quality Parameters
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12.19 Signature-to-Folding Coordination
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12.20 Signature Production in Different Machines
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12.21 Real Press Case Studies (Omega Offset Printers)
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12.22 Practical Exercises for Students
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12.23 Summary of Chapter
CHAPTER 13 – SPECIAL PRINTING JOBS (METALLIC, UV, SPOT, VARNISH, HYBRID)
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13.0
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13.1 What Are Special Printing Jobs?
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13.2 Metallic Ink Printing
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13.3 Pantone Spot Colour Printing
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13.4 UV Coating (Offline & Online)
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13.5 Drip-Off Effect (Offset + UV)
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13.6 Gloss & Matte Varnish (Offset Varnish)
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13.7 Texture Coating
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13.8 Perfume Coating (Scent Coating)
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13.9 Hybrid Jobs: Offset + Screen Printing
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13.10 Printing for Lamination (Gloss, Matte, Velvet)
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13.11 Printing for Foiling (Gold/Silver/Rainbow Foil)
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13.12 Metallic Paper & Synthetic Media
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13.13 Special Printing Defects & Solutions
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13.14 Machine-Specific Behaviour for Special Jobs
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13.15 Real Press Case Studies (Omega Offset Printers)
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3.16 Practical Exercises for Students
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13.17 Summary of Chapter
CHAPTER 14 – HIGH-SPEED PRODUCTION & WASTAGE CONTROL
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14.0
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14.1 What Is High-Speed Production?
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14.2 Why High-Speed Production Matters
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14.3 Factors That Influence High-Speed Production
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14.4 Paper Requirements for High-Speed Production
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14.5 Feeder Settings for High Speed
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14.6 Inking Unit Setup for High Speed
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14.7 Dampening Unit Requirements
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14.8 Register Accuracy at High Speed
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14.9 Delivery System for High Speed
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14.10 Spray Powder Control
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14.11 Environmental Control
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14.12 Wastage Control – The Pressroom Philosophy
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14.13 Common High-Speed Problems & Solutions
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14.14 Machine-Specific High-Speed Behaviour
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14.15 Reducing Make-Ready Time
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14.16 Long-Run Stability Techniques
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14.17 Real Press Case Studies (Omega Offset Printers)
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14.18 Practical Exercises for Students
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14.19 Summary of Chapter
CHAPTER 15 – MAINTENANCE & DAILY/WEEKLY MACHINE CARE
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15.0
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15.1 Importance of Offset Machine Maintenance
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15.2 Types of Maintenance
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15.3 Tools Used for Maintenance
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15.4 DAILY MAINTENANCE
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15.4.2 Cleaning the Dampening Unit
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15.4.3 Cleaning the Blanket
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15.4.4 Feeder Area Cleaning
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15.4.5 Delivery Area Cleaning
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15.4.6 Checking Lubrication Points (Daily)
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15.4.7 Check Packing & Pressure
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15.4.8 Check Dampening Solution
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15.5 WEEKLY MAINTENANCE
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15.6 PREVENTIVE MAINTENANCE (Monthly/Quarterly)
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15.7 Special Maintenance for Multicolour Machines (PM74)
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15.8 Machine-Specific Maintenance Notes
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15.9 Safety Tips in Maintenance
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15.10 Common Maintenance-Related Print Problems
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15.11 Real Press Case Studies (Omega Offset Printers)
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15.12 Practical Exercises for Students
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15.13 Summary of Chapter
CHAPTER 16 – TROUBLESHOOTING COMMON PRINTING PROBLEMS
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16.0
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16.1 Philosophy of Troubleshooting
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16.2 Categories of Common Problems
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16.3 Ink-Related Problems
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16.4 Water-Related Problems
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16.5 Paper-Related Problems
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16.6 Register Problems
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16.7 Pressure & Packing Problems
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16.8 Feeder Problems
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16.9 Delivery Problems
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16.10 Mechanical Problems
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16.11 Environmental Problems
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16.12 Troubleshooting Workflow (Professional Method)
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16.13 Troubleshooting by Machine Type
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16.14 Real Press Case Studies (Omega Offset Printers)
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16.15 Practical Exercises for Students
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16.16 Summary of Chapter
CHAPTER 17 – ROLLER & BLANKET CARE
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17.0
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17.1 Importance of Proper Roller and Blanket Care
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17.2 Types of Rollers in Offset Machines
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17.3 Roller Material and Characteristics
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17.4 Roller Life Expectancy
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17.5 Roller Problems and Their Symptoms
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17.6 Roller Stripe (Pressure) Adjustment
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17.7 Roller Cleaning Techniques
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17.8 Dampening Roller Care
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17.9 Blanket Technology and Characteristics
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17.10 Types of Blankets
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17.11 Blanket Problems and Symptoms
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17.12 Blanket Cleaning
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17.13 Blanket Packing and Pressure Settings
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17.14 Blanket Life Expectancy
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17.15 Roller–Blanket–Plate Interaction
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17.16 Roller Troubleshooting
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17.17 Blanket Troubleshooting
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17.18 PM74-Specific Roller & Blanket Notes
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17.19 SORD-Specific Notes
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17.20 Sahil-Specific Notes
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17.21 Best Practices for Long Roller & Blanket Life
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17.22 Real Press Case Studies (Omega Offset Printers)
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17.23 Practical Exercises for Students
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17.24 Summary of Chapter
CHAPTER 18 – MECHANICAL TROUBLESHOOTING
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18.0
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18.1 Understanding Mechanical Systems in Offset Machines
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18.2 Difference Between Mechanical & Printing Problems
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18.3 Diagnosing Mechanical Problems — Golden Rule
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18.4 Feeder Mechanical Problems
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18.5 Cylinder Problems
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18.6 Gear Problems
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18.7 Roller Mechanical Problems
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18.8 Dampening Unit Mechanical Issues
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18.9 Delivery-System Mechanical Problems
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18.10 Pneumatic System Issues
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18.11 Electrical Problems
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18.12 Machine Timing Problems
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18.13 Mechanical Troubleshooting Workflow
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18.14 Preventive Mechanical Maintenance
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18.15 Machine-Specific Troubleshooting
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18.16 Real Press Case Studies (Omega Offset Printers)
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18.17 Practical Exercises for Students
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18.18 Summary of Chapter
CHAPTER 19 – DAILY & WEEKLY MAINTENANCE (IN-DEPTH GUIDE)
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19.0
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19.1 Why Daily & Weekly Maintenance Matters
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19.2 General Maintenance Principles
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19.3 DAILY MAINTENANCE (Detailed Procedures)
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19.4 WEEKLY MAINTENANCE (Detailed & Advanced)
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19.5 Maintenance Routines by Machine Type
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19.6 Mistakes to Avoid in Maintenance
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19.7 Professional Maintenance Checklists
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19.8 Real Press Maintenance Cases (Omega Offset Printers)
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19.9 Practical Exercises for Students
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19.10 Summary of Chapter
CHAPTER 20 – FULL MAKE-READY PROCEDURES
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20.0
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20.1 What Is Make-Ready?
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20.2 Importance of Make-Ready
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20.3 Pre-Make-Ready Preparation
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20.4 Plate Mounting Procedure
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20.5 Blanket Checking Before Make-Ready
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20.6 Ink Preparation
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20.7 Dampening Solution Preparation
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20.8 Feeder Set-Up
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20.9 Register Setting
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20.10 Impression Setting
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20.11 Pulling Trial Proof
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20.12 Make-Ready for Different Types of Jobs
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20.13 Make-Ready Troubleshooting
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20.14 How Experts Reduce Make-Ready Time
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20.15 Make-Ready Tools
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20.16 Complete Sample Make-Ready Workflow (PM74)
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20.17 Real Press Case Studies (Omega Offset Printers)
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20.18 Practical Exercises for Students
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20.19 Summary of Chapter
CHAPTER 21 – PRINTING QUALITY CONTROL (QC)
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21.0
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21.1 What Is Printing Quality Control?
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21.2 Why Is QC Important in Offset Printing?
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21.3 Core Components of Printing QC
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21.4 Instrument-Based QC vs Visual QC
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21.5 Density Control
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21.6 Dot Gain
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21.7 Grey Balance
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21.8 Register Control
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21.9 Ink–Water Balance QC
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21.10 Slur and Doubling QC
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21.11 Print Defect QC
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21.12 Colour Consistency QC
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21.13 QC for Special Papers
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21.14 QC for Multicolour Jobs (PM74)
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21.15 QC Workflow for Every Job
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21.16 QC Tools Used by Operators
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21.17 QC Records & Documentation
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21.18 Environmental Impact on QC
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21.19 Human Factors in QC
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21.20 Common QC Problems & Solutions
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21.21 Real Press QC Case Studies (Omega Offset Printers)
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21.22 Practical Exercises for Students
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21.23 Summary of Chapter
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