Kerala State Centre for Advanced Printing & Training

K.G.T.E PRINTING
TECHNOLOGY COURSES

SYLLABUS

 PRE-PRESS OPERATION

 PRESS WORK

 POST PRESS OPERATION & FINISHING

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 Kerala State Centre for Advanced Printing & Training

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 Kerala State Centre for Advanced Printing & Training

RULES AND REGULATIONS FOR THE CONDUCT OF

VARIOUS COURSES IN PRINTING TECHNOLOGY UNDER
THE STATE BOARD OF TECHNICAL EDUCATION, KERA.LA

Course
There shall be three separate courses focusing the three major
operational areas in the printing industry.

Course Title
The course title shall be:
1. KGTE Pre Press Operation
2. KGTE Press Work
3. KGTE Post Press Operation and Finishing.

Duration of the Course

The duration of each course shall be one year.

Equivalent courses
The course will supersede/replace all the existing KGTE Printing
Technology Courses offered as detailed below. The equivalency of the
existing courses in relation to the proposed courses shall be as under.

New/Proposed course Equivalent existing course

1. KGTE Proof Reader (Higher)

2. KGTE Stereo Typing (Higher)

KGTE Pre Press Operation
3. KGTE Compositors Work (Higher)

4. KGTE Type Casting (Higher)

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1. KGTE Machine Work (Higher)

KGTE Press Work 2. 2. KGTE Press Work (Higher)

3. 3. KGTE Printers Ware House

(Higher)

KGTE Post Press Operation

1. KGTE Book Binding (Higher)
and Finishing

Medium of Instruction
The medium of instruction shall be Malayalam.

Eligibility for Admission

For admission to the KGTE Printing Technology Courses, the
candidate shall be required to have passed the 10th standard
examination conducted by Board of Public Examinations Kerala State or
any other equivalent examinations recognised by the Board of Public
Examinations, Kerala.

Registration of Candidates for Examination

Joint Controller of Technical Examinations shall issue necessary
guidelines regarding registration of candidates.

Registration of in-service candidates

Candidates employed with the Government of Kerala and
possessing KGTE (Lower) Certificate and experience for a minimum of
five years in the respective area (Pre-Press, Press Work or Post Press
Operation and Finishing as the case may be) will be exempted from

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attending the academic programme through approved institutions and

can register with the O/o the Joint Controller of Technical Examinations
for the end of the year examinations directly. Joint Controller ·of
Technical Examinations shall invite registrations from such candidates
separately. They shall be exempted from the academic requirements
such as minimum attendance, maintenance of practical records, internal
assessment.

Instructional Duration in an Academic Year

The academic year shall consist of a minimum of 36 weeks of
instruction including intervening holidays, but excluding the period of
examination and study holidays. There shall be 7 instructional periods of
55 minutes duration per day and there shall be 5 working days per week
from Monday to Friday and thereby 35 periods per week.
Minimum attendance to appear for the Examinations
A candidate must secure a minimum of 80% attendance to secure
eligibility for examination. In the case of those students with 65% or more
attendance, but could not attain 80% attendance due to medical reasons,
the Principal/Head of Institution, at his/her discretion, may grant the
eligibility to appear for the examination.

Scheme of Evaluation

 The scheme of evaluation shall consist of End of the year

examination in Theory and Practical subjects. The maximum marks
for end of the year examinations for theory and practical subjects
shall be l00 each. The total marks for the course shall be 200 marks.
 All the end of the year examinations will be of 3 hour duration.

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 Polytechnic Colleges and Technical High Schools in the State shall

be the centres for the conduct of theory examinations.

 The Practical Examinations can be conducted at IPT and GPTC,

Shoranur, Institutions under Directorate of Technical Education and
other Institutions under Government having required facilities,
selected by Joint Controller of Technical Examinations.

Examination
In each theory subject, there will be an end of the year examination
conducted by the Board of Technical Examinations as per the pre-
announced notification of examination.

 The time-table for the examination will also be published ahead of

its conduct.

 There will not be any separate supplementary examination.

 The scheme of Question Paper shall be issued by Joint Controller

of Technical Examinations along with notification.

 For practical examinations, the Board of Technical Examinations

shall appoint examiners, who will set a question paper for
conducting practical exercises.

Minimum marks for pass

A candidate must secure a minimum of 40% (forty percentage)
marks in the end examination, in theory and practical for a pass in each
subject. There will be no minimum for pass in the internal assessment,
but the total marks for the end of year examination and the internal

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assessment should not less than 40% (forty percentage) for a pass in
each subject.

Classification of successful candidates

A candidate will be declared to have passed the course only if
he/she secured a pass in all the theory and practical subjects, within the
validity period of his/her registration.

There shall be two classifications of passed candidates:

(i) First Class.

(ii) Second Class.

A candidate will be declared to have passed the course in First Class

if he/she secures a pass in all the subjects, with an aggregate minimum
of 60% (sixty percentage) within the normal duration of the course. All
other successful candidates will be declared to have passed the course in
Second Class.

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KGTE PRE PRESS OPERATION

Subjects of Study, Scheme of Examination and
Evaluation

SI. Subject Periods/ Evaluation

Subject
No. Code Week (marks)

1 PPO 111 Pre Press Operation (Theory) 15 100

Pre Press Operation 20 100

2 PPO 112
(Practical)

Subject Title : Pre Press Operation (Theory)

Subject Code : PPO 111
Periods/week : 15
Total Marks : 100

Time Schedule
Periods

UNIT I Designing for Printing 127

UNIT II Colour Separation 143

UNIT III Softwares for Pre-Press Work I 127

UNIT IV Softwares for Pre-Press Work II 103

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OBJECTIVES
UNIT I - Designing for Printing

1.1 Computer - Input/output devices - Scanner etc.

1.2 Computer Printer - Laser, Inkjet, Dot matrix etc.

1.3 Understand Operating system MS DOS, Windows, Text

manipulation

1.4 Study Layout - Different Types

1.5 Working with Illustrations

1.6 Study Desktop Publishing

1.7 Study Concept of DTP System

1.8 Study Typography

1.9 Study Designing for Printing

1.10 Study Basic Principles of Design

1.11 Preparation of layout, RIP.

UNIT II - Colour Separation

2.0 Study Colour Separation

2.1 Study Basic Colour Theory

2.2 Understand Light and Colour

2.3 Understand Additive Primary Colours

2.4 Understand Subtractive Primary Colours

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2.5 Study Basic Separation Theory

2.6 Study Image Assembly

2.7 Study Imposition--Sheet and Half sheet

2.8 Study Purpose of Proofing

2.9 Understand Digital Proofing

UNIT III - Software for Pre Press Work I
3.0 Study Software for Graphic Arts - Introduction

3.1 Study Page Maker - Basics of Page Maker and InDesign

Job suitability overview of tools in InDesign

3.2 Study Setting up of Printer and Page Setting - Paragraphs,

Bullets, Columns, Drop letters

3.3 Study Creating Style sheets

3.4 Study Importing of Text and Graphics

3.5 Understand Master pages and Multiple Master pages

3.6 Study Layers

3.7 Understand Plug. in Operations - lmposition of pages
3.8 Understanding Paper size and Quality.
UNIT IV - Software's for Pre Press Work II

4.0 Study Photoshop - -Basics

4.1 Study Overview of Tools

4.2 Study Illustrator and Corel Draw, Quark Express

4.3 Study Creating Various Images

4.4 Understand Creating Monograms

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4.5 Understand Saving the File

4.6 Understand Computer to Film (CTF)

4.7 Understand Image Setter - its Principle and Functions

4.8 CTP and Associated Software's

4.9 InDesign, Quark Express and PIFS (page set up software's)

4.10 Thorough understanding on CTP (screen angle)

4.11 CTP Thermal and Violet.

SUBJECT DETAILS
Unit I - Designing for Printing

Design Principles, Typography, Layout, Working with Illustrations,

Desktop Publishing, Concept of DTP System, Input devices, Output
devices, Operating Systems and Text Manipulation.
Unit II - Colour Separation

Colour separation, Basic colour theory, Light and colour, Additive

Primary Colours, Subtractive Primary colours, Basic separation theory,
Image assembly- Stripping and proofing, Imposition--sheet and halfsheet,
Equipment and tools used for stripping, Elementary stripping techniques-
masking sheets, Laying outspread - Printed massing sheet, attaching film
negatives, opaqueing and attaching the flat attaching film positives,
Purpose of proofing, Photo mechanical proofing, Digital Proofing.

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Unit III-Software for Pre Press Work I

Software for Graphic Arts - Introduction, Page maker-Basics of Page

maker and InDesign job suitability overview of tools in InDesign, Setting up
of Printer and Page setting--Paragraphs, Bullets, Columns drop letters,
Creating style sheets, Importing of text and graphics, Master pages and
Multiple master pages, Layers, Plug-in Operations - Imposition of pages.
Unit IV-Software for Pre Press Work II

Photoshop - Basics, Overview of tools, Illustrator and Corel Draw,

Creating monograms, saving the file, Computer to film (CTF), Image setter-
-its principle and functions, CTP and associated software's.

Subject Title : Pre Press Operation (Practical)

Subject Code : PPO 112

Periods/week : 20

Total Marks : 100

Exercise I : Windows OS

Exercise II : MS-Word

Exercise III : Lettering for layouts

Exercise IV : Design--Preparation of design for visiting cards, letter

heads

Exercise V : Preparation of design for title cover

Exercise VI : Designing monograms, Trademarks

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Exercise VII : Proof Reading - Procedure of showing text and marginal

marks

Exercise VIII : Correction of at least four proofs (four exercises)

Exercise IX : Preparation of imposing schemes for two and four

pages - sheet and half sheet methods

Exercise X : Preparation of imposition schemes for eight and

sixteen pages - sheet and half sheet methods

Exercise XI : Identification of image carriers for letter press

Exercise XII : Preparation of image carriers for PS plates, CTP

Plates

Exercise XIII : Acquaintance with Photoshop, Corel draw, InDesign

etc.

Project Work

Preparation of a magazine with cover (of not less than 48 pages).

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KGTE PRESS WORK

Subjects of Study, Scheme of Examination and
Evaluation

Sl. Subject Subject Periods/ Evaluation

No. Code Week (marks)

1 PW 221 Press Work (Theory) 15 100

2 PW 222 Press Work (Practical) 20 100

Subject Title : Press Work (Theory)

Subject Code : PW 221

Periods/week : 15
Total Marks : 100

Time Schedule
Periods
UNIT I : Introduction to Printing Presses 80

UNIT II : Offset Press Works 140

UNIT III : Print Media materials 112
UNIT IV : Maintenance, Cleaning and Safety 100

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OBJECTIVES
UNIT I - Introduction to Printing Presses

1.0 Understand various Printing Presses---Introduction (Explanation

of Principle of Letterpress, Offset, Gravure, Screen printing,
flexography, Digital printing)
1.1 Understand Press Development in Letterpress process Platen
presses, Flat bed cylinder presses and Rotary presses.
(Introduction only required)

1.2 Introduction to Lithography

1.3 Understanding Offset Press

1.4 Understanding (a) Infeed unit (b) Feeder unit

1.5 Study Registration systems

1.6 Study Printing unit

1.7 Study Dampening unit

1.8 Study Inking unit

1.9 Study Delivery unit

1.10 Understand Sheet fed presses

1.11 Understand Single colour sheet fed presses

1.12 Understand Multicolour Sheet fed presses

1.13 Types and Configuration

1.14 Make ready procedure (a) Pre make ready (b) Final make ready.

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UNIT II - Offset Press Works

2.0 Study Offset Presses

2.1 Study its types and configurations

2.2 Study Multi-colour Web presses

2.3 Understand Perfecting printing (Back and back)

2.4 Study Printing materials used for Offset process and job suitability

2.5 Study sequence of printing colours

2.6 Understand Digital printing.

UNIT III - Printing Media Materials

2.1 Ink

2.2 Paper

2.3 Plates

2.4 Blankets

2.5 Chemicals

UNIT IV - Maintenance, Cleaning and Safety

4.1 Quality control and devices

4.2 Maintenance and lubrication

4.3 Trouble shooting

4.4 Safety precautions.

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SUBJECT DETAILS

UNIT I - Introduction to Printing press

Printing Presses - Introduction (explanation of Principle of

Letterpress, Offset and Gravure), Press Development in letterpress
process - Platen Presses, Flat bed cylinder Presses and rotary Presses,
Classify Offset lithography Presses, Understanding Offset Press operation,
Feeder Unit, Registration Unit, Printing unit, Inking Unit, Dampening Unit,
Delivery Unit, Sheet fed presses - Introduction, single colour sheet fed
presses, Multicolor Sheet fed presses.

UNIT II - Offset Press works

Offset Presses, Study Multi-colour Web Presses. Understand
Perfecting Printing (Back and back). Study Printing Materials used for
Offset process and job suitability. Study sequence of printing colours.
Study Web-offset presses, its types and configurations, elements of Web-
offset, Reel stand, Printing unit, Dampening unit, Inking unit, chilling,
Folders, Delivery, Understand Digital printing.

UNIT Ill - Printing Media Materials

Ink-manufacturing, types, drying methods, paper-manufacture,
types, qualities required, sizes, Plates - types, metals used, thickness,
need of graining, methods of graining, Blankets - types of blankets, quality,
manufacture, Chemicals - different chemicals and solutions used for offset
printing.

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UNIT IV - Maintenance, cleaning and safety

Temperature and humidity control, storage of materials, Quality
control and devices, Maintenance and lubrication, Trouble shooting, safety
precautions.

Subject Title : Press Work (Practical)

Subject : PW 222

Code Periods/week : 20

Total Marks : 100

Exercise I : Feeder settings and paper jogging

Exercise II : Plate and blanket fixing--pre make ready.

Exercise III : Make ready on Offset machines

Exercise IV : Printing single Colour Job

Exercise V : Printing Two Colour and multicolor Jobs

Exercise VI : Colour printing by Screen printing method

Project work :

1. Field visit to Offset printing Press and newspaper presses for Study
of web offset printing (Sheet fed).

2. A work record of the activities undertaken during the course to be

prepared and to be presented for evaluation during the term end
practical examination.

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KGTE POST PRESS OPERATION

AND FINISHING
Subjects of study, Scheme of Examination and
Evaluation

Subject Title : Post Press Operation and Finishing(Theory)

Subject Code : PPOF 331

Periods/week : 15

Total Marks : 100

Time Schedule
Periods

UNIT I : Introduction to Binding 100

UNIT II : Sewing and Binding Operations 116

UNIT III : Advanced Bindery Operations 116

UNIT IV : Packaging 100

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OBJECTIVES
UNIT I - Introduction to Binding

1.1 Understanding Definition of Binding

1.2 Study Ware housing - various operations

1.3 Understand Paper sizes - GSM, GSM calculations

1.4 Understand Tools, Equipments and Machineries

1.5 Study Classification of Binding - Letter press, stationary

1.6 Study Account Book Binding, Mechanical Binding

UNIT II - Sewing and Binding Operations

2.1 Folding

2.2 Forwarding

2.3 Gathering

2.4 Collating

2.5 Block binding

2.6 Wire stitching

2.7 Thread sewing

2.8 Case binding

2.9 Finishing operations

2.10 Lamination

2.11 Gold foiling.

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UNIT Ill - Advanced Bindery Operations

3.1 Understand Programmable cutting machine

3.2 Study Folding machine, Bundling machine

3.3 Study Gathering machine, wire stitching machine

3.4 Study Perfect Binding machines

3.5 Study Case binding machines, study flow line machine

3.6 Understand Definition of packaging - types of packaging

3.7 Understand Materials for packaging

UNIT IV - Packaging

4.1 Study the materials used for packaging---paper board, metal, glass,
plastics, timber and textiles

4.2 Study the plastic based packaging materials

4.3 Study the Flexible Packaging

4.4 Understand Speciality Packaging

4.5 Understand Plastic corrugated boxes

4.6 Understand Rigid boxes

4.7 Understand Converting Process - Introduction - Principles of carton

design - Sequence of operations involved in die-making for carton
and envelopes

4.8 Study Die-cutting and creasing make ready Folding and gluing

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SUBJECT DETAILS
UNIT I – Introduction to binding
Defining of Binding, Paper sizes-different types, GSM, Tools,
Equipments and machineries, Classification of Binding - Letter press,
stationary, Account Book binding, Spiral Binding
UNIT II - Sewing and Binding operations

Folding methods, Forwarding operation, Gathering, Collating, Block

binding, Wire stitching, Thread sewing, Case binding, Finishing operations,
Lamination, Gold foiling
UNIT III - Advanced Bindery Operations

Edge decoration-painting, sprinkling, marbling, gilding, Different

covering materials, Binding materials calculations, Finishing - Finishing
Tools, blind blocking and tooling, gaufforing, gliding. Case binding
machines, Perfect Binding machines, Folding machine, Bundling machine,
Gathering machine, wire stitching machine, Programmable cutting
machine, definition of packaging types of packaging, Materials for
packaging.
UNIT IV - Packaging

Materials used for packaging- paper board, metal, glass, plastics,

timber and textiles, Plastic based packaging materials, Flexible packaging,
Speciality packagings, Plastic corrugated boxes, Rigid boxes, Converting
Process Introduction principles of carton design Sequence of operations
involved in die-making for cartons and envelopes, Die-cutting and creasing
make ready Folding and gluing.

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Subject Title : Post Press Operation and Finishing (Practical)

Subject Code : PPOF 332

Periods/week : 20

Total Matks : 100

Exercise 1 : Jogging, Counting, Folding (Hand and machine)

Exercise 2 : Folding, (hand, machine) types of folding

Exercise 4 : Gathering, Collating

Exercise 5 : Sewing practice--various types

Exercise 6 : Forwarding and covering operations- -attaching plates

and Maps

Exercise 7 : Case binding practice--stitching, sewing, perfect binding

Exercise 8 : Account Book Binding

Exercise 9 : Lamination, Varnishing, UV coating

Exercise 10 : Familiarise with Modern Binding machinery

Exercise 11 : Adhesive binding (Perfect binding), wire stitching,

section sewing

Exercise 12 : Cutting machine operations

Exercise 13 : Mechanical binding, spiral, comb, wire, loose leaf etc.

Exercise 14 : Packaging different methods

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