A Report

on
Industrial Training
at
ASHAKHABAR PRAKASHAN PRIVATE LIMITED
Submitted in partial fulfillment of the requirement
For the award of degree of
Bachelor of Technology
in
Mechanical Engineering
(2022-26)
Submitted by:
CHAITANYA
220161620058

Department of Mechanical Engineering

Guru Jambheshwar University of Science &
Technology, Hisar
(Established by State Legislature Act 17 of 1995)
("A+" Grade NAAC Accredited)
 Table of Contents

S.NO CONTENTS PAGE NO.

1 Declaration 1

2 Abstract
2

3 Objectives of Training
3

4 About the Company 4

5 Week 1: Introduction to Printing Press Environment and Offset

6
Printing Technology

6 Week 2: Hands-On Training with Offset Printers

10

7 Week 3: Maintenance and Troubleshooting

14

8 Week 4: Process Optimization and Reporting

17

9 Flowchart
20

9 Result
21

10 Conclusion
23
Declaration

I Chaitanya do here by declare that the project report entitled as "Summer

Training Report", submitted by me to Guru Jambheshwar University of Science &
Technology, Hisar, Haryana for the partial fulfillment of my requirement for the
aware of B.Tech (M.E). This record is my own research work.

This record includes the working of different departments and machines related to
the management of Ashakhabar Prakashan Pvt. Ltd. This record is based on all my
efforts that I have made from all the sources that can.

Place: Prayagraj

Signature

Page | 4
Abstract

Four-week practical industry training, designed to provide students with

hands-on experience and practical exposure within their field of study.

This report outlines the comprehensive experience and technical involvement

as a mechanical engineer within the printing industry (Ashakhabar Prakashan Pvt.
Ltd.). Over the course of my professional engagement, I have had the opportunity
to apply and refine various mechanical engineering principles in the context of,
machinery maintenance, and process optimization.

The working highly dynamic and innovation-driven, presents unique

challenges related to machinery efficiency, material handling, and production
workflow. Being intern I learned by observing the working gears, cylindrical shafts
and other mechanical components.

Under the guidance of mentor, analyzed maintaining the mechanical integrity

of printing machines to improving the operational efficiency of the production line,
while ensuring that safety standards are strictly adhered to.

This report will not only reflect my technical contributions but also serve as a
resource for further advancements in mechanical engineering practices within
company and proving me as a good learner.

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Objectives of the Training:

1. Management/Functional overseeing: To gain hands-on experience in

regulating the components such as gears and transmission systems using advanced
specialized software.

2. Understand maintenance Processes: To learn the key steps involved in the

maintaining the quality and accuracy of the working components within the
machine.

3. Familiarize with Industry Standards: To understand the technical standards,

tolerances, and material requirements necessary for manufacturing precision
components.

4. Improve Problem-Solving Abilities: To develop the ability to identify and

solve design and manufacturing challenges related to parts production.

5. Collaborate with Engineering Teams: To learn how to effectively work within

multidisciplinary teams, including coordination between design and production
departments

Page | 6
ABOUT THE COMPANY:

Ashakhabar Prakashan Private Limited is a private company incorporated on

January 16, 2017, and is based in Prayagraj (formerly Allahabad), Uttar Pradesh,
India. It operates primarily in the manufacturing sector, specifically related to
printing and paper products.

The company is categorized as a micro-enterprise under MSME guidelines and

focuses on manufacturing paper and related products for various printing purposes.

Fig 1.0 Inner View of company

It also serves as a media company covering all sots news from all over the
world and wrapping them into the magazine. This company's focus on publishing
makes it essential part of the local literary and media landscape in Uttar Pradesh

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The company's official registered address is in, Naini, Prayagraj, Uttar Pradesh. It
is a non-government company limited by shares, and it has three directors.

The Company consists of various machinery for offset and other types of
printing. It involves the role of mechanical engineer in order to ensure smooth
running of the machinery and production process.

It as many advance machinery printing fast and good quality of product. It aims
to work at the intersection of traditional mechanics and cutting-edge technology to
keep the printing industry productive and competitive.

Page | 8
 Week1: Introduction to Printing Press Environment
and Offset Printing Technology
Objectives:
 To familiarize with the industrial environment and printing processes.
 To gain an understanding of offset printing technology and the role of
mechanical systems in printing.

Fig2.0 Block Diagram of Heidelberg SM 102V

Activities:
 Orientation:
Attended a comprehensive introduction to the company’s operations, including
a plant tour to see various machines (Heidelberg SM 102V 4) ( Fig2.0) used for
printing, cutting, and binding. Special focus was on the offset printing presses.

 Safety Training:
Underwent safety training, including handling chemicals (inks, solvents) and
personal protective equipment (PPE) use, particularly around moving
machinery.

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 Observation of Offset Printers:
Observed the general workflow of offset printing, focusing on the pre-press
process where image transfer plates are prepared using digital systems,
followed by mounting these plates onto the plate cylinder.

 Study of Machine Components:

Examined the key mechanical components of an offset printer, including:

o Plate Cylinder: Holds the printing plate.

o Blanket Cylinder: Transfers the image from the plate to paper.
o Impression Cylinder: Applies pressure to transfer ink onto paper.

 Basic System Understanding:

Learnt following

o Learned about the role of dampening systems in applying water to

plates for non-image areas, and how ink is applied to image areas.
o Gained an understanding of the sheet-fed offset printing process and
how paper is fed into the press, registered, and then printed.

Technical Insights:
 Observed how the offset printing process relies heavily on the mechanical
precision of rollers and cylinders to ensure perfect alignment and ink
distribution.
 Identified the critical role that temperature and humidity control play in
maintaining print quality and machine performance.

Fig3.0 Roller cylinder arrangement

Page | 10
Summary of Control Details for Heidelberg SM 102V

The Heidelberg Speedmaster SM 102V is a highly automated offset printing press

equipped with advanced control systems for efficient operation and precise control.
Below is a brief overview of the control buttons and systems commonly found on
the SM 102V:

1. Main Control Console:

o Touchscreen Display: Central control hub where operators can
monitor machine status, adjust settings, and select different functions.
This includes print job parameters, ink levels, and system diagnostics.
o Start/Stop Buttons: Used to initiate or stop the printing process.
Emergency stop buttons are also present for immediate shutdown in
case of a malfunction.
2. Sheet Feeder Controls:
o Sheet Alignment and Feed Guide Adjustments: Controls that allow
precise adjustment of paper feed and alignment for different paper
sizes and thicknesses.
o Double Sheet Detector: Ensures that only a single sheet is fed into
the machine at a time to prevent paper jams or printing errors.
3. Ink and Dampening System Controls:
o Ink Zone Adjustment: Fine-tunes the amount of ink applied across
different zones of the printing plate for accurate color control.
o Ductor Roller Controls: Manages ink transfer from the ink fountain
to the rollers.
o Dampening Solution Controls: Allows precise regulation of water
applied to the non-image areas of the printing plate.
4. Plate and Blanket Cylinder Controls:
o Automatic Plate Changer: Allows for quick plate changes between
print jobs.
o Impression Cylinder Pressure Adjustment: Controls the pressure
applied by the impression cylinder on the substrate for crisp, accurate
prints.
o Blanket Wash System: Automated controls for cleaning the blanket
cylinder between runs to maintain print quality.
5. Speed and Output Control:
o Speed Adjustment Dial: Adjusts the machine's operating speed
based on job requirements.
o Sheet Output Counter: Displays the number of printed sheets during
the print run.

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6. Error Detection and Diagnostics:
o Malfunction Indicators: Lights and alarms to signal issues such as
paper misfeeds, ink imbalance, or cylinder pressure problems.
o Diagnostic Menu: Provides access to machine diagnostics for
troubleshooting and maintenance.

Page | 12
 Week 2: Hands-On Training with Offset Printers
Objectives:
 Gain operational proficiency in configuring and calibrating offset printing
presses.
 Acquire skills in precision plate alignment and machine calibration to ensure
optimal printing performance.

Activities:
 Plate Cylinder Alignment:
Participated in the mounting and fine adjustment of printing plates onto the
plate cylinder. Ensured precise alignment using micrometric adjustments,
understanding that even slight deviations could lead to image blurring due to
improper contact between the plate and blanket cylinders. The arrange and
technique is well shown in fig 3.0 .

 Ink Rollers and Distribution Calibration:

Assisted in the setup of ink rollers, focusing on achieving a uniform ink film
across the plate's surface. This involved adjusting roller-to-roller pressure,
checking ink transfer consistency, and controlling ink film thickness to prevent
defects such as ink starvation or over-inking, both of which degrade print
quality.

 Dampening System Adjustment:

Gained knowledge in regulating the dampening system, which ensures non-
image areas of the plate remain ink-free. This included controlling the flow rate
of dampening solution and fine-tuning roller engagement to maintain balanced
moisture and prevent issues like emulsification, ensuring consistent print
quality.

 Troubleshooting Minor Mechanical Issues:

Engaged in diagnosing and correcting common problems, such as ink
distribution imbalances and paper feeding issues. Adjustments included

Page | 13
realigning sheet guides and modifying ink flow settings to resolve uneven ink
application and correcting feeder timing to eliminate paper jams.

Technical Insights:
 Practical experience in the setup and calibration of key components of offset
printers, focusing on plate alignment, ink distribution, and dampening
balance.
 Gained a deeper understanding of how mechanical adjustments, such as
roller pressure and plate positioning, directly influence print quality and
overall machine performance.

Fig 3.0 Printing technique

Page | 14
Controller Details
Ink Zone Adjustment Button:

 Location: Main Control Console. (Fig 4.0)

 Function: Used to fine-tune ink application across different zones of the
printing plate for precise color control. Adjustments help ensure even ink
distribution, enhancing print quality.

Dampening Solution Control Button:

 Location: Main Control Console. (Fig 4.0)

 Function: Regulates the flow of dampening solution to non-image areas of
the plate. Proper control is essential for maintaining balance and preventing
ink emulsification during printing.

Impression Cylinder Pressure Adjustment:

 Location: Front of the machine, near the impression cylinder area.

 Function: Controls the pressure applied by the impression cylinder on the
substrate. Correct pressure settings are vital for achieving crisp and accurate
prints.

Automatic Plate Changer Button:

 Location: Main Control Console. (Fig 4.0)

 Function: Initiates the process of changing printing plates automatically.
This feature streamlines job changes and minimizes downtime between printer.

Fig 4.0 Controller Console

Page | 15
Week 3: Maintenance and Troubleshooting
Objectives:
 Gain proficiency in performing routine maintenance on offset printing
presses to ensure optimal performance and longevity.
 Develop skills in identifying and troubleshooting mechanical faults to reduce
downtime and improve machine efficiency.

Activities:
 Routine Maintenance: I participated in scheduled maintenance routines,
both daily and weekly, to ensure the continuous operation of the offset press.
This involved:

Fig 5.0 Blanket Cylinder Inspection

o Ink Roller Cleaning: Performed thorough cleaning of ink rollers

using designated solvents to remove residual ink and prevent ink
build-up, which can cause inconsistent ink transfer and color
variation. I also inspected roller surfaces for signs of glazing or wear,
which can reduce the roller's ability to maintain proper nip pressure
and ink distribution.

Page | 16
 o Blanket Cylinder Inspection: Regularly inspected the blanket
cylinder for damage, compression set, and ink contamination. The
blanket cylinder plays a crucial role in transferring ink from the plate
to the substrate, and any imperfections can result in print defects. I
checked for signs of fatigue, swelling, or cuts that could compromise
the print quality and conducted necessary blanket changes. Refer to
fig 5.0.
o Lubrication of Moving Parts: Assisted in lubricating key
mechanical components such as bearings, gears, and cylinder shafts,
focusing on friction-prone areas to reduce wear. Proper lubrication is
critical to ensuring the smooth operation of high-speed moving parts
and preventing heat buildup that could lead to mechanical failure.

 Roller Replacement: I assisted in the replacement of worn ink rollers. This

involved:
o Roller Material Selection: Learned about different roller materials,
including rubber and metal, and their suitability for specific
applications. Rubber rollers are ideal for ink distribution due to their
flexibility and ink transfer properties, whereas metal rollers are more
durable but used in the dampening system or in heavy-duty
applications.
o Precision Installation: Ensured the new rollers were installed with
precise roller-to-roller and roller-to-plate pressure settings, using
feeler gauges to measure the nip width. Incorrect roller pressure can
lead to improper ink transfer or even damage to the plate or blanket. I
learned how to adjust the eccentric roller bearings to ensure proper
pressure distribution across the width of the printing press.

 Mechanical Troubleshooting: I worked with the mechanical team to

diagnose and resolve various mechanical issues, such as:
o Paper Jams: Investigated the cause of frequent paper jams, which
were traced back to misaligned sheet guides and feed rollers. I
recalibrated the feeder system, adjusting the paper guide positions and
ensuring consistent paper feeding through the press. Misalignment
was corrected using precision instruments to align the feeder and
ensure smooth paper flow without skewing.

Page | 17
 o Ink Smearing: Diagnosed ink smearing issues caused by excessive
roller pressure. Adjusted the ink form roller pressure using the press’s
adjustment dials, ensuring the correct nip width between the ink roller
and the plate cylinder. Proper adjustment prevented excess ink from
being deposited on the substrate, thus improving print sharpness and
clarity.
o Blanket Cylinder Damage: Assisted in replacing a damaged blanket
cylinder, focusing on the proper mounting and tensioning of the
blanket. This involved tightening the blanket to the manufacturer’s
specified tension to avoid slippage during high-speed printing. Over-
tightening or under-tightening could cause poor ink transfer or
mechanical stress on the cylinder.

Skills Acquired:
 Gained practical knowledge of preventive maintenance techniques for offset
printing presses, including roller care, cylinder inspection, and lubrication of
mechanical parts.
 Developed advanced troubleshooting skills in diagnosing and resolving
common mechanical failures such as paper misfeeds, roller pressure
inconsistencies, and blanket cylinder malfunctions.
 Learned how to adjust key mechanical settings (e.g., roller pressure, feeder
alignment) to optimize print quality and prevent downtime due to
mechanical failures.

Page | 18
Week 4: Process Optimization and Reporting
Objectives:
 Assess the mechanical performance of offset printing presses and identify
opportunities for improving operational efficiency.
 Document and analyze mechanical challenges encountered during the
internship, along with the technical solutions applied.

Activities:
 Process Optimization: I collaborated with the mechanical team to conduct
a thorough analysis of machine setup times, focusing on the efficiency of the
plate mounting, roller adjustment, and calibration procedures.
o Roller Pressure Pre-Setting: One key area identified for
improvement was the pre-setting of roller pressures before running a
print job. By standardizing the pressure settings for specific print jobs,
we minimized trial-and-error adjustments during calibration,
significantly reducing machine downtime and setup time.
o Plate Alignment Optimization: We refined the procedure for
aligning the plate cylinder, using a more systematic approach with
precision measurement tools to ensure accurate registration in the
initial setup phase. This reduced the need for re-alignment during
production runs and improved the overall speed of job changeovers.
By optimizing the mechanical setup, the press achieved higher
throughput with less waste.

 Ink Waste Reduction Study: I participated in a targeted study aimed at

minimizing ink waste during machine calibration and color proofing.
o Ink Flow Adjustment: We found that by carefully adjusting the ink
fountain keys and the ductor roller settings during the initial ink feed,
we could control ink flow more precisely. This allowed for more
efficient ink transfer to the plate, reducing the amount of excess ink
that needed to be cleaned off during the initial setup.
o Ink and Water Balance: Additionally, we fine-tuned the interaction
between the dampening system and ink rollers. By achieving a better
water-ink balance, we minimized ink emulsification, which often

Page | 19
 leads to ink waste and quality issues. These changes resulted in
improved print consistency and lower ink consumption per run.

 Documentation and Reporting: I was responsible for documenting all

mechanical challenges and solutions encountered throughout the internship.
This included:
o Roller and Cylinder Adjustments: Detailed records of roller
pressure settings, blanket cylinder tension, and plate-to-blanket gap
adjustments were maintained. I also documented common mechanical
issues, such as uneven ink distribution, and the corrective actions
taken, such as adjusting roller nip width and recalibrating the ink flow
system.
o Maintenance Protocols: I created a maintenance checklist that
included lubrication schedules, roller inspections, and blanket cylinder
replacement intervals. This checklist emphasized the importance of
adhering to maintenance timelines to prevent mechanical failures and
reduce downtime.

 Presentation of Findings: I presented my findings and recommendations to

the mechanical team, focusing on the importance of frequent inspections of
critical components such as the ink rollers and blanket cylinders. I
emphasized the need for:
o Regular Blanket Cylinder Tension Checks: Ensuring the correct
tension on the blanket cylinder is crucial to avoid slippage and
maintain consistent print quality.
o Routine Roller Inspections: I recommended increasing the
frequency of roller surface inspections, as worn or glazed rollers can
result in poor ink transfer and require more frequent adjustments to
compensate for performance degradation.

Skills Acquired:
 Developed the ability to conduct a detailed mechanical performance
analysis, identifying specific areas for process optimization in offset printing
operations, particularly in machine setup and ink distribution systems.

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 Gained advanced technical reporting skills, focusing on documenting
mechanical challenges and the effectiveness of maintenance protocols and
calibration procedures.
 Enhanced my ability to propose practical mechanical improvements that
minimize downtime, improve print quality, and reduce operational costs
through precise calibration and maintenance strategies.

Page | 21
 Flowchart

Week 1: Introduction

|---> Orientation & Safety Training

|---> Observing Offset Printing Machines

|---> Study of Key Mechanical Components

Week 2: Hands-On Training

|---> Plate Cylinder Alignment

|---> Ink Roller Setup & Calibration

|---> Dampening System Adjustment

|---> Troubleshooting Minor Issues

Week 3: Maintenance & Troubleshooting

|---> Routine Maintenance (Rollers, Cylinders)

|---> Roller Replacement

|---> Lubrication of Mechanical Parts

|---> Mechanical Fault Detection

Week 4: Process Optimization

|---> Machine Setup Improvement

|---> Ink Waste Reduction Study

|---> Reporting & Documentation

Page | 22
Result
Upon completing my mechanical internship in the printing press industry,
specifically working with offset printers, I achieved the following outcomes:

1. Technical Expertise in Offset Printing Machinery:

o I gained hands-on experience in operating and maintaining complex
offset printing presses, particularly in the mechanical aspects of plate
cylinder alignment, roller pressure calibration, and ink distribution.
o I developed a thorough understanding of the mechanical interactions
between key components such as ink rollers, plate cylinders, and
dampening systems, and how these impact the final print quality.
2. Proficiency in Troubleshooting and Maintenance:
o I became adept at diagnosing and resolving common mechanical
issues such as paper jams, ink smearing, and blanket cylinder damage.
My ability to identify root causes and apply effective mechanical
solutions reduced machine downtime and improved printing
efficiency.
o I acquired in-depth knowledge of preventive maintenance techniques,
including roller replacement, lubrication, and blanket tensioning,
which are essential for extending the lifespan of the machines and
ensuring continuous operation.
3. Process Optimization and Efficiency Improvements:
o I contributed to process optimization by identifying areas to improve
machine setup and calibration procedures, such as pre-setting roller
pressures and streamlining plate alignment. These adjustments
significantly reduced setup time and increased production efficiency.
o My participation in the ink waste reduction study led to a measurable
reduction in ink consumption during calibration phases, contributing
to cost savings and more sustainable printing practices.
4. Enhanced Mechanical Reporting and Documentation Skills:
o Throughout the internship, I documented mechanical challenges and
solutions in a systematic manner, creating detailed reports on issues
like roller pressure settings, cylinder maintenance, and
troubleshooting steps. These reports served as valuable references for
the mechanical team to improve future operations.
o I also gained experience in presenting technical findings, offering
recommendations for more frequent inspections of critical

Page | 23
 components and emphasizing the importance of preventive
maintenance.
5. Improved Mechanical Problem-Solving Abilities:
o My troubleshooting skills were greatly enhanced, particularly in
diagnosing mechanical failures and understanding the
interdependency of machine settings, such as roller pressure, ink flow,
and paper handling systems.
o I became more confident in applying mechanical solutions to optimize
machine performance, reduce operational downtime, and enhance
print quality.

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Overall Outcome of the Internship (Brief)

During my internship in the printing press industry, I gained substantial hands-on

experience with the mechanical operation, maintenance, and troubleshooting of
offset printing machines. I developed a solid understanding of key mechanical
components such as plate cylinders, ink rollers, and dampening systems, learning
how they influence print quality and machine performance.

Through practical involvement in routine maintenance tasks and addressing

mechanical issues, I enhanced my troubleshooting skills and contributed to process
optimization efforts, reducing setup times and improving overall efficiency. I also
gained experience in documenting technical solutions and reporting on mechanical
challenges, which sharpened my analytical and communication skills.

Overall, the internship provided me with a strong foundation in mechanical

problem-solving, machine maintenance, and process efficiency, which will benefit
my career in mechanical engineering.

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