Senior Flexo Machine Operator

Job Overview:

We are seeking an experienced Flexo Machine Operator specializing in high-speed flexographic printing for paper cup manufacturing. The ideal candidate will take full ownership of machine setup, web tension control, colour management & ink formulation, preventive machine maintenance, and product quality inspection. You will ensure consistent print quality on food-grade paper board while maintaining maximum machine efficiency and minimal material waste.

Key Responsibilities1. Press Setup & Operation

• Set up multi-color inline or CI flexographic printing presses according to daily production schedules.
• Mount photopolymer plates with high accuracy, configure print cylinders, set gear ratios, and load heavy paper rolls (PE-coated food-grade paper board).
• Monitor and adjust web tension, edge guide alignment, and registration during high-speed printing runs to prevent misalignment or creasing.

2. Advanced Colour Management & Ink Handling

• Mix, formulate, and adjust water-based or food-grade flexo inks to match Pantone (PMS) reference standards and customer-approved proofs.
• Measure and control ink viscosity, pH levels, temperature, and drying rates throughout production shifts.
• Utilize precise color measurement instruments including spectrophotometers and densitometers to maintain target optical density and $\Delta E$ (Delta E) tolerances.
• Select appropriate ceramic anilox rolls (LPI/BCM) and doctor blades depending on ink coverage and graphics requirements.

3. Machine Maintenance & Mechanical Care

• Daily Maintenance: Thoroughly clean chambered doctor blade systems, anilox rolls, ink pumps, impression cylinders, and hot-air dryers at the end of each run to avoid dried ink buildup.
• Preventive Maintenance (PM): Perform routine weekly/monthly mechanical checks, lubricate gears and bearings, inspect pneumatic valves, replace seals, and check drive belts.
• Troubleshooting: Diagnose and resolve operational and print defect issues such as gear marks, haloing, dot gain, streaking, pinholing, or color shifting promptly to limit downtime.
• Anilox & Blade Care: Handle and clean delicate ceramic anilox rollers using safe chemical or ultrasonic cleaning methods without damaging roll cells.

4. Quality Control & Food Safety Compliance

• Inspect printed paper rolls for print clarity, ink adhesion, odor/migration safety (food-grade requirements), and precise die-cut boundary alignment for paper cup blanks.
• Conduct pull-tests, rub-tests, and drying checks to ensure printed ink withstands hot/cold liquid cup forming conditions.
• Maintain cleanroom/hygiene standards suitable for food packaging manufacturing (GMP / HACCP protocols).

5. Waste Reduction & Reporting

• Minimize paper substrate and ink consumption during setup and color matching phases.
• Maintain accurate daily production logs, machine logs, ink usage data, and downtime reports.

Requirements & Qualifications

• Experience: 3 to 5+ years of hands-on experience as a Flexo Machine Operator in paper cup, flexible packaging, or paper converting industries.
• Colour Acuity: Must pass a standard color vision test (Ishihara / Farnsworth-Munsell 100 Hue Test).
• Technical Knowledge:
• In-depth understanding of flexo ink chemistry (water-based inks, pH, viscosity control).
• Hands-on knowledge of spectrophotometers, densitometers, anilox rolls, and chambered doctor blade systems.
• Strong mechanical aptitude for machine maintenance, gear alignment, and pneumatic systems.
• Education: High School Diploma, Technical Trade Certification, or Diploma in Printing Technology / Mechanical Engineering.
• Physical Ability: Able to lift heavy equipment/paper rolls, work in production environments, and handle standing shifts.

Employment Details

• Department: Printing / Packaging Production
• Employment Type: Full-Time
• Shift System: Day / Night / Rotational Shifts
• Location: Ajman/UAE
• Salary : 3000-5000

Pay: AED3,000.00 - AED5,000.00 per month

Application Question(s):

• How many years of hands-on experience do you have operating inline or CI flexographic printing presses specifically for paper cups or paper packaging?
• What types of inks have you primarily worked with?
• Have you ever taken a formal color vision test (e.g., Ishihara test)? Are you comfortable taking one prior to employment?
• How do you adjust and control web tension when running light vs. heavy PE-coated paper board through the press?
• If you notice gear marks (chatter) or dot gain during a high-speed run, what are the first 3 things you check on the machine?
• Walk me through how you adjust ink viscosity and pH level during a long production run. Why is pH critical for water-based flexo inks?
• What is your daily end-of-shift maintenance routine for chambered doctor blade systems and anilox rollers?
• How do you clean plugged ceramic anilox cells without damaging the surface of the roll?
• Since paper cups are food-contact products, what checks do you perform to ensure the ink is safe and fully cured before send-off to the cup-forming department?

Work Location: In person