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Seeking an Expert Gravure Cutter / Cylinder Engraver

💰 $45,000 - $75,000

ManufacturingPrintingSkilled Trades

🎯 Role Definition

As a Gravure Cutter, you are the cornerstone of our high-quality printing process. You will be entrusted with transforming digital designs into precisely engraved cylinders, the very heart of rotogravure printing. This role demands a unique blend of technical mastery, artistic sensibility, and unwavering attention to detail to ensure every cylinder meets exact specifications for color, depth, and clarity. Your work directly impacts the final printed product, making you a critical link in our commitment to excellence and client satisfaction.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Pre-press Technician
  • CNC Machinist
  • Print Production Assistant

Advancement To:

  • Lead Gravure Cutter / Engraving Supervisor
  • Pre-press Manager
  • Production Shift Manager

Lateral Moves:

  • Quality Control Specialist (Printing)
  • Cylinder Finishing & Plating Technician

Core Responsibilities

Primary Functions

  • Precisely operate and monitor state-of-the-art electronic engraving machines, such as HelioKlischograph or Daetwyler systems, to cut images onto copper-plated gravure cylinders.
  • Interpret complex job tickets, technical specifications, and digital proofs to accurately set up machine parameters, including screen angles, cell shapes, and engraving depths.
  • Perform rigorous quality control checks on engraved cylinders using specialized tools like microscopes, test strips, and digital scanners to verify cell integrity and dimensional accuracy.
  • Conduct thorough pre-flight checks on digital image files (TIFFs) to ensure they are optimized for the gravure engraving process and meet all customer requirements.
  • Manage the entire cylinder workflow, from receiving prepared cylinders to final inspection and handoff to the chrome plating department, ensuring a smooth and efficient production flow.
  • Execute routine and preventative maintenance on engraving equipment, including cleaning, calibrating sensors, and replacing consumable parts like diamond styli to ensure peak performance.
  • Diligently troubleshoot and resolve machine malfunctions, software glitches, and engraving quality issues in real-time to minimize downtime and production waste.
  • Maintain meticulous and accurate production logs, recording job details, machine settings, quality control data, and any deviations from standard operating procedures.
  • Safely handle, mount, and dismount heavy gravure cylinders using overhead cranes, hoists, and other material handling equipment in accordance with safety protocols.
  • Collaborate effectively with the pre-press department to diagnose and correct file issues and with the printing department to address any on-press challenges related to cylinder performance.
  • Perform test cuts and generate proof samples from engraved cylinders to secure final approval before proceeding with chrome plating and full production.
  • Monitor and adjust the engraving process for multiple machines simultaneously, ensuring consistent quality and output across all active jobs.
  • Uphold a culture of safety and cleanliness within the engraving department, adhering to all company and OSHA guidelines for machine operation and chemical handling.
  • Assist in managing the inventory of blank and engraved cylinders, ensuring proper storage, tracking, and preparation for upcoming production schedules.
  • Develop and refine engraving curves and color profiles to achieve precise color reproduction and meet the specific demands of different substrates and ink systems.
  • Utilize vision systems and automated inspection technology to identify and flag imperfections that may not be visible to the naked eye.
  • Participate in continuous improvement initiatives aimed at enhancing engraving quality, reducing setup times, and increasing overall departmental efficiency.
  • Provide training and mentorship to junior operators or apprentices on machine operation, quality standards, and safety procedures.
  • Carefully clean and prepare cylinder surfaces both before engraving to ensure proper stylus contact and after engraving to remove any debris.
  • Archive and manage digital job files, engraving parameters, and quality reports for potential reprints and long-term process analysis.
  • Stay current with advancements in gravure engraving technology, software, and techniques to contribute innovative ideas to the team.

Secondary Functions

  • Support the pre-press and quality departments by providing detailed engraving data and analysis for troubleshooting print-related issues.
  • Contribute to the continuous improvement of engraving standards and the development of standard operating procedures (SOPs).
  • Collaborate closely with the planning and scheduling teams to interpret job specifications and ensure digital files are correctly prepared for engraving.
  • Participate in daily production meetings and planning sessions to effectively schedule and prioritize cylinder engraving jobs based on pressroom needs.

Required Skills & Competencies

Hard Skills (Technical)

  • Direct experience operating electronic gravure engravers (e.g., Hell HelioKlischograph, Daetwyler, Ohio).
  • Proficiency with quality control instrumentation, including microscopes, spectrophotometers, and digital cell-depth measurement tools.
  • Strong understanding of the end-to-end rotogravure printing process, from pre-press to finishing.
  • Ability to read and meticulously interpret technical drawings, job orders, and specification sheets.
  • Knowledge of color theory, color management systems, and their application in a print environment.
  • Competency in handling and managing digital file formats, particularly 1-bit TIFFs.
  • Mechanical aptitude for performing machine setups, calibrations, and basic preventative maintenance.
  • Experience with safe operation of material handling equipment such as forklifts and overhead cranes.
  • Basic computer skills for data entry, production logging, and communication (MS Office, ERP systems).
  • Familiarity with cylinder plating (copper, chrome) and finishing processes is a significant plus.

Soft Skills

  • Exceptional attention to detail and a commitment to producing zero-defect work.
  • Strong analytical and systematic problem-solving skills.
  • Ability to work independently with minimal supervision in a high-stakes production environment.
  • Excellent time management and organizational skills to handle multiple jobs and meet tight deadlines.
  • Clear and effective communication skills for collaborating with team members across different departments.
  • A proactive and dedicated approach to workplace safety and quality assurance.
  • Adaptability and a willingness to learn new technologies and processes.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or GED equivalent.

Preferred Education:

  • Associate's Degree or Technical Certification in a related field.

Relevant Fields of Study:

  • Graphic Communications
  • Printing Technology
  • CNC Machining

Experience Requirements

Typical Experience Range:

  • 3-5+ years of direct experience operating electronic gravure engraving equipment.

Preferred:

  • 5+ years of experience in a high-volume flexible packaging, tobacco, or publication gravure printing environment.
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