The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this unit must be achieved in accordance with food safety standards and regulations.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of ability to:

conduct pre-start checks on machinery used for deaeration, mixing and carbonation

start, operate, monitor and adjust process equipment to achieve required quality outcomes

take corrective action in response to typical faults and inconsistencies

complete workplace records as required

apply safe work practices and identify OHS hazards and controls

safely shut down equipment

apply food safety procedures to work practices.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

personal protective clothing and equipment

work procedures, including advice on safe work practices, food safety, quality and environmental requirements

information on equipment capacity and operating parameters

production schedule/batch instructions

specifications, control points and processing parameters

process and related equipment and services, including refrigerant and carbon dioxide

syrup, water and other ingredients as required

sampling schedules and test procedures and equipment as required

documentation and recording requirements and procedures

cleaning procedures, materials and equipment as required.

Method of assessment

This unit should be assessed together with core units and other units of competency relevant to the function or work role. Examples could be:

FDFOP2003A Clean equipment in place

FDFOP2004A Clean and sanitise equipment

FDFOP2011A Conduct routine maintenance

FDFOP2013A Apply sampling procedures

FDFOP2030A Operate a process control interface

MSL973001A Perform basic tests.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

Required skills

Ability to:

access workplace information to identify processing requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary materials and services

conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, confirming operation of the vacuum pump on the deaerator, setting orifice plate and vernier to deliver syrup and water in the required proportions to the mixer, checking supply of refrigerant and carbon dioxide, setting required temperature and pressure settings, cancelling isolation or lockouts as required, confirming that equipment is clean and correctly configured for processing requirements,positioning sensors and controls correctly,ensuring any scheduled maintenance has been carried out, and confirming that all safety guards are in place and operational

start, operate, monitor and adjust process equipment to achieve required outcomes, such as monitoring control points and conducting inspections as required to confirm process remains within specification

on the deaerator, monitor:

water supply

vacuum pump operation

water level/vacuum level

at the mixing state, monitor:

correct blend ratio for product type

brix of the mix

at the carbonation state, monitor:

volume of carbon dioxide injected

temperature

speed of injection

testing carbonation of liquid

monitor supply and flow of materials to and from the process

take corrective action in response to out-of-specification results

for a given syrup:water ratio, determine required operating settings to achieve a given brix result

respond to and/or report equipment failure within level of responsibility

locate emergency stop functions on equipment

follow isolation and lock out/tag out procedures as required to take process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility

demonstrate batch/product changeovers

complete workplace records as required

maintain work area to meet housekeeping standards

use process control systems according to enterprise procedures

conduct routine maintenance according to enterprise procedures

clean and sanitise equipment according to enterprise procedures

use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor

work cooperatively within a culturally diverse workforce

Required knowledge

Knowledge of:

purpose and basic principles of each stage of the process, including the relationships between variables, such as pressure, temperature and volume on processing outcomes

basic operating principles of equipment, such as main equipment components, status and purpose of guards, equipment operating capacities and applications, and the purpose and location of sensors and related feedback instrumentation

services required and action to take if services are not available

the flow of the deaeration, mixing and carbonation process and the effect of outputs on downstream processes, including how each stage of the process affects related stages and how the outputs of this process affect the filling stage

quality characteristics to be achieved by each stage of the process, including the amount of dissolved air to be removed at deaeration, the typical water:syrup ratios for product types and the volume of carbon dioxide to be dissolved in the aerated product

quality and condition requirements of inputs and effect of variation on process performance, such as the characteristics of different ingredients and how they behave when processed,e.g. the difference between processing products containing fruit juice compared with those that do not

operating requirements and parameters and corrective action required where operation is outside specified operating parameters

typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems

methods used to monitor the production process, including inspecting, measuring and testing as required by the process

inspection or test points (control points) in the process and the related procedures and recording requirements, including test procedures for brix and carbonation and other tests as required by the process

contamination/food safety risks associated with the process and related control measures

common causes of variation and corrective action required

occupational health and safety (OHS) hazards and controls

requirements of different shutdowns as appropriate to the process and workplace production requirements, including emergency and routine shutdowns and procedures to follow in the event of a power outage

isolation, lock out and tag out procedures and responsibilities

product/process changeover procedures and responsibilities

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the process, including waste/rework collection and handling procedures related to the process

basic operating principles of process control where relevant, including the relationship between control panels and systems and the physical equipment

routine maintenance procedures where relevant

cleaning and sanitation procedures where relevant

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Policies and procedures

Work must be carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements

Legislative requirements

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes:

the Food Standards Code, including labelling, weights and measures legislation

legislation covering food safety, environmental management, OHS, anti-discrimination and equal opportunity

Workplace information

Workplace information may include:

standard operating procedures (SOPs)

specifications

production schedules and instructions

manufacturers' advice

standard forms and reports

Equipment

Equipment typically includes:

a deaerator

a continuous flow mixing process

a carbonator

Carbonation may include both direct injection through pipework and/or gas absorption under refrigerated and pressurised conditions in a carbonator

Shutdown procedures

Shutdown procedures may include:

cleaning (in some cases cleaning may be carried out by a dedicated cleaning crew)

Services

Services may need to be confirmed. These depend on the nature of the process. Typical examples include:

power

refrigerant

carbon dioxide

water

vacuum/pressure

compressed and instrumentation air