Assessor Resource

FDFOP2036A
Operate an extrusion process

Assessment tool

Version 1.0
Issue Date: March 2024


This unit has application in a food processing production environment. It typically targets the production worker responsible for applying basic operating principles to the operation and monitoring of an extrusion process and associated equipment.

When operators are required to perform batch or product changeover procedures as part of this work process, the procedures should the application of this unit. Where more detailed changeovers are carried out, FDFOP2011A Conduct routine maintenance, should be selected.

This unit of competency covers the skills and knowledge required to set up, operate, adjust and shut down an extrusion process. This unit refers to both wet and dry extrusion processes.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Employability Skills

This unit contains employability skills.




Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

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 extrusion

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.

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

extrusion and related equipment and services

ingredients/blend/mass to be extruded

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.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

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/ingredients and services

conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, selecting and fitting appropriate attachments where required, setting processing parameters, 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, including monitoring control points and conducting inspections as required at each stage of the extrusion process to confirm process remains within specification, such as:

parameters such as throughput

load/work input as measured by rpm (revs per minute)

kilowatts

amps and/or Hz (hertz) at each stage of the process

monitor supply of materials to and from the extrusion process

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

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

collect samples and conduct tests 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 part of the process, including the purpose and methods used to achieve each stage of the extrusion process

basic operating principles of equipment, including 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 extrusion process and the effect of outputs on downstream processes

quality characteristics of extruded output, including required characteristics of mass or blend to be extruded, such as:

gelatinisation and viscosity

dimensions, texture and hardness of extruded product

moisture content

effect of variation in inputs and/or services on process performance

operating requirements and parameters and corrective action required where operation is outside specified operating parameters, including the effect of variation in key variables, such as:

throughput and work input at each stage of the process

effect of time and temperature

barrel pressures and temperatures at each zone

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

screw and barrel assembly wear

die plate wear

wear of conditioner paddles

extruder knife condition

methods used to monitor the extrusion process, such as 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

common causes of variation and corrective action required

contamination risks related to the extrusion process and related control measures

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

product/process changeover procedures and responsibilities

isolation, lock out and tag out procedures and responsibilities

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the extrusion 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 panelsand systems and the physical equipment

sampling and testing associated with process monitoring and controlwhere relevant

routine maintenance procedures where relevant

cleaning and sanitation procedureswhere 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 is 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 the industry includes:

the Food Standards Code including labelling, weights and measures legislation

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

When applied to the pharmaceutical industry, relevant Good Manufacturing Practice (GMP) codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP

Workplace information

Workplace information may include:

standard operating procedures (SOPs)

specifications

production schedules and instructions

manufacturers' advice

standard forms and reports

Extrusion process

The extrusion process typically includes:

feeding/dosing

conditioning/cooking

mixing

extruding

drying and cooling

It may also involve screening/sieving, a final additive addition stage and further processing, such as sheeting or aeration according to product type

Extrusion equipment

Extrusion equipment may include:

ingredients handling and addition equipment

mixers

conditioners

cookers

dryers and coolers

Some systems may also include:

expanders

oil coating systems

screens and sieves

sheeting

cutting/stamping equipment

tray feeders/take off

stackers

Operation of equipment and processes

Operation of equipment and processes may require:

the use of process control panels and systems

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

steam

water

vacuum

compressed and instrumentation air

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Materials are confirmed and available to meet operating requirements 
Machine components and related attachments are selected and fitted to meet operating requirements 
Processing and operating parameters are entered as required to meet safety and production requirements 
Equipment performance is checked and adjusted as required 
Pre-start checks are carried out as required by workplace requirements 
Ingredients and additives are delivered to the extrusion process in the required quantities and sequence 
Preparation of the mass is monitored to confirm that specifications are met and mass is suitable for extrusion 
The extrusion process is operated according to workplace procedures 
Equipment is monitored to identify variation in operating conditions 
Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements 
The extruded product is monitored to confirm that specifications are met 
Out-of-specification product/process outcomes are identified, rectified and/or reported to maintain the process within specification 
The work area is maintained according to housekeeping standards 
Work is conducted in accordance with workplace environmental guidelines 
Workplace records are maintained according to workplace recording requirements 
The appropriate shutdown procedure is identified 
The process is shut down according to workplace procedures 
Maintenance requirements are identified and reported according to workplace reporting requirements 

Forms

Assessment Cover Sheet

FDFOP2036A - Operate an extrusion process
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

FDFOP2036A - Operate an extrusion process

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: