Assessor Resource

FDFOP2072A
Operate a beer filling process

Assessment tool

Version 1.0
Issue Date: May 2024


This unit applies to operators and other personnel responsible for the filling of kegs, bottles and cans with beer products in both large and small breweries. It includes complying with quality and standard operating procedures and conducting of routine changeovers. Where changeovers require maintenance related skills, the unit FDFOP2011A Conduct routine maintenance should be considered.

This unit covers the preparing, operating, monitoring and shutting down of a beer filling process for kegs, bottles and cans. It includes working within quality requirements and standard operating procedures.

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

Prerequisites

There are no pre-requisites for this competency unit.

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:

access workplace information to identify requirements for the beer filling process

interpret the production schedule to determine the type of container required

confirm the supply of necessary materials and services and confirm equipment status and condition

set up and start up the process.

monitor the beer filling process and equipment operation and take corrective action in response to out-of-specification results or non-compliance

conduct changeovers for different product or containers

prepare equipment for cleaning

maintain workplace records

conduct routine maintenance

calculate materials required

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 and environmental requirements

production schedule, batch instructions

material data safety sheets where appropriate

specifications, control points and filling parameters

beer filling equipment

services as required

stock required for the beer filling process

stock flow system

related work areas and communication system

routine preventative maintenance schedule as required

cleaning schedule as required

sampling and testing schedules as required

documentation and recording requirements and procedures

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 include:

Ability to:

access workplace information to identify production requirements for the beverage filling process

select, fit and use personal protective clothing and equipment

identify keg, can and bottle sizes relevant to beer filling operation

identify types of beer products relevant to beer filling operation

interpret the production schedule

confirm supply of necessary materials and services to the filler

confirm equipment status and condition

monitor the beverage filling process and equipment operation to identify out-of-specification results or non-compliance. This may include:

flow rates/quantity

broken bottles

faulty kegs or cans

contaminated product

materials faults

equipment faults

services faults

monitor supply and flow of materials to and from the filler

safely access, isolate and clear jams in filling machine

take corrective action in response to out-of-specification results or non-compliance

report and/or record corrective action as required

replenish the filling process with raw materials, ingredients and packaging consumables

verify that output meets specifications

implement size and product changeovers

sort, collect, treat, recycle or dispose of waste

shut down beverage filling equipment in response to emergency situation

shut down beverage filling equipment in response to routine shutdown requirements

prepare beverage filling equipment for cleaning

maintain work area to meet housekeeping standards

record workplace information

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 includes:

Knowledge of:

purpose and basic principles of the beverage filling process

relationship between the filling process, bright beer and other brew house operations as well as other packaging operations

stages which occur during filling and packaging

requirements of the filling process

types of fillers

aseptic requirements for preparing containers

microbiological considerations in filling and packaging beer

effect of filling on the end product

quality characteristics to be achieved

set up and start up the process. This can involve the use of process control systems, adjusting the filler to product specifications

process specifications, procedures and operating parameters

significance and methods of monitoring control points within the beverage filling process

equipment and instrumentation components, purpose and operation

services used in the filling process

common causes of variation and corrective action required

OHS hazards and controls

procedures and responsibility for reporting problems

shutdown and cleaning requirements associated with changeovers and types of shutdowns

waste handling requirements and procedures

recording requirements and procedures including down time

environmental issues and controls relevant to the filling and sealing 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

aseptic filling and sealing requirements where relevant

sampling and testing procedures where relevant

cleaning and sanitation procedures where relevant

maintain work area to meet housekeeping standards

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.

Beer

Refers to all styles of brewed alcoholic beverages.

Materials used may include:

Bottles, cans, ends (for cans), crowns, carbon dioxide and kegs.

Services may include:

Power, gas, water, steam, hydraulics and air.

Beverage filling equipment may include:

Filling equipment may include:

fillers

pumps

valves

container cleaners

conveyors

handlers and feeding systems for crown seals and can ends

seamers

level detection devices

crowners

cleaners/rinsers

empty container inspectors

coders

clean in place (CIP) equipment.

Filling equipment and operation and monitoring functions may be directly controlled or involve the use of a process control system

Control points

Refer to those key points in a work process which must be monitored and controlled. This includes food safety (critical) quality and regulatory control points as well as inspection points

Monitoring the process may involve the use of production data such as performance control charts

Process operation and monitoring functions may be manual or involve the use of a process control system.

Equipment is monitored

To confirm equipment status involves ensuring that hygiene and sanitation standards are met, all safety guards are in place and that equipment is operational.

Workplace information may include:

Standard Operating Procedures (SOPs); specifications and production schedules

Information systems may be print or screen based.

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
Filling requirements are checked 
Availability of required materials is confirmed 
Availability of services is confirmed 
Pre-operational checks of equipment are conducted including checking that hygiene and sanitation standards are met and all safety guards are in place 
The beer filling process is set to meet production requirements 
The filler process is started up according to company procedures 
Control points are monitored to confirm performance is maintained within specification 
Beer containers (cans, kegs, bottles) are checked against production order and container specifications 
Equipment is monitored to confirm operating condition 
Stock flow to and from filler process is maintained within production requirements 
Out-of-specification product, process, equipment performance is identified, rectified and/or reported 
Size and product changeovers are completed in accordance with batch instructions and standard operating procedures 
Filler process is shut down according to company procedures 
Equipment is cleaned and maintained to meet cleaning schedules and procedural requirements 
Waste generated by both the process and cleaning procedures is collected, treated and disposed of or recycled according to company procedures 
Quality or process outputs are assessed against specifications 
Opportunities for improvement are identified and investigated 
Proposals for improvements are developed and implemented within company planning arrangements and according to company procedures 
Workplace information is recorded in the appropriate format 

Forms

Assessment Cover Sheet

FDFOP2072A - Operate a beer filling 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

FDFOP2072A - Operate a beer filling 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: