Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

FDFCON2006A Mapping and Delivery Guide
Operate a granulation and compression process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFCON2006A - Operate a granulation and compression process
Description This unit of competency covers the skills and knowledge required to set up, operate, adjust and shut down a granulation and compression process
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit has application in a confectionery production environment. It typically targets the production worker responsible for applying basic operating principles to the operation and monitoring of granulation and compression equipment and processes.When batch or product changeover procedures are part of this work process, the procedures should be used to customise the application of this unit. Where more detailed changeovers are carried out, FDFOP2011A Conduct routine maintenance, should be considered.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare the granulation equipment and process for operation
  • Ingredients and additives are confirmed and available to meet operating requirements
  • Cleaning and maintenance requirements and status are identified and confirmed
  • The granulation process is set to production specifications
  • Equipment performance is checked and adjusted as required
  • Pre-start checks are carried out as required by workplace requirements
       
Element: Prepare the compression process for operation
  • Granulated materials are confirmed and available to meet operating requirements
  • The compression process is set to production specifications
  • Equipment performance is checked and adjusted as required
  • Pre-start checks are carried out as required by workplace requirements
       
Element: Operate and monitor the granulation and compression process
  • The process is started and operated according to workplace procedures
  • Ingredients are combined in specified sequence
  • The granulation process is monitored to confirm granules of the required particle size are produced
  • The compression process produces compressed product to specification
  • 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
  • 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
       
Element: Shut down the compression process
  • 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
       


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 confectionery granulation and compression

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

recipe/batch instructions

specifications, control points and processing parameters

process and related equipment and services, including granulation and compression equipment

materials to be processed

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:

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, assignment, 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 granulation and compression process 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, selecting appropriate settings and/or related parameters, cancelling isolation or lock outs 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 granulation process equipment to achieve required outcomes, including preparing granulated mix according to recipe instructions, monitoring control points and conducting inspections as required to confirm process remains within specification

monitor process, including:

granule size

moisture content

fines

supply of materials

product appearance

product weight, thickness and hardness, friability (this may require demonstration of related test procedures)

monitor supply and flow of materials to and from the granulation process and equipment operation to confirm process remains within specification

start, operate, monitor and adjust compression process equipment to achieve required outcomes, including installing/setting punches and dies

monitor supply and flow of materials to and from the compression process to confirm process remains within specification

demonstrate product/batch changeovers

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

complete workplace records as required

maintain work area to meet housekeeping standards

use process control systems according to enterprise procedures

collect samples and conduct tests 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 the granulation and compression process

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 granulation and compression process and the effect of outputs on downstream processes

quality requirements of ingredients for granulating and effect of variation on the granulation process

quality requirements of granulated mass and effect of variation on compression process

operating requirements of both granulation and compression, related 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 granulation and compression 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

contamination/food safety risks associated with the granulation and compression 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 granulation and compression 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 granulation and compression process, including waste/rework collection and handling procedures related to the process

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

sampling and testing associated with process monitoring and control where relevant

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 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 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

Granulation process

Granulation process may be:

wet or dry

Raw materials/ingredients

Raw materials/ingredients are added to the base product, and may include:

adhesives/binders

lubricants

fillers

colours and flavours

Granulating equipment

Granulating equipment may include:

ribbon mixers

granulators

sieves

hammer mills

dryers

Compressing equipment and accessories

Compressing equipment and accessories may include:

single or rotary punch compressors

punches and dies

Operation of equipment and processes

Operation of equipment and processes may require:

the use of process control panels and systems

In-process tests

In-process tests may include:

appearance

hardness

friability

disintegration time

weight

dimensions

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
Ingredients and additives are confirmed and available to meet operating requirements 
Cleaning and maintenance requirements and status are identified and confirmed 
The granulation process is set to production specifications 
Equipment performance is checked and adjusted as required 
Pre-start checks are carried out as required by workplace requirements 
Granulated materials are confirmed and available to meet operating requirements 
The compression process is set to production specifications 
Equipment performance is checked and adjusted as required 
Pre-start checks are carried out as required by workplace requirements 
The process is started and operated according to workplace procedures 
Ingredients are combined in specified sequence 
The granulation process is monitored to confirm granules of the required particle size are produced 
The compression process produces compressed product to specification 
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 
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

FDFCON2006A - Operate a granulation and compression 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

FDFCON2006A - Operate a granulation and compression 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: