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

FDFGR2012A Mapping and Delivery Guide
Prepare malted grain

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFGR2012A - Prepare malted grain
Description This unit covers the skills and knowledge required for operating commercial equipment associated with preparing malted barley or wheat. It covers operating and monitoring steeping, germinating, and kilning equipment.
Employability Skills This unit contains employability skills
Learning Outcomes and Application This unit applies to operators in commercial malting plants who are responsible for converting stored grain into malted barley or wheat. These operators are often known as maltsters. The unit covers the skills used in the malting process from after the grain is received and stored up to the malted barley or wheat being ready for blending, transport or storage. The skills covered by this unit are applied in accordance with enterprise procedures and to specifications determined by senior scientific or production management.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites FDFGR2010A Handle grain in a storage area
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: Steep grain
  • Grain is transferred from storage into steeping equipment
  • Hoses or other wetting equipment are placed correctly to ensure uniform hydration and to avoid damage to grain
  • Grain is immersed, drained and rested for the specified number of cycles
  • Moisture content of grain is monitored during air resting to determine when it is ready for transfer to germination vessels
  • Waste water is discharged to treatment or holding or other facilities according to enterprise and regulatory environmental guidelines
       
Element: Germinate grain
  • Grain is fed into germination vessel or floor
  • Turning and air blowing equipment is set up, operated and monitored
  • Green grain is monitored for humidity, temperature, moisture, chitting/acrospires, and general condition
  • Rate of turning, humidity and temperature is adjusted as required to maintain green grain to specifications
  • Modified green grain is transferred to kiln according to specifications for malt type and results of laboratory testing
       
Element: Operate kiln to produce malt
  • First drying of modified grain is conducted
  • Stopping of germination is confirmed
  • Modified grain is cured through correct combination of air flow and heat for malt product specification, in consultation with the production manager
  • Colour, moisture content and other required specifications are confirmed
  • Malt is cleaned
  • Separated culm is transferred to storage
  • Malt is transferred to storage
       


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 requires that the learner be assessed against at least two different batches of barley or wheat with different specifications for steeping, germination and kilning.

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

Evidence of ability to:

access workplace information and consult with relevant personnel to identify batch requirements for steeping, germination, kilning and malt cleaning processes

select, fit and use personal protective clothing and equipment

confirm equipment status and condition

set up, start and monitor grain transfer equipment

control absorption of water by grain during steeping to achieve specified water content

supply fresh air, heating, cooling and ventilation to specification during germination

safely start and operate kilns to different heat requirements

undertake sampling and testing during steeping, germination and cleaning to determine if grain and malt is within specifications

monitor critical control points in work area

apply dust control procedures in work area

maintain workplace records.

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

material data safety sheets where appropriate

steeping, germination, kilning and deculming equipment and control points. The steeping, germination, kilning equipment may be separate or combined

Steeping, germination and kilning specifications and procedures for at least two different malts

malted grain cleaning equipment.

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 of performance, competency should be demonstrated on at least two occasions to different steeping, germinating and kilning specifications.

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 include:

Ability to:

identify batch and recipe specifications and seeks assistance and relevant approvals when required

achieve specified moisture content in grain through correct combinations of water/air/water steeping cycles

germinate barley to different specifications through correct use of air, humidity and turning equipment

avoid clumping of barley during germination through correct turning

conduct acrospires evaluation and moisture testing

correctly adjust kiln heat settings for drying or curing and for different types and grades of barley and malt

follow specified shutdown processes and equipment and implement cleaning requirements associated with changeovers

monitor control points

undertake corrective action required in the event of variation to specifications and operating parameters

identify OHS hazards and controls

comply with enterprise procedures and responsibilities for reporting problems

comply with enterprise environmental procedures and controls

follow waste handling requirements and procedures

record required production data

undertake routine maintenance procedures

follow dust control procedures

clean and sanitise equipment according to enterprise procedures

maintain work area to meet housekeeping standards

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:

changes to grain from the steeping process

changes in grain during germination

role of humidity and temperature in initiating and controlling germination of grain

common variations in grain quality and type

common customer malt "recipes" used in the enterprise and implications for malt production

standard transfer times between stages e.g. receiving to steeping, steeping to germination, germination to kilning

procedures for dealing with contingencies, breakdowns and other non standard events

contamination avoidance procedures including

jewellery and loose objects in work area

security and access procedures to work areas

pest control procedures

appearance of grains before and after cleaning (deculming)

cleaning requirements associated with changeovers and types of shutdowns

purpose of moisture and acrospires testing within the malting process

equipment cleaning and sanitation procedures

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.

Malt

The term malt includes malt intended for use in beer production, distilling malts, specialty malts such as crystal and roasted malts, and malt for food production.

Services

Services include power, gas, water, steam and compressed air.

Equipment

Includes equipment used for:

storage e.g. bins, hoppers or silos

on site grain transport such as conveyors, blowers, chutes

weighing

metal detection

steeping vessels or towers

pumps, hoses and other wetting equipment

aeration and CO2 extraction

germination vessels including circular or rectangular vessels or boxes

mechanical turning

kilning including tower and flat plant kilns

combined steeping, germination and kiln vessels

cleaning of malt (deculming).

Control points

Refers to the key points in the malting process which must be monitored and controlled. This includes food safety, (critical), quality, and regulatory control points as well as inspection points. Monitoring 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

Equipment monitoring includes ensuring that hygiene and sanitation standards are met, all safety guards are in place, and that equipment is operational and performing to specification. It may also include the calculation of raw materials.

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
Grain is transferred from storage into steeping equipment 
Hoses or other wetting equipment are placed correctly to ensure uniform hydration and to avoid damage to grain 
Grain is immersed, drained and rested for the specified number of cycles 
Moisture content of grain is monitored during air resting to determine when it is ready for transfer to germination vessels 
Waste water is discharged to treatment or holding or other facilities according to enterprise and regulatory environmental guidelines 
Grain is fed into germination vessel or floor 
Turning and air blowing equipment is set up, operated and monitored 
Green grain is monitored for humidity, temperature, moisture, chitting/acrospires, and general condition 
Rate of turning, humidity and temperature is adjusted as required to maintain green grain to specifications 
Modified green grain is transferred to kiln according to specifications for malt type and results of laboratory testing 
First drying of modified grain is conducted 
Stopping of germination is confirmed 
Modified grain is cured through correct combination of air flow and heat for malt product specification, in consultation with the production manager 
Colour, moisture content and other required specifications are confirmed 
Malt is cleaned 
Separated culm is transferred to storage 
Malt is transferred to storage 

Forms

Assessment Cover Sheet

FDFGR2012A - Prepare malted grain
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

FDFGR2012A - Prepare malted grain

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: