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

FDFOP2067A Mapping and Delivery Guide
Operate a brewery fermentation process

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency FDFOP2067A - Operate a brewery fermentation process
Description This unit covers the preparation for and operation of processes used to ferment wort into beer. This includes pitching, fermentation control, yeast propagation and storage, and beer recovery.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit applies to operators and other personnel responsible for operating the fermentation process in a brewery. The unit applies to fermentation processes in both large and small breweries. Work is undertaken to specifications and requirements developed by brewers, supervisors or other qualified personnel. The unit includes complying with quality and standard operating procedures and conducting of routine changeovers.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites FDFOP2071A Identify key stages and beer production equipment in a brewery
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 fermentation process for operation
  • Production 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 fermentation process is set to meet production requirements
       
Element: Operate and monitor the system
  • The system is started up according to specified procedures
  • Control points are monitored to confirm performance is maintained within specification
  • System and sub-system outputs meet specification
  • Equipment is monitored to confirm operating condition
  • Temperature is monitored and controlled to confirm operating condition
  • Pressure is monitored and controlled in order to ensure operating condition
  • Analysis is undertaken to ensure yeast effectiveness and freedom from bacterial contamination
       
Element: Recover beer if required
  • Yeast slurry is put through a beer recovery process in order to minimise beer wastage
  • Recovered beer is routed to appropriate tank or vessel
       
Element: Shut down the system
  • The system is shut down according to company procedures
  • Equipment is cleaned and maintained to meet the cleaning schedule and procedural requirements
  • Waste generated by both the process and cleaning procedures is collected, treated and disposed of or recycled according to company procedures
       
Element: Contribute to continuous improvement of the system
  • 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
       
Element: Record information
  • Workplace information is recorded in the appropriate format
       


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 production requirements and schedules including type of beer being produced

confirm the supply of necessary materials and services to the fermentation process

confirm equipment status and condition

set up and start the process

propagate yeast (laboratory staff will usually undertake initial propagation)

adding oxygen based upon instruction

monitoring temperature

crop yeast for addition to wort

monitor supply and flow of materials to and from the process

add adjuncts as required

take corrective action in response to out-of-specification results or non-compliance and report and/or record corrective action as required

aerate wort/beer to encourage fermentation

conduct product/beer-type changeovers

prepare equipment for cleaning

conduct routine maintenance

operate a beer recovery procedure.

Context of and specific resources for assessment

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

standard operating procedures and related advice on specific safe work practices, company policies and codes of practice relating to OHS

advice on relevant legislation and codes of practice relating to OHS

personal protective clothing and equipment as required

relevant hazard control equipment

manual handling equipment as required

fermentation process equipment

fermentation raw material and other ingredients

information systems 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, 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:

pitch and crop yeast

operate vessel transfer equipment

handle dangerous goods according to procedures

methods of monitoring control points within the fermentation process

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

identify OHS hazards and implement appropriate action

shutdown process and equipment and implement cleaning requirements associated with changeovers

handle waste according to requirements and procedures

clean and sanitise equipment according to enterprise procedures

select, fit and use personal protective clothing and equipment

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:

purpose and principles of the fermentation process

relationship between the fermentation process, the wort production process and the maturation process

stages and changes which occur during fermentation

requirements of fermentation

quality characteristics to be achieved

process specifications, procedures and operating parameters

significance of control points within the fermentation process

equipment and instrumentation components, purpose and operation

vessel cooling systems

common causes of variation and corrective action required

OHS hazards and controls

procedures and responsibilities for reporting problems

environmental issues and controls

shutdown and cleaning requirements associated with changeovers and types of shutdowns

waste handling requirements and procedures

recording requirements and procedures

cleaning and sanitation procedures

sampling and testing procedures

routine maintenance 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.

Fermentation process

The fermentation process may include:

receiving wort

pitching

monitoring and adjusting pressure and temperature

yeast handling and removal

transfer of the beer to maturation.

Services

May include:

power

gas

water

steam

compressed air

refrigeration.

Equipment

Equipment may include:

pumps

fermentation vessels

recovery vessels

separators

cleaning equipment

equipment accessories

valves

vacuum relief systems

aeration equipment

transfer systems

propagation vessels.

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

Monitor the fermentation process and system may include:

Monitoring may include:

use of production data such as performance control charts

monitor for out-of-specification results or noncompliance. These may include:

oxygen

carbon dioxide

gravity

acidity

colour

bitterness

bacteria

chemicals

temperature

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.

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
Production 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 fermentation process is set to meet production requirements 
The system is started up according to specified procedures 
Control points are monitored to confirm performance is maintained within specification 
System and sub-system outputs meet specification 
Equipment is monitored to confirm operating condition 
Temperature is monitored and controlled to confirm operating condition 
Pressure is monitored and controlled in order to ensure operating condition 
Analysis is undertaken to ensure yeast effectiveness and freedom from bacterial contamination 
Yeast slurry is put through a beer recovery process in order to minimise beer wastage 
Recovered beer is routed to appropriate tank or vessel 
The system is shut down according to company procedures 
Equipment is cleaned and maintained to meet the cleaning schedule 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

FDFOP2067A - Operate a brewery fermentation 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

FDFOP2067A - Operate a brewery fermentation 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: