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

FDFOP2073A Mapping and Delivery Guide
Operate a beer packaging process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFOP2073A - Operate a beer packaging process
Description This is a specialist unit that has been developed for the brewing sector. It involves preparing, operating, monitoring and shutting down a packing process including packing processes for cartons, boxes, pallets and wrap-around and shrink wrap packers.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit applies to operators and other personnel responsible for the packing beer into cartons, boxes and pallets in both large and small breweries. It includes complying with quality and standard operating procedures and conducting of routine changeovers. The unit also applies to the use of non air tight wrap-around and shrink wrap packing. Where sealed, airtight film/cello packing is required the unit FDFOP2022A Operate a high speed wrapping process should be selected. Where changeovers require maintenance related skills, the unit 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 There are no pre-requisite units for this competency standard.
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 filler process for operation
  • Packing requirements are checked
  • Availability of required materials is confirmed
  • Availability of services is confirmed
  • Pre-operational checks of packing equipment are conducted including checking that hygiene and sanitation standards are met and all safety guards are in place
  • The packaging process is set to meet production requirements
       
Element: Operate and monitor the packaging process
  • The packing process is started up according to company specifications
  • Control points are monitored to confirm performance is maintained within specification
  • Packages meet specifications
  • Equipment is monitored to confirm operating condition
  • Stock flow to and from packer process is maintained within production requirements
  • Out-of-specification product, process, equipment performance is identified, rectified and/or reported
  • Size/product changeover is completed in accordance with batch instructions and standard operating procedures
       
Element: Shut down packaging process
  • Packer 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
       
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 requirements for the packing process

interpret the production schedule to determine the type of packing required

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

confirm equipment status and condition

set up and start up the process

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

reporting and/or recording corrective action as required

conducting changeovers for different product, product size or packing

shut down equipment

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 packaging equipment

services as required

stock required for the beer packaging process

stock flow system

related work areas and communication system

relevant OHS clothing and equipment

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.

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 includes:

Ability to:

access workplace information to identify production requirements for the packer process

select, fit and use personal protective clothing and equipment

interpret the production schedule

confirm supply of necessary materials and services to the packer

confirm packing equipment status and condition

monitor the packing process and equipment operation to identify out-of-specification results or noncompliance

This may include:

glue seals on cartons

incorrect shape

materials faults (eg. Printing)

incomplete shrink wrapping (eg. Too loose/printing unaligned)

equipment faults

services faults

monitor supply and flow of materials to and from the packer

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

safely access, isolate and clear jams in packaging equipment

report and/or record corrective action as required

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

verify that output meets specifications

implement size/product changeovers

sort, collect, treat, recycle or dispose of waste

shut down packing equipment in response to emergency situation

shut down packing equipment in response to routine shutdown requirements

prepare packing equipment for cleaning

maintain work area to meet housekeeping standards

record workplace information

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 packing process

relationship between the packing process, fillers, labellers, other packaging equipment and palletisers including stages which occur during filling and packaging

stages which occur during filling and packaging

requirements of the packaging process

types of packers

microbiological considerations in filling and packaging beer

effect of packaging 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 packers to product specifications

process specifications, procedures and operating parameters

significance and methods of monitoring control points within the packaging process

equipment and instrumentation components, purpose and operation

services used in the packing 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

sampling and testing 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.

Beer

Refers to all styles of brewed alcoholic beverages.

Services may include:

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

Packing equipment may include

Packing equipment may vary according to type of container and product and may include:

wrap-around packer machine

basket packer machinery

shrink wrap machinery

glue guns

conveyors.

Packing 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
Packing requirements are checked 
Availability of required materials is confirmed 
Availability of services is confirmed 
Pre-operational checks of packing equipment are conducted including checking that hygiene and sanitation standards are met and all safety guards are in place 
The packaging process is set to meet production requirements 
The packing process is started up according to company specifications 
Control points are monitored to confirm performance is maintained within specification 
Packages meet specifications 
Equipment is monitored to confirm operating condition 
Stock flow to and from packer process is maintained within production requirements 
Out-of-specification product, process, equipment performance is identified, rectified and/or reported 
Size/product changeover is completed in accordance with batch instructions and standard operating procedures 
Packer 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 
Workplace information is recorded in the appropriate format 

Forms

Assessment Cover Sheet

FDFOP2073A - Operate a beer packaging 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

FDFOP2073A - Operate a beer packaging 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: