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

SUGPJCP2A Mapping and Delivery Guide
Operate a juice clarification process

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency SUGPJCP2A - Operate a juice clarification process
Description This is a Specialist unit. It covers the operation of the juice clarification process from the juice tanks through to the clarifiers.
Employability Skills Not applicable.
Learning Outcomes and Application Not applicable.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not applicable.
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 clarification process for operation
  • Raw juice is and available to meet production requirements
  • Services are confirmed as available and ready for operation
  • Equipment is checked to confirm readiness for use
  • The clarification process is set to meet production requirements
       
Element: Operate and monitor the clarification process
  • The clarification process is started up and operated according to company procedures
  • Control points are monitored to confirm performance is maintained within specification
  • Clarified product meets specifications
  • Equipment is monitored to confirm operating condition
  • Out-of-specification product, process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure
  • The workplace meets housekeeping standards
  • Workplace information is recorded according to workplace recording requirements
       
Element: Handover the clarification process
  • Workplace records are maintained in accordance with workplace procedures
  • Handover is carried out according to workplace procedure
  • Clarification operators are aware of system and related equipment status at completion of handover
       
Element: Shut down the clarification process
  • The appropriate shut down procedure is identified
  • The clarification system is shut down according to workplace procedures
  • The clarification system is prepared for storage in shut down mode
  • Maintenance requirements are identified and reported according to workplace reporting procedure
       


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 assessment process must address all of the following items of evidence.

Ability to:

1. Access workplace information to identify production requirements

2. Select, fit and use personal protective clothing and/or equipment

3. Confirm supply of necessary materials and services

4. Prepare lime, flocculant and saccharate for addition

5. Liaise with other work areas

6. Confirm equipment status and condition

7. Set up and start up the process in both automatic and manual modes

8. Monitor the process and equipment operation to maintain the process within the required parameters. This typically involves visual inspections and conducting tests to monitor characteristics such as:

juice temperatures

steam pressure

condensate flow and quality

throughput

juice pH

ESJ turbidity

addition rates

raw juice quality

clarifier mud levels and quality

equipment condition

9. Monitor supply and flow of materials to and from the process

10. Take corrective action in response to out-of-specification results

11. Record workplace information

12. Demonstrate shift handover procedure

13. Shut down equipment in response to an emergency situation

14. Demonstrate an operational shut down procedure

15. Prepare equipment for cleaning/maintenance

16. Maintain work area to meet housekeeping standards

May include the ability to:

17. Use process control systems

18. Clean and sanitise equipment

19. Take samples and conduct tests

Knowledge of:

20. Purpose and basic principles of clarification. This includes heating, liming, juice degasification and flocculant addition

21. The circuit flow of this process and relationship to related processes. This includes the consequences of poor clarification on downstream processes

22. The effect of recycle streams on the clarification process

23. The purpose and role of materials added

24. Effect of faulty preparation of materials

25. Quality characteristics of raw juice and of clarified product

26. The impact of dextran on sugar quality

27. The function of the incubation tank and starch removal

28. The effect of addition rates on the process

29. The effect of variation in process parameters

30. Conditions that can cause deterioration in juice

31. Significance and method of monitoring control points within the process

32. Equipment purpose and basic operating principles of juice clarification equipment

33. Operating requirements and parameters

34. Services used

35. Common causes of variation and corrective action required

36. Hazards and controls

37. Purpose and limitations of protective clothing and equipment

38. Lock out and tag out procedures

39. Procedures and responsibility for reporting problems

40. Environmental issues and controls

41. Waste handling requirements and procedures

42. Recording requirements and procedures

May include knowledge of:

43. Basic operating principles of process control where relevant. This includes the relationship between control panels and systems and the physical equipment

44. Cleaning and sanitation procedures

45. Sampling and testing procedures

Relationship with other standards

Pre-requisite units

There are no pre-requisite units for this competency standard.

Co-assessment of related units

Other units of competency relevant to the work role should be assessed in conjunction with this unit. This may include:

SUGPCPS2A Collect and prepare samples

SUGPPST2A Conduct standard tests

SUGZPCI2A Operate a process control interface

Resources required for assessment

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

Operating procedures and related advice on equipment operation including advice on safe work practices and environmental requirements

Personal protective clothing and equipment

Product and process specifications and operating parameters

Juice clarification equipment

Materials including raw juice to be clarified

Services as required

Material Safety Data Sheets where appropriate

Housekeeping standards and procedures

Advice on environmental management issues relevant to work responsibilities

Workplace information recording systems, requirements and procedures

They may also require

Cleaning procedures, sampling schedule and procedures and maintenance procedures and tools depending on the work requirements.

Assessment requirements

For information on how to assess this competency standard and who can assess, refer to the Assessment Guidelines for this Training Package.


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.

Not applicable.

The range statement indicates the context for demonstrating competence. This statement is a guide and unless otherwise indicated, items may or may not apply as required by the work context.

Work is carried out in accordance with company policies and procedures, manufacturer's recommendations, legislative requirements, codes of practice and industrial awards and agreements. Codes of practice include the Sugar Milling Operations Industry Code of Practice

Workplace information can include Standard Operating Procedures (SOPs), specifications, production schedules and manufacturer's specifications

Clarification equipment may include tanks, juice pumps, juice heaters, flash tank, lime storage and mixing plant, saccharate tank, flocculant addition system, clarifier

Confirming equipment status involves conducting relevant pre-start checks, confirming that cleaning standards are met, all safety guards are in place and equipment is operational. It may also involve checking operation/calibration of measuring instrumentation

Operation and monitoring of equipment and processes typically requires the use of control panels and systems

Services may include power, steam, water, compressed and instrumentation air

Materials can include lime, flocculants, enzymes, phosphoric acid, saccharate and preservatives

Where tests are conducted as part of operation, typical requirements are for pH and thymol testing

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

Control points refer to those key points in a work process which must be monitored and controlled

Work may require the ability to work within a team environment

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
Raw juice is and available to meet production requirements 
Services are confirmed as available and ready for operation 
Equipment is checked to confirm readiness for use 
The clarification process is set to meet production requirements 
The clarification process is started up and operated according to company procedures 
Control points are monitored to confirm performance is maintained within specification 
Clarified product meets specifications 
Equipment is monitored to confirm operating condition 
Out-of-specification product, process and equipment performance is identified, rectified and/or reported according to workplace reporting procedure 
The workplace meets housekeeping standards 
Workplace information is recorded according to workplace recording requirements 
Workplace records are maintained in accordance with workplace procedures 
Handover is carried out according to workplace procedure 
Clarification operators are aware of system and related equipment status at completion of handover 
The appropriate shut down procedure is identified 
The clarification system is shut down according to workplace procedures 
The clarification system is prepared for storage in shut down mode 
Maintenance requirements are identified and reported according to workplace reporting procedure 

Forms

Assessment Cover Sheet

SUGPJCP2A - Operate a juice clarification 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

SUGPJCP2A - Operate a juice clarification 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: