This unit has application in an edible oils production environment. It typically targets the production worker responsible for applying basic operating principles to the operation and monitoring of flake preparation 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. |
ELEMENT | PERFORMANCE CRITERIA |
1. Prepare oil and emulsion phases | 1.1. Oil requirements are identified and oil is transferred to meet production requirements 1.2. Ingredients for addition are confirmed and available in required quantities 1.3. Ingredients are added to oil phase to meet recipe specifications 1.4. Oil stock is drawn to make emulsion 1.5. Ingredients are added to water phase to meet recipe specifications 1.6. Oil stock and emulsion meet specifications |
2. Prepare the drum and flaking equipment for operation | 2.1. Oil stock and water phase are available to meet operating requirements 2.2. Cleaning and maintenance requirements and status are identified and confirmed 2.3. Machine components and related attachments are fitted and adjusted to meet operating requirements 2.4. Processing/operating parameters are entered as required to meet safety and production requirements 2.5. Equipment performance is checked and adjusted as required 2.6. Pre-start checks are carried out as required by workplace requirements |
3. Operate and monitor the flaking process | 3.1. The process is started and operated according to workplace procedures 3.2. Equipment is monitored to identify variation in operating conditions 3.3. Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements 3.4. The process is monitored to confirm that specifications are met 3.5. Out-of-specification product/process outcomes are identified, rectified and/or reported to maintain the process within specification 3.6. The work area is maintained according to housekeeping standards 3.7. Work is conducted in accordance with workplace environmental guidelines 3.8. Workplace records are maintained according to workplace recording requirements |
4. Shut down the flaking process | 4.1. The appropriate shutdown procedure is identified 4.2. The process is shut down according to workplace procedures 4.3. Maintenance requirements are identified and reported according to workplace reporting requirements |
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Required skills |
Ability to: access workplace information to identify oil and emulsion phase preparation requirements select, fit and use personal protective clothing and/or equipment confirm supply of necessary oil type, ingredients for addition and services prepare oil and water phase according to procedures prepare emulsion according to procedures conduct pre-start checks on refrigeration and flaking process, 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 valves and 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 process equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as: operation of addition/dosing equipment drum speed emulsion temperature ammonia suction temperature flake thickness flake temperature moisture level salt level evenness of curtain fall monitor supply and flow of materials to and from the process take corrective action in response to out-of-specification results demonstrate batch/product changeovers 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: principles of forming a water in oil emulsion, including an understanding of the types of emulsifiers used purpose and basic principles of the flaking process, including a basic understanding of stages of crystallisation of oil types used 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 flaking process and the effect of outputs on downstream processes quality characteristics to be achieved by each stage (oil phase, water phase and refrigeration/flaking process) quality requirements of oil and ingredients used and effect of variation on process performance operating requirements and 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 production 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 process and related control measures, including the risk of cross-contamination where tempered product mixes with untempered product common causes of variation and corrective action required occupational health and safety (OHS) hazards and controls, including the risks of working with ammonia and procedures to follow in the event of a leak product/process changeover procedures and responsibilities requirements of different shutdowns as appropriate to the 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 procedures and responsibility for reporting production and performance information environmental issues and controls relevant to the process, including waste/rework collection and handling procedures related to the process and procedures for containing spills basic operating principles of process control, 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 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 flake preparation 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 production schedule/batch instructions specifications, control points and processing parameters oil and water phase preparation equipment and services drum and flaking equipment oil and ingredients as required 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: FDFOP2003A Clean equipment in place FDFOP2004A Clean and sanitise equipment FDFOP2011A Conduct routine maintenance FDFOP2013A Apply sampling procedures FDFOP2030A Operate a process control interface PMLTEST300B 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. |
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/recipes production schedules and instructions manufacturers' advice standard forms and reports |
Preparation and processing equipment | Preparation and processing equipment may include: tanks heat exchangers ingredient addition systems brine and tepid water loops refrigeration system flaking/drum |
Stages for oil phase | Stages for oil phase typically include: oil transfer and pasteurisation addition of ingredients, such as emulsifiers and other ingredients as required Stages for emulsion stage typically include addition of brine and water to oil stock and addition of other ingredients as required. The emulsion is then transferred to the flaking process |
Operation of equipment and processes | Operation of equipment and processes may require: the use of process control panels and systems |
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 refrigeration compressed and instrumentation air |
Unit sector | Grocery products and supplies |
This unit contains employability skills. |
Not applicable.