FDFOP2019A
Fill and close product in cans

This unit of competency covers the skills and knowledge required to set up, operate, adjust and shut down a primary packaging process that fills product into cans and hermetically seals containers using a closer or seamer.

Application

This unit has application in a food processing packing environment. It typically targets the production worker responsible for applying basic operating principles to the operation and monitoring of a filling and closing process and associated equipment.

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.


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Prepare the filling and closing process for operation

1.1. Materials and packaging components/consumables are confirmed and available to meet operating requirements

1.2. Cleaning and maintenance requirements and status are identified and confirmed

1.3. Machine components and related attachments are fitted and adjusted to meet operating requirements

1.4. Operating parameters are entered as required to meet safety and production requirements

1.5. Equipment performance is checked and adjusted as required

1.6. Pre-start checks are carried out as required by workplace requirements

2. Operate and monitor the filling process

2.1. The process is started and operated according to workplace procedures

2.2. Equipment is monitored to identify variation in operating conditions

2.3. Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements

2.4. The process is monitored to confirm that filled and closed containers meet specifications

2.5. Out-of-specification product/process outcomes are identified, rectified and/or reported to maintain the process within specification

2.6. The work area is maintained according to housekeeping standards

2.7. Work is conducted in accordance with workplace environmental guidelines

2.8. Workplace records are maintained according to workplace recording requirements

3. Monitor closure and seaming stage

3.1. The closing stage is monitored to confirm that closures and seams meet specifications

3.2. Out-of-specification process outcomes are identified, rectified and/or reported to maintain the process within specification

3.3. The workplace meets housekeeping standards

3.4. Workplace records are maintained according to workplace recording requirements

4. Shut down the filling and closing 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

Required Skills

Required skills

Ability to:

access workplace information to identify processing requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary materials and services

prepare/condition product for filling as required

conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, selecting appropriate settings and/or related parameters to suit filling requirements, cancelling isolation or lockouts as required, confirming that equipment is clean, correctly configured for filling and seaming requirements, positioning sensors and controls correctly, ensuring any scheduled maintenance has been completed, and confirming that all safety guards are in place and operational

start, operate, monitor and adjust the filling process and equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as:

fill temperatures

headspace

vacuum

visual appearance of the product

line speed/throughput

monitor supply and flow of materials to and from the process

start, monitor and adjust the closer to confirm alignment and formation of the seam

monitor control points and conduct inspections related to the seaming/closing process, including confirming that coding is correct

take corrective action in response to out-of-specification results

conduct product/batch 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

demonstrate shift handover procedure

maintain work area to meet housekeeping standards

use process control systems according to enterprise procedures

inspect seams according to enterprise procedures

collect samples and conduct tests 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:

purpose and basic principles of filling and closing, including the properties and requirements of packaging materials used, hermetic sealing and properties of containers used for this purpose, coding requirements and related legal requirements, such as product weight

the flow of this process and the effect of the filling and seaming process on downstream processes

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

quality characteristics of the filled and closed container, including seam components and integrity requirements within level of responsibility for inspection

effect of raw material characteristics on filling and seaming

quality parameters for cans and ends

methods used to prepare product for filling

effect of process variables, such as headspace, fill temperature and vacuum on the process

operating requirements and parameters and corrective action required where operation is outside specified operating parameters, including restart procedures following a crash or jam up

typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems

techniques used to monitor the production/packing 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 issues associated with filling and seaming and related control measures

common causes of variation and corrective action required

occupational health and safety (OHS) hazards and controls

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

product/process changeover procedures and responsibilities

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the process, including waste collection and handling procedures related to the process

basic operating principles of process control, where relevant, including the relationship between control panels and systems and the physical equipment

sampling and testing procedures, where relevant, such as seam inspection procedures

cleaning and sanitation procedures where relevant

Evidence Required

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 filling and closing cans

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.

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

production schedule

information on equipment capacity and operating parameters

specifications, control points and operating parameters

filling and closing and related equipment and services

materials to be filled as required

packaging components/consumables

sampling schedules and test procedures and equipment as required

cleaning procedures, materials and equipment 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

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.


Range Statement

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

production schedules and instructions

batch/recipe instructions

manufacturers' advice

standard forms and reports

Product preparation

Product preparation can include:

acidifying

brining or syruping

exhausting

Product

Product may be hot or cold filled

Can seam components

Can seam components include:

body hook

end hook

countersink

seam thickness

seam juncture and overlap

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 are appropriate to the process to be operated. Typical examples include:

power

steam

water

vacuum

compressed and instrumentation air


Sectors

Unit sector

Operational


Employability Skills

This unit contains employability skills.


Licensing Information

Not applicable.