ELEMENT

PERFORMANCE CRITERIA

1 Prepare the wort

production process

for operation

1.1 Production requirements are checked

1.2 Availability of required materials is confirmed

1.3 Availability of services is confirmed

1.4 Pre-operational checks of equipment are conducted

1.5 The wort production process is set to meet production requirements

2 Operate and monitor

the wort production system

2.1 The wort production system is started up according to company procedures

2.2 Control points are monitored to confirm performance is maintained within specification

2.3 Required tests are undertaken

2.4 System and sub-system outputs meet specification

2.5 Equipment is monitored to confirm operating condition

2.6 Out-of-specification wort, process and equipment performance is identified,rectified and/or reported

2.7 Production and other workplace information is recorded in the appropriate format

3 Shut down the wort production system

3.1 The wort production system is shut down according to company procedures

3.2 Equipment is cleaned and maintained to meet cleaning schedules and procedural requirements

3.3 Waste generated by both the process and cleaning procedures is collected, treated and disposed of or recycled according to company procedures

4 Contribute to continuous

improvement of the wort production system

4.1 Quality or process outputs are assessed against specifications

4.2 Opportunities for improvement are identified and investigated

4.3 Proposals for improvements are developed and implemented within company planning arrangements and according to company procedures

Required skills includes:

Ability to:

set up and start the milling process

set up and start the mashing and lautering process

set up and start the wort separation process

set up and start the wort boiling and cooling process

add raw materials e.g. hops, malt

operate a heat exchange procedure

operate a cool wort aeration procedure

transfer fluids and materials between vessels

handle dangerous goods

operate and monitor equipment associated with wort production

monitor control points

identify OHS hazards and controls

select, fit and use personal protective clothing and equipment

undertake shutdowns and changeovers

comply with procedures and responsibilities for reporting problems

comply with environmental procedures and controls

follow waste handling requirements and procedures

record required production data

undertake routine maintenance procedures

collect samples and conduct tests according to enterprise procedures

clean and sanitise equipment according to enterprise procedures

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 wort production process

relationship between the wort production process and the fermentation process

stages and changes which occur during wort production

requirements of wort production

purpose of malt, hops, water, adjuncts and the preparation procedure

correct procedures for handling dangerous goods

dust explosion hazards and control procedures

quality characteristics to be achieved

wort process specifications, procedures and operating parameters

the importance of temperature, temperature control systems and temperature intervals during wort production

Purpose of equipment and instrumentation components

significance and methods of monitoring control points within the wort production process

common causes of variation and corrective action required

cleaning requirements associated with changeovers and types of shutdowns

procedures for reporting problems

sampling and testing 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:

access workplace information to identify production requirements for the wort production process

interpret the schedules and specifications

confirm the supply of necessary materials and services to the wort production process

confirm equipment status and condition

set up and start specified equipment including any process control systems

monitor the wort production process and equipment operation to identify out-of-specification results

monitor supply and flow of materials to and from the process

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

conduct product/beer type changeovers

maintain workplace records.

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

information on specifications, control points and production parameters

wort production equipment

wort production raw materials/ingredients

services as required

stock required for the wort production process

stock flow system

related work areas and communication system

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

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.

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.

Wort production process

The wort production process may include:

receiving raw ingredients

measuring raw ingredients

milling malted grain to produce grist

whirlpool (wort calcification)

mashing conversion to create fermentable wort

wort separation

boiling

cooling process

wort oxygenation

production quality checks

transferring to fermentation vessels.

Materials and ingredients

Materials and ingredients used in wort production may include:

malted cereals

hops

water

liquid and solid adjuncts such as sugars

process aids

oxygen.

Services

May include:

power

gas

water

steam

compressed air

refrigeration.

Required tests

Required tests may include:

starch testing (mash tun)

gravity (cool wort)

acidity (cool wort)

colour spectrometer (cool wort)

bitterness (cool wort).

Wort production equipment

Wort production equipment may include:

brew house mill

malt batch weighers

storage systems (silos etc.)

whirlpools

mash tuns

mash conversion vessels and mash cookers

lauter tuns

automated hops addition systems

heat exchangers

aeration equipment

filters

coppers and kettles

valves

pumps

water treatment systems

tanks

mixing, blending and cleaning equipment

spent grain handling equipment

equipment accessories

monitoring instruments (starch, gravity, acidity, colour and bitterness)

transfer systems and equipment.

Control points

Refers to the 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 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

Equipment monitoring includes ensuring that hygiene and sanitation standards are met, all safety guards are in place, and that equipment is operational. It may also include the calculation of raw materials.

Workplace information may include:

Standard Operating Procedures (SOPs); specifications and production schedules.

Information systems may be print or screen based.